http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/RSS.ashxRA PagesTue, 16 Sep 2008 21:13:53 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=1mAKING mODerN LIVING pOSSIbLe SolutionS t r e N D S A N D t O p I C S t H A t I m p A C t I N D u S t r Y EnVisioneering SM An Industry Leader 75 Years in the Making Danfoss Celebrates its 75 Year Anniversary eNGINeerING + eNerGY eFFICIeNCY + eNVIrONmeNt = eNVISIONeerING VOLume 7 / ISSue 2 / 20082008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=2mAKING mODerN LIVING pOSSIbLe When Danfoss was born — The future belonged to those ready to invent it. Our founder, Mads Clausen, designed and marketed the first Danfoss expansion valves in 1933, when global economic conditions could not have been worse. When we began, even back in those hard times Mads Clausen’s vision revealed a bright future, ripe for invention. From that beginning 75 years ago, Mads Clausen’s foresight made—and still makes Danfoss a world leader in innovative mechanical and electronic products and solutions: For HVAC and refrigeration, motion control, and heating; and for water, wind, and solar applications as well. Today 22,400 Danfoss people work with a passion for technology in 70 manufacturing facilities around the world. That Danfoss passion is embodied in what we call EnVisioneeringSM. EnVisioneering yields innovative solutions, each one highly energy efficient and with a concern for protection of our environment. Today, seventy-five years after Mads Clausen founded Danfoss, we remain dedicated to inventing the future. Because Mads Clausen’s spirit and foresight still guide our Company today, the future we see is as bright as ever for us and for our customer partners. To see how EnVisioneering can enhance your project’s bright future, visit www.Envisioneering.Danfoss.com ENGINeerING + ENerGY eFFICIeNCY + ENVIrONmeNt = ENVISIONEERING2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=3VOLume 7 / ISSue 2 Dear Readers, A lot has happened since Danfoss first eyed conservation and engineering in the manufacturing industry 75 years ago. Since then, economies have integrated, populations have moved into cities, environmentalism has become a business issue of interest, and through it all, Danfoss has remained committed to innovation and customized products that allow its customers to conserve energy. though the company’s client base, product line, and revenues have grown considerably, its approach to doing business has been consistent. We chose to highlight the company’s 75th anniversary in this issue because we believe that 75 years in business represents a milestone for any company. Danfoss, perhaps, differentiates itself from some companies that enjoy legacy success because it has maintained steady values while expanding into different countries and cultures. Now, Danfoss employs 22,400 people globally and produces more than 250,000 components every day. We are observing some positive trends: energy consumption becoming more efficient because of new technologies and greater attention paid to conservation. We relish our role as innovator of energy conservation technologies and as a convener of ideas in this evolving industry. As always, your comments and feedback are welcome. 1933–2008 : A look back on our 75 year history. timeline on pages 3–8. Contents / 2 / FROM THE COVER 2 / An Industry Leader 75 Years in the making 8 / What it takes to get to 75 years / 10 / CASE STUDIES 10 / 20% of uS electric power provided by Wind 12 / VLt® Drives—an Alternative to Water towers / 14 / NEWSWORTHY 14 / training equipment for Students at Humber College of technology and Advanced Learning, Canada 16 / Next enVisioneering Symposia Series to Focus on the private Sector The Editors solutions@danfoss.com Information contained in the Danfoss EnVisioneering Solutions may be republished only with permission of Danfoss and always with credit to Danfoss EnVisioneering Solutions. Comments, suggestions, and contributions are welcome. This publication should not take the place of appropriate technical or legal advice related to company-specific circumstances. Danfoss EnVisioneering Solutions does not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication. prODuCt HIGHLIGHtS tHIS ISSue more Friendly Drives2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=4A N I N D u S t r Y L e A D e r years IN tHe mAKING D A N F O S S m A K e S C O m p O N e N t S that drive socially responsible and energy-efficient equipment performance, but until its customers start putting windows on the equipment—to expose the Danfoss-engineered parts inside—the company won’t receive its fair share of credit from the general public. And that has been just fine with the company. Since Mads Clausen founded Danfoss 75 years ago, the landscape of the company’s industry has changed dramatically, but it has maintained a consistent profile as a company committed to engineering products that help industries perform more efficiently. Because its components work so well, it has built its reputation on trust and quality despite being virtually invisible to the end user.2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=5Comments for future development, reflecting on the last 75 years and looking ahead: “We can see a number of trends that are influencing our industry and society as a whole, and we believe these trends will have impact the next many years. The trends include rising fuel prices, increased focus on energy efficiency as well as environmental impact. Danfoss has the technologies to meet many of the challenges presented by these major trends: the majority of our products save energy or use very little energy to run, for example. We are combining what we do well, with what we believe in. We have a passion for technology, and that passion will help drive us in the future.” — Jørgen Clausen, President and CEO 1933 Mads Clausen Under the name Dansk Køleautomatik og