http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/RSS.ashxRA PagesTue, 03 Jul 2007 12:15:16 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=12007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=2Who in the world spends all day fixing problems that havent happened yet To John Labora, good isnt good enough. If its not broken he still fixes it. If its good it has to be better. He cant help it. And we wouldnt have it any other way. Most of the time, hes on the production floor with his sleeves rolled up, looking for ways to make the process run smoother, faster and more efficiently. Problems really havent got a prayer. With people like John involved, customers can count on getting a reliable product, on time, every time. Total reliability is a way of life at Danfoss. Its engineered into every single product from the ground up. Please visit us on the Web at www. northamerica. danfoss. com to see how our engineering and products make life easier for our customers. Who in your world builds reli ability into every product they develop We do. John Labora, manufacturing engineer Controls Compressors Condensing Units Gear Motors Adjustable Frequency Drives Valves Controllers Oil Pumps Thermostats Danfoss Dependable. 2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=3Vol. 2 Issue41Danfoss Dependable. CONTENTS Volume 2, Issue 4 WHAT WAS THE GREATEST INNOVATION EVERThe wheel The space shuttle The Internet When we think of innovation we think of those break throughs that have changed the way people live, inventions that have shattered notions about what is possible. And yet some of the most exciting innovation happens much more quietly, every day, within the industries we work. Improving technologies to solve realworld problems leads to the kind of tech nological advances that impact markets. In these pages you will nd stories of innovations that are improving processes, the environment, or quality of life. In every case, inspiration arose from customer demands and the rest was hard work turning an idea into a real solution. We wish all our readers a Successful and Happy New Year THE EDITORS, solutionsdanfoss. com www. northamerica. danfoss. com Ingenuity and Real World Vision Lead to Innovation . . . . . . . . . . . . . . 2 Back to Nature for Natures Sake Alternative Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Geothermal HVAC Keeps Health Care Facility Residents Comfortable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Flexibility in Variable Speed Control Leaps Forward with New Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Radiant Heat Gives Luxury Home a Warm Touch . . . . . . . . . . . . . . . . . 10 Fault Detection and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Product News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Jeff Duncan North America Motion Controls Nick Farrara Danfoss Flomatic Jennifer Hutchins Corporate Communications Aneta Stephens North America Heating Lisa Tryson North America Air Conditioning and Refrigeration DANFOSS SOLUTIONSis published for the benet of Danfoss customers. Information in the DANFOSS SOLUTIONS may be republished only with permission of editorial and always with credit to DANFOSS SOLUTIONS. Comments, suggestions, and contributions are welcome. This publication should not take the place of appropriate technical or legal advice related to companyspecic circumstances. DANFOSS SOLUTIONSdoes not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication. Design by Arista Advertising, Inc. www. Arista Advertising. com Dear Reader, 2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=4Creative impulse is part of human nature and every minute countless new ideas arise. The real challenge is to turn one of those ideas into an invention that people embracethis is innovation. Take, for example, Jack Kilby who forty years ago showed his coworkers a 716 by 116 inch slice of germanium. He didnt know his integrated circuit chip would revolutionize the computer industry. But the inventor had arrived at his discovery with a clear purpose in mind to replace the unwieldy and timeconsuming method of wiring together components and transistors. The computer chip is an innovation in the truest sense of the word, a rethinking of old methods that resulted in a leap in technology and took the marketplace by storm. Innovation is not always as dramatic or as farreaching as the computer chip. But the constant drive to create better technology and processes is what propels businesses forward and leads to true progress. Often innovation happens when a realworld challenge leads to a totally new way of doing things. This is the case with such advances as the modular Danfoss VLT Automation Drive FC 300 Series featured in this issue and the TU valve with bimetal connections that provides all of the benets of stainless steel expansion valves with copper connections to reduce time, cost, and complexity for brazing valves. An inventor with a vision In the 1920s, an engineer on the remote Danish island of Als named Mads Clausen worked with existing temperature control products and improved upon them to patent a number of components, including the radiator thermostat. This set the foundation for the company that is now the global industrial enterprise Danfoss AS. Clausen built his success on more than good ideas the inventor was focused on developing marketable products on which he could build a thriving busi ness. It is this spirit of realworld innovation that continues to fuel the company today. 