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DOE OSTI2018

Higher Efficiency HVAC Motors

The objective of this project was to design and build a cost competitive, more efficient heating, ventilation, and air conditioning (HVAC) motor than what is currently available on the market. Though different potential motor architectures among QMP’s primary technology platforms were investigated and evaluated, including through the building of numerous prototypes, the project ultimately focused on scaling up QM Power, Inc.’s (QMP) Q-Sync permanent magnet synchronous motors from available sub-fractional horsepower (HP) sizes for commercial refrigeration fan applications to larger fractional horsepower sizes appropriate for HVAC applications, and to add multi-speed functionality. The more specific goal became the research, design, development, and testing of a prototype 1/2 HP Q-Sync motor that has at least two operating speeds and 87% peak efficiency compared to incumbent electronically commutated motors (EC or ECM, also known as brushless direct current (DC) motors), the heretofore highest efficiency HVACR fan motor solution, at approximately 82% peak efficiency. The resulting motor prototype built achieved these goals, hitting 90% efficiency and .95 power factor at full load and speed, and 80% efficiency and .7 power factor at half speed. Q-Sync, developed in part through a DOE SBIR grant (Award # DE-SC0006311), is a novel, patented motor technology that improves on electronically commutated permanent magnet motors through an advanced electronic circuit technology. It allows a motor to “sync” with the alternating current (AC) power flow. It does so by eliminating the constant, wasteful power conversions from AC to DC and back to AC through the synthetic creation of a new AC wave on the primary circuit board (PCB) by a process called pulse width modulation (PWM; aka electronic commutation) that is incessantly required to sustain motor operation in an EC permanent magnet motor. The Q-Sync circuit improves the power factor of the motor by removing all failure prone capacitors from the power stage. Q-Sync’s simpler electronics also result in higher efficiency because it eliminates the power required by the PCB to perform the obviated power conversions and PWM processes after line synchronous operating speed is reached in the first 5 seconds of operation, after which the PWM circuits drop out and a much less energy intensive “pass through” circuit takes over, allowing the grid-supplied AC power to sustain the motor’s ongoing operation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Data-driven occupant-behavior analytics for residential buildings

Many advances have been made in building technology to help save energy, but influencing the behavior of the occupants is still necessary to achieve low-energy use targets. One of the most practical ways to influence and change occupant behaviors is through incentives. Developing incentives for energy-saving and quantifying the impact of occupant behaviors are both active areas of research. Here, we propose a data analytics framework for detecting changes in occupant behaviors, which will help build an analytics feedback loop from behavior impact to incentive design. The framework has two major parts. The first forecasts energy consumption for each occupant, while the second determines a probability distribution for changes in energy consumption. The parts are interchangeable with other existing machine learning and statistical methods. A specific instantiation of the framework, using kernel ridge-regression for forecasting and k-means to find an empirical behavior distribution, is described in detail. An HVAC use-case with 5 different incentivized behaviors is used as an example to show that the framework can detect behavior changes induced by incentives. Furthermore, we show that some simpler behavior-change detection methods do not work, further justifying the use of advanced analytics.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

R&D Opportunities for Natural Gas Technologies in Building Applications

This report summarizes the results of stakeholder outreach activities related to natural gas building technologies and identifies R&D initiatives across several applications where further investigations could result in substantive energy cost savings for U.S. buildings.

03 NATURAL GAS↗

DOE OSTI2016

Brookfield Homes Passive House Performance Evaluation

TO4 3.1.3: Brookfield Homes Short-Term Results TO5 3.1.3: Brookfield Passive House Monitoring To further define its market position on high performance homebuilding, Brookfield worked with IBACOS and the Building America program to design and construct a Passive House (PH) certified model home in Denver, CO to evaluate advanced building technologies and to use as a marketing tool for potential homebuyers. Brookfield used a new architect and a new floor plan as a standard production model and constructed it to the PH standard as an upgrade option. This PH was completely built and certified in August 2013.

