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tech.mag01/2009NEW IDEAS AT A GLANCEDies ist der neue Claim von ebm-papst

EditorialTable of contentDear customers, partners and friends ofebm-papst:Over the past year, the European marketsfor heating have been predominantlycharacterised by regressivetrends. We were only able to observepositive growth through renewalon the German and Dutch markets.It is pleasing to note thatcondensing appliance technologyhas become established asan energy-efficient form of heating,not only in many Europeancountries, but also in the UnitedStates.Despite the financial crisis andfears of recession, we at ebmpapstare looking optimisticallyto the future, for the current de -velopments are both a challengeand an opportunity for us. Environmentallycompatible heating technologiesare an investment in a cleanfuture, so we have quickly picked upon current trends for the trade fair ISHin Frankfurt and developed a range ofinnovative products that are now readyfor series production.By extending the NRG range for greater heatoutput, the optional integration of venturi in ourblowers, the NRG with mass flow sensor and lastbut not least the market-ready LambdaConstantSystem for modern upper heating value burners,ebm-papst has its fingers on the pulse of the times, withenergy savings and at the same time emissions reductions.With the new gas blower for heat output up to 1 MW,ebm-papst has extended this range upwards. This willcreate new markets, in particular in the industrial environment,markets that can now be serviced with this newblower. The HyBlade ® range of axial fans in air/water heatpumps with EC technology sets new standards withrespect to energy efficiency and noise behaviour, as doesthe aerodynamically optimised plastic centrifugal fan. Forpellet-fired heating systems, ebm-papst offers centrifugalblowers and induced draft fans for the fresh air andexhaust air. For such applications, these satisfy the stricteststandards with respect to service life, noise and costeffectiveness.Completely new is the plastic gearbox forthe pellet feed, which is characterised by its very highstandard of refinement. These are only a few examples.As you can see, we at ebm-papst are continuing to focuson innovation, quality and service. We look forward to presentingour latest developments to you at the ISH or in apersonal meeting at your offices.I hope that you will enjoy reading our new magazine,tech.mag, and that it will provide you with many new andinteresting ideas.Stefan BrandlManaging Directorebm-papst Landshut GmbHPage:04 – 0809 – 1314 – 1617 – 2223 – 2627 – 30New EC centrifugal fans with backward curved blades:Saving energy with air-conditioning and ventilation systemsAn intuitively usable software solution for PDA and smartphone:Control fans remotely now via BluetoothModern technology enables a new approach to solutions in theautomobile industry: LED headlights require special fansExtremely quiet across the entire speed range:Energy-efficient EC fans for air/water heat pumpsFor maximum “air purity”:First fan series with antibacterial actionLocation-independent, ideal oxygen supply without adjustment effort:Centrifugal blower with mass flow sensor for exact air supply23

New EC centrifugal fans with backward curved blades:New EC centrifugal fans with backward curved blades:Saving energy with air-conditioning and ventilation systemsSaving energy withair-conditioning andventilation systemsebm-past meetsincreasingly stringentenvironmental andeconomic requirements!Today, saving energy is more importantthan ever. Large potential savings can beattained with fans used in ventilationand air-conditioning technology, asthese are often operated with highduty cycles. If the right technology isused, not only energy, but greatdeal of money can be saved.Meanwhile, lawmakers have alsocome around to ensuring that thejob is done correctly. Starting inJanuary 2011, motors will haveminimum efficiency classes thatare established at present inthe eco-design directive (basedon the framework directive2005/32/EC - Energy using productsdirective). Responsiblemanufacturers have alreadyreacted to this and offer corres -ponding energy saving fans –fans that will not only fulfil thespecified requirements in thefuture, but significantly exceedthem even now.The motor and fan specialist ebm-papstMulfingen has completely revised the socalledplug fan series, which was designedespecially for operation in ventilation and airconditioningtechnology, to meet increasinglystringent environmental and economic re -quirements (Image 1). Available in eight sizes withimpeller diameters of 250 to 560 mm and drive outputsof 400 watts to 6 kilowatts, the new designs coverall conceivable applications in the field of ventilation andImage 1: Selection from the new plug fan series.air-conditioning technology or in climate control systems(so-called HVAC systems). The feasible air flows lie between300 and 10,000 m³/h with a corresponding pressureincrease of up to 1,000 Pa. On one hand, the overall efficiencyof the fans was optimised with respect to the expectedminimum efficiency requirements, on the other, theacoustic behaviour was significantly improved. This wasmade possible by the selection of materials used, the wellthought-out design details and the state-of-the-art ECtechnology used with the drives.ebm-papst EC technology brings advantagesIn connection with energy-saving measures, it is no longerpossible for anyone to get around the subject of EC tech -nology. By means of the integrated electronic controlsystem, EC motors can change speed continuously toadapt to the requirements and operate at a high efficiency;therefore, they consume significantly less energy with thesame air performance as AC drives (Image 2, see page 6).However, the potential energy savings are realised not onlywhen operated under full load, but also primarily whenoperated under partial load. This is a distinctive feature ofEC motors. When operating under partial load, they lose45

