Condensation Energy Modules of BETA type Page 1 of 19
Energy module of BETA type is a compact and condensation air heating appliance equipped with wide modulating gas burner. Our latest technology design is patented P.389021 dated on 11.09.2009. Energy module installed inside HVAC units Energy module installed inside HVAC units with mineral wool insulated sections with foam insulation sections Regardless its heating power, each energy module of BETA type performs in modulating way. The burners used in our technology are the appliances of premixing type. They are equipped with special composite heads made by BEKAERT company. Burners, heat exchangers as well as the basic ICS controllers have been designed and put together into technology that has to produce heat for any HVAC and AHU units in the most efficient and the safest way. The standard energy module technology designed for HVAC units equipped with the fans of variable air flow, guarantees the best performance of the individual energy module between 100% to min. 30% of the HVAC unit fan air flow. It is achieved by means of using the so-called dynamic control (DC) of the gas burner. DC automatically changes the burner power that depends on the momentary air flow that is measured by the air flow detector (AFD) towards the set temperature inside the ventilated room in relation with the external temperature. Depending on the model. the standard TDR Turn-down-ratio of a single energy module is generally 10 : 1. Another words, the appliance modulates its heating power from 10% upto 100%. The safety and functioning method of DC system was checked and tested at the Laboratories of Oil and Gas Institute (INiG of Krakow) under the Innovation Program of European Union report No. 4723A112. The same laboratory verified the efficiency of the condensation energy modules. The technology reaches the highest efficiency of 105% while working below 50% or 70%, of tested appliance s power, depending on the model. The efficiency of the energy module full power is 93% or 96%, depending on the model. The reference tests were carried out on energy modules of 115 kw and 150 kw power report dated on 18.03.2013. Page 2 of 19
That drives to the conclusion that energy module technology is one of the best possible air heating solution especially during the so-called transition periods (autumn/winter and winter/spring) or generally during the mild winter, when the heat requirements drop below 50% of nominal heating power of the installation. At that time, the widely modulating gas burners will change their power in a smooth way and the energy modules will gain the additional heat from the flue gas and the air used for the gas burning process. The appliances will perform in full condensation with the efficiency above 100%. Comparing the condensation energy modules of BETA type with composite head premixing burners to the standard heating sections with low modulating, boiler burners as far as the fuel consumption is concerned, we may say that the energy modules consume from 15 to 40% of gas less than the standard air heaters. burner special cover Energy module of BETA type split version Burner standard cover Gas burners of energy modules of BETA type Page 3 of 19
Energy modules are manufactured in both, RIGHT air flow and LEFT air flow version depending on the version of Air Handlin unit in which they will be installed: RIGHT air flow direction LEFT air flow direction Page 4 of 19
In any installation where the technological aspects require continuous performance of the heat source of the HVAC unit regardless the external temperature level, it is recommended to apply the highly efficient energy modules units. The unit o 2 energy modules is the most frequent application suitable for this purpose. The modulating gas burners of energy modules guarantee smooth control of the heating power with TDR Turn-down-ratio generally at 20 : 1. It means that the working field of the unit starts from 5% and ends up at 100% of the total power of the machine. The huge TDR values have direct influence on the heating comfort level and on the savings of the fuel consumptions. The second factor is additionally influenced by the special control algorithm that is always applied as the standard solution to the ICS basic controller: Algorithm of controlling 2 energy modules unit control class of BETA-ZM-Plus type: 1. The first energy module starts up and continues working until reaching 50 70% of its power. Values between 50% to 70% are the set parameters. When the power demand exceeds the set parameter, 2. the controller starts up the second burner making it work between 10 to max 40 50% of its nominal power. 3. Both the energy modules work together keeping their power levels below half of their nominal power. The energy modules condensate and gain the additional heat from the flue gas and the air used for the burning process. It is their most efficient performance reaching above 100%. 4. In case the higher power is needed, both energy modules continue upto their maximum heating power. B Width L Length 2 Energy Modules Unit of ZM-BETA type Basic dimensions of the appliance Page 5 of 19
Comparing the condensation energy modules units of ZM-BETA type with composite head premixing burners to the standard heating sections with narrow modulation, boiler burners as far as the fuel consumption is concerned, we observe that the energy modules units consume from 20 to even 50% of gas less than the standard air heaters. From the earliest stage of design the energy modules as well as the energy modules units were foreseen to be installed inside empty sections of any of the HVAC or Air Handling units: Basic dimensions of the single appliance of BETA type installed inside the HVAC units L Length B Width Page 6 of 19