3300 B. C. Evidence of rst wheel 1450 Johann Gutenberg introduces movable type 1769 James Watt debuts steam engine piston 1851 John Gorrie receives patent for rst refrigeration system 1640 Blaise Pascal invents adding machine 1752 Benjamin Franklin discovers lightnings electrical properties 1837 Louis Jacques Daguerre introduces photography Ingenuity and Real Lead to Innovation2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=5BEYOND INSPIRATION For every Jack Kilby or Thomas Edison there are thousands of inventors whose ideas never make it past a sketch or a conversation. And there are thousands of others who invest enormous amounts of time and money to develop a contraption that hardly gets noticed. Innovation does not occur in an isolated mind, but requires a vision of how an idea will impact the real world. In the article Are you an Innovation Guru from The Innovation Guru Journal, Elaine Dundon and Alex Pattakos dene innovation with four building blocks creativity, strategy, implementation, and protability adding value monetarily or to the organization. It takes all these factors to bring ideas to fruition and make an impact on the market. It often requires a team, rather than a single inventor, to take a stroke of ingenuity to the point of viable innovation that will strengthen business. BREAKING THE RULES WHILE MAINTAINING FOCUS Research shows organizations that have the most success introducing innovative products tend to focus on highimpact projects rather than spending a lot of time and resources on many lowimpact endeavors. This requires not only a culture of creativity, but also a thorough understanding of customer needs and market trends. It is this kind of focus on purposeful invention that has led to innovations within industry. Innovation is a matter of breaking the rules while maintaining focus. Kilby understood this perfectly and thats why when he stood before his coworkers with his toothpickthin chip, he launched a revolution in computing as we know it. What makes an organization innovative Innovation Management, The Innovation Guru Journallists the following characteristics of innovative organizations They encourage all employees, partners and suppliers to take an active role in innovation They welcome new ideas and new approaches They look to the future to anticipate the customers future needs They redene the rules of the game and challenge complacent competitors They empower their customers with information and more control over the purchasing process They embrace new technology to strengthen their competitive advantage 1884Paul Nipkow proposes mechanical scanner that set basis for television technology 1866Alfred Nobel invents dynamite 1957Russia releases the rst articial satellite, Sputnik 1903 Wright Brothers introduce enginepowered airplane 1885Karl Benz builds worlds rst practical automobile powered by internalcombustion engine 1959 Jack Kilby applies for computer chip patent World Vision 1876 Alexander Graham Bell introduces telephone2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=64 GLOBAL WARMING, OZONE DEPLETION AND LEGISLATION are some of the key factors that affect refrigerants used today and will continue to in the future. Some of the most troublesome ozonedepleting substances are chlorofuorocarbons CFCs and hydrochlorouorocarbons HCFCs. CFCs include refrigerants like R12, widely used just a few years ago and still in use. HCFCs include R22, used in many airconditioning systems and in commercial applications including supermarkets. Another HCFC, R123, found application in large environment cooling systems, known commonly as chillers. Due to efforts to reduce ozone depletion, these are two major groups of common refrigerants that will soon no longer be available to us. Yet our need for mechanical cooling continues to grow. To ll the void, research and investigation into various alternatives are taking place and some of them are already in use. In Danfoss scientic and application laboratories, research into alternative refrigerants like CO2 drives the development of new refrigerants and market demands. While some international accords provide for curtailment of greenhouse gases, the Montreal Protocol made production of CFC refrigerants illegal after 1995, and immediately banned their use as aerosol propellants. HCFCs hydrochlorouorocarbons are also ozonedepleting substances and, under the terms of the Montreal Protocol, the production and consumption of HCFCs the most common is R22, will be phased out in developed countries by the year 2015. HCFCs are used extensively in the refrigeration and air conditioning industry. When released into the atmosphere, CFCs and HCFCs contribute to both ozone depletion and global warming, raising public concern. Alternative Refrigerants Any uid can be used as a refrigerant. All thats needed is a sufcient supply of the uid and the ability to control pressure so that you can boil the refrigerant in an evaporator at a temperature that is the proper holding temperature for the product you want to refrigerate. Danfoss Dependable. Vol. 2 Issue4 Alternative Refrigerants Back to nature for natures sake Carbon Dioxide Most commercial carbon dioxide comes as a byproduct of other processes, like ethanol production by fermentation and ammonia manufacture. 