FAN EFFICIENCY REGULATION PART I (1632 words)

Fans consume 18% of the electricity sold to commercial and industrial buildings, and 40% of the kwh consumed by
a constant volume HVAC system. The simple payback for higher fan efficiency is often less than two years. That is
why fan system efficiency is a major topic of interest in our industry, and a huge opportunity for industry players to
increase sales and earnings by providing more efficient fans, and by expanding their scope of fan related work.
In 2010, the Air Movement and Control Association (AMCA) introduced Fan Efficiency Grades, which allows
purchasers to compare the peak efficiency performance of different fans models. Fan Efficiency Grades are, like
EER (Energy Efficiency Ratio) or SEER (Seasonal EER) for air conditioners, a figure of merit that is computed at
the highest efficiency peak operating point of the fan a point that is almost never actually occurs in the field. That
is not to diminish the importance of grading fan performance potential, just as the air conditioning industry grades
air conditioner performance potential using EER or SEER ratings. It is important to note, that the standardized full
load conditions defined by EER and integrated part load conditions used in SEER computations are also seldom if
ever experienced in the field.
The greater opportunity for improvement in air conditioning systems is insulation, heat-recovery ventilation and setpoint controls that reduce the demand for cooling. The use of EER ratings does not provide a measure of these other
variables affecting operating efficiency of the building which may be more impactful than the unit EER. Building
designers are encouraged to deal with these issues separately, because they lower the load on the HVAC system, and
allow the desired comfort levels to be achieved with less energy, regardless of SEER level.
The greater opportunity for fan system efficiency is similarly driven by the air-moving system design, and
elimination of efficiency robbing system effects in the ductwork, and at the fan inlet and outlet.
There is another overlooked but important difference between air conditioners and fans related to the operating
efficiency of the system. It is widely accepted that if the air conditioning load is 5 tons, the most efficient unit to
select is a 5-ton unit. Over-sizing air conditioners increases power use, just as oversizing the engine in a car reduces
fuel efficiency. Not so with fans. In fact, there are typically 5 or 6 different fan selections (different fan sizes) that
will work well for every application, each with a different efficiency for the application, and of course, a different
price. Generally, the largest fan selected will use about half the power of the smallest, but of course the larger fan
will cost more and take up more space. So, the selection of the fan size that will be used becomes an important,
impactful decision increasing the fan size reduces fan power dramatically. This is quite different from an air
conditioner. Oversizing the air conditioner increases energy use, while oversizing the fan decreases energy use.
Most outside the fan industry do not appreciate how impactful fan sizing is on efficiency. The paradigm of right
sizing of mechanical equipment often leads designers to do the wrong thing with fans; to use a smaller fan that
consumes as much as double the power, but which lowers the fans initial cost. This is an especially bad trade off
since most fans consume their first cost in power use over just a few months. In other words, fans are not an asset;
they are an energy use liability. And the size of that liability varies inversely with the size of the fan.
Making this even more difficult is that manufacturers will assign this same Fan Efficiency Grade (FEG) to most fan
sizes in a geometrically similar fan line. If the 16 diameter fan has an FEG of 67, so too the 24 fan will be rated at
FEG 67. Both fans could be selected for many applications, yet the larger fan will always use less energy. That is
why the fan efficiency requirements added in the 2013 version of ASHRAE Standard 90.1 include a requirement
that the fan be selected within 15 percentage points of its peak efficiency, in addition to requiring an FEG minimum
rating of 67. It is important to understand, that the restriction on fan selection, requiring that all selections be within
15 percentage points of peak efficiency, has been far more impactful on fan system operating efficiency than the
limitation of peak efficiency above FEG 67.