New EC centrifugal fans with backward curved blades:Saving energy with air-conditioning and ventilation systemsNew EC centrifugal fans with backward curved blades:Saving energy with air-conditioning and ventilation systems“The new plug fans:quiet, compact and energy saving!”far less efficiency than asynchronousmotors of the same output.Likewise very important in connectionwith ventilation and air-conditioningtechnology devices is the noise level.Here too, EC drives are the betterchoice, because they do not produceany motor noise when regulated.In contrast, asynchronousmotors driven by a frequencyinverter, primarily under partialload, produce resonance noisethat results in the typicalunpleasant motor hum.Another advantage is that thenew plug fans are very compact.The electronically commutatedexternal rotor motor is directlyintegrated into the impeller, whichreduces the installation dimensions.The belt drive otherwisecommonly used between the motorand the fan is no longer necessary(Image 3). This reduces not only therequired installation volume – alwaysdesirable for ventilation and air-conditioningtechnology – but also the associatedinstallation effort. Of course, this also meansthat there is less wear and tear which keepsservice costs low over the long term. With respectto hygiene requirements, it makes sense touse direct-drive EC fans instead of belt-drive fans,because the inevitable belt abrasion can have a negativeimpact on the air quality.Image 2: Energy consumption of an EC fan compared to an AC fan.Design improvements to the impellerTo optimise a fan, however, it is not sufficient to onlyimprove the motor technology. The impeller also plays animportant role. Aerodynamic improvements contribute toincreased efficiency and reduced noise emissions. EvenImage 3: Space savings by using EC fans (top) versus systems with anAC fan and belt drive (bottom).Image 4: The impeller was optimised again for the new series; comparebefore (left) and after (right).small details can have a large effect. The optimised bladegeometry with a diagonal trailing edge, for example,improves the aerodynamic behaviour as well as the runningsmoothness (Image 4). The same is true for the nozzlecontour implemented in the new series. Previously a pressuretap was integrated here to regulate differential pressurevia a threaded nipple (Image 5). A ring line is also possibleon request. The position of the impeller on theexternal rotor motor is selected to yield aerodynamic aswell as installation-related advantages.The new fan series can also score points in terms of lifeexpectancy. To achieve a low motor bearing load andwithstand the long-term high circumferential speeds, theimpellers with their seven backward curved blades aremade completely of aluminium. The material is beneficialfor the weight of the fans and at the same time offers ahigh measure of stability. The individual blades are weldedon, which likewise adds to stability and service life.The fans are designed for a service life of more than40,000 operating hours. That corresponds to a continuousoperation of more than 4.5 years, operating underImage 5: Nozzle with threaded nipple(left), nozzle with ring line (right).full load and at themaximum permittedambient temperature.When operating underpartial load or at lowerambient temperatures,the value is significantlyhigher.Analogue and digitalcontrolAs you would expect,practical control optionsare built into themodern fans. The electronics integrated into the drivesare not only perfectly tuned to the EC motors used, butcan also be controlled via an analogue 0-10 V signal ordigitally via an RS485 ebmBus interface (for size 310 andup). In particular, if multiple fans are used, the bus networkingoffers big advantages. From making configura -tions during commissioning to performing service, alarmdiagnosis and maintenance, dealing with the technologyImage 6: Plug-and-play solutions for easy assembly (left with mountingplate, right with spider).67

New EC centrifugal fans with backward curved blades:Saving energy with air-conditioning and ventilation systemsAn intuitively usable software solution for PDA and smartphone:Control fans remotelynow via Bluetoothbecomes substantially easier if the techniciancan use a central computer to accessthe fans. Aside from the correspondingPC software, a PDA and smartphonecapableversion is now available withwhich the networked fans can beconfigured, monitored and controlledremotely via a Bluetooth interfacewithout a cable connection.But even those who rely on analoguetechnology need not foregocomfort. With a compact EC controldevice, up to 30 EC fans canbe controlled by a 0-10 V analogueline, or their operating datacan be monitored on the displayof the control device.(likewise improved) selection program, which is availableeither as independent software or as a DLL module forintegration in user-specific device configuration programs.In addition, therefore, the life cycle costs of the respectivefan can be calculated. This enables the user to see inadvance which potential savings the new plug fans willbring them in practical operation. With this new EC plugfan series, highly efficient, easily regulated and highperformancefans for ventilation and air-conditioning technologyare easily accessible.The electronicsintegrated can alsobe controlled analogor digital.The new plug fans are availablein different installation variants(Image 6), such as with a “mountingspider” or installed mountingplate for a simple anti-vibrationmount, which is usually implementedduring design-in. The power electronicsintegrated in the EC motors arecompatible with all common supplyvoltages; depending on the motor type,either from 200 V to 277 V for single-phaseAC or 380 V to 480 V for three-phase currentsupply. The frequencies lie at 50 or 60 Hz,respectively. The air performance and efficiencyare unaffected by frequency changes. This meansthat the same fan type can be operated on differentpower systems without further ado. Selection of the fansuited to the respective application is facilitated by aDipl.-Ing. Ralf Mühleck (left)Project Engineer / Domestic SalesDipl.-Ing. (FH) Uwe Sigloch (right)Head of Project Management / Sales Europeebm-papst Mulfingen GmbH & Co. KGImage 1: When many fans are used, networking and communication via a bus system like ebmBusV3 or ModBUS is indispensable.89