2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=7Vol. 2 Issue45Danfoss Dependable. Natural uids, particularly the hydro carbon HC isobutane have been used for many years. This is the same uid used in gaspowered candles and cigarette lighters. It too is common, natural, and relatively cheap. It offers little threat to the ozone layer, and it has a very low greenhouse effect. However, it is also explosive under pressure, and though its temperature range works well, leaks are potentially very dangerous. Therefore it is used in small quanti ties, as required for home refrigerator systems. Still, because it is ammable, there is much resistance to its use in North America. Before there were CFC refrigerants like R12, a lot of refrigeration systems used ammonia, which today is in wide use in industrial systems. It is naturally occurring industrial quanti ties are manufactured, and a very efcient refrigerant. Unfortunately for commercial and home users, ammonia is highly toxic. Though it is possible to use it in some food storage ware houses, it isnt used where there is an elevated risk of leaks, and copper piping cannot be used with it components must be highgrade steel. Commercial and residential use of ammonia weaned when CFCs were introduced in the early 1920s. CO2as a Viable Alternative Another refrigerant in use prior to the introduction of the CFCs is carbon dioxide CO2. Its completely natural certainly isnt explosive, and its not toxic except that in high concentra tions it displaces oxygen, because it is heavier, making breathing difcult. CO2was still being used in 10 of refrigeration systems as late as 1956 and is making a comeback. Interest has been renewed for several reasons legislation and NGOs, environmental policies of major, global end users, and it has no ozone depletion potential at all and has very little global warming effect. Danfoss is putting considerable effort into researching the use of CO2as a refrigerant. In 1994, Danfoss started investigating, and successfully created technology for, application of CO2in automotive airconditioning. Danfoss developed CO2compressors and controls in the RACE consortium Refrigeration and Automotive Climate under Environmental Aspects, a Brite Euram Program. After the feasibility study was successfully completed, Danfoss sold its automotive knowledge to Robert Bosch in 1999. Currently Danfoss is applying its knowledge and experience to stationary applica tions for CO2refrigerant. The one drawback to CO2is the very high pressures at which a CO2refrigeration system must operate. Danfoss laboratories solved the problems of the highpressure CO2 refrigeration cycle, and today has developed a range of products for CO2systems. There has been consid erable interest in the Danfoss type TN compressor, designed and built speci cally for CO2applications. With CO2 compressors, Danfoss has successfully proven a technology and looks to the future for development. Interest in CO2refrigeration continues to grow, both in cascade systems, where it is used in a conjunction with more traditional refrigerants to allow the entire system to operate at positive pressure, and in systems where CO2 alone is used. No one refrigerant is the right solution for all applications. Ammonia, HFCs, and HC refrigerants are all viable alternatives for certain markets and applications, but as the dynamics of the market change, CO2 has spurred interest. And where there is interest, Danfoss innovates. 2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=86 An openloop groundwaterbased system was installed to maintain indoor comfort for the 151bed skilled nursing facilitys new 30, 000squarefoot wing. The modern poddesign building has central living rooms anchoring 51 apartmentstyle quarters, each with individual temperature control. The system takes full advantage of natural thermal capabilities with a highly efcient design that makes optimal use of equipment, including Mammoth interior watersource heat pumps and Danfoss VLT variable frequency drives. Due to its potential to save energy and preserve the environment, the project qualied for an 189, 000 grant from the New York State Energy Research and Development Authority NYSERDA. Extensive research showed that conditions were just right for a geothermal system, says Timothy Morrison, director of environmental services for The Heritage Group, the organization that man ages and operates Heritage Green. Its been running so well that we never have to use the backup boiler, which we were required to provide by regulation. Morrison anticipates the system, which was installed in July 2002, will show major savings once the fullyear data is available. On average watersource heat pumps deliver three to four times the amount of energy they consume. In general geothermal systems save from 20 to 60 percent over conventional heating systems. When designing the expansion, The Heritage Group turned to BCS, a company that provides designbuild mechanical, energy performance contracting, automated temperature controls and facility and process control solutions, to design and install the HVAC heating systems for the new wing. The big attraction to geothermal has been energy efciency, says Scott Derby, regional manager for BCS. We are seeing a lot more interest in this type of system as more facilities have success with it and demonstrate the potential to save money. A WEALTH OF SAVINGS IN THE SOIL Geothermal systems either draw heat from the soil, in closedloop systems that pump an antifreeze solution through underground pipes, or through an openloop system like the one at Heritage Danfoss Dependable. Vol. 2 Issue4 Geothermal HVAC Keeps Health Care Facility Residents Comfortable I n the rural countryside of upstate New York, nature keeps Heritage Green Health Care Center residents comfortable all year round. Temperature swings are extreme in the town of Greenhurst, dropping to