Elevator Modernization Case Study

8/19/2019 Elevator Modernization Case Study

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Energy-Efficient Elevator Machines

ThyssenKrupp Elevator Americas

ThyssenKrupp Elevator AMS

Energy Monitoring Program

Technical Analysis Study Report (TASR)

Level III Analysis

SUBMITTED BY

Brad NemethThyssenKrupp Elevator2600 Network Drive, Suite 450Frisco, TX 75034

CUSTOMER

Hyatt Place175 Paoakalani AvenueHonolulu, HI 96815

VERSION: 4.0


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DISCLAIMER

This report is not intended to serve as an engineering design document, but is intendedto provide estimated energy-efficiency savings associated with the proposed project.

The information and recommendation represented in this report have been reviewed for

their technical accuracy and are believed to be reasonable and correct.

ThyssenKrupp Elevator AMS is not liable if the projected estimated savings or economics

are not actually achieved because of varying operating conditions. All savings and

cost estimates are for informational purposes and are not to be construed as a

design document or as guarantees. The customer should independently evaluate the

information presented in this report and in no event will ThyssenKrupp Elevator be held

liable if the customer fails to achieve a specified amount of energy savings, operation of

their facilities, or any incidental or consequential damages of any kind in connection withthis report or the installation of the recommended measures.


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CONTENTS

SECTION 1: OVERVIEW1.1 Project Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2: ENERGY BASICS

2.1 How Elevator Technology Evolved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 How an Elevator Consumes and Regenerates Energy . . . . . . . . . . . . . . . . . . . . 4

2.3 Electricity Billing Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Peak vs. Off-Peak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Energy-Use Analysis Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 3: PROJECT DETAILS

3.1 Starting Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

The Client . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Previously Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Energy-Use Analysis Findings & Recommendations . . . . . . . . . . . . . . . . . . . . . . 8

Current Energy Consumption Baseline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Recommended Energy Reduction Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Estimated Project Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Energy Performance Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overall Project Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17


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1.1 Project Summary

This report provides a case study to demonstrate the key energy-saving components

of an elevator modernization. Hyatt Place is a 20-story hotel with two high-rise

elevators installed in 1974. The previously existing elevators were powered by motor

generators (MG) and DC (direct current) hoist motors controlled by electromechanical

relay controllers. The project consisted of replacing the DC motors with high-efficiency

permanent-magnet hoist machines with regenerative drives and previously existing

relay logic controllers were replaced with ThyssenKrupp TAC 50-04 micro-processor

controllers. This modernization allowed Hyatt Place to improve elevator reliability and

ride quality, while reducing electrical consumption of the elevators by 56 percent.

Overview of Improvement

PREVIOUSLY EXISTINGEQUIPMENT

NEW EQUIPMENT

Machines Geared Gearless

Hoist Motors 20 HP DC Permanent-magnet motor AC(alternating current)

Motor Generators 10 kW - 15 HP DC Removed (no longer necessary)

Controllers Relay Logic ThyssenKrupp TAC 50-04 with smartdestination-based software andregenerative drive technology

Group Controllers Removed (no longer necessary with theTAC 50-04 advanced communicationalgorithms)

Lighting Incandescent LED

Cab Interior Hall Fixtures Dated, worn looking Modern cab and hall fixtures, low-VOC-emitting material

1. OVERVIEW


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// Technical Analysis Study Report // ThyssenKrupp Elevator // 2

2.1 How Elevator Technology Evolved

The following definitions and timelines are for the generalized purpose of identifying existing technologies and available alternatives.

There are multiple generations of hoist motors, hoist machines, drives and controllers available in the industry.

DRIVES & MOTORS

Motor Generators (MG) are traditional hoist systems that consist of a DC hoist motor powered from a DC generator.

DC hoist motors were used because a DC motor has a high starting torque and good speed control. An AC induction

motor turns the DC generator and the generator output is directly connected to the DC hoist motor. This hoist system

is the least energy efficient.

Silicon Controlled Rectifiers (SCR) drives are solid-state devices that can rectify AC power to DC power. SCR drives

represent the next progression from motor generator sets since it became possible to produce DC voltage from an AC

power line. Two common types of SCR drives are a six-pulse and a 12-pulse. The 12-pulse drives reduce distortion

problems on power feed lines.

