enhanced refrigeration solutions -...

Enhanced Refrigeration Solutions

[email protected] Director of Marketing, CO2 Business Development

CMPX Show Thursday March 19th ,2014

mailto:[email protected]


Supermarket Commercial HVAC

C-Stores Data Centres

Customer Pains

1. Profitability 2. Precise Temperature 3. Downtime 4. Energy Cost 5. Predictive Maintenance 6. Sustainability 7. Balancing Inventory/Turns 8. Remote Monitoring 9. Consistency of Suppliers 10. Lack of Skilled Workforce 11. Keeping up with Technology 12. Warranty Cost 13. Need To Differentiate 14. Justify Sell Price 15. Top Line Growth

End User Contractor Wholesaler OEM

4

Agenda-Enhanced Refrigeration Solutions

3

2

1 Compressor Protection and Diagnostics New Optimized Refrigeration Scroll Digital Compressor Capacity Modulation

• HVAC • Supermarket • Commercial Refrigeration

Benefits of Floating Head Pressure Benefits of Low Pressure Systems Vs Traditional Set points

4

5

CoreSenseTM Compressor Protection and Diagnostics

CoreSenseTM Technology “New To The Industry”

What It Is: • Compressor As A Sensor • To Monitor And Interpret Compressor

And System Information • Delivers Advanced Protection,

Diagnostics And Communications • Enhances Performance And

Reliability

Why We Did It: • Differentiation – Added Value • Technology With Real Benefits

Discus w/ CoreSense Protection

CoreSense Technology Is Being Rolled Out Across All Of Our Major Product Platforms

Discus w/ CoreSense Diagnostics

Ref Scroll w/ CoreSense Diagnostics

Outdoor Condensing Unit

CoreSense Diagnostics Module

Service Contactor

Indoor Condensing Unit

A/C Scroll w/ CoreSense Communication

ComfortAlert PerformanceAlert

SecureStart™

* Primarily Used In Supermarket Applications

*

9 Emerson Confidential

Compressor Diagnostics Have Impacted Failure Rates & Will Continue To Improve

Discus With CoreSense Diagnostics Warranty Performance

New

Phase 1 • Oil/Motor Protection • Current Diagnostics

Phase 2

• Advanced Motor Protection

• Voltage Diagnostics • Communication

Phase 3 • Future Enhancements

Electronics Evolution

‘05-’06

‘07-’09

0%

5%

10%

15%

20%

25%

30%

35%

40%

Liqu

id R

efri

gera

nt(F

lood

ed S

tart

Or R

unni

ng)

Hea

t(H

i Com

p. R

atio

, Ret

urn

Gas

, etc

.)

Con

tam

inat

ion

Mot

or B

urn

No

Def

ect F

ound

Filename/Presenter-Topic: 3/11/2014

LED Status Indications for Discus

LED Status Indications

• Green ON And Steady No Faults

• Green Flashing Warning

• Yellow Flashing Trip

• Red Flashing Lockout

Slide 10

New Discus III

Improved Reliability with CoreSenseTM Technology Onboard

Ref K5 Has CoreSense Diagnostics For Improved Reliability, Advanced Monitoring, Protection & Communication Capabilities

CoreSense™ Technology Provides Additional Field Information Through Mobile Applications

CoreSense Communication - Options B) Connect to E2

Controller C) Connect To Computer

1. Modify User Adjustable Features

2. Review/Download Compressor History

3. Use As Data Logger

A) External LED On CoreSense

1. Modify User Adjustable Features

2. Review/Download Compressor History

3. Use As Data Logger

1. Multi-color LEDs indicate type of failure

2. Enables quick troubleshooting

CoreSenseTM For R-410A Commercial Scrolls

Delivers Enhanced Reliability On-Board 20-60 HP R-410A Copeland Scroll Compressors ZP236, ZP296, ZP385,ZP485, ZP725

Protection • Scroll And Motor Temperature Diagnostics • Phase Monitor • Short Cycling • Locked Rotor • Fault History Communications • Modbus Protocol

NEW!