subzero in the winter and soaring to 80plus degrees in the summer. But an abundant underground water reservoir, supplied by the surrounding foothills of the Allegany Mountains, holds steady at about 51 degrees Fahrenheit. These are perfect conditions for a geothermal system that uses the earths natural heating properties. Natural Heat As of 2001, U. S. total installed electric gener ating capacity was 813 gigawatts GW. Of this total, 74 was thermal mainly coal and natural gas, 12 nuclear, 12 hydro, and 2 renewables geothermal, solar, wind. U. S. Department of Energy2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=9Vol. 2 Issue47Danfoss Dependable. Green Health Care Center that draws heat directly from groundwater. Groundwater maintains a constant temperature year round in most parts of the world and it is relatively easy to tap with a simple pump, pipe, and heatexchange system loop. Geothermal systems operate on the principle of utilizing the energy stored in the earth. By moving energy to and from the ground, buildings are heated and cooled. The earth has the ability to absorb and store heat energy. To use that stored energy, heat is extracted from the earth through a liquid medium groundwater and is pumped to the heat exchanger where heat energy is exchanged between the ground water and the buildings water source heat pump loop. In the summer, the process is reversed and the indoor heat is extracted from the building and trans ferred to the earth through the liquid and heat exchanger. In addition to plentiful water supply, closedloop geothermal solutions also require water quality testing for things like hardness, acidity and iron. The systems cause no pollution because heat is simply taken from or added to the water via heat exchangers. We basically borrow energy from the ground, says Derby, and then its simply returned from where it came from. Its a great way to utilize renew able energy. With geothermal systems there is always concern, however, that too much water will be drawn from the aquifer supply. Preconstruction testing by BCS showed that the system at Heritage Green did not affect the water column even after pumping 1000 gallons per minute for 24 hours. We always suspected we had a large pocket of water underneath part of the prop erty and after the testing, we were con dent we found a sustainable source for renewable energy, said Morrison. In fact, the water table was so high that only two, 10 supply wells, less than sixty feet deep, were needed. Each of the two water wells is tted with a 30HP Bell Gossett submersed pump to send water up through the piping system to the heat exchangers, where the energy is extracted. The well water leaves the heat exchangers and is sent back to the ground via four replacement wells. The ground water temperature has a minimum exchange of about 7 to 8 degreescompare that to up to 40 to 60 degrees differential that an airtoair heat pump handles, and even greater differentials for standard furnaces. In the summer the process is reversed and the indoor heat is extracted from the building and transferred to the earth. Both well pumps are equipped with Danfoss VLT variable frequency drives to regulate the amount of water pumped through the system. The two 15HP building loop pump exchangers are also equipped with Danfoss VLT 6000 HVAC drives for precise pump motor control and maximum energy efciency. CONSISTENT IN ALL CONDITIONS Varying sun exposure to the building calls for different internal heating and cooling loads, which the geothermal system handles effectively. Heat pumps use the refrigeration process to transfer heat energy from the ground to the living space for heating and from the living space to the ground for cooling. Though the heat pumps may have to run more on cloudy, cold days they do not run less efciently. Unlike conventional furnaces, the heat pumps dont need to create heat but rather harvest existing heat, which means energy savings. In winter, its easier to capture heat from the moderate water temperature than from the atmosphere when temperatures are2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=108 O ver the past decade, signicant advances in variable speed drive technology have increased functionality, heightened performance, enhanced communications capabilities, opti mized unit size and improved reliability. Yet, selecting drives has become increasingly challenging as the range of applications grows. Now drives adaptability takes a leap forward with the launch of a modular, open technology platform. The advent of the Danfoss VLT Automation Drive FC 300 is changing conventional thinking about motor control exibility. Manufacturing process demands for motor control can vary from simple speed to control to highperformance positioning, responsiveness and accuracy. Traditionally, this required the production facility to install numerous drive types from several suppliers, posing problems in mainte nance costs, production efciency, and user complexity. The latest generation of Danfoss variable frequency drives involves an innovative modular design to handle every specic motor control requirement with a single product platform. This exibility means industries can take advantage of motor control performance for any application while keeping costs down. At Danfoss Drives headquarters in Denmark, the components of the Automation Drive units are produced in large volume then built to custom reconguration in a sophisticated assembly process. The plant uses advanced robotics and automation in a genius logicsetup. Through this mass