1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

Thus, the focus on FEG ratings is an unfortunate diversion, since fan selection matters more. That is not to say that
FEG ratings are not important. It is only to say that FEG ratings are far less important than the limits which may be
imposed on fan selection.
In Europe, new standards have been issued which describe how to grade fan + motor + drive efficiency levels, or
Fan Motor Efficiency Grade (FMEG). This metric is similar to FEG, but includes motor and drive losses, adjusted
based on two conditions (use of speed control, and drive design integration). Like FEG, FMEG ratings do not deal
with the greater variable of fan selection and air system design. Both FEG and the wire to air FMEG efficiency
grades are valuable metrics which describe a fans potential, but they divert attention from the larger opportunity to
improve operating efficiency by influencing how fans are selected, and how fan systems are designed.
FAN EFFICIENCY AT THE DESIGN POINT
Fan manufacturers from the Air Movement and Control Association (AMCA) negotiated with Efficiency
Advocates1 to form a consensus agreement supporting a different metric that has been recommended to DOE for
their regulation of commercial and industrial fan efficiency. During 2014, the AMCA committee shifted from FEG
or FMEG plus a 15 point selection window, to a new metric called Fan Efficiency Ratio (later re-named by DOE
as the Fan Energy Index, or FEI) This FEI metric compares the DOE regulated maximum fan input power
(numerator) to the actual fan power at the system design point (denominator). The DOE maximum input power
requirement (DOE calls this the Fan Electrical Power standard, or FEPstd) is determined by a formula:

For fans that normally have no discharge duct, the formula uses static pressure rise and a target static efficiency
which is expected to be around 62%. For fan categories that are normally ducted, the formula will use total pressure
rise and a total efficiency target that is expected to be around 68%. Since this DOE power requirement varies with
flow and pressure, it focuses attention on fan efficiency at the design point, rather than at peak efficiency or any
arbitrary point or points.
Most in our industry realize that installed fans seldom operate at design conditions because system pressure losses
are only estimated.. Fan speed is adjusted at the jobsite, increasing or reducing the power needed to provide the
design airflow levels, overcoming the actual air system resistance encountered. So, the design point used to select
and purchase the fan is not correct, but it is MUCH closer to the actual jobsite conditions than is the peak efficiency
used in FEG and FMEG. Critical to DOE regulation is that the design point generally governs the fan sale.
Today, fan speed is controlled by sheaves and belts or by a variable frequency drive (VFD). The broad
commercialization of VFDs has driven prices down, so fan companies can now supply a vfd for a direct drive fan at
about the same price as a belt drive fan with no VFD.
Of course, increased focus on fan efficiency at design conditions raises the perception of value for commissioning
(to document actual system pressure loss, and fan efficiency) and for performance monitoring that tracks fan
performance and energy use over time. The Internet of Things will eventually make monitoring to support
continuous commissioning practical.
AIR SYSTEM DESIGN & CAPACITY CONTROL MATTER ALSO
Just as insulation and set-point control impact the load on and energy consumed by an air conditioning system, duct
design and component sizing impact the load on and energy consumed by a fan. The efficiency of the air system
design determines the resistance to airflow that the fan must overcome. Fan inlet and outlet conditions are also
impactful, because they can alter the shape of the fan curve and fan power demands.
1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

Fan power varies with the cube of any change in airflow. So, for a given air system and fan, if you cut the flow in
half, you should reduce the fan speed in half and if you do that, energy draw will drop to one-eighth. Most fan
systems are either on or off, but the loads they serve are continuously variable. So, logic would suggest that the
capacity of the fan, the air conditioner, the heating system should also vary rather than running at full capacity
intermittently. In the case of the fan, varying the speed to match the load pays great dividends. (Essentially, the fan
is oversized when running at partial speed oversized fans are more efficient.)
So, variable speed is an attractive option to improve efficiency, if matched with system controls that exploit the
savings possible from running the fan slower. And when variable speed is packaged with a direct drive fan that
exactly meets the design point flow and pressure at the motor synchronous speed, variable speed is priced
comparable to a constant speed belt drive fan.
NEXT ISSUE
Next months installement on fan efficiency will examine the Department of Energy fan regulation recommendation
that grew from 19 full days of negotiation between May and September of 2015. DOE has generally followed
negotiated terms-sheet consensus recommendations. This rule will have a profound impact on commercial and
industrial air system designs the next article will explain the consensus recommendation and how DOE regulation
will impact your practice.
FAN EFFICIENCY REGULATION PART II

(2144 words)