An intuitively usable software solution for PDA and smartphone:Control fans remotely now via BluetoothAn intuitively usable software solution for PDA and smartphone:Control fans remotely now via Bluetooth“The networking over a bus systembrings a lot of advantages”By the end of the 1990s, Bluetooth hadalready become an industry standard forremote networking of devices over shortdistances and is now an indispensablepart of everyday life. Bluetooth formsthe interface over which smallmobile devices like mobile tele -phones and PDAs as well as computersand peripheral devices cancommunicate with each other,without any elaborate or burdensomecable connections. Nowthe refrigeration and air-conditioningindustry can enjoy thistechnology as fans can also becontrolled remotely via Bluetooth.Fans in ventilation and air-conditioningtechnology rarely go italone, but usually work in teams.Typical examples of this are foundin greenhouses, multi-storey buildingfacades or the numerous ceilingfans without which clean roomtechnology would be inconceivable.Often several hundred, sometimes evenseveral thousand fans, perform theirduties in such applications. But even smallerfacilities, such as supermarkets, usuallyuse multiple fans. In all of these cases, net -working over a bus system brings advantages(Image 1). From making configurations duringcommissioning to performing service, alarm diag -nosis and maintenance, dealing with the technologybecomes substantially easier if the technician can use acentral computer to access the fans, which are usuallyinstalled in places that are difficult to reach, e.g. on theceiling, on the roof or directly in the facade.Wireless communicationThe motor and fan specialist ebm-papst Mulfingen hasrecognised this need and offers bus-compatible as well asenergy-saving EC fans for the most diverse applicationareas. But since it is not always worth using a computerwith smaller solutions, or because people in larger facilitiesmay also use a more mobile communication option,there is now a PDA and smartphone-capable version inaddition to computer software with “Fan Control 3.1”. Itcan be used to configure, monitor and remotely control allfans networked over the ebmBus via Bluetooth (Figure 2)without any cable connections. This will also be possiblefor those who use the Modbus, which is particularly widespreadin the industrial sector; then, even mixed operationwith other devices on the same bus is possible. Both theebmBus and the Modbus are physically based on anRS485 two-wire connection; they work in half duplexmode and permit a transfer rate of 9600 (ebmBus) or19200 Baud (Modbus) with line lengths up to 1200 m.Technology that is easy to work withThe technology is simple to use. For example to commu -nicate with the fans wirelessly, the Bluetooth adapter(Image 3, page 11) needs only to be installed within signalrange of the operator, so that the corresponding data canImage 2: Bluetooth is a trademark owned by Bluetooth SIG and is usedby ebm-papst under licence.be transferred over the interface of the PDA or smartphone.The adapter converts the Bluetooth signal into anRS485 bus signal and vice versa. The connected fans provideit with a current supply, so it does not need its own.The wireless data transfer uses the public-domain2.4 GHz ISM frequency band; distances of up to about20 m can be bridged.The “Fan Control 3.1” control software runs on PDAs andsmartphones that work with the Windows Mobile 2003operating system or higher. It can be operated intuitively,so that configuration and diagnostics tasks can be carriedout very easily with up to 255 fan groups, each with amaximum of 30 fans. The main screen allows the mostimportant information to be available immediately. Afterthe user logs in, the fan icons for the selected group aredisplayed on the screen. The software automaticallysearches all fans installed on the bus and displays them inImage 3: To communicate with the fans wirelessly, the Bluetooth adapterneeds only to be connected to the bus and installed within signalrange of the operator. It converts the Bluetooth signal into an RS485 bussignal and vice versa.Image 4: Important information appears on the main screen right away.After the user logs in, the fans are detected and displayed. The colour ofeach symbol indicates the operating state.the order in which they were found (Image 4). The deviceaddress appears below the respective symbol. The colourof the icon provides information on the current operatingstate. Green stands for perfect function, yellow indicates acommunication problem and a red symbol signals that analarm mode was identified for this fan.If you go further into the menu, you can take a closer lookat each of the fans. In addition, all current values can bedisplayed for the motor temperature, the current operationmode, all programmed set and actual values, and the lasterrors of each fan. The error messages are saved in thefan's electronics, so they are kept even if no PDA or smartphoneis connected. The production date of the fan or itselectronics and the operating time are further items ofinformation that can be called up in this way and often1011

An intuitively usable software solution for PDA and smartphone:Control fans remotely now via BluetoothAn intuitively usable software solution for PDA and smartphone:Control fans remotely now via Bluetooth“Fan settings can quite simplycalled up via PDA”provide the service technician with importantinformation. Also shown here is thecurrent value of the operating hourmeter that is integrated in the electronics.Fan settings can not only be calledup via PDA, they can also be modified.It is possible, for example, toassign a different network ad -dress to a fan, to switch betweenvarious operation modes (closedloop speed control, PWM control,sensor control) or to adjustthe programmed set values,such as for speed or direction ofrotation (Image 5). This is pos -sible either with numericalentries, or one can work herewith clear, graphic representa -tions (Image 6) and then simplymove the colour-coded set valuepoints or the limit lines on thescreen accordingly. The software isoffered in numerous languages andtherefore can be used worldwide.copy it to the others. At the same time, you can change thenetwork address of the fan. The copied data can also besaved in a file, e.g. for archiving or support, and then betransferred from there to a fan at a given time. If a fan isreplaced, for example, all settings can be copied quicklyand reliably to the replacement device.These software products open up versatile configurationpossibilities for bus-compatible EC fans, which can beoperated easily using handy smartphones. Controllingfans via the Bluetooth interface will make work substan -tially easier for service technicians globally.Image 5: All fan settings can be modified via PDA orsmartphone.Image 7: With the “Fan Clone” expansion, you cantransfer previous settings to as many other devices asdesired without any trouble and very quickly.Reading out data and transferring it toother fansThe software also supports the servicetechnician if a ventilation or refrigerationsystem is set up with multiple fans. With the“Fan Clone” expansion, once you have con figuredsettings, you can transfer them to as many otherdevices as desired without any trouble and very quickly.You need only to read out the values of the one fan andDipl. in Business Information Tech. (BA) Markus HummDevelopment of computer-based control softwareebm-papst Mulfingen GmbH & Co. KGImage 6: Settings can be modified not only by numerical entries, but also via graphic representations. You can shiftthe colour-coded set value points (a) or the limit lines (b) on the screen.1213