Array↗

DOE OSTI2013

Technology Solutions Case Study: Replacement of Variable-Speed Motors for Furnaces

In conjunction with the New York State Energy Research and Development Authority (NYSERDA) and Proctor Engineering Group, Ltd. (PEG), the Consortium for Advanced Residential Buildings (CARB) evaluated the Concept 3™ replacement motors for residential furnaces in eight homes in Syracuse, NY. These brushless, permanent magnet (BPM) motors can use much less electricity than their PSC (permanent split capacitor) predecessors. This evaluation focuses on existing homes in the heating-dominated climate of upstate New York with the goals of characterizing field performance and cost-effectiveness. The results of this study are intended to be useful to home performance contractors, HVAC contractors, and home efficiency program stakeholders. Tests and monitoring was performed both before and after fan motors were replaced. Average fan power reductions were approximately 126 Watts during heating and 220 Watts during cooling operation. Over the course of entire heating and cooling seasons, these translated into average electric energy savings of 163 kWh, with average cost savings of $20 per year. Homes where the fan was used outside of heating and cooling mode saved an additional $42 per year on average. Results indicate that BPM replacement motors will be most cost-effective in HVAC systems with longer run times and relatively low duct static pressures. More dramatic savings are possible if occupants use the fan-only setting when there is no thermal load.

air handler unit↗

DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (CRADA Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (Final Report)

36 MATERIALS SCIENCE↗

DOE OSTI2022

Market Barriers and Drivers for the Next Generation Fault Detection and Diagnostic Tools

Commercial buildings in the U.S. consume as much as 30% excess energy compared to buildings that operate fault free and efficiently. Fault detection and diagnostic (FDD) platforms help to continually identify operational inefficiencies and maintain low-carbon performance. However, the recommendations generated by FDD tools need to be implemented by technicians, resulting in delays or lost savings opportunities. Recent research advances showed fault AUTOcorrection integrating with commercial FDD offerings filled this gap. Seven innovative AUTOcorrection algorithms were integrated into two FDD platforms and deployed across four buildings. The enhanced tools successfully correct faults focusing on incorrectly programmed schedules, override not released, control hunting, rogue zone, and suboptimal setpoints. Although its technical efficacy has been proven in the field, fault AUTO-correction is still early in the deployment cycle and opportunities and barriers need to be understood to reach its full potential in market transformation. This paper broadly introduces the new technology that automatically corrects HVAC faults. The authors describe in detail technology potential, market barriers, and enablers for scalability based on field testing results and interviews with the FDD providers and facility managers. The interviewees agreed that AUTO-correction can reduce the extent to which savings are dependent upon human intervention, scale building operators’ ability to act on FDD findings (especially for facilities with small operation teams), and achieve significant savings. To enable scalable deployment, future efforts are needed to overcome the barriers such as cybersecurity and accountability concerns from building operators and standardization of control parameters used in building automation systems.

Pritoni, Marco↗

DOE OSTI2017

Advanced Manufacturing for Thermal and Environmental Control Systems: Achieving National Energy Goals

This project was part of a regional initiative in the five counties of Central New York (CNY) that received funding from the U.S. Department of Energy (DOE) and four other federal agencies through the 2012 Advanced Manufacturing Jobs and Innovation Accelerator Challenge (AMJIAC). The CNY initiative was focused on cultivating the emergent regional cluster in “Advanced Manufacturing for Thermal and Environmental Control (AM-TEC).” As one component of the CNY AM-TEC initiative, the DOE-funded project supported five research & development seed projects that strategically targeted: 1) needs and opportunities of CNY AM-TEC companies, and 2) the goal of DOE’s Advanced Manufacturing Office (AMO) to reduce energy consumption by 50% across product life-cycles over 10 years. The project also sought to fulfill the AMO mission of developing and demonstrating new, energy-efficient processing and materials technologies at a scale adequate to prove their value to manufacturers and spur investment. The five seed projects demonstrated technologies and processes that can reduce energy intensity and improve production as well as use less energy throughout their lifecycles. The project was conducted over three years in two 18-month budget periods. During the first budget period, two projects proposed in the original AMJAIC application were successfully completed: Seed Project 1 focused on saving energy in heat transfer processes via development of nano structured surfaces to significantly increase heat flux; Seed Project 2 addressed saving energy in data centers via subzero cooling of the computing processors. Also during the first budget period, a process was developed and executed to select a second round of seed projects via a competitive request for proposals from regional companies and university collaborators. Applicants were encouraged to form industry-academic partnerships to leverage experience and resources of public and private sectors in the CNY region. Proposals were evaluated by a national panel of experts. Three projects were selected for awards and were completed successfully during the second budget period: Seed Project 3 focused on enabling self-powered furnaces to permit residents to shelter in place during power outages; Seed Project 4 addressed development of a novel method of controlling air conditioning systems that could enable flexible load matching in market segments not possible with existing technologies; and Seed Project 5 focused on the creation of smarter occupancy sensors to enable effective highly localized demand based ventilation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2012