In addition to the built-in application, the energy module can be also applied as an individual heating section of BETA-O type fixed inside its own casing. It is usually used as the last section of the HVAC unit with a short tunnel connection: Energy Modules of BETA-O type inside their own casings The most frequent applications of energy module in BETA-O version: 1. Energy module in BETA-O version is usually applied to the HVAC installation of the place limits where the dimensions of the air handling unit decide. In this case, the module inside its own casing may be situated in any place of the main ventilation duct however before any further air distribution lines. In some situations, it can be also installed just after the air handling unit. The minimum safety distance between the unit and the energy module has to be kept. It is usually between 500 mm and 2000 mm depending on the air volume of the HVAC unit and the heating power of the energy module. The said distance is to protect heat sensitive elements of the unit from the heat radiation of the energy module combustion chamber. Ignoring the distance may cause the overheating problems but these may only appear in case of failure of power supply. That slows the HVAC unit s fans that become unable to cool down the energy module. There are no such problems during the usual working mode as the HVAC fans have to be assisted by the fan coasting system that keeps them running after the burner is switched-off. 2. It is also used in the already existing HVAC installation as the result of: a. heat deficiency caused by the extension of the existing project whose water boiler house is too small to provide the additional heat to water heating sections installed inside the existing HVAC units. In this case, the energy module with its gas burner usually becomes the secondary source of heat. The module either starts when the maximum power of the water section is not enough or both appliances work together in the so-called economic mode. b. combination of heat pumps units with gas heating source. The energy module takes over the functioning in low temperature conditions which have negative influence on the efficient performance of the pumps. Both technologies may also work together in the so-called economic mode. Page 7 of 19
c. economic calculation that makes the user replace the existing electric heaters of ca. 20 kw power and more. This situation appears frequently in the regions where gas running costs are much smaller than electricity bills. d. problems in fixing and repairing of the existing gas air heaters installed inside HVAC units reasonable long time ago. That happens either when the production of already installed models of appliances seized up or the spare parts and worn up units are not possible to be reached on the local market. Both, energy modules of BETA type designed to be installed inside the HVAC units as well as BETA-O type fixed inside their own casings, are always equipped with elements, units and systems that are characteristic for our patented technology whose task is to provide heat for any kind of air handling units in the most efficient, safe and economical way. The energy module technology consists of: 1. combustion chamber, 2. highly efficient, condensing heat exchanger combined with the chamber all along its length, 3. gas burner equipped with the composite head dedicated to operate either with ICS 0-10V basic or ICS HACT main controller. 4. the ICS 0-10 V basic or ICS HACT main controller. The first one controls the energy module and modulates the burner whereas the second one controls the complete, multi-section HVAC unit, 5. air flow detector, 6. double thermostatic system with the additional temperature sensors placed within energy module space, 7. FGTMS flue gas temperature measuring system directly combined with overheating protection and burner dynamic control systems. The BETA-O with its own casing is additionally equipped with: 8. thermally insulated module casing with inspection door closing the gas burner section. There is a place foreseen for a by-pass air dumper installation inside the casing in case the HVAC unit air flow is bigger than the energy module standard air output, 9. connection flanges fixed on both inlet and outlet of the air side, 10. energy module base in a form of 4-leg-postument with the fixing holes. In some energy module of BETA and energy modules units of ZM-BETA type one can also find some special applications that are offered to some of the HVAC units manufacturers. The additional applications are know as GEA Standard and they consist of: 11. by-pass air dumper automatic control unit, 12. ASBSP Automatic System of Burner Starting Power of the energy module gas burner The GEA Standard expression appeared after the energy modules equipped with the above applications were installed, started-up and successfully run at 3M projects in Wroclaw (PL). Page 8 of 19
Energy module inside its own casing: Air inlet to the energy module Backside of the module - flanges Air outlet of the energy module Gas burner behind inspection door Open burner compartment, ICS controls, by-pass drive Front side of the module, flue gas outlet and condense drain Page 9 of 19