Modern technology enables a new approach to solutions in the automobile industry:Modern technology enables a new approach to solutions in the automobile industry:LED headlights require special fansLED headlights requirespecial fansModern materials andproduction methodsallow a variety ofapplications.Thanks to the brighter more powerful light,LED chips can now also be used for vehicleheadlights. With their long service lifeand compact size, they are increasinglybecoming an interesting alternative tohalogen or gas-discharge lamps es -pecially as they are mechanicallyextremely robust. The high degreeof efficiency also saves energy andthus fuel. How ever, as the activechip surface is extremely small,it must be well cooled. In particular,fans specially optimizedfor the requirements of vehicleheadlights enhance the requiredairflow and thus support activecooling. High reliability and longservice life are compulsory forall headlight components.Extremely bright LEDs operate high -ly efficiently. In comparison theyrequire less space and thus openup new design possibilities for head -lights and the front fascia of vehicles.This is one reason why the premiummanufacturer Cadillac is now relying ona full LED headlight for a high-beam, lowbeamand daytime running light manufacturedby Hella in its Escalade Platinum model.The light specialists cooperated with the fanspecialists ebm-papst from St. Georgen in theBlack Forest to provide the indispensable activecooling. Thus, a completely new type of headlightemerged with interesting technical innovations withregard to electronics, optics and cooling air supply (Image 1).Sophisticated motor vehicle applicationAll components in automobiles constantly suffer fromvibration, acceleration and oscillation, e.g. due to potholes.There is also an extremely wide temperature range inwhich all components are required to function reliably.The Escalade is fitted with a headlight package, comprisingthe casing and an array of 7 LEDs, a corresponding projectionlens of optical glass as well as the air leading insertthat is so important for the cooling and the actual fan itself.The colour temperature of the LEDs is approx. 5.500 Kelvinand is thus considerably closer to daylight with approx.6.000 K than light produced by Xenon bulbs with approx.4.000 K and they are not as strainful on the eye. As theheadlight is designed as a unit, the optical values must notalter before, during and after assembly. This requiresspecial handling during the manufacture and installation ofthe components.Tailor-made fansSpecial plastics were chosen to avoid degassing. The fancomponents are manufactured in the usual manner byinjection moulding, however, the melting point of the resis -tant material is considerably higher, so that the injectionmoulding system had to be converted from water coolingto oil cooling and the cycle times adapted accordingly.Even minor details that are important after successful testruns for series production, had to be kept in mind. Accordingto Michael Weißer, member of the development team:“Attention must be paid even to the most trivial things, i.e.marking the fans to ensure the high reliability of the entiresystem. Individual components must be traceable, yet thestandard solution of a label with numbers or barcode wasnot practicable. The direct marking of the fans solved theproblem.”Image 1: Full LED headlight by Hella for the Cadillac Escalade Platinum.1415

Modern technology enables a new approach to solutions in the automobile industry:LED headlights require special fansExtremely quiet across the entire speed range:Energy-efficient EC fans forair/water heat pumpsThe heat source LED is mounted on heat sinks, the coolingairflow is directed onto the heat sink from behind via guidevanes. The chip temperature of the LED is thus loweredconsiderably and the service life increases drastically.Special ball bearings with optimized lubrication were usedto provide a long operating time and the temperaturerange that is usually found in vehicles. This ensures thatextreme temperature fluctuations and high impactsduring operation do not affect either the lubrication or theoptimum running clearance of rotor and stator. The PCBand the drive electronics mounted in the fan, are protectedby a special insulation lacquer (Image 2). The speed canbe regulated if required. The fan propeller itself has asickle blade profile with winglets to ensure a high flowrate and high static pressure at minimum power input andlow operating noise.competence and the specialist on the optimization of thefan within the scope of the specifications. This type ofinteraction saves development time, money and enablesboth state of the art cooling and application solutions.Modern materials and production methods allow fanstoday to be tailor-made for a variety of applications. Theearlier the fan specialist with his know-how is incorporatedin the project planning, the sooner the specifications canbe fulfilled. The user can then concentrate on his coreImage 2: Axial fan with and without soft suspension (decoupling).Michael WeißerProject Manager Fan Systems Automotiveebm-papst St. Georgen GmbH & Co. KGSource: Stiebel Eltron GmbH & Co KG1617