Fans consume about 18% of electricity purchased in commercial and industrial buildings. Most commercial fans
also consume their initial cost in energy expense in less than one year. While fan efficiency varies with aerodynamic
shape, under-sizing fans to reduce first cost has a stronger negative influence on fan efficiency. That is why U.S.
Department of Energy (DOE) is considering a novel approach which would reward right-sizing fans in addition to
improved aerodynamic design.
Last month, CSE published the first part in this series, which explained why the peak based metrics Fan Efficiency
Grade and Fan Motor Efficiency Grade (FEG and FMEG) which are documented in AMCA 205, and ISO 12759
were not chosen by fan manufacturers in their consensus recommendation to the DOE. Under the terms sheet
resulting from a public DOE sponsored ASRAC2 negotiation, the DOE is expected to adopt a new fan efficiency
metric called a Fan Energy Index, or FEI. FEI is the ratio of the maximum power allowed by the DOE Standard to
the actual power of the fan selection at every (any) combination of airflow and pressure rise, rather than at a defined
test point or points (such as peak efficiency used by FEG and FMEG, or some other defined flow and pressure).
The FEI metric, which applies to fans alone and fan/motor or fan/motor/drive combinations, effectively extends the
conventional DOE regulatory approach beyond the fan design to address, motor, transmission, variable speed drive
and fan selection. This new approach will be transformational to model codes and standards for energy efficiency
including ASHRAE 90.1, 189.1, and the International Energy Conservation Code.
This Part II in our series documents the consensus recommendation that we believe will become the DOE rule,
details the proposed efficiency metrics FEP (Fan Electrical Power) and FEI (Fan Energy Index), explains how FEI is
deterministically linked to projected energy savings, and how it can be used in specifications, codes, standards and
utility programs.
Background, Status & Timing of the DOE Fan Efficiency Rule
DOE announced its intention to regulate commercial and industrial fan efficiency on June 30, 2011. Since then, the
Air Movement and Control Association (AMCA) worked to develop a consensus that was acceptable to fan
1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

manufacturers and Efficiency Advocates1. For Efficiency Advocates, the objective was to save as much energy as
possible. For fan manufacturers, the strategic intent became:

1. Drive the market to more efficient fans

2.
Minimize the negative financial impact on small business manufacturers and customers
3. Facilitate prescriptive efficiency rebates that are effective and easy to administer
4. Save as much energy as possible.
Ten AMCA members3 participated in 19 days of meetings from May 5 to September 2, along with 4 efficiency
advocates, 7 HVAC manufacturers (members and staff of the Air Conditioning, Heating and Refrigeration Institute),
and 4 other individuals from NEBB (the National Environmental Balancing Bureau), CTI (Cooling Technology
Institute), NEMA (National Electric Manufacturers Association), and DOE (the Federal Department of Energy). The
final consensus vote showed support for a comprehensive terms sheet from all except two participants. We expect
that the consensus terms sheet will guide DOEs draft of fan efficiency regulation, to be published in 2016. The final
terms sheet is published by DOE at http://www.regulations.gov/#!documentDetail;D=EERE-2013-BT-STD-00060179.
A proposed rule and test procedure is expected early in 2016, and the final rule by year end 2016. The rule will
become mandatory 5 years later. However, DOE will invite manufacturers to use the DOE metric and test standard
sooner, and will accept certifications early (probably in 2017), so the engineers (and utility rebate programs) may
begin to specify DOE certified efficiency levels 2-3 years early.
Regulation & Metric Applies at All Operating Conditions 1-200 bhp
All fans offered for sale at operating conditions that require 1 to nominally 200 fan-shaft horsepower will be covered
by the rule, unless they are on an exclusion list. The terms sheet recommends a long list of exclusions, either
because fan energy is already part of another DOE regulation, the fan application requires a design that
compromises efficiency, or because the fan type is so rarely used that its aggregate energy use is trivial.
The DOE standard will establish a maximum input power (called FEP std, or Fan Electrical-input Power) that varies
with flow and pressure at the fan design point. That means that the regulation applies at an infinite set of conditions
which define the particular design/selection point flows and pressure rises that are offered for sale. The maximum
fan shaft power allowed at operating point i allowed by DOE will be calculated in accordance the following
equation:

1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

Unprecedented, but not a precedent

No other DOE regulation is applied at all conceivable operating conditions. Other rules choose representative test
conditions which provide a fair indicator of the products RELATIVE efficiency during operation.
Unfortunately, as we discussed in Part I of this article series, a fans efficiency does not behave like the efficiency of
other products. Every fan can be both very efficient, and very inefficient, depending on what flow and pressure it
operates at. This renders the traditional regulatory approach ineffective. The DOE regulatory standard will be
applied at any and all operating conditions, so certification of fan performance must also be done at any and all
operating conditions offered for sale in the regulated range. For those outside the fan industry, this may seem like an
unreasonable regulatory burden, but not so for those who make, rate and sell fans. You see, fans are blessed with
well-ordered laws of physics collectively called the fan laws which enable one to run a 20-minute fan test at one
speed, and rate the fan and other larger fans at untested speeds accurately.
So, the peculiar nature of fan efficiency (which can be nearly anything, depending on conditions) comes with the
blessing of fan laws that provide a means to deal with the challenge. Thank God for the gift of fan laws, because
without them, regulating to raise ACTUAL fan operating efficiency would not be practical.
Fan Energy Index (FEI)
While DOE will judge compliance strictly based on FEP (electrical power supplied to the fan assembly), the DOE
test standard will describe a Fan Energy Index as the ratio of the FEP standard (maximum power input allowed, as
described above) over the FEP (actual power input) of the fan at its design point. This ratio is 1.0 or greater for all
compliant fan selections. AMCA expects that FEI ratings will become the most common description of fan
efficiency in the marketplace, since FEI uses this first DOE rule FEP standard as the benchmark to which fan
efficiency will be compared forever. We expect that the DOE regulation will require that FEI ratings must tie to FEP
levels that are certified by the manufacturer to DOE.
Details of the FEI metric are documented in a white paper posted on the AMCA web site at
http://www.amca.org/resources/FER_Whitepaper_single%20pages.pdf. DOEs nomenclature is slightly different
than in the white paper DOE refers to FEI which includes motor and drive losses, while the AMCA paper refers to
Fan Efficiency Ratio (FER) which considers the fan only.

AMCA has recommended that the FEI rating be doubled for any fan whose speed is dynamically varied in response
to a variable load. (Note these words are carefully chosen - AMCA advocates this FEI credit ONLY when the fan is
actually modulated, not when it is simply capable of modulation.) This doubling of the FEI reflects a conservative
estimate of the reduction in annual energy cost of a speed controlled fan. Note that a fan with variable speed must
still comply with the design-point FEP requirements. In other words, the DOE will regulate based on FEP at the
design point only (full speed), but may authorize the use of an inflated FEI in marketing materials and product labels
that benefit from variable speed control.
FEI requirements will also appear in engineer specifications, rebate programs, in stretch codes, and in ASHRAE
standards before th DOE rule goes into effect. Rebate programs are likely to require DOE certification of FEP, and
compliance with the DOE test standard requirements.

1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

Target Efficiency
Efficiency Advocates and AMCA jointly recommended that DOE establish target efficiencies such that the weighted
average non-compliance rate of fan selections which were sold in 2012 is no greater than 25%, and that the noncompliance rate of selections in the following categories does not exceed the values listed below:
a.
b.
c.
d.

Belt Drive Centrifugal Powered Roof Ventilators

Belt Drive Axial Powered Roof Ventilators
Belt Drive In-line Centrifugal & Mixed Flow Fans
Belt Drive Forward Curved Fans