Playas Grid Reliability and Distributed Energy Research

The future looks bright for solar and renewable energies in the United States. Recent studies claim that by 2050, solar power could supply a third of all electricity demand in the country’s western states. Technology advances, soft policy changes, and increased energy consciousness will all have to happen to achieve this goal. The New Mexico Institute of Mining and Technology (NMT) and the Department of Homeland Security (DHS) perform various training and research activities at this site. Given its unique nature, Playas was chosen to test Micro-Grids and other examples of renewable distributed energy resources (DER). Several proposed distributed energy sources (DERs) were not implemented as planned including the Micro-Grid. However, Micro-Grid design and computer modeling were completed and these results are included in this report. As part of this research, four PV (solar) generating systems were installed with remote Internet based communication and control capabilities. These systems have been integrated into and can interact with the local grid So that (for example) excess power produced by the solar arrays can be exported to the utility grid. Energy efficient LED lighting was installed in several buildings to further reduce consumption of utility-supplied power. By combining reduced lighting costs; lowering HVAC loads; and installing smart PV generating equipment with energy storage (battery banks) these systems can greatly reduce electrical usage drawn from an older rural electrical cooperative (Co-Op) while providing clean dependable power. Several additional tasks under this project involved conducting research to develop methods of producing electricity from organic materials (i.e. biofuels, biomass. etc.), the most successful being the biodiesel reactor. Improvements with Proton Exchange Membranes (PEM) for fuels cells were demonstrated and advances in Dye Sensitized Solar Cells (DSSC) were also shown. The specific goals of the project include: 1) Instrumentation of the power distribution system with distributed energy resources, demand-side control and intelligent homes within the town of Playas, NM, 2) Creation of models (power flow and dynamic) of the Playas power distribution system, 3) Validation of the models through comparison of predicted behavior to data collected from instrumentation, and 4) Utilization of the models and test grid to characterize the impact of new devices and approaches (e.g., distributed generation and load management) on the local distribution system as well as the grid at large. In addition to the above stated objectives, the research also focused on three critical challenges facing renewable distributed energy platforms: 1) hydrogen from biomass, 2) improved catalyst support systems for electrolysis membranes and fuel cell systems, and 3) improved manufacturing methodologies of low cost photovoltaics. The following sections describe activities performed during this project. The various tasks were focused on establishing Playas as a “…theoretical and experimental test bed…” through which components of a modern/smart grid could be characterized. On a broader scale, project efforts were aimed at development of tools and gathering of experience/expertise that would accelerate progress toward implementation of a modern grid.

09 BIOMASS FUELS↗

DOE OSTI2024

Residential HVAC Fault Data Collection Plan – Refrigerant Undercharge and Overcharge Faults

