PRODUCTS > FILTRATION

AIRFLOW OPTIMIZER BOOSTER FAN AND VARIABLE SPEED DRIVE

AIR-FLOW OPTIMIZER

Dryer efficiency depends on sufficient airflow. When infrastructure challenges produce ducts that are restricted or excessively long, back pressure in the ducting increases and dryer efficiency decreases. Airflow Optimizer booster fan and variable speed drive packages are tailored for optimum drying efficiency. We can accommodate any combination of airflows in virtually any backpressure situation.

The ability of a commercial dryer to meet its designed efficiency is limited by its capacity to move air out of the exhaust ducting. Undersized ducting or excessive duct length can create pressure problems at the dryer and lead to decreased dry times by 50% or more in natural gas dryers. Energenics Airflow Optimizer systems are designed to restore the efficiency of the commercial dryer and are configured based on dryer specific ducting conditions. Variable speed controls and a pressure monitoring device are used to modulate system fan speed based on real time conditions of duct airflow. It is common to see dry time efficiency increase by 25% immediately after installation of an Airflow Optimizer System, removing the bottleneck in your laundry operations.

Call customer service at (800) 944-1711 to learn more about our Airflow Optimizer Systems today!

Air-Flow Optimizer | Energenics Corporation

Pressure Transducer

Tube Axial Inline Fan

Variable Frequency Drive

Air-Flow Optimizer Blueprint | Energenics Corporation
Product Support Information

Maintains exhaust system air flow to optimize drying.

FEATURES

  • Maintains Optimal Airflow
  • Fully Automatic Operation After Start-up
  • Controls Fan Operation

BENEFITS

  • Minimize Drying Time
  • No User Input Required
  • Conserves Energy

APPROPRIATE PLACEMENT

  • Air Free Flat
  • Air Free Round
  • Air Free Duct (OPL)
  • Inline Series

HOW IT WORKS

The primary component of the Airflow Optimizer (AFO) system is a pressure sensing transducer that in conjunction with a VFD and booster fan, allows dryers to perform at the manufacturers airflow specifications. By measuring back-pressure at the lint filter, the AFO ensures airflow in the exhaust system is always balanced, even when dryers are cycling on and off in different intervals. The AFO will quickly and automatically adjust the booster fan output to match airflow from the dryers. The system is programmed to monitor continuously for optimal exhaust air balance.

CASE STUDIES

OPTIMIZING UNIQUE VENTING CHALLENGES

A large upscale resort hotel in Southern California has a large laundry with 8 dryers and 2 ironers in the basement exhausting 30 stories to the roof with a booster fan. The issue was variable airflows with different dryers on/off exacerbated by the abnormal ducting necessary by the layout of the hotel. The result was very inefficient drying and finishing because the resulting system back pressure varied by over 4″ W.C. Installing the Air-Flow optimizer compensated for the constantly changing airflow and presently the back-pressure is now .3″ w.c. By eliminating over/under drying cause by varying airflow they now have very consistent production with very high quality.
UPSCALE RESORT IN SOUTHERN CALIFORNIA
A central laundry in Texas was experiencing inordinate transfer holds due to lack of dryer availability. After installing the Air-Flow Optimizer resulting in the elimination of excessive transfer holds the laundry experienced a 33% increase in system productivity. This increase in productivity eliminated the need to utilize one extra day to complete their production requirements. This resulted in savings of over $100,000/yr. operating costs.
CENTRAL LAUNDRY IN TEXAS
A nursing home in the Midwest currently operates with 5 back pressure sensitive dryers. The challenge was their desire to collect lint that bypasses the built-in dryer screens by installing an external lint filter. To avoid excessive back pressure they installed an Air-Flow optimizer to control a booster fan. This system resulted in system backpressure of less than .25″ w.c. Well below the dryers maximum allowable back pressure.
NURSING HOME IN THE MIDWEST
A large laundry with 5 large continuous batch dryers with built-in lint screens required 2-4 hours of labor to maintain and empty lint screens. Having an automated system the customer wanted to fully automate the system with a central self-cleaning lint filter. The lint filter was installed with a booster fan and an Air-Flow Optimizer to compensate for the varying airflows caused by dryers cycling on/off at different times. The result was a system back pressure of .12″ W.C.; well below the dryer manufacturer’s maximum allowable back pressure.
LARGE LAUNDRY WITH 5 LARGE CONTINUOUS BATCH DRYERS AND BUILT-IN LINT SCREENS

    FREQUENTLY ASKED QUESTIONS

    WHEN IS A BOOSTER FAN REQUIRED?

    When the ducting is restricted by length of run or number of elbows to create a backpressure in excess of .5” W.C. A typical installation is a multi-story building or an installation with a long horizontal run. In most cases a length of duct in excess of 50 feet will require a booster fan.

    WHAT TYPE OF FAN IS TYPICAL FOR BOOSTING AIRFLOW WITH A DRYER(S)?