ApparatFabrik, Mads Clausen begins running his business. The first valves, ARV and TRV, are introduced.2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=6COVer StOrY CONtINueD Danfoss Reacts to Global Phenomena Not lost on anyone at the company—at headquarters in Denmark or state-side—is the contention that its products solve problems that transcend borders and cultures: the consumption of energy and water resources, and also environmental conservation. The past 75 years have seen energy use increase dramatically because of demographic change and environmentalism become mainstream because of widespread access to information. This means population growth and domestic migration patterns have both dramatically shaped Danfoss during the past 75 years into what it is today. The United States’ population has grown in volumes since Danfoss’ beginning in 1933, from 125 million residents then to an estimated 304 million residents today. While this surge in population has fueled industrial growth and domestic prosperity, it is also responsible for massive pollution and resource consumption. At the same time, migration into cities caused resource consumption to increase across the board, from the gasoline that fuels cars to the natural gas that heats large office buildings and the electricity that cools them. This migration has made the energy profiles of appliances and buildings particularly troubling as homes are built and buildings ascend. Many consumers know that compact fluorescent lighting is far more efficient than incandescent bulbs; what many don’t know is that many appliances have the potential to be just as efficient. The U.S. Energy Policy Act of 2005 included a provision for adopting real-time pricing of electricity, a measure that would give great financial incentive to automate electricity use. Mixed with its appliance efficiency standards and other measures, the American Counsel for an Energy-Efficient Economy estimates the law will reduce consumer electricity and gas bills by more than $20 billion by 2020, although critics point out the law provides heavy subsidies for the already profitable oil and gas industries. The Counsel also estimates that by Migration into cities caused resource consumption to increase across the board, from the gasoline that fuels cars to the natural gas that heats large office buildings and the electricity that cools them. 1950 75 YEARS O F DAN FOSS Danfoss Convention Distributors from 21 countries meet in Nordborg at the “Danfoss Convention”. Two year old Jørgen M. Clausen inaugurates a new factory. Bitten and Mads Clausen take a study tour to the USA. 1966 1956 New compressor type Danfoss Flensburg is set up as an independent company. PEE-WEE compressors are introduced and quickly edge out the Pancake type. A new organizational structure is implemented: Mads Clausen and seven Directors head the company. Mads Clausen dies On August 27, Mads Clausen dies at the age of 60. Andreas Jepsen is appointed Managing Director. Bitten Clausen lays the foundation stone for a new factory in New Delhi in India. 4 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=7increasing the number of appliances and consumer goods that are required to perform up to a certain standard, by 2020 consumers would save $4 on their electricity and gas bill for every $1 invested in meeting the new standards, given those consumers actually replace equipment instead of service it to improve its efficiency. And advancing technology keeps on raising the efficiency potential of appliances in relation to their upfront costs. These appliances are not among the leading sellers in their respective industries because their advanced technology increases the upfront cost. Tax policy can provide rebates or attach the costs of these appliances to a larger debt instrument such as a home mortgage. Elsewhere, a carbon tax that reflects the inevitable healthcare costs of breathing polluted air would affix a cost to climate change and make efficient appliances much more attractive economically. The number of large commercial or residential structures has also increased along with the nation’s population. The U.S. Green Building Counsel estimates that commercial and residential buildings account for 70 percent of electricity use, 38 percent of CO2 emissions, and a significant percentage of materials use. According to green building consulting firm Capital E, high-performing buildings can earn a profit of from $49 to $67 per square foot during the first 20 years of occupation. Retrofitting an inefficient building with new, efficient systems, including appliances and automation systems, can cut energy use by 20 to 50 percent. The Energy Efficient Building Retrofit Program, which the William J. Clinton Foundation oversees, is enabling five of the world’s largest banks and four of the leading energy service companies to retrofit buildings in 16 cities. Aside from efficiency policy, alternative sources of energy, most notably wind turbines, are emerging to lessen the dependence on oil sources. The United States consumes 25 percent of global oil output, and it imports 70 percent of that supply, spending $700 billion annually. But because of flat land assets in the Midwest, it has potential to generate tremendous amounts of energy from wind turbines. Wind power is not the single magic-bullet solution to the energy dilemma, however. Many observers endorse policy that provides incentives to replace outdated equipment with more energy-efficient models to lessen consumption while at the same time upping investments in the numerous alternative sources to achieve greater independence from oil-based energy. 1975 Design prize An extensive sales promotion campaign including TV commercials is launched for radiator thermostats. At the Hannover Exhibition in Germany, Danfoss is awarded the design prize IF 75 for the hydraulics motor ORT. 1968 The frequency converter Electronics begin to seriously make an entry in Danfoss with the frequency converter VLT® 5. After some difficult years, compressor sales are increasing substantially. This also applies to the number of employees: 5,738 in Denmark; 1,372 in Flensburg. 