Slide 14

Ref K5 Scroll

Current Scroll Delta

LT Efficiency 7.8 6.9 13%

MT Efficiency 16.1 13.9 16%

Sound (dBA) 80 86 6 Weight (lb) 135 221 86

Jan 2012

Next Gen 7-15HP Scroll Delivers Unmatched Energy Efficiency & Reliability

$35K

$40K

$45K

$50K

$55K

$60K

Discus Competitor Recip.

K5 Scroll

Annu

al E

nerg

y C

ost

@ $

0.10

/kW

h +$3,830

-$1,654 Baseline

New Digital L.T. Scroll 7–15 HP with Electronic Vapor Injection

Discharge Temp Sensor

Electronic Vapor Injection

CoreSense and Digital Modulation Control

Oil Fill Port

Oil Sight Glass

Discharge Connection

Suction Connection


7.1

7.4

6.5 6.7 6.9 7.1 7.3 7.5

ZB75KCE ZB76K5E

20/120 EER

15.6

18.9

0.0

5.0

10.0

15.0

20.0

ZB75KCE ZB76K5E

20/70 EER

7.5

7.9

7.2

7.4

7.6

7.8

8.0

ZF33K4E ZF34K5E

-25/70 EER

High Efficiency Performance AHRI & Optimized at Low Condensing

4.4

4.9

4.0 4.2 4.4 4.6 4.8 5.0

ZF33K4E ZF34K5E

-25/105 EER

+ 11%

+ 5%

+ 6%

+21%

6.9

7.3

6.6

6.8

7.0

7.2

7.4

ZF33K4E ZF34K5E

LT Weighted EER

13.9

16.6

12.0 13.0 14.0 15.0 16.0 17.0

ZB75KCE ZB76K5E

MT Weighted EER

Med

ium

Tem

p Lo

w T

emp

+ 6%

+19%

LT Weighted EER = 0.8*(-25/70 EER) + 0.2*(-25/105 EER) MT Weighted EER = 0.8*(20/70 EER) + 0.2*(20/120 EER)

Digital Compressor Technology, Design and Applications Copeland Scroll Digital™,Discus Digital™ and Variable Speed Compressors

Why Modulation?

Precise Load Matching – When supply and demand are largely different

Better Seasonal Efficiency – Reduced Power Consumption & Running Costs – Lower CO2 Emission – Compliance to Minimum Efficiency Regulation

Standards

Improved Comfort – Precise Temperature and Humidity Control

CO2 Emissions

Comfort

System Capacity Strategies – Refrigeration

Single-Compressor Condensing Unit

Even Parallel Rack

Uneven Parallel Rack

Distributed Systems

VFD and Swing Compressor

Digital Discus Capacity Modulation

Modulation Technologies – A/C Tandem / Trio

– Multiple Std On/Off Compressor • Capacity Variation By Switching Compressors On And

Off

Digital – Mechanical Unloading

• Capacity Variation By Loading Or Unloading Scroll Set

Inverter – Variable Speed Compressor Motor

• Capacity Variation By Changing Motor Speed

Scroll Set Profile

Comprises Two Scroll Parts

Fixed Scroll

Orbiting Scroll

24 24

Loaded (1) Full Capacity

1.0 mm Scroll Separation

Unloaded (0) Zero Capacity

Time (sec)

4

20 40 60

20% Capacity

16 4 16 4 16 4 16

80

Percentage Of Full Capacity

Perc

enta

ge O

f Ful

l Pow

er

ZRD, ZPD, ZBD, ZFD

Copeland ScrollTM Digital Compressor Operation (10 to 100% Capacity Modulation)

0%

20%

40%

60%

80%

100%

0% 20% 40% 60% 80% 100%

Digital Compressors Commercial A/C, Process Cooling

System Challenges Changeover / Bypass (COBP)

As Zones get Satisfied in A/C, cold air is re-circulated back to the unit causing Low Suction Pressure and