35% of selections
50% of selections
40% of selections
45% of selections

AMCA provided the Lawrence Berkeley National Lab, who analyzed data for the DOE, with a database of 1.3
million fan selections that were sold in 2012. This represented 46% of the American market in the regulated range.
This database enabled analysis of a statistically significant confidential sample of the market.
AMCA also used this database to estimate what target efficiency levels match with the 25% average noncompliance rate, and the higher limits on the least efficient categories described above. The best forecast is that the
target static efficiency for non-ducted fans will be 62% at the fan shaft, and the target total efficiency for ducted fans
will be 68% at the fan shaft.
Note that the flow and pressure constants in the FEP formula (250 cfm and 0.4 pressure differential, respectively)
effectively raise the power input allowed at lower flows and pressures. The flow constant produces a result that is
similar to the Fan Efficiency Grade curves, recognizing that very small fans (and low flows) are less efficient due to
the physics of airflow. Fan Efficiency Grades are detailed in AMCA 205 and ISO 12749. The pressure constant
increases the allowable power at lower pressure levels, recognizing the practical limitation of 0 efficiency at 0
differential pressure. While low pressure fans use less power as they increase in diameter, it is impractical to drive
low pressure fans to become too large. The pressure constant solves this issue.
Another way to think of this a fan running at 0.2 of static pressure will be fan power limited at a level that is 3
times greater than the target efficiency would indicate. (Note that 0.2 + a pressure constant of 0.4 = 0.6, which is 3
times greater than 0.2.) In other words, if the target efficiency in the DOE formula were 63%, the operating
efficiency requirement for this selection at 0.2 would be only 21%. This may seem like an unreasonable gift for
smaller fans and lower pressures, but higher losses at low flows, low pressures, and in small fans are inescapable.
The pressure and flow constants in the FEP formula correctly represent the actual map of efficiency degradation
exhibited by the most efficient aerodynamic fans available, as flows and pressures decline.
Curing a non-compliant selection can be done with either a larger fan, or a more aerodynamic design. (If you think
about this statement, and imagine yourself as a molecule of air running through the fan, a larger diameter wheel
allows you to traverse the gauntlet at a slower speed, with corners more gradual, reducing turbulence. So a larger fan
IS more aerodynamic. Another way to say this is that running air thorough the fan at a slower air-speed creates less
turbulence.) Both a larger fan and a better aerodynamic shape have cost and strategic implications to fan
manufacturers and their customers. The good news is that compliant fans are available in production today, which
means that the marketplace will determine what fan competitors do to boost efficiency, while DOE will dictate the
maximum power allowed, driving engineer specifications to demand higher efficiency, either with a larger fan or a
more aerodynamic shape.
NEXT ISSUE - PART III
The third and final installment in this series will expand our understanding of wire-to-air fan efficiency, and how
non-fan components (motor, transmission, variable speed drive) are incorporated into the DOE regulation. The
article will explain the trade-offs between selection of a more aerodynamic fan shape, a larger diameter fan, and a
1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

more efficient motor, transmission and variable speed drive. We will predict how fan manufacturers will change
their business practices to facilitate growing demand for higher efficiency, and what you can specify to boost fan
efficiency.

FAN EFFICIENCY REGULATION PART III (2685 words plus figures)

The U.S. Department of Energy (DOE) estimates that their Commercial Fan Efficiency rule will save about 7
quadrillion btus of energy. To put that in perspective, America consumes about 100 quads of energy from all
sources, for all uses, 60% of which is turned to waste heat. (See figure 1). The DOE estimates that commercial and
industrial fans consume 1.4 quads, or 18% of commercial/industrial energy use. Fan energy is a big deal - it matters
in the overarching objective to reduce energy waste. Some support this objective to reduce global warming, while
others simply want the consumer to get a fair shake to provide those who have to pay for building energy use with
the lowest life-cycle cost alternatives.

The first two installments in this 3-part series introduced a new DOE efficiency metric (Fan Energy Index, or FEI)
that represents a new approach to efficiency regulation. The underlying maximum Fan Electrical Power (FEP)
results from a formula that varies with flow and pressure. In other words, the DOE efficiency requirement varies
with the fan design conditions that govern its selection and purchase.
1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