Pulse Width Modulation (PWM) can be used to control either an AC or DC motor and utilizes several types of power

transistors. ThyssenKrupp Elevator’s PWM 10k drive provides 10,000 pulses, compared to a 6- or 12-pulse SCR.

These transistors are switched on and off rapidly in a technique known as Pulse Width Modulation (PWM).

Variable Voltage Variable Frequency (VVVF) drives eliminate the need for a DC hoist motor and replace it with an AC

motor. VVVF provides many of the same advantageous characteristics of the DC motor, such as smooth acceleration

and deceleration and excellent speed control without the issues related to usability of power.

Regenerative Motors (Regen Motors) produce energy when the motor is in an overhaul condition. In an elevator, this

occurs when the motor is used to brake a descending unit. Until recently, the electricity generated was sent through

a series of resisters that dissipated the energy as heat into the machine room. With the introduction of regenerative

drives, the energy produced can be fed back into the building or power grid. Because the harmonics are purified, there

is no line loss and 100% of the power that is harnessed is usable.

Permanent-Magnet Motors have performance advantages over DC excited-synchronous motors and are becoming

more common in fractional horsepower applications because they are smaller, lighter, more efficient and reliable.

Large industrial motors originally used wound field or rotor magnets. Permanent-magnets have traditionally been used

only on smaller motors because of the difficulty in finding a material capable of retaining a high-strength field. Recent

improvements in material technologies have made it possible to create high-intensity permanent-magnets, allowing

the development of compact, high-power motors without the extra real estate of field coils and excitation means.

2. ENERGY BASICS

OLDEST

NEWEST


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3

Sheave

Ring Gear

Motor Shaft

MACHINERY

Geared Machine

A geared driving machine is one that utilizes a geared-reduction unit between the motor and the drive sheave. The

main advantage of this design is that a less powerful motor can be used to drive it. A geared system, usually designed

to run at 350 feet per minute or less (though they can go faster), sacrifices speed to its gearless counterpart. Geared

systems are often used in slower-moving passenger and freight elevators.

Gearless Machine A gearless driving machine is a direct-drive system in which there is no reduction gear between the motor and the

drive (or hoisting) sheave. That is, the drive sheave is connected directly to the motor and brake. Gearless designs are

used in the world’s tallest structures. They are efficient and used for driving speeds greater than 500 feet per minute.

CONTROLLERS

Electromechanical Relays (EMRs) traditionally have been the components of choice for elevator controllers based on

their price, functional characteristics and availability. EMRs have served effectively in numerous applications, but their

use of mechanical contacts to switch a load subjects contact points to oxidation and breakdown over the life cycle of

an elevator unit. EMRs also display bounce, an undesired condition manifested by a short period of pulsed electrical

current upon mechanical contact, rather than a clean transition from zero to full current.

A group controller is needed with an electromechanical relay. Group controllers allow individual elevators to

communicate, or know what each elevator position is relevant to one another, allowing the controllers to determine

which elevator should answer each hall call. In a group controller, this process is rudimentary – the controller

determines which elevator should answer the call using a rudimentary process where the direction the person wishes

to travel is used to determine which elevator should respond to that request.

Micro-Processors were developed as a result of emergent semiconductor technologies and offer advantages over

their electromechanical counterparts. Technical parameters to consider when selecting either an EMR or micro-

processor controller include service life, reliability, isolation voltage, on resistance (RON), output capacity and package

dimensions. Although each type of relay has its advantages in cost or performance, micro-processor controllershave become the optimal choice in many applications based on their high reliability, long service life, lower power

consumption and smaller package size/footprint relative to EMRs. Advances in semiconductor manufacturing

technologies have also reduced the cost gap between the EMR and micro-processor controller, making the micro-

processor controllers cost effective in a growing number of applications.

With a micro-processor controller installed, group controllers are no longer needed. In the TAC 50-04 controller, TKE

exclusive algorithms provide advanced intelligence to dispatch elevators with improved efficiency. Factors such as

weight, direction and length of travel are all incorporated into the controller calculations. This provides the enhanced

performance as well as eliminating the need for a passive controller and its associated wiring—further reducing overal

environmental impacts.