Control Issues

Digital Benefit in Rooftop Applications Tight Air Temperature Control

– Comfort Improved Humidity Control

– Comfort Tight Supply Air Flow Control

– Increased Efficiency – Possibilities to reduce air flow to Minimum

Reliability Simple No Oil Return issue No risk of resonance associated as Inverter

Competitive Applied Costs

Higher Average Evaporating Temperature – Increased Efficiency

Filename/Presenter-Topic: 3/11/2014 28 Emerson Confidential

Emerson’s Capacity Modulation Solution Precise System Control From 10 to 100%

EC3-D72 Synchronization

Controller

Electronic Valve (10 to 100%)

Digital Scroll (10 to 100%)


Valve/Controller for Digital Applications EC3-D72

Copeland Scroll

0-10V Cooling Demand For EC3-D72

Temperature Sensor

Pharmaceutical Process

End User Benefits • Eliminated Downtime • Production efficiency increased • Product quality; never better • Temperature within +- 0.5C • Humidity within +- 0.5% RH

30

Customer Pain • Downtime due to poor temperature and humidity control

during the manufacturing process of codeine pills • Temperature swings 5 to 6F • Humidity Swings 15 to 20% RH

Execution • 1 Digital Tandem Unit with ZPDT360 • 1 EX6-EC3-D72 kits to control 2 evaporators

Copeland Digital Scroll™ Launch Package,

June 2012

Closed Loop Digital Controller (XC643) for Copeland Digital Compressors

Copeland Discus Digital™

Copeland Scroll Digital™

Digital Scroll Controller for Multi Room

XC643

1 Digital, 1 Fixed

Use of a Copeland Digital™ will maintain a higher average suction pressure in the system.

Converting “Open” to “Closed” Cases

End User Benefits • 60%+ Reduction in Energy (Verified with M & V) • Utilities Rebate • Tight Temperature Control • Improved Product Quality • Increased Shelf Life • Warmer Isles, Increased Dwell Time in Isles

Contractor Benefit • Working on Securing an Additional 160 Stores potential

Customer Pain • High Energy Bills on 36’ of Dairy Case • Large Temperature Swings in Cases • Latent Pain, Product Quality & Shelf Life

Execution • Added Doors to 36’ of Dairy Cases • Replaced 10HP Fixed Capacity compressor with 5HP Copeland Digital Scroll • Added XC634 Digital Scroll Controller

Open

Closed

Digital Compressors For Supermarkets Or Commercial Racks

35

Unloading Range Comparison

0%

20%

40%

60%

80%

100%

Copeland 3D Digital

10%

Capacity

66%

Capacity

Variable

Unloading

up to 90%

33%

Capacity

Increments

40-100%

6 cylinder

2 banks

Typical SH

VS

36

1. Enters Compressor 2. Passes Through Body 3. Into Valve Plate 4. Compressed by Pistons 5. Exits Compressor

Discus Digital Refrigerant Gas Flow

Loaded

Unloader pistons allows suction gas flow into valve plate

Valve assembly routes suction gas above unloader pistons

37

Discus Digital Refrigerant Gas Flow

1. Enters Compressor 2. Passes Through Body 3. 4 Unloader Pistons Block Gas

Before Entering Valve Plate

Unloaded

Unloader pistons block suction gas flow into valve plate

Valve assembly routes discharge gas above unloader pistons

Copeland Discus DigitalTM Continuous Capacity Modulation

From On Copeland Discus Compressors

– 3D - 10%-100% Capacity – 4D (55-100%) & 6D (40-100%)

Applicable On New & Potentially Existing Discus Compressors

Patented Technology

Time Tem

pera

ture

Tightens Temperature Control

Digital Control Module

Time (sec)

10 10 10 10 10 10

0 20 40 60

50% Capacity

System

Needs 50%

Capacity

Here is How

to Deliver

50% Capacity

Not Needed With ISD v2.x

Results In Narrow Operating Temperature Range

Inverter Technology


Copeland Scroll Variable Speed • Compressor (1800 to 7000 rpm)