    Usually a belt driven tubeaxial round duct fan is used. A tubeaxial fan will handle dryer lint and also operate at high temperatures created in the drying process.

    WHERE IS THE FAN USUALLY MOUNTED?

    It is normally mounted in close proximity to the downstream side of the lint filter. The fan speed will also have a faster response time with a variable frequency drive equipped application.

    WHAT HAPPENS WHEN A SINGLE SPEED BOOSTER FAN IS ON AND SEVERAL OF THE DRYERS ARE OFF?

    It is essential that the booster fan and dryers are handling matching airflow volumes. An Airflow Optimizer with variable frequency drive will control the booster fan speed to keep the airflow within proper operating parameters. At the very least, a barometric damper should be installed between the filter and the fan if an Airflow Optimizer is not installed.

    WHAT IS THE RESULT OF THE BOOSTER FAN DRAWING MORE THAN THE DRYERS ARE EXHAUSTING?

    If the filter has a lint bag, it will be drawn into the filter. The result will cause the redeposited lint to be pulverized into a powder consistency allowing it to go through the screen.

    SHOULD I USE A BAG OR RIDGED CONTAINER TO STORE THE LINT UNDER THE LINT FILTER?

    It is necessary to use a ridged lint container. Never use a lint bag to store lint when using a booster fan.

    WHY DOESN'T THE FAN ALWAYS RUN WHEN EQUIPPED WITH AN AIRFLOW OPTIMIZER?

    If the backpressure is below the set point, the fan assist is not required and the fan will stay turned off until the set point is reached.

    HITACHI WJ-200 VARIABLE FREQUENCY DRIVE (VFD)

    MY DRIVE IS ALWAYS ON EVEN WHEN THE DRYERS ARE NOT RUNNING WHY?

    Hitachi inverters can run values in the slight negative, further reducing backpressure and also removing condensate from the dryer cylinders while not in operation. In northern climates this is especially useful when outside temperatures are low and nighttime inactivity can result in the cold air returning down the duct into the dryer baskets. This cooling of air produces water and the potential for a delayed startup the following morning.

    IF I DONT WANT THE DRIVE TO RUN ALL NIGHT WHAT CAN I DO?

    Adjust parameter F001 to 55.00; this will change the set point to a slight positive. To access parameter F001 press the ESC key until F001 appears, then press set.

    YASKAWA P-7 VARIABLE FREQUENCY DRIVE (VFD)

    WITH POWER SUPPLIED TO THE DRIVE THREE VALUES APPEAR ON THE DISPLAY WHAT EXACTLY DO THESE NUMBERS MEAN?

    Example Display:

    The upper value should read parameter U1-02, this is the real-time output frequency of the inverter measured 0-60 in Hertz. This should, with multiple dryers running, be fluctuating constantly.

    The middle value should read U1-38, this is the set-point in inches water column at which the drive will initialize. Under normal conditions it should ALWAYS be .12”w.c.

    The bottom value should read U1-24, this is the real-time backpressure in inches water column the dryers are experiencing. Once the value exceeds .12” w.c., the drive will initialize automatically and fluctuate the output in hertz (speeding and slowing the fan) in an effort to maintain a desired backpressure of .12”w.c. If this value is higher than the value shown in U1-38, and the fan is not running, call Energenics for support at 800-944-1711.

    HOW SHOULD THE PRESSURE TUBING BE PLUMBED INTO THE PRESSURE TRANSDUCER?

    The pressure transducer is the small box connected by 3 wires to the drive. The tubing should be run from the intake of the lint collector (high pressure side pre-screen on the filter) into the high port on the transducer without kinks or restrictions. Plumbing it to the low port will produce an inactive drive.

    AFTER REVIEWING THE FIRST TWO FAQ ANSWERS I STILL CANNOT IDENTIFY THE PROBLEM WHAT DO I CHECK NEXT?

    Make sure the pressure tubing has no kinks, cracks, or lint built up inside it, disconnect both ends of the hose and use compressed air to clean the tubing out. Verify the wiring from the transducer matches the drawing shown on the inside of the panel. Also verify there is a jumper wire installed between terminals S1 and SN on model P-7. For model V-1000 the jumper should be between SC and S1. Using a multi-meter, ensure the proper voltage is supplied to the inverter.

    INDUSTRY LEADERS IN LINT MANAGEMENT

    Energenics is widely regarded as a leading player in lint management, having developed over 10,000 commercial dryer lint filters and thousands of indoor air filtration devices. Our product portfolio includes UV light and chemical technologies that are utilized for disinfecting surfaces involved in processing healthcare textiles. Working closely with competent manufacturers and equipment distribution partners, we strive to deliver unparalleled levels of cleanliness while reducing laundry operating costs.

    Call Energenics today to learn more about our Air-Flow Optimizers.

    (800) 944-1711