Previously Existing Geared Machine

OLDEST

OLDER

NEWEST

NEWEST


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2.2 How an Elevator Consumes and Regenerates Energy

When an electric motor accelerates or maintains velocity, it consumes energy. But when this same electric motor brakes or decelerates

a body in motion, the motor becomes a generator of energy. This energy has traditionally been considered a nuisance,

but with the invention of integrated regenerative drives, this “waste” energy is sent back into the electrical grid.

Power is consumed in a traction elevator first, by the

gravitational pull on ascending cabs that are heavier than thedescending counterweight and second, by the gravitational

pull on ascending counterweights when they are heavier than

descending elevator cabs.

Power is generated in a traction elevator first, by the

gravitational pull on descending cabs that are heavier thanthe ascending counterweight and second, by the gravitational

pull on descending counterweights when they are heavier than

ascending elevator cabs.

In the case of power generation, the mechanical energy of the

descending car or counterweight causes the elevator motor to

function as a generator (or re-generator) of electricity.

The elevator also produces electricity when the motor works as

a braking system to decelerate. Conventional elevator systems

dissipate this untapped electricity as waste heat, routing itthrough electrical resistors in the elevator shaft or machine

room, using essentially the same principle as an electric toaster.

This waste heat is not only inefficient, but can raise the ambient

temperatures in elevator machine rooms and often require

additional cooling.

CONSUMING ENERGY GENERATING ENERGY

Cab Weight > Counterweight Cab Weight < CounterweightCab Weight < Counterweight Cab Weight > Counterweight


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2.3 Electricity Billing Factors

PEAK VS. OFF-PEAK

Power consumption is typically represented by kilowatts or kW.

Utility and power distribution companies typically charge by kW,

however, different rates apply to the time of use – peak demandusage versus off-peak usage.

POWER FACTOR

Another element in understanding energy use and distribution

is the power factor or, in simple terms, how much effort it takes

to push electricity through a building or power grid. The power

factor indicates how efficiently a building accepts and uses

electricity.

Power Factor = Active power/Apparent power = kW/kVA

= Active power/(Active Power + Reactive Power)

= kW/(kW + kVAr)

Higher kVAr indicates low power factor and vice versa. In

electrical terms kW, kVA, and kVAr are vectors and must be

summed.

kVA

kVAr

kW

2.4 Energy-Use Analysis Options

Audits can provide baseline data and recommendations for how

to best manage upgrades of elevator components in order to

improve energy efficiency. An organization can often receive tax

incentives or rebates from utility companies if i t can significantlyreduce energy consumption. Not all energy audits are the same

and it is helpful to understand the various levels of audits that are

performed.

An energy audit is the key to a systematic approach to decision-

making regarding energy conservation. The primary function

of this energy audit is to identify all of the energy streams in an

elevator system in order to balance total energy input with energy

use. The four main objectives of an elevator energy audit are as

follows:

1. To establish an energy-consumption baseline

2. To quantify energy usage according to its discrete functions

(e.g. machine, lighting, standby)

3. To validate pre- and post-elevator modernization

4. To identify existing energy-cost reduction opportunities

Elevator energy audits vary in depth, depending on the potential

for energy and cost reductions at a specific site and the project

parameters set by the client.

Though a recognized standard for auditing elevator energyefficiency does not specifically exist, ASHRAE (American Society

of Heating, Refrigerating and Air-Conditioning Engineers)

is recognized as an industry standard for energy audits.

ThyssenKrupp Elevator has adopted the ASHRAE standards for

the energy audits of elevators.

ThyssenKrupp Elevator provides Level I, II, and III audits

depending upon building needs. In order to qualify for tax

incentives and rebates from utility companies, an organization

must get a Level II or III audit.

Completing an energy audit of a facility provides an organization

with customized Energy Conservation Measures (ECM’s) designed

to ensure significant energy savings as well as CO2 emission

reductions.

Power factor is the ratio of true power or watts to apparent power

or volt amps, so the theoretical best value for a power factor

is one (on a scale of zero to one). In an electric power system,

a load with a low power factor draws more current than a load

with a high power factor for the same amount of useful power

transferred. The higher currents increase the energy lost in the

distribution system and require larger wires and other equipment.

Because of the costs of larger equipment and wasted energy,

electrical utilities will usually charge a higher cost to industrial or

commercial customers where there is a low power factor.