Basic parameters of BETA type energy modules: Energy module Power Power Dimensions in mm Weight AC supply 230V 50 Hz Model BETA min. kw max kw Height H Width B Length L Gas connection Flue gas outlet in kg Max current consumption IS020BETA 1,5 20 350 865 1040 ¾ 80 85 380 W IS025BETA 2 25 350 865 1040 ¾ 80 87 380 W IS032BETA 3 35 350 865 1040 ¾ 80 89 380 W IS040BETA 3,5 45 350 865 1040 ¾ 80 94 380 W IS050BETA 4,5 55 485 865 1040 ¾ 100 110 420 W IS060BETA 5,5 68 485 865 1040 ¾ 100 115 420 W IS070BETA 6,5 78 485 865 1040 ¾ 100 120 420 W IS080BETA 7,5 88 485 1080 1040 ¾ 100 125 450 W IS090BETA 8 98 485 1080 1040 ¾ 100 130 450 W IS100BETA 8,5 150 485 1080 1040 ¾ 100 135 450 W IS120BETA 10 132 615 1240 1120 1 100 175 480 W IS130BETA 11 145 615 1240 1120 1 100 180 480 W IS150BETA 12 160 615 1240 1120 1 100 185 480 W IS170BETA 14 185 750 1390 1120 1 130 242 550 W IS200BETA 16 210 750 1390 1120 1 130 248 550W Attention! The height values of the energy module concerns the appliances without by-pass system. They may vary depending on the air flow volume passing through the energy module section. The same concerns also weights. Page 10 of 19
Basic parameters of ZM-BETA type energy modules units: Condensation Energy Modules of BETA type EM Unit Power Power Dimensions in mm Weight AC supply 230V 50 Hz Model ZM-BETA min. kw max kw Height H Width B Length L Gas connection Flue gas outlet in kg Max current consumption ZM070BETA 3 78 700 865 1040 2 x ¾ 2 x 80 190 2 x 380 W ZM100BETA 5 110 970 865 1040 2 x ¾ 2 x 100 220 2 x 420 W ZM150BETA 7 156 970 865 1040 2 x ¾ 2 x 100 247 2 x 420 W ZM200BETA 9 230 970 1080 1040 2 x ¾ 2 x 100 318 2 x 450 W ZM300BETA 13 320 1230 1240 1120 2 x 1 2 x 100 390 2 x 480 W ZM400BETA 19 420 1500 1390 1120 2 x 1 2 x 130 470 2 x 550 W Energy Modules Unit installed inside HVAC unit empty sections Total heating power - 156 kw Page 11 of 19
ZM-BETA Energy Module Units - 3M Installation in Wroclaw: Condensation Energy Modules of BETA type CAIRplus HVAC Units manufactured by GEA Installation Contractor - TKT ENGINEERING of Wroclaw Page 12 of 19
Energy modules controllers: Basic ICS0321 (0-10V) or 0921 (0-10V) controller together with running program controls the modulation of the gas burner and moves smoothly the air dumper of the by-pass system. Additionally, there are certain ON/OFF signals that may control switching on and off of some auxiliary equipment such as the extraction fans or air destratifiers. The controller contains the 2-stage overheating protection system with dynamic modulation control of the gas burner: 1st stage an electronic control of the burner heating power that automatically changes in relation with the air flow volume through the heat exchanger section. Implementation of this solution was based on the users suggestions. When the air filter gets more and more dirty there is less and less air to cool down the hot surfaces of energy module. In the past, such situation usually ended up in the breakdown of energy module and the HVAC unit. Now, the system slowly limits the power of the burner proportionally to the decrease of the air flow. If the installation is connected to BMS or other monitoring systems the decrease of the air flow as well as the power limits of the burner will be signaled to the user. If there are no any monitoring systems in the installation, the slow decrease of the temperature inside the ventilated room will be surely noticed by the occupants of the room or by the running crew of the installation. Such a behavior of machines is to make the responsible person go and check the situation and immediately change the dirty air filters. The system will be going down with the heating power until the so-called safety level of minimum air flow able to cool down the energy module is finally reached. At that moment the controller activates: 2nd stage of the system that consists of the mechanical and electronic thermostatic group. The limit thermostat shuts off the burner of the energy module. Parallel to his action, the fan coasting system upholds its functioning until the module is safely cooled down. If the energy module is accompanied by the by-pass system controlled automatically, the air dumper will also start closing the air passage in order to drive as much air as possible directly to the heat exchanger section in order to increase the cooling capacity. Main ICS0321-HACT or 0921-HACT Controller together with running program, contains the identical functions as the basic controller plus additional signals to run and monitor performance of multi-section HVAC unit in any configuration applied to the modern HVAC technology on the European markets. After the process elements and units such as temperature and pressure sensors, electric drives of the air dumpers, mixing valves drives, frequency actuators of fans and rotary exchangers are connected to the ICS-HACT controller it will offer the full control of the complete HVAC unit equipped with the gas energy module. The controller will monitor the phases of operation enabling the user to set the timeand temperature parameters in 9 daily intervals, different for the each day of the week. The main controller is always supplied with the remote manipulator that helps the user with easy and remote monitoring of the installation operation phases as well as setting the time-and temperature parameters in 9 daily intervals, different for the each day of the week. Any of our ICS controllers provide the possibility of communication with the BMS monitoring systems by communication protocols of MODBUS ASCII and MODBUS RTU origin via RS485 connection. 500 meters is the maximum length of the twisted-4-pair UTP computer cable that connects the manipulator to the ICS controller fixed on the HVAC unit. Page 13 of 19