Extremely quiet across the entire speed range:Energy-efficient EC fans for air/water heat pumpsExtremely quiet across the entire speed range:Energy-efficient EC fans for air/water heat pumps“EC motors: energy-efficiently, durable,extremely quiet and simple to control”Heating supplies today require conceptsthat use renewable energies instead offossil fuels. It is becoming ever moreapparent how much heating potentialwe have in our immediate environment.For example, air/water heatpumps make use of the heat energycontained in the external air forheating and for preparing hotwater. That even works in thewinter time. Fans provide for thenecessary air exchange via thepump evaporator. Here, the bestresults are achieved when thefans are driven by modern ECmotors. They work energy-efficiently,are durable and extremelyquiet.Today, air/water heat pumpsare available on the market intwo versions, configured for usein either indoor or outdoor installations(Image 1). Each places differentre quirements on the fans used.With the indoor configuration, theexternal air is drawn in through oneduct and blown out through another.Pressure is lost in these air ducts. For thisreason, centrifugal fans are especially wellsuited for this application as they are generallysuperior in generating a high pressure. Thefact that they are very compact is also beneficialfor air/water heat pumps configured for indoor installation,as there is usually limited space available. Spacerequirements are usually less of a problem for outdoora) b)Image 1: Air/water heat pumps are available either for inside installation(a) or for outside installation (b).configurations. Here, the evaporator is attached as anoffset exterior unit with a refrigerant pipe leading inwards.Another possibility is to exchange the heat outside using abrine heat exchanger and to integrate the refrigerantcircuit completely on the inside. Such installations usuallyuse axial fans. Pressure losses due to long intake and outletducts are eliminated here, allowing the axial fans to beoperated at low speeds.Axial and centrifugal fans in all sizesTo enable the right fan solution to be found for everyair/water heat pump, the motor and fan specialistebm-papst Mulfingen offers both axial and centrifugal fansin different sizes (Image 2 and 3). Centrifugal fans with adiameter of up to 630 mm and axial fans with a diameter ofup to 910 mm are predominantly used in the field of heatpumps. These can achieve an air performance of up to30,000 m³/h. These fans are powered by modern ECmotors, which are available in various sizes, depending onthe power output required. Depending on the amount of airrequired and the desired dimensions, the motor sizes maybe combined with different impellers. In each case, theuser will benefit from the advantages of EC technology, andwill do so in several respects.Image 2: HyBlade ® axial fan in EC technology with 800 mm impellerradius.Image 3: Plastic centrifugal fan in EC technology with 450 mmimpeller radius.To employ air/water heat pumps, you must tackle theissue of noise development. Besides the compressor, thefan used is the second relevant source of noise, and soshould work as quietly as possible. This is particularlyimportant during the quiet hours of the night, when theapproved limit values of DIN 18005 and noise abatementguidelines must be complied with inside, and more importantly,outside the building. Whenever possible, large fansshould operate at low speeds to keep noise emissionslow. The simple controllability of the EC motor then bringsnatural advantages as the speed can be reduced furtherat night without any problem. This eliminates the need toswitch off the heat pump to avoid trouble with the neighbours.Speed control, sound pressure level and operatingnoiseReducing the speed of the fan in the example by just100 rpm will reduce the sound pressure level by 4 dB(A),meaning a reduction in noise level of more than one half(Image 4). By contrast, such an adjustment on an AC fan,e.g. for a night-time reduction, would not be possible withoutadditional measures. Moreover, EC motors are muchquieter in operation than other types of motor, and are soover the entire speed range. The typical resonance levelsassociated with motors operated with a frequency inverter,and “phase noise” have been eliminated, since a dif -ferent operating principle is involved (Image 5, page 20).Image 4: Relationship between sound pressure and speed on a size 630centrifugal fan. Reducing the speed by just 100 rpm effects a 4 dB(A)reduction in the sound pressure level.1819