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ASHRAE LEVEL I

WALK-THROUGH ANALYSIS/

PRELIMINARY AUDIT

The most basic audit is a Level I audit. It is

also referred to as a simple audit, screening

audit or walk-through audit. It involvesminimal interviews with site personnel,

a brief review of elevator equipment and

other operating data and a walk-through

of the facility. Auditors will identify areas

of significant energy waste or inefficiency.

The data compiled is then used for the

preliminary energy-use analysis and a

report detailing potential energy savings.

This level of detail is adequate to estimate

energy-efficiency projects.

Services:

• Brief survey of the building

• Savings analysis of energy conservation

measures (ECMs)

• Identification of potential capital

improvements meriting further

consideration

ThyssenKrupp Elevator provides an online

tool for estimating energy consumption that

is based upon operating parameters andtraffic patterns of both real and simulated

buildings1. With a minimal amount of

input, the energy can be predicted based

on several assumptions that emulate

conditions consistent with building type,

use and traffic patterns. This energy

calculator estimates the baseline energy

consumption and predicts potential energy

savings from modernization.

The calculations and parameters usedin ThyssenKrupp’s energy calculator

are modeled after actual-use data

within our test facility. It is periodically

cross-referenced with actual energy

measurements from on-site metering

during the pre- and post-audits of similar

elevator modernizations.

ASHRAE LEVEL II

ENERGY SURVEY AND ANALYSIS

A Level II audit includes the preliminary

ASHRAE Level I analysis, but also includes

more detailed building energy usage.

Onsite monitoring of the elevator machineduty cycle affords better estimates for

machine run time versus idle time, which

helps to identify lighting and energy use

patterns. Understanding these energy

patterns enables better management of

energy use.

Average wait times (waiting for an

elevator), average transport times and

traffic patterns are determined. This

information is then used to either optimizethe elevator characteristics (when

technology permits) or suggest overlay

systems, such as smart destination-based

software to improve tenant satisfaction.

Services:

• More extensive building survey (over

many days)

• Breakdown of energy use by machine,

drive, generators, lights, transformers,

exhaust fans, heaters and cooling units• Savings and cost analysis of all energy

conservation measures

• Identification of potential rebate

programs offered through utility and

transmission companies

ASHRAE LEVEL III

DETAILED ANALYSIS OF CAPITAL

INTENSIVE MODIFICATIONS

A Level III audit is also known as a

comprehensive audit, detailed audit or

technical analysis audit. This audit focuseson potential capital-intensive projects and

involves more detailed field-data gathering

and a more rigorous engineering analysis.

It provides detailed project energy usage

and savings calculations with a high level

of confidence.

A Level III audit measures the energy

consumption analysis on the existing

elevator equipment. Existing utility data is

supplemented with sub-metering of majorenergy consuming systems.

Services:

• Attention to capital-intensive projects

• More detailed field analysis

• In-depth discussions with utility

companies

• Submittal of rebate application,

subsequent follow-up

• Pre- and post-energy consumption

metrics with a high level of accuracy

1ThyssenKrupp’s energy calculator is available at: http://www.thyssenkruppelevator.com/energy%20calculator/energy.aspx


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PASSENGERCAR #1

PASSENGERCAR #2

Stops 19 19

Capacity (lbs) 2500 2500

Speed (fpm) 350 350

Average CarLoad

300 lbs 300 lbs

OperatingHours*

10 hours/day5 days/week52 weeks/year

10 hours/day5 days/week52 weeks/year

Estimated DutyCycle*

35% 35%

*Operating hours and estimated duty

cycle data are not available for this

project. Both elevators were out of service

because the entire building was already

under renovation when the elevator

modernization began.

3.1 Starting Point

THE CLIENT

Hyatt Hotels Corp. expanded its presence in Hawaii with the conversion of the Ocean

Resort Hotel Waikiki into the Hyatt Place Waikiki Beach. The 451-room hotel, which is

located at the Diamond Head end of Waikiki, was being renovated and repositioned to

become a 425-room Hyatt Place when the elevator modernization project began.

The Hyatt wanted improved ride performance, improved dispatching, energy efficiency,

increased dependability and an interior cab face lift. Without a costly replacement of

the entire elevator, the Hyatt wanted to make a 30-year-old elevator look, ride and

perform like a brand new elevator.