Other, additional functions of ICS controllers: Condensation Energy Modules of BETA type automatic control of the air by-pass system - ICS 0-10V basic controller. Installation requires the 0-10 V electric drive to be mounted on the by-pass air dumper. If the air flow of the HVAC fan is bigger than the standard air output of the energy module the by-pass has to be introduced to the installation in order to let some part of the air pass over the energy module section. In order to reach the optimum performance efficiency of the heating appliance the set point of the by-pass aperture has to be regulated quite precisely during the start-up and regulation procedures. However, when there is no need for the air heating the controller opens the air dumper and sets it in its fully OPEN position in order to let the whole air pass through all possible apertures. Fully open position of the by-pass section makes the air pressure drop decrease. According to some users of this particular application, this function has its influence on the electric energy savings, especially when the installation consists of many HVAC units with gas energy modules. CTP electronic control of the air mixing chamber ICS HACT main controller. Installation requires the 0-10 V electric drive or drives mounted on the air dumper or dumpers of the mixing chamber. CTP stands for Chosen Temperature Priority. Its main task is to control the air dumpers of the mixing chamber in an automatic way. The user chooses the reference level of temperature of the air (lower or higher) for the automatic settings of the mixing chamber. During the heating season, the set temperature inside the ventilated room is the set point for mixing chamber operation. At that time, the air mixing chamber works mainly on the already heated, internal air with an appropriate amount of the fresh air for ventilation, automatically added. In summer time it is quite opposite. The fully fresh external air temperature or the already cooled down internal temperature becomes the set (chosen) temperature that governs the automatic opening and closing of the mixing chamber. Heating comfort level. This expression has been mentioned several times in here therefore it needs a few words of explanation. There are many definitions of heating comfort. The simplest one that may refer to the designed nature of our technology describes it as the minimum possible amount of shut-offs of the energy module s burner after reaching the set temperature inside the ventilated room. This has to keep the air flow to that room on the same, uniform level regardless the external temperature. The users of energy module technology as well as the users of other heating solutions installed inside the HVAC units usually recognize the following levels of the heating comfort: 1. Low level of heating comfort the minimum power of the heating appliance enables reaching the t temperature rise on the level between 10 to 8 C for the appropriate air flow of the HVAC fan. In this case, the temperature of the air directed to the room my drop from 10 to 13 C or even more after the burner shuts-off and the HVAC fan cools down the heat exchanger of the air heater. It usually refers to the low and medium efficiency air heaters equipped with 1 and 2 stage burners as well as the modulation boiler gas burners of 3 : 1 TDR Turn-down-ratio. Page 14 of 19
2. Medium level of heating comfort the minimum power of the heating appliance enables reaching the t temperature rise on the level between 8 to 5 C for the appropriate air flow of the HVAC fan. In this case, the temperature of the air directed to the room may drop from 8 to 10 C after the burner shuts-off and the HVAC fan cools down the heat exchanger of the air heater. It usually refers to the medium efficiency air heaters equipped with the modulation boiler gas burners of 3 : 1 and even 5 : 1 TDR Turn-down-ratio. 3. High level of heating comfort the minimum power of the heating appliance enables reaching the t temperature rise on the level of 3 C and below for the appropriate air flow of the HVAC fan. In this case, the temperature level is more or less uniform. The burner shuts-off when there is no need for heating. It usually refers to the high efficiency condensation air heaters equipped with the modulation premix type gas burners with at least 10 : 1 TDR Turn-down-ratio. 4. Optimum level of heating comfort - the minimum power of the heating appliance enables reaching the t temperature rise on the level of 2 C and below for the appropriate air flow of the HVAC fan. In this case, the temperature level is uniform regardless the external temperature. The burner shuts-off when there is no need for heating. It usually refers to the high efficiency condensation air heaters equipped with the modulation premix type gas burners with at least 12 : 1 TDR Turn-down-ratio of single machine and at least 20 : 1 TDR Turn-down-ratio of a unit of 2 energy modules. Nowadays, the definition of optimum level is applied not only to the heating effect but also to cooling performance of the HVAC unit equipped with the air mixing chamber. In both cases it is the way of controlling the mixing chamber that has the direct influence on the highest heating and cooling effects. In our technology it is achieved by the application of CTP system installed in our ICS HACT main controller that is responsible for multi-section HVAC unit performance mentioned on page 14. Apart from the stable temperature of the air during the heating seasons as well as in the summer time the word optimum requires something more extra and that particular technology is able to offer it to the final users. It is the significant energy cost saving that always appear in properly designed and implemented installations. Page 15 of 19
Condensation Energy Modules type BETA inside CAIRPlus HVAC units manufactured by GEA 3M Installation in Wroclaw (PL) Page 16 of 19
Condensation Energy Modules type BETA inside SILVER HVAC units manufactured by SWEGON Fire Arms Manufacturers in Radom (PL) Page 17 of 19
Condensation Energy Modules type BETA inside VENTUS HVAC units manufactured by VTS TRW Breaking Systems in Gliwice (PL) Page 18 of 19
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