Extremely quiet across the entire speed range:Energy-efficient EC fans for air/water heat pumpsExtremely quiet across the entire speed range:Energy-efficient EC fans for air/water heat pumps“The optimised impeller vanes contibuteto low noise emissions”While switchable AC motors do workquietly, it is only possible to control theirspeed in two levels (Y/Δ).The freely controllable EC fans alsomake regular defrosting of the evaporatoreasier. During the defros -ting process, the fan continues torun at low speed without pumpinglarge volumes of air. This rulesout the possibility of the fanfreez ing, and may eliminate theneed for vent heating, dependingon the design and constructionof the heat pump. Ifdefrosting is not conductedregularly, but rather accordingto requirements, the currentspeed value of the fan can beused for monitoring. A drop inspeed indicates a possibility oficing.–– ebm-papst EC control–– Frequency inverter with sine filter–– Phase noise without sine filter–– Phase noise with sine filter–– TransformerImage 5: Noise behaviour of various types of motor in comparison(green: ebm-papst EC motor, rest: AC motors with various controlsystems).Extensive testing has confirmed the benefits that can beattained by using various materials in a com pound. Thealuminium inlet absorbs the mechanical forces and en -sures a durable connection to the rotor, while the plasticencapsulates the carrier structure, giving the blade its optimisedaerodynamic shape. Winglets, familiar from aeroplanetechnology, can also be realised. This also has apositive effect on noise behaviour. At the same time, theoverall weight of the fans is reduced by the use of plastic.This is an advantage that cannot be under estimated for thecraftsman installing and servicing the device.Energy-efficient and ready for use worldwideHeat pumps are designed to use as little primary energyas possible to generate the required heat output. It is truethat the compressor is a much larger consumer of electricalenergy than the fan. However, it still pays for itself ifthe fan works with maximum efficiency. Here again, ECtechnology has become established. Image 7 shows theinput capacity of two identical fans with different motors.AC motorThe fan with the EC motor requires approx. 200 W lesspower than the one with the AC motor. If we assume aworking time of 2,000 hours per year and energy costs of0.17 euro per kilowatt-hour, the saving is almost 70 euro.The low energy consumption of EC technology meansthat it also makes an important contribution to re ducingcarbon dioxide emissions.There are additional arguments in favour of EC technology,because the external rotor design places the motorin the impeller, the fans are very compact and can beeasily integrated in tight spaces. Moreover, EC drives canbe used with any power supply, without the need formodification, in single-phase operation from 200 to 277 V(50 Hz and 60 Hz) and with three-phase AC between 380and 480 V (also 50 Hz and 60 Hz). This has the logicaladvantage that the same fans canbe employed anywhere in the world.Also, just a few fans in the range areDifference inpower inputP1enough to cover practically allrequirements for new equipment,service and replacement.Optimised according to aerodynamiccriteriaImpeller vanes optimised according toaerodynamic criteria also contribute tolow noise emissions. The impellers on thecentrifugal fans are made of a high-strengthplastic material, as are the nozzles. Theinjection moulding process makes it possibleto adapt the geometry to suit the requirements ofthe application concerned.On the axial fans, the HyBlade ® blades (Image 6) redefinestandards with respect to noise be haviour and efficiency.Image 6: HyBlade ® blades: The aluminium inlet absorbs the mechanicalforces, ensuring a durable connection to the rotor, while the plas -tic encapsulates the carrier structure, giving the blade its optimisedaerodynamic shape.EC motorEC motorAC motorImage 7: Energy comparison between an EC fan and an AC fan under identical aerodynamic con -di tions (centrifugal, 630 mm diameter). Power input is 200 W less with EC technology than it is withAC technology.Durable and reliableAt the same time, EC motors arehighly durable. Because they workwith such great efficiency, the motorwarming is less than that of ACmotors, significantly prolonging theservice life of the ball bearings. Inaddition, it is not pos sible to overloadthe EC motors used. If theimpeller should be blocked, the integratedelectronics will switch themotor off and will periodicallyattempt to restart it. Just some of2021

Extremely quiet across the entire speed range:Energy-efficient EC fans for air/water heat pumpsFor maximum “air purity”:First fan series withantibacterial actionthe reasons to explain why EC fans are increasingly beingused in air/water heat pumps. A trend that will surely growin the future.Dipl.-Ing.(FH) Andreas SaligProject Engineer – Domestic Salesebm-papst Mulfingen GmbH & Co. KG2223

For maximum “air purity”:First fan series with antibacterial actionFor maximum “air purity”:First fan series with antibacterial action“The new line of antibacterial axial fans:antibacterial and energy-saving”Hygiene is a top priority, both in the field ofmedicine and in food technology. If germsor bacteria accumulate on different surfaces,this could be critical for certainapplications, for the surface serves asthe transfer medium for microorganismsthrough contact with hands,tools or other objects. At the sametime, there is the problem of colonisation:surfaces serve as concentrators,“multipliers” and disseminatorsof microorganisms.These microorganisms can bekilled by cleaning with commondisinfectants. However, conventionalcleaning agents have nolong-term effect. It may thenhappen that just a short timeafter being disinfected, the treatedsurface may again showssigns of colonisation with thepotential for cross-contamination– that is transmission to otherobjects. Specially treated coatingsor materials are today able tosustainably keep microorganismsclear from surfaces.In the field of fans, a wide variety of usesare opening up in the medicine and foodsectors. They supply laboratories and operatingtheatres with the necessary fresh air, extractwarm air when it is not needed or even objection -able, and transfer both hot and cold air to where it isneeded. As a rule they are integrated into systems ordevices in such a way that they cannot normally beaccessed, or can only be accessed with difficulty. Duringdesign and installation, conditions usually exclude thepossibility of severe contamination within the fans. How -ever, small dirt particles or microorganisms such as germsor bacteria can accumulate on the fans and from there theyare transported in ventilation systems along with the freshair or cooled air flow. This means that in some circumstancesthe actual fresh-air equipment can become thetransmitter for germs and bacteria.Exploiting the anti-microbial effect of silverVarious manufacturers in medicine and food technologythus demand that component manufacturers shouldproduce more devices from anti-microbial materials orwith appropriate coatings. This prompted the motor andfan specia list ebm-papst from Mulfingen, Germany todevelop a whole line of antibacterial-treated axial fans.Here, ebm-papst has drawn on the expertise of AgionTechnologies from Wakefield, Massachusetts to producematerials endowed with silver ions. The Americans havebeen working on the anti-microbial effect of silver formore than a decade and have conducted extensive testson this, both in the laboratory and in various applications.A zeolite endowed with silver ions (Image 1) – bothof these are naturally-occurring materials – is mixed intothe base polymer providing continuous antimicrobialIon exchangeZeolitee.g. sodium ionSilver ionsImage 1: The anti-microbial Agion system: Zeolite endowed with silver ions.action to the surface as needed (Image 2).Here, it is beneficial that silver ions onlyhave an effect on simple cell structuressuch as germs, bacteria or fungus.More complex cell structures such asplants, animals or human tissue arenot attacked. All in all, the silverions render microbes harmless ina number of different ways: catalyticoxidation is used to throttlethe oxygen supply, a reactionwith cell membranes preventsthe absorption of nutrients, andeffective sterilization to preventmultiplication. Not only do thematerials endowed with silverions inhibit and reduce unwantedgerms and bacteria, theyalso have the desired long-termeffect. Silver ions only becomeactive when dampness or microorganismscome into contact withthe material. This means the silverionreservoir is only activated whenit is actually required.Presentation of fan series at thetrade fair Chillventa in October 2008The range of antibacterial-treated axialfans were presented to the public for the firsttime at the Chillventa. These fans are compellingwith their low noise levels and maximum airflow. The line provides a total of five fans with adiameter of 172, 200, 230, 250 and 300 mm, whichdeliver an average air flow of 200 to 1,400 m³/h. Thefans work in ambient temperatures ranging from -30°C toBacteriaPlastic or Coating or FiberSurface film of moistureAGION ® ParticlesAg releaseEnvironmentSurfaceEngineeringImage 2: Fighting bacteria at the interface. By endowing a polymer withAgion particles, it is possible to sustainably combat microorganisms onthe surface.+50°C. They can easily be distinguished at a glance fromconventional fans by the typical OP green colour of theendowed plastic material (Image 3). Apart from theirantibacterial properties, the axial fans also have otherbenefits: the energy-saving motor (see box page 26) sig -nificantly reduces energy consumption and thus runningcosts. The fans have already demonstrated their reliabilityand function in numerous laboratory and field tests. Thewhole line has been available since late 2008. These fanswill surely open up numerous applications in the fields ofmedicine and food technology (Image 4, page 26).Image 3: Antibacterial fans can easily be distinguished at a glancefrom conventional fans by the typical OP green colour of the endowedplastic material.2425