1983 1989 Bitten Clausen Bitten Clausen steps down from the Board, but remains the Chairman of the Foundation. One more milestone is reached: compressor no. 100,000,000. VOLume 7 / ISSue 2 / 2008 5 New generation A new generation of the radiator thermostat, type 2000, is launched on the market. Employee no. 1,000 celebrates 25th anniversary. Andreas Jepsen retires as Managing Director and is replaced by Harald Agerley.2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=8COVer StOrY CONtINueD The Repetition of History: Danfoss Then and Now Its history is not easily summarized in brief, but a few milestones stand out. Clausen, an engineer, founded the company in 1933 as a sole proprietorship with one product: an expansion valve for refrigeration systems. Ten years later, it had grown to 179 employees and 37 products. Employees from 21 different countries met at the “Danfoss Convention” in 1950, reflecting the rapid globalization of that decade. Danfoss hired its 1,000th employee in 1952 and its 2,000th the next year—doubling the employee population in one year and forever transforming the community’s historically agrarian society into a future global technology and manufacturing pioneer. In truly globalizing the company’s footprint, Danfoss named Jørgen Mads Clausen, Mads Clausen’s eldest son, to be its President and CEO in 1996. Jorgen supercharged the global expansion of Danfoss and its dedication to the environment. In 1994, it issued its first environmental statement in its annual report for that year. Today, Danfoss employs 22,400 people globally and produces more than 250,000 components every day. It’s coincidental that industry in the United States finds such value in the innovation of a Danish company. From that first valve in 1933, Danfoss has built innovative products while being environmentally and socially responsible—such responsibility has always been a Danish cultural phenomenon, and it persists at Danfoss to this day. globalization: Today, Danfoss employs 22,400 people globally and produces more than 250,000 components every day. 1992 Danfoss to the East The Building Controls Division sets up production and sales in Poland. The company Danfoss Poland produces and distributes radiator thermostats and other Danfoss products. The company Danfoss Russia A.O. is set up and production and sales begin the year after. At the beginning of 1993, Danfoss sets up a new production company in Slovenia for the production of compressors. 1994 Maneurop S.A. In 1994, Danfoss acquires the majority of shares in the French company Maneurop S.A., which produces compressors for airconditioning systems and refrigeration applications. The recently acquired company supplies goods to key American producers. 1996 1997 Jørgen M. Clausen Henry Petersen retires and is replaced by Jørgen M. Clausen who is appointed Managing Director. Danfoss begins operations in China. 75 YEARS O F DAN FOSS Danfoss Mexico Factories open in Mexico, China and Slovenia. The balance shifts so that the majority of Danfoss employees work in companies outside Denmark. EU Environmental prize The Danish Minister of the Environment awards Danfoss with the EU Environmental prize 1995, in the category ”Green products”. Nessie has replaced oil hydraulics with tap water. In 1997, ”The green diploma” is given to the Transmission Division in Gråsten, Denmark, which is certified according to the British standard BS 7750. 6 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=9The Next Steps: Recognizing Its Role As Industry Convener In 1933, the best way to lead was by example, and while the same holds true today, telling the country about that leadership does not hurt. The maturation of communications, specifically the rise of the internet, has changed Danfoss’ approach to advocating conservation and social responsibility. In 1933, the best way to lead was by example, and while the same holds true today, telling the country about that leadership does not hurt. Select industry leaders, academics, policy-makers, and members of the mainstream press have collaborated to raise awareness of conservation issues far above its level in 1933. While these groups do not always agree on the best measures to take, the endgame for each of them is a cleaner, more efficient society. Danfoss’ EnVisioneering symposia, held frequently during the last several years, have become repositories for new ideas, policy-driving discussion, and industry convention. After 75 years of commitment to energy efficiency, Danfoss is embracing its role in convening different audiences and industries to discuss what can be done to quell energy overconsumption and focus more on preserving resources. 2000 Sauer-Danfoss The most important event of the year takes place on May 3, when the Sauer Inc. Annual General Meeting approves the merger with Danfoss’ mobile hydraulics activities. Consequently, around 16 percent of the Danfoss Group was demerged and merged into the company Sauer-Danfoss Inc. 2004 Danfoss China The strategy to make China Danfoss’ second home market is launched. The reason is the marked Chinese development, including, not least, the increasing focus on the country’s energy consumption. 2003 DEVI With effect from January 1, Danfoss takes over the share capital in DEVI A/S with 425 employees to strengthen the group’s floor heating activities. In France, the Water Controls Division acquires Desbordes with 76 employees. 