customization process, a myriad of congurations is possible, but due to the latest manufacturing systems a unit can be built and tested within two hours. Software specically developed for the VLT Automation Drive FC 300 Series controls assembly dictated by the customers request and can provide nextday delivery. The customer specic order is congured by a dened type code and the Danfoss system checks whether or not the variant has been produced before. If it hasnt, the automated system gener ates all the necessary manufacturing documentation and information nec essary to produce the unit, without impacting the delivery schedule and sets in motion a Just in Time process that assembles, tests and delivers the product with languageand product specic manual. Danfoss Dependable. Vol. 2 Issue4 PRODUCT FEATURE below zero, allowing warm air to blow through the ventilation system. In the summer watersource heat pumps use the consistent groundwater temperature as the starting point so less energy is needed for cooling. The Heritage Green system provides heat exchange capability for 360 gallons per minute gpm and is equipped to handle the heating for the entire 151bed facility, when the older section is renovated to include geothermal. The central mechani cal system is essentially contained in the underground wells and pumping systems. No chiller, cooling tower, or boiler plant is necessary. A compact mechanical room is all that is needed to house the plateframe heat exchangers, BG building loop pumps, small Patterson Kelly backup boiler, valves, Danfoss drives and the systems controls equipment. To control 54 zones, including resident rooms and common areas, there are also 54 separate heat pumps. Each occupant has individual environmental control, says Morrison. The heat pumps maintain individual room and area climate condi tions within tight parameters. The entire geothermal system is controlled and monitored by a Webbased automated controls system, installed by BCS through a remote system, which allows Morrison to keep tabs on every component using his laptop, including temperature set points, pump activity, well pressure, graphical trending, etc. The LAN Web based system is integrated to The Heritage Groups multicampus ber optic network which also links three of their other health care facilities several miles away. I watch this thing con stantly, says Morrison. And so far the system has met all of our expectations. Flexibility in variable speed control leaps forward with new drives2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=11Vol. 2 Issue49Danfoss Dependable. ONE SOLUTION FOR EVERY DEMAND The same drive concept is applied to motor control throughout an industrial operation, from general performance to servo, to a single machine or an entire production line, eliminating the need to utilize various versions of drives solutions. The VLT Automation Drive FC 300 Series meets demands of AC motor applications from General Purpose to Permanent Magnet with power demands from fractional to 10HP 200600VAC. It also is compatible with other drives solutions, easily recongured to match application modicationsrecon guration is plugandplay. A typical manufacturing facility may include a conveyor, for example, that requires a variable frequency drive to control the process speed widely varying load conditions, while at the same time another part of the installation demands a unit to control a packaging machines coordinated operation. The VLT FC 300 Series addresses all these specications. A standard version of the drive meets load changing and precision speed control demands of the conveyor, while the same drive equipped with the appropriate available modules can be applied to a high performance packaging application in order to meet positioning, synchronizing, and highshaft operation. In the case of a positioning conveyor installation, the VLT Automation Drive units Precise Pulse Reference follows the encoder from a master to make sure the conveyor operates at the appropriate speed and prod ucts come to exactly the right place at the right time. The products will stop with preci sion regardless of load conditions as the drive adjusts for the speed of the object as it passes the sensor for a precise stop. A SMART DRIVE The VLT Automation Drive monitors, analyzes and takes action to make sure production continues to run smoothly. The user can program it to adapt to complex operations at various points in the line using the built in Smart Logic Controller for essential control functions or an optional MCO Programmable Logic Controller for advanced operations. Combining the two solutions allows the user to replace external PLC equipment in most situations, lowering costs and making installation easier. The controller is simple to congure and enables the drive, motor and application to work together through a preprogrammed chain of events, or by monitoring peripheral devices such as load sensors, photoelectric sensors, dancers, encoders, or other common feedback devices. The FC 302 version automatically makes the sequence through the operation after it receives the initial start command, following the predetermined customer programmed operating prole. At the end of the opera tion the unit will stop to await the next start command, or the Condition Controller can be programmed to generate an internal start and reinitiate the entire process. A SAFE AND RELIABLE DRIVE The VLT Automation Drive FC 300 Series handles safety challenges with a variety of enclosure grades, builtin protection against electrical disturbances, and