EQUIPMENT CONDITION

Machines Geared Geared machines were originally usedbecause they require a less powerful motorto drive it, but any time mechanical energyis transferred from a motor shaft through aseries of gears, there is inherent energy loss.

Hoist Motors 20 HP DC A DC hoist motor was originally installed forhigh starting torque and good speed control.

Motor Generators 10 kW - 15 HP DC An AC induction motor was required to turnthe DC generator, which powered the DChoist motor.

Controllers Relay Logic Electromechanical relay controllersrelied upon magnetism between metalcontacts, which means that the mechanicalcomponents wore out over time and tooklonger to operate.

Lighting Incandescent Incandescent bulbs, which weretechnologically advanced at the time ofconstruction, are now well known to be theleast energy-efficient option for lighting.

Cab Interior HallFixtures

Dated, worn looking 30 years of wear and tear made the elevatorcomponents appear unreliable and in need

of maintenance.Elevator Code Not up to code Elevator would stop during a power outage,

leaving passengers stranded until powerwas restored.

PREVIOUSLY EXISTING EQUIPMENT

Year Built: 1974

Number of Floors: 20

Number of Elevators: 2

Line Voltage: 208V

3. PROJECT DETAILS


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3.2 Energy Use Analysis Findings & Recommendations

ThyssenKrupp Elevator provided a Level III energy audit for the Hyatt.

CURRENT ENERGY CONSUMPTION BASELINE

Since the elevator modernization project began after the building renovation was alreadyunderway, the duty cycle and traffic patterns of the previously existing elevators could

not be captured for this study. The figures below are estimates for one run (empty

elevator sent from the bottom to the top floor and then back down).

Energy Consumption Baseline

Lighting 0.72 kWh

Controller* 1.33 kWh

Motor 0.13 kW/run

RECOMMENDED ENERGY REDUCTION PROJECT

As a result of the Level III energy audit, ThyssenKrupp Elevator recommended that

the DC motors be replaced with high-efficiency permanent-magnet hoist machines.

The permanent-magnet motor will increase energy efficiency because high-intensity

permanent-magnets are used instead of drawing from an external electrical source.

Permanent-Magnet Motor

DC Motor

*Included all standby power excluding hoist motion.


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The audit findings also recommended installing regenerative drives to feed the

energy produced directly back into the building. Previously existing controllers were

recommended to be replaced with ThyssenKrupp TAC 50-04 micro-processor controllers

in order to improve ride dispatching, improve energy efficiency, reduce noise and

provide precision acceleration/deceleration and leverage accuracy. ThyssenKrupp

was also able to offer a gearless option for these elevators, which until recently was

unavailable in elevators operating at speeds below 350 fpm. ThyssenKrupp is the only

company currently offering the 2:1 roping that is required to accommodate the more

energy-efficient gearless motor.


RECOMMENDED EQUIPMENT

Machines Geared Gearless

Hoist Motors 20 HP DC Permanent-magnet motor AC

Motor Generators 10 kW - 15 HP DC Removed (no longer necessary)

Controllers Relay Logic ThyssenKrupp TAC 50-04 with smartdestination-based software

Lighting Incandescent LED

Cab Interior Hall Fixtures Dated, worn looking Modern cab and hall fixtures, low-VOC-emitting material

Elevator Code Not up to code Up to code according to equipmentdesign safety compliance and life-safetycompliance standards


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ESTIMATED PROJECT RESULTS

It was estimated that electricity use will result in a 48 percent reduction in electricity costs. Estimates of project electricity savings were

made by utilizing ThyssenKrupp Elevator’s Energy-Cost Analysis:

Previously Existing Drive Type MG

New Drive Type VVVF Regen


NEWEQUIPMENT

Application Type Geared Gearless

Speed (fpm) 350 350

Capacity (lbs) 2500 2500

CWT% (if applicable) 45% 50%

Net Travel (ft) 200 200

Roping (if applicable) 1:1 2:1

# of Cars in Group 2 2

Transformer No Yes

Local Electrical Cost $0.10000 per kW-h

Elevator operating hours per day 10 hours

Elevator operating days per week 5 days

Elevator operating weeks per year 52 weeks

Average load in car 300 lbs

% running duty cycle 35%

Include Power Factor No

Application Data Variable Parameters

ANNUAL COST SAVINGS

PER UNIT

$543PER GROUP

$1,086PERCENTAGE

48%

$500 $1,000 $1,500 $2,000 $2,500

ANNUAL COST

PER GROUP$2,258

PER GROUP$1,172

PER UNIT$1,129

PER UNIT$586

MGVVVF

$0


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3.3 Results

TESTING PROCEDURES

ELITEpro energy-data loggers were used during controlled test runs to measure the

previously existing motor generators against the new permanent-magnet hoist system.