2005 Mads Clausen: 100 years Danfoss’ founder, Mads Clausen, would have been 100 years old in 2005, and it is celebrated on a global scale. The TR6 valve is launched in the USA in response to new American requirements of the energy consumption of air-conditioning systems in private households. In just a few months, it gains a large share of the market. VOLume 7 / ISSue 2 / 2008 72008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=10COVer StOrY CONtINueD Commitment to Values and Innovation Key to 75 Years in the market The numbers speak for themselves: statistics show that six out of ten new businesses in Denmark close down within two years. they also suggest that only one in four celebrates its 10th anniversary. So, 75th anniversaries are something out of the ordinary. but, what does it take to survive—and for companies to transport that success to new markets? Some research shows that the key is to have core values and core businesses which take the company’s first years as their starting point. In popular terms, a company’s childhood and youth are important for how the company copes. Companies which are in a position to retain their core values have the strength to survive. per boje, who in 1994 published a book on mads Clausen and Danfoss, singled out Danfoss’ focus on development as the decisive factor. “Danfoss has a range of mature products, such as the radiator thermostat, but the company has managed to be innovative which has kept it going and resulted in extra products. the most important factor is that you are prepared for continuous improvements and changes,” he said. boje emphasizes one more vital factor: very early, the company has actively made an effort to obtain employees with the required skills, not least through the support of the engineering College in Sonderborg, Denmark. Also, the company played a major role in the promotion of commercial training which is offered in the region. “It is always tricky to get employees to move to far-away places, but this is how they dealt with the problem.” but, which dangers are lurking? Will they persist? boje points out that Danfoss’ strength is that family-owned companies can afford to have longer-term goals – and also have the advantage of being able to act fast. there is no question of doubt who has the decision-making authority. meanwhile, family ties also pose a danger: is it possible to compose an appropriate managerial team? “In popular terms, this is what we call the buddenbrooks syndrome. Danfoss is still only in its second generation, but experience shows that it is in the third generation that you are faced with challenges. there is a great deal of challenges which need to be dealt with. If they aren’t, conflicts of competencies could arise,” he says. Currently, a so-called family governance is being prepared which lays down the framework for how new generations of the Clausen family can be integrated into the company. boje considers this to be vital. 75 YEARS O F DAN FOSS 2006 12 acquisitions Acquisitions include the American company Scroll Technologies, with 750 employees, and Hago, the world’s largest producer of steel nozzles. 2007 No. 2,000 Today Danfoss celebrates 75 years Danfoss continues to be a world leader, celebrating 75 years in the Heating and Air Conditioning industry, and 40 years in Motion Controls. Second largest Increased globalization has made America the second largest market for Danfoss products. Danfoss China reaches 2,000 employees in May. At the end of the year, a total of 22,323 people work at Danfoss. 8 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=11prODuCt HIGHLIGHt Danfoss Introduces more Friendly Drives Designed with powerful features to save energy, and for ease of programming by refrigeration and HVAC technicians, the AKD 102 variable frequency drive provides enhanced food product healthfulness and lengthens compressor service lifetime. today’s supermarket customers can select from an ever-expanding variety of foods. Display cases are constantly restocked to ensure continuity of offerings. that said, escalating energy costs demand that supermarket operators avail themselves of every opportunity to get the most efficient performance possible from the refrigeration plants that maintain a healthy environment for meats, produce, cheeses and other dairy products, and frozen foods, and to maximize product life in storage. Danfoss has long served the supermarket industry, helping to satisfy food codes and provide consumers with healthy, attractive foods. the Danfoss AKD 102 variable frequency drive, when applied to refrigeration compressors, answers the need for a variable frequency drive for supermarket applications. Drives are programmed so that the equipment’s delivered capacity very closely matches the load. this is done by efficiently varying the speed of the compressor, pump, or fan in response to feedback from the system served by the equipment. but variable frequency drives have the reputation of being difficult to program and commission. Danfoss has provided the solution by delivering a drive with far fewer programming steps than have been required. the AKD 102 drive speaks refrigeration language, using terms and parameters long familiar to refrigeration technicians instead of often-puzzling electronic terms. A setup wizard, presented on the drive’s display, is a standout feature. the software wizard leads the installer through a logical, comfortable, and easy-to-follow setup. the wizard covers the three most common applications in supermarket refrigeration: compressors, condensers, and pumps. A single keypad stroke brings forth another feature, a context-sensitive online manual, a Danfoss drive innovation that technicians found very attractive during their involvement in the development process. the keypad and display module can be removed from the drive to be used as a handheld device to clone settings to other drives. All drives in the AKD 102 series, from 1.5 to 125 Hp, use the same setup wizard, display, logical menu structure, and built-in manual, so that technicians use the same methods for setup, commissioning, adjustment, and troubleshooting throughout the horsepower range. For refrigeration