Heating, ventilation, and air-conditioning (HVAC) systems can develop faults due to poor installation practices or gradual wear and tear, leading to decreased HVAC system’s efficiency, compromised thermal comfort, and shortened equipment lifespan (EERE, 2018). Automated fault detection and diagnosis (AFDD) technologies offer a solution by identifying energy-wasting HVAC faults, such as inadequate indoor airflow and incorrect refrigerant charge, and guiding technicians to enhance system efficiency. In the realm of residential HVAC, AFDD can be implemented through various fault detection and diagnosis capabilities, sensor configurations, and target applications. These technologies typically fall into three categories: smart diagnostic tools, original equipment manufacturer (OEM)-embedded tools, and add-on tools. Smart diagnostic tools employ temporarily installed sensors to directly measure HVAC system characteristics, while OEM-embedded tools utilize factory-installed sensors to identify faults or assess system performance. However, both these types of AFDD technologies are often only accessible for high-end HVAC equipment or require additional sensor installation by qualified technicians, resulting in high investment costs and limited applicability for low-income residential buildings. On the other hand, add-on tools rely solely on data from smart thermostats and meters to detect faults by continuously analyzing equipment runtime or energy usage. As smart thermostat and meter costs decrease and their prevalence increases, these tools can be readily deployed in low-income residential buildings. However, they possess limited capabilities as they rely solely on basic trend analysis. Enhancing such tools with advanced machine learning algorithms can significantly improve their effectiveness.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

End-Use Savings Shapes Measure Documentation: Advanced Rooftop Unit Control

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

End-Use Savings Shapes Measure Documentation: Heat Pump Rooftop Units With Exhaust Air Energy Recovery

This technical report documents the Advanced Rooftop Unit Control End Use Savings Shapes (EUSS) measure, including providing a description of the technology, modeling methods, and the energy savings calculated from applying the measure to applicable across the US commercial building stock using ComStock to quantify its potential. This measure replaces gas furnace and electric resistance rooftop units with high-efficiency variable speed heat pump rooftop units (HP-RTU) that include exhaust air heat or energy recovery. The measure uses the same assumptions and technology as the variable speed HP-RTU measure from EUSS 2023 release 1 but adds energy recovery to precondition outdoor ventilation air to reduce HVAC loads. The HP-RTU compressor lockout temperature is modeled as 0 degrees Fahrenheit; below this temperature, the heat pump is set to shut off. The unit is sized based on the design cooling loads, with backup electric resistance heating addressing any remaining loads including heating hours below the compressor lockout temperature when there is no heat pump heating.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

Technology Solutions Case Study: Selecting Ventilation Systems for Existing Homes

In multifamily buildings, particularly in the Northeast, exhaust ventilation strategies are the norm as a means of meeting both local exhaust and whole-unit mechanical ventilation rates. The issue of where the "fresh" air is coming from is gaining significance as air-tightness standards for enclosures become more stringent, and the normal leakage paths through the building envelope disappear. Researchers from the Consortium for Advanced Residential Buildings (CARB) found that the majority of high performance, new construction, multifamily housing in the Northeast use one of four general strategies for ventilation: continuous exhaust only with no designated supply or make-up air source, continuous exhaust with ducted make-up air to apartments, continuous exhaust with supply through a make-up air device integral to the unit HVAC, and continuous exhaust with supply through a passive inlet device, such as a trickle vent. Insufficient information is available to designers on how these various systems are best applied. In this project, the CARB team evaluated the four different strategies for providing make-up air to multifamily residential buildings and developed guidelines to help contractors and building owners choose the best ventilation systems.

apartments↗

DOE OSTI2015

Through the Past Decade: How Advanced Energy Design Guides have influenced the Design Industry

Advanced Energy Design Guides (AEDGs) were originally developed intended to provide a simple approach to building professionals seeking energy efficient building designs better than ASHRAE Standard 90.1. Since its first book was released in 2004, the AEDG series provided inspiration for the design industry and were seen by designers as a starting point for buildings that wished to go beyond minimum codes and standards. In addition, U.S. Department of Energy’s successful Commercial Building Partnerships (CBP) program leveraged many of the recommendations from the AEDGs to achieve 50% energy savings over ASHRAE Standard 90.1-2004 for prototypical designs of large commercial entities in the retail, banking and lodging sectors. Low-energy technologies and strategies developed during the CBP process have been applied by commercial partners throughout their national portfolio of buildings. Later, the AEDGs served as the perfect platform for both Standard 90.1 and ASHRAE’s high performance buildings standard, Standard 189.1. What was high performance a few years ago, however, has become minimum code today. Indeed, most of the prescriptive envelope component requirements in ASHRAE Standard 90.1-2013 are values recommended in the 50% AEDGs several years ago. Similarly, AEDG strategies and recommendations have penetrated the lighting and HVAC sections of both Standard 189.1 and Standard 90.1. Finally, as we look to the future of codes and standards, the AEDGs are serving as a blueprint for how minimum code requirements could be expressed. By customizing codes to specific building types, design strategies tailored for individual buildings could be prescribed as minimum code, just like in the AEDGs. This paper describes the impact that AEDGs have had over the last decade on the design industry and how they continue to influence the future of codes and Standards. From design professionals to code officials, everyone in the building industry has been affected by the AEDGs.