The elevators being tested were servicing the same elevator bank and same number offloors. Elevators were sent from the bottom to the top floor and then back down with a

variety of loads and no intermediate stops. Data was logged at the same sampling rates

for both elevators and measurements of the kVAr and average kW were taken for both

the MG and the new permanent-magnet machines. A review of the data verified that no

anomalies or events skewed the data or introduced uncommon patterns.

ENERGY PERFORMANCE RESULTS

The energy use logged during the test runs is shown below. The permanent-magnet

motor outperformed the MG in all five test runs. The permanent-magnet motor consumed

45 percent to 70 percent less energy than the MG, depending upon the elevator load.

The controller standby energy use was 55.9 percent less with the new TAC 50-04 micro-

processor controller, and the new LED lighting contributed to an 85.9 percent reduction in

lighting energy use.

3.32 Incandescent Lighting vs. LED Lighting per run


NEWEQUIPMENT

LESS ENERGY USED

Lighting 0.724 kWh 0.102 kWh 85.9%

3.31 Relay Logic Controller vs. TAC 50-04 Controller


NEWEQUIPMENT

LESS ENERGY USED

Controller Standby 1.332 kWh 0.588 kWh 55.9%


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3.33 Motor Generator vs. Permanent-Magnet Motor

Average kW per run, 0 lbs (no load)

PM MG

0.05867 0.13367

56.1%

-10

-5

0

5

10

15

20

25

K W

Average kW with 0 lbs

One Cycle (kWh)

COMBINED - MG vs PM

PM MG

0.05233 0.11666

55.1%

-10

-5

0

5

10

15

20

25

K W


One Cycle (kWh)

COMBINED - MG vs PM


Average kW per run, 320 lbs

Motor Generator

Motor Generator

Permanent-Magnet Moto


MG = Motor Generator GearedMachine

PM = Permanent-Magnet MotorGearless Machine




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PM MG

0.04667 0.10033

53.5%

-10

-5

0

5

10

15

20

25

K W


One Cycle (kWh)

COMBINED - MG vs PM

PM MG

0.046 0.08433

45.5%

-10

-5

0

5

10

15

20

25

K W


One Cycle (kWh)

COMBINED - MG vs PM

Motor Generator

Motor Generator



MG = Motor Generator GearedMachinePM = Permanent-Magnet Motor

Gearless Machine




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3.38 Generator vs. Permanent-Magnet Motor

Average kVAr per run, 0 lbs (no load)



PM MG

0.061 0.20433

70.1%

-10

-5

0

5

10

15

20

25

K W


One Cycle (kWh)

COMBINED - MG vs PM

-1

2

3

5

7

9

k V A r

Average kVAr with 0 lbs

COMBINED - MG vs PM

The kVAr measurements reveal yet another way that the modernized equipment can improve the energy efficiency of the building.

The lower kVAr measurement for the new equipment indicates that the new equipment accepts and uses electricity more efficiently.

This is because a lower kVAr indicates a higher power factor, that could result in lower electricity costs in cases where the local

utility company considers the power factor in commercial billing calculations. The data shows that the new permanent-magnet

drive increases the power factor by 8 to 44 percent depending on motor loading conditions, which could generate an additional 10

percent in cost savings.

Motor GeneratorPermanent-Magnet Motor

Motor GeneratorPermanent-Magnet Moto

MG = Motor Generator GearedMachinePM = Permanent-Magnet Motor

Gearless Machine




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OVERALL PROJECT RESULTS

Two factors in the Hyatt modernization project diminished the

actual energy cost savings. Typical 1970’s construction in this

location utilized 208 line voltage, therefore a transformer was

required in order to bring the line voltage up to industry standards.

Energy required to run the transformer diminishes the net energyreduction by about 10 percent. Also, if the local utility company’s

billing calculations utilized an adjusted rate due to lower power

factor, then the Hyatt can realize an additional 10 percent reduction

in energy costs. In any case, it is anticipated that this building will

notice a 50 to 60 percent reduction in energy consumption under

normal operating conditions.