compressors, matching cooling capacity to constantly changing supermarket loads without excessive compressor cycling is a challenge. An AKD 102 drive on one compressor means much less cycling. Compressor rack capacity is always exactly matched to the load, resulting in a higher COp. With variable capacity to match fixture loads, there is no wasted capacity and no wasted energy. because cycling is dramatically reduced, compressor life is extended and maintenance costs are lower. Fans for both condensers and air handlers show significant savings when their speed is controlled by an AKD 102 Danfoss drive. this means that if cooling capacity calls for fan speed reduction of 20%, power consumption is reduced by more than 50%. because systems operate much of the time at part load, reducing speed to match load results in considerable saving of power and money. using an AKD 102 drive for variable speed operation of outdoor condenser fans also provides a solution for fan noise, avoiding the need for costly architectural modifications to meet zoning regulations. Fixed speed fans can only start at full speed and stop abruptly, creating an annoying noise pattern 24 hours every day. With an AKD 102 drive programmed to gradually bring fans from minimum speed to required capacity, there is significantly less noise put into the local environment by operation at lower speed and with th2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=12CASe StuDY ONe WIND SYStem prODuCtS » mbS 3000 pressure transducers endure high overpressures » mbt temperature sensors provide reliable input to wind turbine control electronics » KpS temperature switches provide on-off limits 20% of US electric power A C C O r D I N G t O the Global Wind Energy Council, more than 20 percent of US electric power could be provided by wind by 2030, reducing the use of natural gas by over 10 percent. In 2007, 35 percent of the new power generation capacity in the United States came from wind power. For today and for future generations, that is welcome news, and a demanding challenge that excites Danfoss EnVisioneering. In 1979, Danfoss partnered with Vestas Wind Systems A/S of Denmark, the world’s leading wind turbine manufacturer, to supply them with components for their wind energy system. Vestas has since then delivered thousands of wind turbines with Danfoss components to more than 60 countries. Today, Danfoss is the world’s leading supplier of pressure transmitters, temperature sensors, and heat exchangers to the world’s wind turbine manufacturers. PROVIDED by WIND The first Danfoss components supplied to the wind energy industry were its justly renowned pressure transmitters and temperature sensors. Later innovations by Danfoss engineers and scientists include new designs for gear motors and brazed plate heat exchangers. When a windmill drives a turbine to generate electricity, the wind-driven blades are linked to the power-generating turbine by hydraulics. The hydraulic system transmits power and is also used to control yaw (direction the blades face) and blade pitch (the attack angle at which the blades meet the wind). The hydraulic system is regulated by control electronics that require precise, dependable, repeatable sensor performance in order to assure consistent smooth functioning and continuous (rather than erratic) motion of the blades. Danfoss MBS pressure transducers, KPS temperature switches, and MBT temperature sensors 10 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=13meet the demand day in and day out, and excel in handling the extreme weather conditions that the exposed windmills must face, from searing dry heat in summer to near-arctic conditions in winter. Robust MBS 3000 pressure transducers have been tested through millions of cycles, and can endure high overpressures. A fully welded stainless steel housing and patented sealing protect against aggressive and extreme environments. Accuracy is ensured by a laser-trimmed electronic circuit. Ultra-compact, high precision Danfoss MBT temperature sensors provide reliable, repeatable input to wind turbine control electronics to maintain the temperature of the hydraulic oil so that transmission efficiency is kept optimal. Other wind systems use Danfoss KPS temperature switches to provide on-off limits when certain critical temperatures are reached. Other Danfoss products that are entering the wind power industry are frequency converters and power electronics, both from the Danfoss Motion Controls Division. Since 1990, wind has been the most rapidly growing alternative source of energy. The world’s supply of fossil fuels will not serve us far into the future. Just as importantly, while there is plenty of (if expensive) oil available today, and coal deposits still exist, the dangers from burning these fuels is known to virtually everyone. The carbon dioxide produced contributes in large measure to the problem of global warming. As we generate greater and greater amounts of carbon dioxide by burning more and more fossil fuel for energy generation, heat contained in the “greenhouse” built of combustion products traps the Sun’s heat, preventing its radiation back into space. It is by this mechanism that global warming occurs. Wind energy is certainly receiving continually increasing interest. Recently one of America’s most powerful oilmen, T. Boone Pickens, went public with strong suggestions that alternative energy, especially wind energy, must become a priority whose realization can save us from utter dependence on foreign oil. He intends, he says, to construct on 200,000 acres north and east of Amarillo, Texas, the largest wind farm in the world, to generate 4,000 megawatts of electricity. This would nearly double the 2,700 megawatts Texas wind farms were generating at the end of 2006. Pickens indicated in his news conference that the US must be prepared for the time when those traditional energy sources become excruciatingly costly. It was disturbing news from a man that has built an empire on Texas petroleum. Today’s power generating windmills are high technology versions of one of civilization’s oldest means of generating power. Danfoss is deeply interested in wind energy systems, and continues to strive for innovations and improved products that will increase the portion of the world’s windproduced power. 