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Integrating a Saving Energy controller in Existing Air Condition units Case Study

Integrating a Saving Energy controller in Existing Air Condition units Case Study. TLC – miniature T emperature L imit C ontroller. TLC - Temperature Limit Control Unit requirements Fits to any existing A/C (Air Condition) system

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Integrating a Saving Energy controller in Existing Air Condition units Case Study

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  1. Integrating a Saving Energy controller in Existing Air Condition units Case Study

  2. TLC – miniatureTemperature Limit Controller • TLC - Temperature Limit Control • Unit requirements • Fits to any existing A/C (Air Condition) system • Does not require any modification in the existing controller of the A/C • Hidden inside the A/C unit • Enables limits for both Cooling and Heating • Saving Energy will not disturb the users of the A/C • Easy, quick and simple installation

  3. TLC – operation mode T1 – Return Air Temperature sensor T2 – Supply air Temperature sensor Heating Temp. Limit knob Cooling Temp. Limit knob To Compressor Supply 230VAC A/C controller output to compressor line

  4. TLC – Features • Saves energy and electricity costs without disturbing the A/C users • Overriding the energy waste of end-users who select high Heating set-point and low Cooling temperature set-point • Very small unit that fits into any existing A/C system • Very Simple (2 knobs) adjusting • Easy installation – Does not require any external or internal preparations

  5. Test procedure • The test was made along 6 months in 4 different departments • TLC was installed in each A/C on the output line from the control electric board of the A/C to the compressor • 2 Time counters were installed in each A/C • Counter 1 – on the line before the TLC (counting the hours that the A/C controller set the compressor to work) • Counter 2 – on the line after the TLC (counting the hours the compressor is actually working)

  6. Test procedure Counter 1 Counter 2 To A/C compressor From the A/C control box

  7. Results by departments The test showed an average of 40% saving in the working hours of the compressors comparing to A/C units without TLC installed

  8. Savings calculations Air Condition units (window, top, split, mini-central) Total labor hours (yearly) @ plant 2400 Total working hours for 1 A/C (60% of the time) 1440 Average energy consumption of A/C 2.5 KW KW/Hour cost (localy) 13.5 cents A.C operation cost per hour 2.5 * 13.5 = 33.75 cents Total yearly expenses per A/C without TLC 1440 (hours) * 0.3375 cents = 486 US$ Total savings per A/C per year (30% calculation) is 145.80 US$

  9. Summary Total savings for one A/C unit (yearly) 145 US$ Investments costs (TLC + installation) 100 US$ Return of investment within 8 months (100/145 = 0.68) A/C units in plant 7000 Total yearly savings 7000 * 145 US$ = 1015000 US$

  10. Conclusion Adding TLC in all 7000 plants A/C units Will save 1 Million US$ On yearly electricity bills - Which are 5% of the total Electricity bills of the plant

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