Advanced Energy Design Guides↗

DOE OSTI2014

Technology Solutions Case Study: Evaluation of Ventilation Strategies in New Construction Multifamily Buildings, New York, New York

In multifamily buildings, particularly in the Northeast, exhaust ventilation strategies are the norm as a means of meeting both local exhaust and whole-unit mechanical ventilation rates. The issue of where the "fresh" air is coming from is gaining significance as air-tightness standards for enclosures become more stringent, and the "normal leakage paths through the building envelope" disappear. Consortium for Advanced Residential Buildings researchers have found that the majority of high performance, new construction, multifamily housing in the Northeast use one of four general strategies for ventilation: continuous exhaust only with no designated supply or make-up air source, continuous exhaust with ducted make-up air to apartments, continuous exhaust with supply through a make-up air device integral to the unit HVAC, and continuous exhaust with supply through a passive inlet device, such as a trickle vent. This research effort included several weeks of building pressure monitoring to validate system performance of the different strategies for providing make-up air to apartments.

apartments↗

DOE OSTI2018

A novel Variable Refrigerant Flow (VRF) heat recovery system model: Development and validation

As one of the latest emerging HVAC technologies, the Variable Refrigerant Flow (VRF) system with heat recovery (HR) configurations has obtained extensive attention from both the academia and industry. Compared with the conventional VRF systems with heat pump (HP) configurations, VRF-HR is capable of recovering heat from cooling zones to heating zones and providing simultaneous cooling and heating operations. Moreover, this could lead to substantial energy saving potential and more flexible zonal control. In this paper, a novel model is developed to simulate the energy performance of VRF-HR systems. It adheres to a more physics-based development with the ability to simulate the refrigerant loop performance and consider the dynamics of more operational parameters, which is crucial for representing more advanced control logics. Another key feature of the model is the introduction of component-level curves for indoor units and outdoor units instead of overall performance curves for the entire system, and thus it requires much fewer user-specified performance curves as model inputs. The validation study reflects good agreements between the simulated energy use from the new VRF-HR model and the laboratory measurement data across all operational modes at sub-hourly time steps. The model has been adopted in the official release of the EnergyPlus simulation program since Version 8.6, which enables more accurate and robust assessments of VRF-HR systems to support their applications in energy retrofit of existing buildings or design of zero-net-energy buildings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Membrane-based Ionic Liquid Absorption System for Ultra-Efficient Dehumidification and Heating

The project team – comprising the University of Florida (UF), GTI Energy, and Modine Manufacturing – sought to develop a highly efficient heat-powered absorption cycle with combined dehumidification and heat pumping. This DOE-supported project advanced the technology from a TRL of 3 to 6, culminating in the development of a 1,000 CFM system. Key innovations implemented in the system addressed the low efficiency, size, cost, and reliability challenges of conventional absorption cycles. Specifically, the system was enabled by: (1) a semi-open cycle that allowed simultaneous dehumidification and heat recovery, (2) non-crystallizing ionic liquids (ILs) that enabled “double-effect” operation at elevated temperatures without the need for costly control equipment, (3) a compact membrane-based absorber that confined the IL and directly cooled it to achieve low dew points, and (4) a novel, highly integrated desorber–condenser assembly that reduced size, weight, and cost. The technology was developed with commercial HVAC applications in mind, particularly for separate sensible and latent cooling (SSLC), an innovation aimed at achieving independent and more efficient humidity control.

42 ENGINEERING↗