Utilizing Digital Retrofits to Achieve Capacity ModulationE360 Webinar • September 26, 2017

Chris RaffelLead Application EngineerEmerson

Speaker

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Chris RaffelLead Application EngineerEmerson

Chris Raffel has spent his entire 33-year career with Emerson. He started with the company in 1984 as a product evaluation/applied mechanics technician. Afterward, he worked as a product evaluation/multi-area technician before moving onto positions such as: project technician/group leader; reciprocating engineering senior project coordinator; new product launch application engineer; lead sales engineer; and lab operations manager before accepting his current role as lead application engineer.

His various experiences within the company have allowed him opportunities to work in: product research and performance testing; field support and training for end users, OEM customers and contractors; and technical and sales support.

He is a graduate of Rets Tech Center in Centerville, Ohio.

Goals for Today’s Discussion

• Digital Operation

• Supermarket Rack Upgrade — Selecting the Right Compressor

• Supermarket Digital Upgrade — Energy Study

• Questions

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Refrigeration Industry Trends

• Retrofitting existing R-22 and R-404 systems with 448/449

• Merchandising upgrades based on efficiency and flexibility

• Desire to maintain more consistent product temperature

• Pressure to reduce spoilage

• Improve energy efficiency and system reliability

• Shortage of time and qualified technicians to complete retrofit plans

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What Is Digital?

• Copeland™ digital technology is fundamentally different from inverter-based modulation.

• The capacity modulation of the digital compressor is achieved by averaging the time between a “loaded state” and “unloaded state”.

• It is unique, reliable and very simple to apply.

Digital Discus™Digital Scroll™

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How Does Digital Discus Work?

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Digital Valve De-Energized Digital Valve Energized

How Digital Scroll Works

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Digital valve opens, allowing discharge gas to:

Poll Question

• Have you used digital modulation?

– Yes

– No

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Supermarket Racks/Foodservice

Walk-in Coolers/FreezersRefrigerated Warehousing

Commercial AC Systems

Process Chillers/Air Dryers

What Types of Systems Can I Upgrade to Digital?

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Why Include Digital in Your Refrigeration Retrofit and Remodel Projects?

• Reduces compressor cycling

• Increases contactor life/system reliability

• Improves system load match capability

• Improves suction setpoint range

• Improves energy efficiency

• In some cases, suction setpoints are lowered to compensate for swings in suction pressure due to compressor cycling. By increasing the suction setpoint, an energy savings can be achieved.

• For every 1 PSI increase in suction pressure, compressor power is reduced by approximately 2 percent.

• Up to 30 percent more efficient than using hot-gas bypass

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Significant Part-Load Efficiency Improvement With Copeland Scroll Digital

Digital Scroll vs. Hot Gas Bypass Efficiency Comparison

Goals for Today’s Discussion

• Digital Operation

• Supermarket Rack Upgrade — Selecting the Right Compressor

• Supermarket Digital Upgrade — Energy Study

• Questions

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Poll Question

• Are you specifying modulation on rack selection or remodel projects? If so, what method?

– Not using modulation

– Hot gas bypass

– Digital

– Variable speed

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Supermarket Rack UpgradeSelecting the Correct Compressor

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Digital Leads to Paradigm Shift in Rack Design

15 15 8 5 3

6D 6D 4D 3D 2D

46 hp

Rack A, Traditional Configuration – Actual Store

15 12.5 12.5 6

6D 4D4D 3D

46 hp

Digital

Rack A, Configuration With Digital – Actual Store

• 50% capacity unloading• Poor load matching• Significant compressor cycling• High in-rush current

• Increased steps of unloading• Better load matching• More compressors needed• Increased equipment costs

• Variable unloading up to 90%• Excellent load matching• Reduced number of compressors• Lower capital equipment costs

Early Rack Configurations

23 23

46 hp

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Evaluating Existing Racks for Digital Retrofit

4D 4D 4D 3D

Existing Rack for Digital Retrofit

*Be aware of other compressors sharing the same suction group.

180,000 BTU

180,000 BTU

180,000 BTU

100,000 BTU

4D 4D 4D 3D

Digital Retrofit, No Evaluation

180,000 BTU

180,000 BTU

180,000 BTU

100,000 to10,000

UNL

4D 4D 4D 3D

Digital Retrofit With Evaluation

180,000 BTU

180,000 BTU

90,00090,000

100,000 to10,000

Traditionalunloading creates capacity gaps

Digital retrofitimproperly applied increases cycling

Digital retrofitproperly applied reduces cycling

DGTL

DGTL

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Supermarket Applications — Digital Upgrade MT Rack

Significant and immediate reduction in compressor cycling

Digital Discus activated

72 psi 8 psi

Digital retrofit

89% reductionin suction

pressure range

2D

3D

6D From 900 starts per day to 12 starts in four days

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Dairy Case With Discus Digital Activated

Case Temperature Range Narrows Significantly

ProductDegradation

ExcessiveOperating Costs

DigitalProductIntegrity

15 0F

1.25

0F

Case temperature fluctuations reduced

90% to 1¼ 0 °F

Copeland Digital Discus activated

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Goals for Today’s Discussion

• Digital Operation

• Supermarket Rack Upgrade — Selecting the Right Compressor

• Supermarket Digital Upgrade — Energy Study

• Questions

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Poll Question

• Have you been involved in energy improvement projects? If so, what were the results?

– Not involved

– Negative results

– Break-even results

– Excellent results

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Supermarket Digital UpgradeEnergy Study

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Digital Discus Compressor Upgrade Measurement and Verification

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Overview:• 20-year-old, 45,000 sq. ft. grocery located in southwestern Ontario

• Medium- and low-temperature centralized rack system

• System (total 164 hp) operates with 10 semi-hermetic Copeland compressors

Objective:• Analyze the energy impact of the medium- and

low-temperature racks of retrofitting one compressor on each to a Digital Discus compressor

Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)

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Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)

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Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)

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Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)

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Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)

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Questions?

DISCLAIMERAlthough all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated herein or that other measures may not be required.

Thank You!

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