For maximum “air purity”:First fan series with antibacterial actionLocation-independent, ideal oxygen supply without adjustment effort:Centrifugal blower with massflow sensor for exact air supplyEnergy-saving motor (ESM)The energy-saving motor is based on the provenexternal-rotor motor principle, with the rotor turningaround the stator within. Compared to the otherwisecommonplace shaded-pole motor (Q-motor), a threefoldincrease in efficiency is achieved. Higher efficiencyalso means that less waste heat is given offinto the surrounding area. Resulting in even moreenergy savings, e.g. in refrigeration technology, asless energy is required from the outset for the coolingprocess. Axial fans with energy-saving motors havebeen developed principally for use in cooling anddeep-freeze appliances, but increasing numbers ofother applications are being found, particularly aboveall in the fields of aerodynamics and air-conditioningtechnology.Image 4: Typical application in food technology, e.g. in a refrigerationunit.Dipl.-Ing. (FH) Gunter StrengManager – Platform Developmentebm-papst Mulfingen GmbH & Co. KGImage 1a: Fireplace insert with river rock design.2627

Location-independent, ideal oxygen supply without adjustment effort:Centrifugal blower with mass flow sensor for exact air supplyLocation-independent, ideal oxygen supply without adjustment effort:Centrifugal blower with mass flow sensor for exact air supply“The aerodynamic air conduction preventsunwanted vortex generation”Fire can seem alive, and has been a popularitem for home decor since time imme -morial. Hearths or fireplaces with aglass window accentuate the am -bience. Modern gas-powered fireplaceinserts unite the pleasantatmosphere of open flames withthe rather mundane purpose ofheating the room. Like a livingcreature, fire needs food, i.e. fueland atmospheric oxygen in anexact, chemically pre-determinedratio. This is the only way toensure optimum, energy-savingoperation of the fireplace, freeof hazardous substances (noNO x or CO). Conventional atmos -pheric “flame burners” alwaysrequire exact adjustments onsite.However, temperature andair pressure fluctuations continu -ously change the fresh air volumethat is aspirated. Today, a newfresh air blower with integratedmass flow sensor offers the perfectalternative. Independent of externalinfluences, the fireplace is always suppliedwith exactly the atmospheric oxygenvolume that is required for the corres -ponding fireplace output. Adjustmentson-site are unnecessary.Open fireplaces combine the useful with the beautiful.Closed fireplace inserts with a window providebetter efficiency without having to give up the opticaleffect of the flames. Bodart & Gonay, the specialist forhigh-quality fireplace inserts, offers gas-fired versions inaddition to the wood-burning types. With the atmosphericburner design, the gas burns with a beautiful, lively flamein the fireplace. The stove expert is collaborating with themotor and fan specialist, ebm-papst Landshut, Germany,to improve the effectiveness of combustion and theconven ience of installation and operation. The result is afresh air blower that is perfectly adapted to the requirementsof state-of-the-art fireplace inserts.Visual appeal and premium engineeringMany different fireplace inserts are available on the market.In each particular case, the material characteristics, manufacturingquality, safety and, not least, a suitable design areof great importance. High-quality fireplace inserts havealways met these requirements. A variety of models, withvariable widths and shapes, in the wood-burning designwith realistic ceramic wood or the river rock fireplacedesign, fulfil many desires (Image 1a + b). The objective ofImage 1b: Fireplace insert with ceramic wood.a product revision was to ensure faster installation andeasy, user-friendly operation. Stove manufacturers rely onmodern technology to improve heating comfort and makeinstallation and maintenance easier.Understanding the nature of gas combustion is the backgroundof all of their efforts. Theoretically, a defined quantityof oxygen is required in order to oxidise, or in otherwords, burn gas completely. If there is too little air (oxygen),carbon does not burn completely and highly toxic, suffo -cative carbon monoxide is produced, moreover, preciousheat is lost. On the other hand, if more air is supplied thanis required, the excess air is heated unnecessarily and theheat is discharged via the chimney or flue. In practice,minimal excess air was found to be the ideal value.Warm gas expands, becomes lighter and rises up thechimney or flue. This creates suction that pulls fresh, coldair from below and keeps the fire going. On older fireplaceinserts, a technician adjusts the exact air volume foroptimum combustion using a restrictor. Since gases, suchas air, are subject to temperature and air pressure fluctu -ations, these conditions inevitably change the mass flowrate of a fixed restrictor, which is adjusted only once. Thus,similar to the Lambda control system for cars with catalyticconverters, an accurate mass determination of fresh air isrequired to optimise height and colour of the flames andheat output.A blower with the right touchVia a controlled blower (Image 2), the actual required airflow can now be controlled independent of technical andphysical variables such as chimney or flue pipe length,intake system, air temperature and air pressure. Air massper unit of time is used as the sole measured value. Forexample, when the air is cold and therefore more dense, aImage 2: NRG 118 gas blower with mass flow sensor.smaller air volume is conveyed than for less dense,warmer fresh air. The new blower operates with a restrictoron the intake side, which creates a laminar fresh air flow.Part of the aligned air current, which has a homogenousspeed, is routed through a bypass and over a semicon -ductor element. The mass flow sensor then determines theactual aspirated air mass. The fan aspirates the air that hasbeen combined into a single air flow again and transports itto the duct leading to the stove (Image 3). The rotor bearingsare lubricated for life and allow maintenance-freeoperation; the aerodynamic air conduction preventsunwanted vortex generation and unwanted operating noisein the fresh air.BypassAirMass flow sensorImage 3: Schematic drawing of the new blower.Laminar flow elementAir2829