– 3T (ZPV36), 5T (ZPV60)

– UL Recognized As A Matched Set

• Over-Speed In Heating Improves HSPF • Meets Energy Star EER Requirements • Turndown In Cooling Enhances

Comfort And Improves SEER

Pd (D

isch

arge

Pre

ssur

e)

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5

Ps (Suction Pressure)

0.0

-0.1

0. 0 0. 1 0. 2 0. 3 0. 4 0. 5 0. 6 0. 7 0. 8 0. 9 1. 0 1. 1 1. 2 1. 3 1. 4 1. 5

45 ~ 70s-1

30s-1

25s-1

20s-1

C/R: 7.5

15s-1

C/R: 1 + 0.2

C/R: 2

90s-1

120s-1

60, 125

20, 114

20, 70

60, 137

18, 126

60, 82

60, 150

31, 143

40, 126

13, 121

20, 110 2, 107

-20, 80

-20, 70

-1,118

-10,105

-20,90

65

70

75

80

85

90

95

100

105

110

115

120

125

130

135

140

145

150

155

-25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65

Con

dens

ing

Tem

pera

ture

(F)

Evaporating Temperature (F)

ZPV36K1E-1E9 Operating Envelope: SH20⁰F, SC15⁰F, Amb95⁰F 230Vac Drive Input

1800 rpm, Minimum Speed 2700 rpm, Heating or Cooling Speed 2900 - 4500 rpm, Heating or Cooling Speed 6000 rpm, Heating Only Speed 7000 rpm, Maximum Heating Speed 6000 rpm, 5DegF SH 7000 rpm, 5DegF SH

Emerson Climate Technologies Confidential Emerson Climate Technologies Confidential Emerson Climate Technologies Confidential Emerson Climate Technologies Confidential

49,70

Copeland Digital Scroll™ Launch Package,

R407C

Digital Scroll Operating Envelope

Conventional Supermarket Rack

Newlon – 041130 End User Presentation 43

44

Digital Discus

Medium Temp Rack-Suction Pressure Rack suction pressure range narrows significantly with Digital Discus

Product Degradation

Excessive Operating Costs

Digital Precision

39 p

si

6 ps

i

Digital Discus Activated

Suction Pressure Narrows by 85% to 6 psig

5 Compressor Rack With Discus Digital Activated Compressor Cycling Reduced By 56% With Discus Digital

3DS3R17ML-TFE-A23 (08E03844R)

3DB3R12ML-TFE-A23 (08E01922R)

3DB3R12ML-TFE-A23 (08E03087R)

3DB3R12ML-TFE-A23 (08E03088R)

3DSDR17ML-TFE-A23 (08E03845R)

Digital Retrofit

Before Digital After Digital

Comp 1

Comp 2

Comp 3

Comp 4

Comp 5

Compressor Cycling:

56% Reduction

Floating head


Low Condensing Considerations • Increased Capacity

– Digital Modulation Prevents Excessive Cycling – Electronic Expansion Valve Ensures Precision

Superheat Control Across Entire Capacity Range

• Low Pressure Ratio – Copeland Compressors Approved To Operate At:

• 50°F Min. Cond. Temp. For Medium Temp. Applications*

• 40°F Cond. Temp. For Low Temp. Applications

– Electronic Expansion Valve Operation Not Affected By Low Pressure Differentials

• Flash Gas In Liquid Line

– Adequately Size Expansion Valve To Digest Flash Gas Or Design To Ensure Liquid At Expansion Valve

Compressor Cycling

Digital Installed => 56% Cycle Reduction

25°F

50°F

75°F

100°F

125°F

150°F

-50°F 0°F 50°F

Con

d. T

emp.

Evap. Temp. *Refrigerant Specific

Compressor Operating Envelopes

Med. Temp.

Low Temp.

High Temp.