20% of US electric power could be provided by wind by 2030, reducing the use of natural gas by over 10 percent. Danfoss Ventures formed Danfoss Wind Systems to develop and deliver innovative, energy efficient, environmentally responsible products for wind systems, working closely with many Danfoss divisions to promote products for use by wind turbine manufacturers. VOLume 7 / ISSue 2 / 2008 112008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=14CASe StuDY t WO 3 5 0 H p D A N F O S S V Lt ® A Q u A » provides significant energy savings and reduces water losses » constant pressure at variable flow conditions » provides between 200 and 1600 Gpm at a pressure of 70 pSI WATER TOWERS L I K e m A N Y A r e A S A C r O S S the United States and around the world, the community of Loves Park in northern Illinois is growing. Of course, along with growth comes the challenge of expanding services in a manner that is not only workable, but also cost-effective in both the near and long term. As new subdivisions and businesses were added to the Loves Park water distribution system, the city was faced with how to best serve the growing demands. The community was already served by five water wells and three 500,000-gallon water towers that helped to maintain adequate system pressure. But growth along its eastern edge meant that more and more demands were being placed on the system. Without the introduction of additional capacity into the system, the increased flow would eventually cause a decrease in pressure. The city’s water department decided to install a new well to provide this additional capacity. The new well is 1400’ deep and is fitted with a submersible pump located roughly 800’ below the surface. Jerry Janzen at Instrument Control Systems in Plymouth, Minnesota, designed the system required to efficiently operate the pump motor. “In order to maximize the control and energy efficiency of the well and pumping station, we used a 350 HP Danfoss VLT® AQUA variable frequency drive,” says Jerry. The drive is connected to the city’s SCADA system, allowing it to run the pump motor at whatever speed is called for to maintain the appropriate system pressure. By matching the actual demands of the water distribution system and running the pump at less than full speed, the drive is able to provide significant energy savings and VLT® Drive—an alternative to 12 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=15reduce water losses. Furthermore, it gives the Loves Park water department the ability to plan for future expansion. As new developments are built and flow increases further, the drive will automatically run the pump motor at whatever speed is necessary to meet the increased demands and maintain the pressure setpoint. One of the primary advantages of using a variable frequency drive is the capability to provide constant pressure at variable flow conditions. The Danfoss VLT AQUA drive at Loves Park’s Well Number 6 provides between 200 and 1600 GPM at a pressure of 70 PSI. In many ways, this is a preferable alternative to using water towers, which are far more costly both to install and to maintain. It was determined that using a medium voltage motor would further reduce overall costs due to the significantly smaller diameter motor cables that it would require. This is due to the fact that as the voltage increases, the amount of current required to perform the same amount of work decreases. The 460 VAC output of the Danfoss VLT AQUA drive is wired to a step-up transformer, which brings the voltage to 2400 VAC. The output of the transformer is then fed through a sine wave filter to ensure that the waveform is exceptionally uniform, prolonging the life of the motor. At 460 VAC, the motor would have required very thick cables to carry the current needed to operate the pump. But at 2400 VAC, the current required is much lower, meaning that a smaller gauge of wire could be used. With 800 feet of cable, this resulted in a significant savings. The use of a variable frequency drive also minimizes equipment stress. By significantly reducing the number of starts required of the well pump, the drive maximizes the pump motor’s longevity. Controlling the acceleration and deceleration when starting and stopping further lowers stress to the motor as well as reducing water hammer in the pipe system. The drive will also allow the city to work on their water towers without impact to water distribution. “Right now, this pumping station is filling the gap,” says Craig McDonald, Loves Park Water Department Supervisor. “But it will also allow us to bypass a tower in order to maintain it while still providing water to the people who rely on it”. The variable frequency drive provides the system with the flexibility to meet the needs of the community, both today and in the future. The variable frequency drive will allow the city to work on their water towers without impact to water distribution. energy efficiency In order to maximize the control and energy efficiency of the city’s water department well and pumping station, Loves Park used a 350 HP Danfoss VLT® AQUA variable frequency drive VOLume 7 / ISSue 2 / 2008 132008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=16NewsWOrTHY r E C E n T n E W S A n D U p D AT E S F r O M D A n F O S S Training Equipment for Students at Humber College of Technology and Advanced Learning, Canada there is a long Danfoss tradition of interest and involvement in education and training and Danfoss has built mutually beneficial connections with