In addition to the reduction in energy use, the cycle time, or the

time it takes to go from the bottom to the top floor and then back

down has improved by 8 seconds (22 percent) with the new

permanent-magnet hoist system. This is due to two main factors– (1) the previously existing MG hoist system could not operate at

the specified 350 fpm due to performance issues, and (2) the new,

solid-state controller allows for improved speed over the traditional

mechanical switches and relays. This improvement in dispatching,

ride time, ride performance and reliability results in improved guest

satisfaction in the newly renovated facility.

Several factors contributed to improved ride performance after

the modernization process was complete. First, vibration in the

elevator was significantly decreased. Vibration is defined as a

variation with time of the magnitude of acceleration, when themagnitude is alternately greater and smaller than a reference

level. Within a moving elevator, vibration is caused by surfaces

and a component vibrating strongly enough to turn them into

a secondary sound source. This vibration is generated by an

elevator moving through the shaft and changes in intensity

during the acceleration, full speed and deceleration elements of

each elevator ride. Apart from this vibration, elevator passengers

are also generally subjected to a high frequency vibration

generated by a primary source vibration through the rotating

drive machinery which is transmitted into the elevator car by the

suspension ropes. The rotating components transmitting vibrationare classified as motors, sheaves, rollers, bearings and gears

which all have differing levels of frequency generation which,

at high rotating speeds, should be dynamically balanced to

reduce unwanted vibration. The ThyssenKrupp Elevator exclusive

geared to gearless conversion improved ride performance to an

industry record of 9 to 12 m-g*. Most elevators utilizing gearedmachines are unable to limit vibration below 15 to 20 m-g. Ride

performance has also improved because the elevators can now

level themselves more precisely at the stopping point of each

floor. This is a common issue for aging elevators, and with

these modernizations, the leveling along with acceleration and

deceleration issues were remedied.

The previously existing machines were noisy and took up a

large amount of space, making it difficult to plan where the

machine rooms were placed in relation to the guest rooms. The

new equipment reduces the noise in the machine room, thusimproving guest satisfaction in the adjacent hotel rooms. The

required amount of space in the room itself was also reduced by

approximately 12 percent, thus providing greater flexibility for

the architects that designed the renovated hotel. The previously

existing equipment also used carbon brushes that contributed to

dust in the machine room. The modernization project eliminated

the carbon dust associated with carbon brushes, reduced the

frequency with which the air filters needed to be replaced and

improved indoor air quality.

The new elevators are also fit with ThyssenKrupp’s signature ULEnvironment listed cab interiors. UL Environment verified that

the materials used in the modernization process were low-VOC-

emitting material compliant with the stringent indoor air quality

standard established by California’s Section 01350 (CA 01350). A

new backup, uninterrupted power supply (UPS) was also installed,

enabling passengers to safely exit the elevator in the event of a

power outage.

Overall, the modernization of the elevator cab and hall fixtures

mean the elevators provide a more peaceful, reliable and safe

ride for the guests and significant savings on energy costs for thebuilding owner.

*Acceleration is normally expressed in terms of milli-g (m-g) or one

thousandth of a “g” (.001 g)


19/22


Modernized Elevator at Hyatt Place Waikiki Beach

Image is a not an exact representation of an elevator product.

Gearless Permanent-Magnet Motorwith VVVF Drive

Counterweight

2:1 Roping


20/22

17

APPENDIX A: PICTURES OF PREVIOUSLY EXISTING EQUIPMENT AND NEW EQUIPMENT

Previously Existing Equipment

Heater bank for waste-energy dissipation Relay logic controllerMechanical floor position controller

Motor generator Geared machine


21/22


TAC 50-04 controller Governor

New Equipment

PM Hoist Machine


22/22

ThyssenKrupp Elevator

P.O. Box 2177, Memphis, TN 38101

Phone (877) 230-0303

thyssenkruppelevator.com

All illustrations and specifications are based on information in effect at time of

publication approval. ThyssenKrupp Elevator reserves the right to change specifications

or design and to discontinue items without prior notice or obligation. Copyright © 2011

ThyssenKrupp Elevator Corporation.

Documents

Elevator Modernization Case Study