Energy efficient fansets

NEW

GENERATION

EC

FANS AND MOTORS

EC technology plays an integral role in Searle's condensers and

dry coolers providing effective capacity control whilst retaining
high energy efficiency and low noise levels, all at a competitive
price.

THE

EC

FANSETS

1. Reduced energy usage and low operating cost,

providing short pay-back periods

These speed control fansets can provide significant benefits

over alternative motors and are ideally suited to the following
application areas:

ADVANTAGES OF

2. Continuous speed control across the full

operating range

Commercial refrigeration
Building HVAC
Industrial refrigeration
Process Cooling
Power Generation
Convenience Stores

3. Low noise compared to a similar unit fitted with

step control
4. High efficiency across the full operational range
5. Long service life, with robustness comparable
to an asynchronous motor and 3 year warranty

Searle has the technical expertise to advise and select products

for any application where energy efficiency,
low-noise and cost-effective solutions
are required.

WHAT

IS

6. Operation at peak load via the overspeed

function is pre-programmed into the control
system
7. Night-time set back - at night, operation at
extremely low noise can be achieved through
step-less speed control

EC TECHNOLOGY?

EC (Electronically Commutated)
technology is a tried and tested
technology which has been
utilised by Searle for a number of
years. The motors used in EC
fansets are simply brush-less DC
motors with characteristics similar to
a "shunt" motor. Unlike the conventional
motors where an AC current in the stator
induces the magnetic field in the rotor, EC motors use
permanent magnets, so the current in the stator is used solely to
generate the torque not secondary magnetic fields. Therefore,
with fewer losses the EC motor is inherently more efficient than
the AC motor.

8. Built in fail-safe features, including individual

integrated electronics, self-regulating motors
and internal motor protection
9. Power input lost as heat is reduced by 1/3
compared to a conventional AC motor
10. Integrated protective features; Phase failure
detection; Over-current and temperature
11. Simple or complex control strategy possible
12. Networked and bus-linked installations are easy
to realise (RS485)

Conventional DC motors use brushes to switch the supply and

these wear over time; the new generation of EC motors use
commutation electronics to sense the rotor position and switch
supply. As switching is undertaken electronically with no
physical contacts there is no wear and so reliability is increased.

13. Simple to connect to AC mains supply

Fig.1 Sound pressure level across the speed of a technical application in refrigeration
3-phase asyncronus motor

EC motor

L/dB(A)

1
2

L/dB(A)

80

80

70

70

60

60

50

50

1
40

40

30

30

200

300

400

500

n/rpm

700

800

900

1000

1. Phase control
2. Conventional frequency inverter (4kHz pulse frequency)
3. Modern frequency inverter (16kHz pulse frequency, SVM)

200

300

400

500

n/rpm

1. Conventional EC motor
2. New Searle EC motor

700

800

900

1000

Fig.2 Cumulative capital and energy cost comparison

HIGH

ENERGY-SAVING POTENTIAL

The cost of energy has nearly tripled in recent years1

and is predicted to rise in the future. Rising energy
costs means energy efficiency is becoming a key
industry issue and is rising in importance on end-user
criteria. A Searle unit equipped with EC technology has
a high energy-saving rating, which in turn, translates
into lower running costs.

16,000
Step

Total Cost ()

14,000

ol
contr

EC Technology

12,000
10,000
8,000
6,000

The energy savings gained by relying on EC technology

translates into short payback times when measured
against the initial procurement costs. Moreover, the
maintenance-free and exceptionally high service life
results in additional big savings.

2,000

SAFETY

Refrigeration plants operate 24 hours a day, therefore,

both energy costs and fail-safety are crucial factors. EC
motors are equipped with several fail-safe features
helping to ensure disruption is minimal in the event of a
failure.

1.5

Fig.3 Power consumption of EC compared to inverters

1.8

90

1. Inverter
2. EC

1.6

80

1.4

70

1.2

60

50

SOUND LEVELS

0.8

40

1.

0.6

30

2.

POWER INPUTS

0.4

20

0.2

Each motor is fitted with an individual power unit, unlike

traditional units with a single inverter. Should an EC fan
inverter fail the other fans on the unit will remain fully
functioning and in most cases compensate for the loss
of one fan.

10
1.
2.

0
0.0

0
1.0

2.0

3.0

4.0

5.0

Air Volume (m/s)

In addition each fanset has internal motor protection.

Fig.4 EC Speed control features

RS485 ebmBUS
Lin In.: 0-10V / 4-20mA
Supply 10/20V for sensor
Master/Slave out

Alarm relay:
NO/ NC

3-Phase power supply

380-480V, 50/60Hz, PE

6.0

Sound Pressure Level (dB)

FAIL-SAFE

Note: To compare between a step controlled unit and one

fitted with EC technology a typical MDG condenser with
12 pole fans has been used

EFFICIENCY AND LOW NOISE

The EC motor has a high efficiency at every speed. At

nominal speed, there is energy saving of around 10%
when compared to conventional AC options. At
reduced speed the saving is substantially more
pronounced. Where noise levels are a key
consideration, a unit with EC technology helps by
reducing perceived noise when compared to a similar
unit with step control.

0.5

Year(s)

Power Input (kW)

HIGH

4,000

DAY & NIGHT

FUNCTIONS

At night, operation at extremely low noise

can be achieved through step-less speed
control, providing an efficient answer to
night-time setback. This speed step can
be preset via speed selection.

ADDITIONAL

Fig 5. EC vs AC configuration

EC

FEATURES AS STANDARD

The EC range of fansets have many other

technical benefits over AC motors and
inverter control.

PID control amplifier for simple single

fan control

PFC (Power Factor Controller)

Phase failure detection

Interference suppression filter

Motor protection

Motor & noise filter

Power supply sensor

Control via 0-10V, 4-20mA analogue or

PWM digital possible

Simple connection, AC mains input

can be between 380 and 480 volts,
50 / 60 Hz,

Shielded leads are not necessary to

comply with EMC regulations, as the
controls are mounted on the motor

AC

The EC fanset offers a simpler connection than

the traditional AC fanset with less external
items required.

The EC axial fans are also renowned for

their minimal mounting depth and their
high air performance. In short, EC fanmotors can be as simple, or as
sophisticated as required.

BACKING

OUR BELIEFS

We are so confident in the product that

we offer a three-year warranty on all Dry
Cooler and Condenser models fitted with
EC fansets and motors2 .

Note: Isolators and

control box shown are
additional extras

1
2

Data taken from UK Electricity Market contract prices (Energy only) from January 2003 to September 2005
This is subject to standard Searle Terms and Conditions of Sale and excluding corrosion through application misinterpretation.

Searle Manufacturing Company

Newgate Lane Fareham
Hampshire PO14 1AR UK

Telephone
Facsimile
Email
Website

+44 (0)1329 823344

+44 (0)1329 821242
sales@searle.co.uk
www.searle.co.uk

We reserve the right to change in whole or part, the specification detaled in this brochure without prior notice and, when necessary to achieve continuous production, to use alternative competitive designs of sub contract
components made by various manufacturers.
Issue No. Nov 05/01

Part No. 273-103-045