conformal coating for printed circuit boards. A Safe Stop func tion for category 3 installations according to EN 9451 prevents unintentional starts. To leverage the power and performance potential of the VLT Automation Drive, a highly effective heat management design for the units power components has been incorporated. The VLT Automation Drives modularity and exibility position it to quickly and costeffectively address existing and future market demands. The user interface for the VLT Automation Drive FC 300 Series is simple to operate. The intuitive Local Control Panel LCP has total display capabilities, including graphs and charts and six set language options, plus a local language option. Quick menus, illuminated buttons and other features also were developed through intensive user studies. Installation is simple with such attributes as the twopiece plugin terminal blocks for all connections and the springloaded terminations for logic wiring. A FRIEN2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=1210 The owners of a beautiful luxury home located in Clifton, Virginia, learned through their travels to Europe about the benets of radiant oor heating. When they returned they wished to nd a hydronic system ideal for their 18, 000squarefoot residence. Conventional forcedair systems or other heating methods produce uneven heat and send the highest temperatures upward, toward the ceiling. Hydronic radiant heating, popular in Europe and Asia, is gaining momentum in the United States. It radiates heat from the oor for even, gentle warming of a building. This means more indoor comfort and potential to decrease monthly fuel bills. The Clifton house was divided into 23 individual zones including a private theatre, recreational rooms, a number of bedrooms and other living areas. Surrounded by serene, delightfully landscaped gardens and shponds, the homes lush setting was also per fect for a snow and ice melt system and pool heating. Looking for the ultimate in indoor and outdoor comfort, they hired Dan Foley of Foley Mechanical in Alexandria, Virginia, to do the job. Foley turned to Danfoss for its expertise in radiant heating and zone panel systems. The Danfoss ZCP system was extremely costeffective, says Foley. We saved several weeks on the job by installing the preengineered and prefabricated panels. FROM THE FLOOR UP There are typically three components to a radiant heating system a heat source, a distribution piping system, and controls. The heat source in hydronic radiant oor heating systems is usually a boiler or a hot water heater. A circulator pump near the water supply manifold moves the water from the mixing valve to the supply manifold and into the distribu tion piping system tubing inside the oors. A properly designed radiant oor system will not exceed 29C 85F. To select how warm or cool a room or entire home will be, controls set the system to a particular tempera ture. A manifold system with a thermostat typically located in an accessible wall cavity controls a series of simple valves that are used to regulate the ow of water through each zone. Floor heating is much cleaner and healthier than the alternative. It reduces the spread of dust, pollen, and other airborne pollutants. Anyone with allergies can appreciate this benet. Since oor heating is builtin, it doesnt affect the appear ance of a room and allows complete design freedom. Furniture can be placed anywhere without concern over how it affects the performance of the heating system. Floor heating is virtually silent, helps keep oors clean Danfoss Dependable. Vol. 2 Issue410Danfoss Dependable. Radiant Heat gives luxury home a Warm Touch Photographs Copyright 2003, Bill Burton2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=1311Vol. 2 Issue4Danfoss Dependable. and dry and can increase property values. Other benets include easy and unlimited zonability, and easy maintenance. It also offers longrange environmental benets. Fuel converted to electricity at a central plant is about 40 efcient, between the plant and a remote home. Onsite energy source, such as the boiler, is 87 efcient. Zoning a variety of rooms for different temperatures has the potential to reduce energy consumption. The system and controls installation process however, could be time and labor intensive. To reduce the installa tion time Danfoss offers prefabricated, preengineered and prewired Zone Control Panels. To many homeowners and contractors, todays traditional hydronic systems are a maze of controls and piping. Jobs that involve onsite engineering and fabrication result in extended installation time and unexpected costs. Control wiring and testing repeatedly require the services of additional trades. The prefabricated panels avoid these problems. In the Clifton application, Brian Wheeldon and Todd Skuce of Danfoss Heating Division rose to the challenge with technical and engineering support. They laid out the entire boiler room indicating zones for each ZCP panel. Foley says the application knowledge is as important as the products and that the time reduction with the ZCP is signicant. The heating system not only provided indoor comfort but also the dream snowmelt system and pool heating the homeowners desired. The warm coziness of radiant heat, snowfree driveways and a warm pool created a perfect environment for the homeowners. There are no more hot or cold spots and no drafts. More than 90 percent of homes in Europe use hydronic heat. In the United States, about 8 percent heat homes with hydronic systems. Did You Know2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=1412 