In this third installment, we will consider the synergy that exists between the fan, motor, transmission and variable
speed drive, and re-cast the FEI metric as wire-to-air for a driven, controlled fan system. And we will project how
manufacturers and specifiers will alter their practice in response to growing demand for higher efficiency.
Wire to Air
The DOE regulation of fan efficiency will be based on line power feeding the driven fan assembly, compared to the
air-power (cfm* pressure rise) leaving the fan. This approach encourages fan manufacturers to exploit the synergies
between the fan, its motor, the belt (or direct) drive transmission, and a variable speed drive. Synergies take many
forms:
Air flowing over the motor can be used to cool motor windings, but there is no rating standard for
air over motors, because the air-over effects are specific to each fan. A fan manufacturer may
exploit this synergy to improve motor efficiency and lower cost, then certify FEP levels of the
assembly at a variety of design conditions.
Motors can be placed strategically inside the fan inlet to improve fan aerodynamics.
Fans may be customized to deliver any flow and pressure at a motors synchronous speed. This
enables more fans to become direct drive, eliminating belt losses.
Motors, drives and speed controllers all exhibit different efficiencies depending on their design
and the loads they carry. Selecting the right combination of non-fan components to maximize the
fan system efficiency at the actual design point is encouraged by a wire-to-air based regulation.
Default efficiency values will be published by DOE for motors, speed controls and belt drives, so that a fan whose
certification allows any motor or drive to be used can certify wire-to-air efficiency using these default values.
Default motor, transmission and variable speed drive losses are added to the maximum fan shaft power allowed by
DOE. The total is expressed as the wire-to-air FEPstd watts input. DOE rules will judge all fans against this one
standard which includes belt drive and motor losses.
Testing to determine compliance and subsequent certification to DOE may be based on fan shaft power, adjusted
with the same default values for non-fan components DOE will publish in the standard. This approach is expected to
be used when the fan manufacturer does not know what motor or drive will be used with the fan.
Compliance testing and certification may also be based on measurements of a line power input to a fan system that
is offered for sale (fan + motor + transmission + variable speed drive when present).
Finally, the fan manufacturer may choose to offer part or all of a fan system with particular motor(s),
transmission(s), and/or variable speed drive(s), certifying the wire-to-air efficiency of each package offered for sale
using a mix of either default or tested performance of the non-fan components. Use of tested values will generally
boost the efficiency rating of the fan system, but will make the fan manufacturer responsible for efficiency of nonfan components (motor, transmission, variable speed drive if included) that are certified with tested values. Note
that the fan manufacturer does not become responsible for the performance of non-fan components if default values
are used.
That means that a direct drive fan which has no belts (and no belt losses) will have a lower FEP (and a higher FEI)
than a belt drive fan if the manufacturer decides to certify the wire-to-air performance using either default or
tested values. Fan assemblies with motors and VFDs whose tested, certified performance is better than default
values will also raise the energy index of the fan.
Testing/Rating
AMCA 210 has been recommended as the basis of DOEs test standard, allowing a test at any speed that is offered
for sale. Fan laws may be used to rate at other speeds and to rate geometrically similar larger fans, so long as at least
1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