Benefits of Floating Head Pressure


Low Condensing Introduction

Floating Head Pressure with 70ºF min SCT

Temperature Variation

Condenser TD = 15ºF

40°F

50°F

60°F

70°F

80°F

90°F

100°F

0 4 8 12 16 20 24

Tem

pe

ratu

re

Time (hrs)

Energy Saving Opportunity

Fixed Head Pressure set

at 100ºF

Ambient

Energy saving • Capacity and power input

Capacity and power input at +40°F evaporating temperature

10

11

11.5

12

12.5

13

13.5

85 105 125

Condensing temperature °F

Cap

acity

TO

NS

6

7

8

9

10

11

12

13

14

Pow

er in

put k

W

Q P

Condenser

Compressor

1 lb

Greater Capacity, Less Power Achieved By Reducing Compression Ratio

Low Temperature System

Med Temperature System

High Temperature System

Evap

orat

ing

/ Con

dens

ing

Tem

p

110ºF

70ºF

40ºF

20ºF

0ºF

-20ºF

270 psig 270 psig 270 psig

150 psig 150 psig 150 psig

16 psig

60 psig

85 psig

16 psig

60 psig

85 psig

Floating Head

Floating Head

Floating Head

∆254 psig

∆134 psig

∆210 psig

∆90 psig

∆185 psig

∆65 psig

R-404A System Pressures

System Dynamics

Vancouver, BC 91% of the year < 60°F Ambient

Saskatoon, SK 87% of the year < 60°F Ambient

Calgary, AB 90% of the year < 60°F Ambient

Winnipeg, MB 84% of the year < 60°F Ambient Toronto, ON 80% of the year < 60°F Ambient


Removing Headmaster for VFD

Variable Frequency Drives for 3 phase Motors

Three Phase Motors

0102030405060708090

100

0 10 20 30 40 50 60 70 80 90 100

% Speed

% H

P a

nd

To

rqu

e

HPTorqueFlow

At 80% Speed (Flow), theoretical Power consumption is 50% of rated.

Existing Designs

Benefits of Emerson’s Electronic Valve Gate Port Design

Flow

(cap

acity

)

Stroke / Steps

100%

100%

50%

50% 80%

10%

Emerson EX – Valve

Gate Port Design

Valve Capacity Range Travel Time EX4 = 0.5 - 5T, 750 Steps / 1.5 Seconds EX5 = 1.5 - 14T, 750 Steps / 1.5 Seconds EX6 = 3 - 34T, 750 Steps / 1.5 Seconds EX7 = 9 - 94T, 1,600 Steps / 3.2 Seconds EX8 = 25 - 250T, 2,600 Steps / 5.2 Seconds 8

../../../../../My Videos/Videos/Training/EX8 RMOV0036.wmv

EC3 and EX Valves Superheat Controller and Electronic Valve

Replaces: – Liquid Line Solenoid Valve – TXV – Crankcase Press Regulators

System Challenges: – Wide Load Variations – Floating Head Pressure – Inconsistent Liquid Quality – Large Evap. Performance – Cryogenics (Ultra Low)

9

+35°F Cooler, R-404A (25°F SST)


Energy-Efficient System Electronic Control + Digital Modulation

Conventional System Energy-Efficient Solution

Disable/Remove 1. Head Pressure Control Valve 2. Liquid Line Solenoid Valve 3. Hot Gas Bypass Solenoid Valve 4. Hot Gas Regulator 5. TXV 6. Crankcase Pressure Regulator

Add 1. Electronic Expansion Valve 2. Digital Modulation

1

3

5

1

2

The Energy-Efficient System Enables • Low Condensing Operation • Enhanced System Performance

6

2

4

Low Pressure Drop System Benefits

• Reduce Energy Usage • Precise Temperature Control • Precise Humidity Control • Reduced Defrost Time • Increased System Capacity • Reduce Refrigerant Charge • Reduced Leaks • Reduced Downtime • Complete Capacity Modulation • Improves Profitability • Improved Product Quality • Prevents Floodback with EX when Evaporator Fan Motors burns out