S o much information, so little time. We have so much data so easily available to us today that putting it all to use is just not possible. In refrigeration control and monitoring, systems like Danfoss ADAPKOOL have hundreds of sensors to collect performance and environmental data that we might need at any time tuning refrigeration equipment or satisfying health department requirements. ADAPKOOL systems also include alarms that warn of conditions that are or might be dangerous to the safety or healthfulness of stored products. Research at the Danfoss refrigeration lab oratories has led to new ways for analyzing and using sensor information, and we now have algorithms to predict with some certainty when a specic kind of equip ment malfunction will occur. Two steps are involved in the process. Fault detection is about sensing that something is not working according to design. Then, fault diagnosis begins, in much the same way as a health professional evalu ates a collection of symptoms to diagnose and identify an illness. Once a correct diagno sis has been made, it is possible to take curative action specic to the problem. Danfoss calls the new functional algorithms FDD Fault Detection and Diagnosis, and has begun to include the new program modules in its controller software. FDD makes the control system aware of degraded equipment performance, enabling pinpoint intervention by service personnel before the refrigeration system fails to meet performance requirements. FDD can nd degradations that will cause increased energy consumption or perhaps cause damage to equipment. FDD also enables conditionbased maintenance as opposed to preventive maintenance and faultbasedmaintenance that are the current standard. Preventive is when you perform service in anticipation of a fault. Faultbased is when service is not performed until a fault has occurred. In conditionbased maintenance you perform service before the fault occurs, when FDD tells you one is about to occur. Conditionbased maintenance avoids costly breakdowns, eliminates unnecessary maintenance, and allows the service provider to schedule work to his advantage. The FDD software module can inform a monitoring center so that a dispatched service technician arrives with foreknowledge of the problem. Never was the expression forewarned is forearmed more true. Knowing the nature of the problem, the servicing organization can decide the priority of the call, and the technician can save time by being prepared with tools and spare parts to service the specic problem. Algorithms pinpoint problems caused by dirty or blocked condensers. Also in develop ment are modules that will point to icing evaporators, overloaded display xtures, case airow blockage, evapora tor fan faults, and refrigerant loss. FDD algorithms are sophisticated, but they require only the usual sensors found in most supermarket systems. Most are based on computing energy balance with great precision, and by considering the energy levels in different ways to determine what situations probably exist. Then more data is considered to target the problem. FDD started as an academic discipline based on the concept of analytical redundancy. It is another innovative Danfoss solution that makes its customers more secure and more able to enjoy their productive business life. Danfoss Dependable. Vol. 2 Issue4 Fault Detection and Diagnosis2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=15Vol. 2 Issue4Danfoss Dependable. Servo Like Performance at Half the Cost with Sync Pos Danfoss Drives VLT 5000 FLUX Series drives are now available with an optional Sync Pos control card for additional positioning and synchronizing control. The Sync Pos control card is programmable to suit specic application requirements, greatly enhancing drive operation without requiring extra panel space or wiring. A combination of the VLT 5000 FLUX Series drive and Sync Pos option provides servolike performance at only 5075 the cost of a typical servo system. VLT 5000 FLUX Series drives provide dynamic ux vector control for applications up to 500 HP, and are designed with the latest Digital Signal Processing DSP technology to fulll the high performance market for closed loop AC drives. These drives are ideally suited for applications requiring precise closed loop control, including hoisting, precise positioning, elevators, centrifuges, and torque control applications, among others. For more information, contact Danfoss Drives 800 4326367. Engineered Panel Solutions Panel solutions are available across Danfoss complete family of drive products and power sizes. They provide a complete control solution in nearly any industrial application that uses variable frequency drives for machine and process control. Panels are available in preengineered congurations, or can be customized to meet specic application requirements. Preengineered panels feature fuseddisconnect panel and bypass panel congurations, 2 and 3 contactor bypasses, and common startstop functionality. Additional features include Undervoltage relay Dual motor selection various Fuse and disconnect options various Enclosure sizes and environmental ratings Control switches Indicator lights Inputoutput lters, and Meters. Custom panels provide harmonic solutions, system communications and inputoutput reactors in NEMA 1, 3R, 44X, and 12 enclosures. Additional features include Auxiliary enclosure for customersupplied equipment Alternative mounting congurations Heatingcooling options Air ltration Soft starter panels Soft starter for AFD bypass panels