three fan diameters in a geometrically similar fan line are tested. When geometry is not similar, manufacturers may
use rating algorithms called Alternative Efficiency Determination Methods" (AEDMs) which are demonstrated to
be correct via the test of two fans in a fan line rated with the AEDM. The AEDM must predict performance within
5% of the tested value. The manufacturers AEDM remains the confidential property of the fan manufacturer, and
will be revealed to DOE only after a check test failure, and then only under cover of a confidentiality agreement.
Certification
Manufacturers will certify the FEP of their fans in the regulated range (1 to 200 bhp) of flow and pressures offered
for sale, showing that their power input levels are below the maximum allowed by the DOE regulation. This will be
done with a table of values, a curve plot, or (as recommended) selection software. Certified data will be posted on
the DOE web site, and selection software will be linked.
Engineered to Order fans whose performance is not described in a catalog or selection program will be certified
after the fan is shipped, and then only at the design point that was sold.
DOE Surveillance Testing
DOE intends to test fans to affirm manufacturer certified data. DOE will choose fans for testing whenever they wish
for any reason, but DOE is expected to focus their testing on fans where the risk of failure is high. AMCA hopes to
demonstrate to DOE that the risk of failure of AMCA certified products is low. If they are successful, it is logical
that the surveillance risk for AMCA certified products will also be low.
Labeling
DOE will require that certain information appear on a label or nameplate, including FEI and design point flow and
pressure rise when the design point is known. When the design point is not known, a reference web-site address will
appear, where the compliant operating range of the fan can be found.
Distributors
Distributors and manufacturers who sell finished goods from inventory will carry an obligation to either confirm that
their customers design point is within the fans compliant range, or to inform their customer of the fans compliant
range at the time of sale. Documentation of the compliant range will be posted or referenced on the DOE web site.
Embedded Fans
Customers who purchase and embed fans into their equipment (Original Equipment Manufacturers, or OEMs) will
also have compliance responsibilities similar to distributors and other re-sellers. If the OEM specifies the fan design
point flow and pressure when they buy the fan, and the fan will operate within its compliant range, the OEM has no
further obligations. If the OEM purchases fans without specifying the design point, the OEM must then assure that
their customers design point for the fan-bearing unit requires the fan to operate in its compliant range or inform the
customer of their products compliant range of operation.
None of these obligate the OEM to certify to DOE. However, if the OEM purchases fan components and constructs
the fan (or a fan array4), then the OEM becomes the fan manufacturer and must certify the fan performance to DOE.
Note that if the manufacturer purchases fans as part of an array, and assembles the array, the DOE certification can
be handled by the fan manufacturer based on the fan array that was sold. If the fan or fan array cannot be practically
removed from the unit for testing, certification is based on a dimensionally similar fan in an AMCA 210 test set-up.
Fans embedded into DOE regulated equipment will be exempt from the fan rule if the DOE regulatory metric for the
unit that embeds the fan includes the fan energy. Since DOE regulates the efficiency of commercial unitary
1. Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
2.
3.
4.

Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

equipment through 62.5 tons using a metric that includes the supply and condenser fans, these fans are exempt from
the fan rule. But the DOE unitary metric does not include the return or exhaust fans, so they will not be exempt. Grid
connected fans in air handlers, large unitary above 62.5 tons, agricultural equipment, paint booths, etc. will be
covered.
Comparing American to European Fan Efficiency Regulation
European regulation and the current provisions of ASHRAE 90.1 endeavor to reduce fan energy by establishing a
minimum efficiency threshold at the fans peak efficiency. A fan whose peak efficiency is below this threshold is
not allowed on the market. The energy saving proposition is that these non-compliant fans will be replaced by more
efficient designs.
As discussed in the first article of this series, raising peak efficiency does not necessarily mean that the fan will use
less energy. Fans designed to run at low pressure conditions are optimized around those conditions, and not their
peak, so a fan with a higher peak efficiency may have a lower operating efficiency at lower pressures. Further, it
bears reminding that fans are generally purchased by an entity that never pays for the utility/operating cost. So, a
price increase to fund the higher cost of a more efficient fan has an infinite payback to the customer who is making
the purchase decision. In many cases, we would expect this buyer would respond to a higher price by substituting a
smaller diameter, less efficient, lower cost fan.
This is not to say that savings will not happen as a consequence of raising peak based metrics it is only to say that
there is no deterministic linkage between raising peak efficiency, and lowering energy use by fans.
Fan Energy Index (FEI) is indicative of Energy Savings
In contrast, the FEI rating is proportional to savings at the fan design/selection point. An FEI rating of 1.1 means
that the fan will save 10% of the baseline energy allowed by DOE at the design conditions of the fan. If the fans
FEP (Fan Electrical Power) is 9 kilowatts, and its FEI is 1.1, the DOE standard is 9.9 (because 9.9/9.0 = 1.1), and
the savings in operation relative to the DOE standard is 0.9 kw at the design point, or 10% of the 9 kw FEP. This is
not a guess its a certainty that is certified to DOE.
This makes FEI ratings much more relevant to building occupants who are paying the utility bill, and to those who
reasonably expect savings from the investment they have made in higher efficiency.
DOE Rule will maximize savings from re-design investments
In other rules, manufacturers invest to replace their least efficient models, regardless of the volume they sell or
savings that will be generated or they drop models from the market and cede the space to more efficient designs
from competitors. Product models that are above the DOE threshold are unlikely to receive investment to boost
efficiency there is no need.
This DOE Fan rule will be quite different, in that it will not cause ANY fan to be forced off the market, since every
fan can be sufficiently efficient at the right conditions to exceed the DOE limit. However, fans that have poor
aerodynamics will offer for sale a smaller envelope of compliance to DOE standards. (See figure 2).