Simplified Efficient Solution

Cold Storage Warehouse takes Advantage of low Ambient Temperatures

Customer Pain • High Energy Bills (108HP of Equipment 4 x 27HP Units) X 2 • 100,000 lb of Turkeys, pull down 4°C down to -25°C. • 72 hours Required to Pull and Hold • Production maxed out

Execution • New Equipment with Copeland Discus III (575V) 27 HP LT. • New Electronic EX Valve on each Evaporator • VFD Condenser fan control down to 60°F SCT Minimum (old system was set for 110°F SCT)

End User Benefits • Calculated Energy Savings $240,000 / year

• Start up Occurred Spring 2012

• Pull Down Time 48 hours ( 33% faster) • Increased Capacity by 33% • Two Months After Opening, Power issue (208V) to the Facility took out all Evaporator Fan Motors….and Rack Cycled off on Low

Pressure rather than Liquid Slugging Compressors • End User is Thrilled with Increased Profitability

Indirect Impact (kg CO2) 50,000 <---Energy x Life x Conversion Factor

Direct Impact (kg CO2) 32,019 <---%Leak x Life x Charge x GWP TEWI (Metric Tons of CO2) 82.0 <--- (Indirect + Direct) x 1 tonne/ 1,000 kg

Environmental Impact

Equivalent to take 16 passenger Vehicles off the road for 1 year

Taking Advantage of Low Ambient

Standard System

Condenser

Compressor

Evaporator

6DP3F93KE

60F Condensing During 50% of the Year

Floating Head System

6DP3F93KE

Double the Energy Efficiency Ratio

62% More Capacity

Enhanced Supermarket Solution

Alarm Resolution

Energy & Maintenance Reports

Setpoint Management

Smart Dispatch

Demand Response

Site Administration


Enhanced C-Store Solution

Alarm Resolution

Energy & Maintenance Reports

Setpoint Management

Smart Dispatch

Demand Response

E2 Controls

Diagnostics Distributed Controls

Variable Speed Drives

Belts & Sheaves

Scroll Compressors

Site Administration


End User Comments after 2 Month Pilot C-Store


HVAC Control

Humidity monitoring & control

Indoor Air Quality monitoring

Refrigeration Condenser

Systems

Power Monitoring / Demand Shed

Interior & Exterior lighting control

Exhaust fan control

Heater control

Refrigeration Control & Temperature Monitoring

Enhanced Restaurant Solution E2 -The core of a comprehensive, integrated site management system, providing intelligent monitoring & control of HVAC, refrigeration, lighting, plus many other devices & systems

Remote interface enables easy integration With Remote Software & Services

Enhance Data Centre Solution - Retrofit

End User Benefits • Excess of 30% in Energy Savings (Calculations) • Remote Adjustment & Monitoring • Centre Can implement at other Data Centers

OEM Wholesaler Contractor End-User

3 2 1

Customer Pain • Active Pain High Energy Cost • Latent Pain Lack of Equipment Connectivity

Execution • Floating Head Strategy – 28 EX valve Kit Opportunity

• Suggested CoreSense for ZR300 • Suggested Control Technique VFD for Cond. Motors • Suggested E2 Controller for Valve, CoreSense and

VFD Connectivity


Using Data Monitored Across Enterprise To Identify Opportunities And Improve Performance C

ritic

al R

ack

Alar

ms

Enterprise-Level Monitoring

Using Store-Level Data Across Enterprise To Improve TCO

Maintenance & Energy Perspective: • Maintenance Savings Via Remote

Troubleshooting • Identify Worst Performing Stores &

Focus Improvement • Establish Benchmark & Best Of Class


[email protected] Director of Marketing, CO2 Business Development

Contractor Business Development Managers [email protected] (Ontario) [email protected] (Quebec/Maritimes) [email protected] (Western Canada)

Application Engineering [email protected] (Manager of Technical Services) [email protected] (Application Services)







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