Cable entryexit options Dual motors and Multiple drives in a single enclosure. Danfoss has also developed unique panel solutions to meet a wide range of customer design requirements, such as dock levelers, conveyors, hangar doors, wood working machines and scissor lifts. For more information, contact Danfoss Drives 800 4326367. PRODUCT NEWS Extended size for steel check valves Danfoss Flomatic Corporation introduces an extended size range series 80DICL Ductile Iron Check Valve and series 80S6CL Stainless Steel Check Valves in 2 through 6 in two different models. These new valves incorporate a patented lock type pipe connection for PVC drop pipe called Certa Lok, a trademark by Certain Teed Corporation. The groove lock makes it easier to assemble or disassemble the pipe by hand, without special tools and eliminates extra ttings. The new 2 size complements other larger sizes through 6 in both Stainless Steel and Ductile Iron. The model 80DICL Ductile Iron Check Valve is fusion epoxy coated inside and out with a patented poppet assembly and a high strength unleaded body with a stainless spring and NITRILE Buna N seal. The 80S6CL is all 316 Stainless Steel body construction including internal parts with a VITON , which is a registered trademark with Du Pont Dow Elastormer, LLC, sealing. Both models are also available with an optional NPT threaded male end, model 80MDICL. The 80DICL and the 80S6CL series valves will provide excellent service with PVC well drop pipe. The new Certa Lok type connections check valves extends Danfoss Flomatic Corporations Ductile Iron series 80DI valves and Stainless Steel series 80S6 NPT female threaded valves, the most popular valves in the water well industry today. They are specically designed for use with submersible water well pumps or other applications where it is necessary for check valve to be installed in the w2007-07-03T12:15:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/Solutionsv242004/?Page=16January AHRInternational Airconditioning, Heating, and Refrigeration Expo. January 2628, 2004, Anaheim Convention Center, Anaheim, CA, Danfoss Booth 4729. AKC Supermarket Electronic System Training January 2728, 2004, Baltimore, MD. For more information call 4109318250. Series 10002000 Electronic Control Training January 29, 2004, Baltimore, MD. For more information call 4109318250. February IIAR International Institute of Ammonia Refrigeration February 29March 3, 2004, Gaylord Palms Resort Convention Center, Kissimmee, FL. 54th SWRA RSES Conference February 2628, 2004, 54th SWRA RSES Conference, Best Western Landmark Hotel, Metairie, LA. March Canadian Mechanicals Exposition 2004, CMX 2004 March 2527, 2004, Metro Toronto Convention Centre. The National Trade Show and Learning Forum for the heating, ventilation, air conditioning, refrigeration and mechanical plumbing industries. April AKC Supermarket Electronic System Training April 2728, 2004, Baltimore, MD. For more information call 4109318250. CALENDAR OF EVENTS Please mention that you read about the event in Danfoss Solutions HOW TO CONTACT DANFOSS BALTIMORE, MD 7941 Corporate Drive Baltimore, MD 21236 4109318250 Fax 4109318256 www. acr. danfoss. com www. danfoss. comusic Refrigeration Air Conditioning Industrial Controls Components for Oil Burners GLENS FALLS, NY Flomatic Corporation 145 Murray Street Glens Falls, NY 12801 5187619797 Fax 5187619798 EMail omaticomatic. com www. omatic. com Water Controls LOVES PARK, IL Danfoss Drives 4401 N. Bell School Road Loves Park, IL 61111 8156398600 Fax 8156398000 www. namc. danfoss. com Drives Industrial Sales MILWAUKEE, WI 8800 W. Bradley Road Milwaukee, WI 53224 4143558800 Fax 4143556117 www. namc. danfoss. com www. na. water. danfoss. com Danfoss Graham HVAC Danfoss Water Wastewater Nessie Water Hydraulics MISSISSAUGA, ONT 7880 Tranmere Drive Mississauga, ON L5S 1L9 Canada 9056766000 Fax 9056760279 www. danfoss. ca Heating Controls Motion Controls SOMERSET, NJ Danfoss Bauer 31 Schoolhouse Road Somerset, NJ 08873 1212 7324698770 Fax 7324698773 www. danfoss. comdrivesus Gearmotors Danfoss and Johnstone Announce Alliance DANFOSS INC. , AIRCONDITIONING AND REFRIGERATION DIVISION and Johnstone Supply recently jointly announced a new alliance. The two companies have agreed that Johnstone will enjoy the benets of the Danfoss Authorized Full Service Wholesaler program. Beginning in the Fall of 2003, a greatly expanded offering of Danfoss and Danfoss Maneurop airconditioning and refrigeration products will be available through Johnstone Supply wholesale outlets in several regions. The Full Service program will focus on the critical store level activities that enhance the wholesalers ability to deliver real value to their customers, explained Jeffrey Douglas, vice president for aftermarket at Danfoss Inc. Our partnership will include regular training, professional marketing, and a high level of technical support. Mark Westerback, marketing manager for Refrigeration Products at Johnstone Supply, explained, Our goal is to continually improve on the depth and breadth of our product offering to our customers. Expanding our Danfoss offering complements our existing lines and positions Johnstone to be a complete source for all of the HVACR technicians needs. The local training, support and technical services that Danfoss has committed to provide will benet our stores and help us become the premier choice for the contractors in these markets. Furthermore, increased availability in these regions will improve the contractors ability to acquire Danfoss products. 2007-07-03T12:15:16+02:00