Location-independent, ideal oxygen supply without adjustment effort:Centrifugal blower with mass flow sensor for exact air supplyLocation-independent, ideal oxygen supply without adjustment effort:Centrifugal blower with mass flow sensor for exact air supplyDue to its compact design, the blower canbe installed vertically or horizontally inany position (Image 4). For pipe-in-pipesystems (fresh air is aspirated outsidearound the flue pipe), the new systemmakes it possible to readily bridge achimney or flue length of up to 40 mcompared to only approx. 3 to 4 mattainable up until now. Thanks toa built-in, industry-standard inter -face, the smooth-running blowercan be installed at an easilyaccessible location in the ex -haust gas system. The connectionfor data transmission to theburner controller may be up to100 m. The blower controls and,upon request, transmits themass flow actual value, speedand intake air temperature to theburner controller. The burner controllerguarantees the safety of theentire system (Image 5). Dependingon the heat output which isprogrammed via the software, theburner controller outputs the requirementfor the corresponding mass flowto the fuel gas control valve and fresh airblower. An additional safety feature is thecontinuous plausibility comparison betweenthe mass flow signal and the value calculatedfrom the blower speed and air temperaturebased on the characteristic curve of the blower.This ensures optimum air flow within a range ofapprox. 3 – 17 g/s, which corresponds to usable heatoutput of approx. 7 to 15 kW. The robust blower is capableImage 4: Mounting position of the blower.of conveying fresh air of up to 70 °C; temperatures above75 °C trigger the blower to send a warning signal to theburner controller. So, overheating can be counteracted in atimely manner by restricting the burner capacity.The symbiosis of timeless design and modern technologyallows new, better combustion characteristics for homeheating systems as well. With the focus on the correctMass flow set valueBurner controller(BC)Actual value: mass flow,speed, temperatureMass flowcontrolledblowerGas valveIonisationSafety functionShutoff after faultGas quantity set valueMass flow airGasBurnerImage 5: Block diagram of the combustion control system.HeatFlame heightchemical requirements, the mass flow controlled blowerconveys just the air volume that is re quired. The settingsare independent of external factors, saving installation andmaintenance costs. Combined with the gas savings due tooptimised combustion, the enjoy ment of an open firewatching the leaping flames becomes a much more environmentallyresponsible activity.Dipl.-Ing. (FH) Siegbert HartauerSales Project Engineerebm-papst Landshut GmbH3031

Art.-Nr. 40022-7-8811 - SC-02/09-4,0’Printed in Germanyebm-papstMulfingen GmbH & Co. KGebm-papstSt. Georgen GmbH & Co. KGebm-papstLandshut GmbHBachmühle 2D-74673 MulfingenPhone +49 (0) 7938 / 81-0Fax +49 (0) 7938 / 81-110info1@de.ebmpapst.comHermann-Papst-Straße1D-78112 St. GeorgenPhone +49 (0) 7724-81-0Fax +49 (0) 7724-81-1309info2@de.ebmpapst.comHofmark-Aich-Straße 25D-84030 LandshutPhone +49 (0) 871-707-0Fax +49 (0) 871-707-465info3@de.ebmpapst.comwww.ebmpapst.comDies ist der neue Claim von ebm-papst