many trade schools and technical universities. One such connection is with Humber College of technology and Advanced Learning in Ontario, Canada. Humber College has 19,000 full-time students and more than 55,000 part-time students pursuing a diverse array of technical pursuits. In Humber’s two-year HVAC technician program, students gain in-depth knowledge of the design and operation of HVAC mechanical systems, and also become certified for work with gas-fired equipment. the three-year program has all of the two-year curriculum’s content and in addition, students earn credentials in energy management systems including direct digital control (DDC), Variable Air Volume systems (VAV), variable frequency drives, and the various lighting technologies used in today’s buildings. each year, Humber accepts approximately 120 new students into its refrigeration and air conditioning programs. there are hundreds of applicants. Successful students who graduate receive a technologist’s Diploma, a highly respected achievement in their industry. Jamie Kitchen, training manager at Danfoss in baltimore, graduated from Humber College in 1989, later becoming an instructor there for more than five years. He has had a continuing interest in the school’s programs going forward from those early days of his career. As he began to develop the North American Danfoss training programs for refrigeration and air conditioning, Kitchen contacted present faculty and administrators at Humber with the goal of building a Refrigeration Training Products, LLC, Baton Rouge, Louisiana (USA) manufactures standard and custom refrigeration and air conditioning training boards. www.RefrigerationTrainingProducts. com. Contact Sales@RefrigerationTrainingProducts.com partnership to share experiences and gain foresight into what might be the training and education needs of the industry, and how those needs could best be met today and in the years to come. early on, Humber staff expressed their need for training aids that were more robust and had more flexibility for training; that would allow instructors to demonstrate both normal function and malfunction, and give students a learning experience that involved as many of their senses as possible under as realistic conditions as could be had in a classroom. And then, well, if the units could be quieter and also less expensive, even better. Jamie Kitchen contacted Joel eggart, a Danfoss Oem account manager who is also a principal of rtp (refrigeration training products, LLC). Working together, Danfoss, rtp, and Humber College further developed the “Humber wish list.” Humber was impressed with the specifications and designs that the trainer 14 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=17experts delivered. A working prototype, its heart a Danfoss tF4CLX hermetic compressor, was built with a Danfoss tu stainless steel thermostatic expansion valve in series with a Danfoss eVu compact solenoid valve and Danfoss DmL filter drier and a Danfoss sight glass. pleased with the prototype, no changes were made, and the college gave Danfoss an order for six units specifically designed for basic refrigeration cycle and controls training; two more advanced units with dual evaporators and evaporator pressure regulators; and a transportable board that will fit into a high impact plastic case easily shipped wherever needed. the training boards that refrigeration training products manufactured were extended range r-404A units that could be operated at a broad range of temperatures, and could be used to demonstrate anything an instructor planned: normal operation, low load operation, high head pressure, short cycling, and other conditions, as well as basic and advanced technician skills. each had large built-in high and low pressure gauges as well as multiple gauge ports where students could connect their own gauges or practice recovering refrigerant or charging the system. In addition, the larger stationary dualcircuit units had Danfoss KVp evaporator pressure regulators and could demonstrate evaporators in parallel with a different temperature on each of the two circuits. the cost of a traditional refrigeration training board is about $10,000 to $15,000. Humber college would have to spend over $100,000 for enough of those units to meet their classroom and laboratory needs. the units that Danfoss provided cost the college just over $30,000—less than one third of the current going price. And with the efforts of Danfoss and rtp, the highly flexible training boards delivered had every feature and capability the college wanted. Humber College of technology and Advanced Learning in part defines itself as “a multi-disciplinary institution of higher education which emphasizes connections with working life and economic development. It offers an applied approach to technical and professional education.” the values it espouses are excellence, Learner Focus, Innovation, and respect. A partnership with Danfoss is thus natural for the college, and has been indeed successful and mutually beneficial. both partners firmly believe that their working together will improve the quality of education and training for North American technicians for generations to come. When the new training boards arrived, one of the Humber laboratory technicians who tested them remarked that the boards were so incredibly quieter than the training boards they had been using that for the first time he could discuss their operation with students without shouting. Humber College of Technology and Advanced Learning , Etobeicoke, Ontario, Canada (north of Toronto) describes itself as a polytechnic institution and states its mission as “Humber develops broadly educated, highly skilled and adaptable citizens who significantly contribute to the educational, economic and social development of their communities. www.Humber.ca Contact: Enquiry@Humber.ca VOLume 7 / ISSue 2 / 2008 