1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

Figure 2.

Compliance Range Depiction on a Fan Curve. Source: Greenheck

More aerodynamic fans will enjoy a larger compliance envelope. But even the most efficient fan will be limited in
its compliant application range. Every fan will be non-compliant in some range of operation. (See Figure 2). It is
instructive to imagine how a non-compliant selection will be resolved. Competitor A, whose fan becomes noncompliant, has the option of selling a larger diameter fan. Competitor B, whose fan is more aerodynamic, can offer a
smaller, potentially cheaper fan. Presumably, the customer will prefer the lower priced alternative, which is the more
aerodynamically shaped, smaller diameter fan.
This competitive scenario occurs near the compliant envelope of EVERY fan, regardless of how aerodynamic the
fan is. Consequently, a manufacturer who chooses to improve aerodynamic shape will be rewarded with a larger
compliant selection range, and the ability to sell a smaller diameter (presumably lower cost) fan.
Where do you invest to improve efficiency? Every fan is a candidate for re-design to improve efficiency, and the top
priority for investment will be where the greatest number of inefficient selections are made. Investment is therefore
encouraged by the regulation where the greatest savings will be generated at the fan selection/design point,
maximizing the benefit (in terms of savings generated) from the limited capital available for this kind of investment.
More bang for the buck. More savings. A better outcome.
Fan System Synergies will be exploited
Since the DOE rule is based on the efficiency of a driven fan (wire-to-air), manufacturers may expand the
compliant range of their fan by certifying a package that includes a particular motor, transmission and variable speed
drive if these non-fan components are more efficient than the DOE default values, or if their packaging into the fan
improves the aerodynamic performance of the assembly. An expanded compliant range means a higher FEI level,
and at the fringes of compliance, a smaller diameter, lower cost fan.
Fan manufacturers can be expected to offer DOE-certified fan systems for this reason, and to fully exploit the
synergies that arise only when the fan, motor, transmission and variable speed drive are considered as a package.
Customers may choose to buy these optimized packages, or to buy the fan alone with a lower efficiency rating or
larger diameter.
Recommended Use in Specifications, Codes, Standards, Rebates

1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.

It should be axiomatic that if FEI ratings are proportional to savings in operation, this metric should be attractive for
use in fan specifications, codes, standards and efficiency incentive programs. Fan manufacturers will be working
with ASHRAE committees, code authorities and model rebate developers to encourage use of the new DOE metric
Manufacturers will also engage to fully inform design engineers regarding the new rule, how to specify FEI, and to
consider new more efficient designs.
Fan energy is a big deal there is lots of energy used (18% of commercial and industrial electricity), with
tremendous savings potential. Fan efficiency improvements are indeed low hanging fruit that can be harvested by
simply specifying FEI levels at or above the DOE minimum, generating savings that are predictable. In general, the
higher initial cost of higher efficiency will be paid back very quickly (in less than 2 years, often in less than one).
Folks worked hard to develop consensus positions that supported the intent of this DOE rulemaking and because
that was true, the DOE rule is expected to generate impressive savings that maximize the favorable impact of
efficiency investments made by manufacturers and customers.

1.
2.
3.
4.

Efficiency Advocates include the National Resource Defense Council, The American Council for an Energy Efficient Economy, the
Appliance Standards Awareness Project, the Northeast Energy Efficiency Association, Southern California Utilities, and others
ASRAC is an acronym for the Appliance Standards Rulemaking Federal Advisory Committee, which acts like a board of directors
authorizing working groups to negotiate rules and test standards, whose recommendations are then endorsed by ASRAC.
AMCA members participating in the DOE Fan Working Group are, New York Blower (Chair), Twin City Fan-Clarage (Co-chair)
Greenheck, Carnes, ebm Papst, Howden, Acoustiflo, Berner, Trane, AMCA, AGS Consulting.
A fan array is a group of fans drawing from a common plenum, discharging into a common plenum. Condenser fans are not covered
by his definition, because they discharge to atmosphere, not a plenum.