152008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=18NewsWOrTHY C O N t I N u e D next EnVisioneering Symposia Series to Focus on the private Sector SM As part of its ongoing enVisioneering Symposia Series, in April, Danfoss convened energy regulators, policy-makers, and observers for a conference on energy-efficiency strategies, which offered valuable insights into energy policy and technology. the next conference in the series is slated for Nov. 14 in Carlsbad, California and will focus on what the private sector needs in order to promote energy conservation and sustainability. this conference will coincide with the Air Conditioning, Heating, and refrigeration Institute’s (AHrI) annual meeting. Advances in energy-efficiency technologies have created further opportunities for companies to base business and revenue models around energy conservation. Observers saw interest in energy efficiency and conservation move from college campuses to boardrooms long ago, but regulatory policy, new conservation advocates, and many emerging technologies continue to conspire and change how companies can make money from energy efficiency today. Now, in light of sky-high energy prices, downplaying the economic return of conservation technology in lieu of technologies that find, acquire, and transport energy is not a sensible approach. Conference participants will give balanced input to the following thoughts: 14 NOV emb er The next conference in the series is slated for nov. 14 in Carlsbad, California and will focus on what the private sector needs in order to promote energy conservation and sustainability. » What business models can profit from energy conservation, not energy acquisition? » How can business encourage consumers and business owners to replace old, inefficient equipment with new, more efficient equipment? this is the first step toward carbon neutrality. » energy providers have incentives to sell more energy when they should have incentives to sell less energy. How can that be reversed? the theme for the 2008 enVisioneering Symposia Series is “breakpoint: energy efficiency at a Crossroads.” It will explore the energy efficiency challenge from 30,000 feet and ground level, seeking out the experiences, best practices, insights and discoveries that can help decision-makers meet the demands of the energy-efficient built environment. 2008 marks the third consecutive year in which Danfoss has hosted the enVisioneering Symposia Series. the company launched the series in August 2006 to create an ongoing dialogue among industry, the policy community and thought leaders in research and development. 16 eNVISIONeerING SOLutIONS2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=19SubSCrIbe Subscribe today by emailing solutions@danfoss.com to Solutions Today, technology is facing higher energy, environmental, and application demands, which are putting pressure on how products and systems are designed and manufactured. In turn, engineering is being called upon for new concepts, technologies, and solutions, often provided by teams working collaboratively between disciplines and across geographical boundaries. EnVisioneeringSm Solutions tracks the latest innovations in the field and provides up-to-date industry news. Subscribe to EnVisioneering Solutions by sending your full name and address to solutions@danfoss.com ENGINeerING + ENerGY eFFICIeNCY + ENVIrONmeNt = ENVISIONEERING2008-09-16T21:13:53+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol7Issue22008/?Page=20DANFOSS LOCATIONS BALTIMORE, MD 7941 Corporate Drive baltimore, mD 21236 410-931-8250 / Fax: 410-931-8256 www.danfoss.us » refrigeration & Air-Conditioning » Industrial & Heating Controls TALLAHASSEE, FL Danfoss turbocor 1769 paul Dirac Drive tallahassee, FL 850-504-4800 www.turbocor.com » Oil-Free Compressors for refrigeration and Air-Conditioning W W W . D A N F O S S . u S GLENS FALLS, NY Danfoss Flomatic Valves 15 pruyn’s Island Drive Glens Falls, NY 12801 800-833-2040 / Fax: 800-314-3155 e-mail: flomatic@flomatic.com www.danfossflomatic.com » Water Controls LOVES PARK, IL 4401 N. bell School road Loves park, IL 61111 815-639-8600 / Fax: 815-639-8000 www.danfossdrives.com » Drives MILWAUKEE, WI 8800 W. bradley road milwaukee, WI 53224 414-355-8800 / Fax: 414-355-6117 www.danfossdrives.com » Drives » Nessie High pressure Water Systems MISSISSAUGA, ONT 6711 mississauga rd., Suite 410 mississauga, Ontario L5N 2W3 905-285-2050 / Fax: 905-285-2055 www.na.heating.danfoss.com » Heating Controls » motion Controls MOUNTAINSIDE, NJ Danfoss Hago, Inc. 1120 Globe Ave. mountainside, NJ 07092 908-232-8687 / Fax: 908-232-7246 www.hagonozzle.com » Components for Oil burners SOMERSET, NJ Danfoss bauer 31 Schoolhouse road Somerset, NJ 08873 732-469-8770 / Fax: 732-469-8773 www.danfoss.com » Geared motors 2008 Calendar of Events September 2008 » HARDI: Heating, Air-Conditioning and Refrigeration Distributors International October 25–28, 2008 JW marriott Desert ridge resort and Spa, phoenix, AZ » Comfortech September 10–13, 2008 Georgia World Congress Center, Atlanta, GA September 16–20, 2008 Hilton Hotel, Indianapolis, IN » RSES Annual Conference NOVember 2008 » RETA: Refrigerating Engineers » IHACI’s 29th Annual HVAC/R/SM and Technicians Association September 24–26, 2008 Hershey Lodge and Convention Center, Hershey, pA Products & Equipment Tradeshow November 19, 2008 pasadena Convention, Center, pasadena, CA OCtOber 2008 DeCember 2008 » ChillVenta » International Workboat Show 2008 December 3–5 morial Convention Center, New Orleans, LA 15–17 October 2008 Nuremberg, Germany Federation Technical Exposition & Conference October 19–22, 2008 mcCormick place, Chicago, IL Visit Danfoss booth #21015 Hall b » WEFTEC: Water Environment Keep up-to-date on the latest news about Danfoss products and your industry at www.danfoss.us To find out more about Danfoss North America, contact us via email: solutions@danfoss.com2008-09-16T21:13:53+02:00