http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/RSS.ashxRA PagesTue, 03 Jul 2007 12:47:02 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=1MAKING MODERN LIVING POSSIBLE Experts Speak Out On The Energy Issue 2 Variable Frequency Drives Step Up Cooling Control In Supermarkets 7 Designbuild Firm Mixes Up Efcient Solution For Juice Maker 10 Customers Get Payback Info From Energy Analysis In A Box 14 Advanced Motion Control Solutions For Industrial Processes 16 Product News 202007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=2Great partners create the coolest ways to control hot energy coststhats En Visioneering SM. MAKING MODERN LIVING POSSIBLE High energy costs make everyone sweateven ice machine makers. Thats why an industryleading icemachine manufacturer looked to Danfoss for an innovative solution. They liked what they saw a unique combination of engineering innovation, energy eciency, and environmental responsibility that we call En Visioneering SM. As an En Visioneering partner, Manitowoc Foodservice Group leveraged our experience in helping industry leaders meet critical challenges. By applying customengineered Danfoss lter driers, compressors, expansion valves and solenoid valves, Manitowocs SSeries ice machines now lead the way with 25 more energy eciency, plus greater reliability. Dont sweat the details of your next HVACR challenge. Get a fresh perspective at www. envisioneering. danfoss. com ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=3CONTENTS Volume 5, Issue 2 We are proud to say that the Danfoss En Visioneering SM approach, announced earlier this year, has already achieved notable success. We have been getting the word out about how we inspire partnerships through engineering innovation, energy eciency, environmental responsibility, and sustainable business growth. More importantly, we have been showing how this approach leads to product and application solutions that raise standards in performance and eciency. Our advertising campaign related to En Visioneering has won several readership awards and we have launched a conference series that brings together top thinkers in the HVACR, motion control and industrial automation sectors to address issues that impact our industries. One of those topics is energy savings. In this issue of En Visioneering Solutions you will learn about the latest technological developments in energy eciency and how they are being applied to achieve better business results responsibly. As always, your comments are welcome. THE EDITORS, solutionsdanfoss. com www. envisioneering. danfoss. com The Experts Speak Out On The Energy Issue Dr. Stephen O. Andersen, Director of Strategic Climate Projects, United States Environmental Protection Agency US EPA Kristen Taddonio, Strategic Climate Projects, US EPA and Stephen Yurek, General Counsel for the Air Conditioning and Refrigeration Institute ARI . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Variable Frequency Drives Step Up Cooling Control In Supermarkets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Designbuild Firm Mixes Up Efcient Solution For Juice Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Customers Get Payback Info From Energy Analysis In A Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Advanced Motion Control Solutions For Industrial Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Product News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 This publication should not take the place of appropriate technical or legal advice related to companyspecic 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. Design by Arista Advertising, Inc. www. Arista Advertising. com Dear Readers, MAKING MODERN LIVING POSSIBLE When Energy Prices Hit The Pocketbook, Consumers Listen 2 Designbuild Firm Mixes Up Efcient Solution For Juice Maker 4 Customers Get Payback Info From Energy Analysis In A Box 8 Variable Frequency Drives Step Up Cooling Control In Supermarkets 10 Advanced Motion Control Solutions For Industrial Processes 13 Product News 16 1Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM Jeff Duncan North America Motion Controls Jennifer Allison Corporate Communications Aneta Stephens North America Heating Lisa Tryson North America Refrigeration and Air Conditioning DANFOSS ENVISIONEERING SOLUTIONS is published for the benet of Danfoss customers. Information in the DANFOSS ENVISIONEERING SOLUTIONS may be republished only with permission of editorial and always with credit to DANFOSS ENVISIONEERING SOLUTIONS. Comments, suggestions, and contributions are welcome. 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=4En Visioneering Solutions discusses the energy issue with three top experts in industry and government. The current energy crisis might be better characterized as an inef ciency crisis. 2Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING En Visoneering Solutions What is the true scope of the energy crisis today Stephen O. Andersen e energy crisis is a multidimensional challenge of protecting prosperity in the face of diminishing reserves of nonrenewable resources while at the same time protecting the environment and quality of life. My job at the Environmental Protection Agency EPA is to use voluntary partnerships to help protect the climate. I have the advantage that any longterm solution to the energy crisis will necessarily have to protect the climate. Many atmospheric scientists agree that human activities, such as the use of fossil fuels, are contributing to signicant rise in greenhouse gasesespecially CO2and that climate change and global warming are real consequences. ere is uncertainty about how fast the climate will change and whether the earths natural systems will respond in ways that ameliorate the damage. Regardless of how you view climate change science, it is clear that it takes time to nd alternative energy sources and to improve the technical performance of technologies used in manufacturing, transportation, and all other human endeavors. Kristen Taddonioe current energy crisis might be better characterized as an ineciency crisis. e prevalence of inecient products, practices and infrastructure in todays world keep energy demandand consequently priceshigh and contribute to environmental problems. Energy eciency and renewable energy are solutions that help the environment and increase energy availability at the same time. on the EXPERTS SPEAK OUTENERGY ISSUE Energy prices are on the rise, fossil fuel resources are decreasing, demand for energy is increasing, and climate change is recognized and documented by science and policy making communities. These issues pose major challenges globally, but there is an upside they lead to innovative thinking and new technologies for energy efciency. Here En Visioneering SM Solutions discusses the energy issue with three top experts in industry and government Dr. Stephen O. Andersen, Director of Strategic Climate Projects, United States Environmental Protection Agency US EPA Kristen Taddonio, Strategic Climate Projects, US EPA and Stephen Yurek, General Counsel for the Air Conditioning and Refrigeration Institute ARI. Interview with Dr. Stephen O. Andersen and Kristen Taddonio The SUCCESS IN EFFICIENCY GETS BOTTOMLINE RESULTS2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=53Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM En Visioneering Solutions discusses the energy issue with three top experts in industry and government. The current energy crisis might be better characterized as an inef ciency crisis. 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=6Manufacturers are going beyond the standards and trying to compete to be the one with the highest SEER rating. En Visioneering Solutions What are the main causes of the surge in demand and the shortage in supply that has led to the energy shortage Stephen O. Andersen ats a complex question, but fundamentally we are experiencing an unanticipated consequence of success success in economic development, technological advancement, and health and medicine. Increasingly large populations live longer and consume more products that are based on nite energy resources that geologically accumulated over millions of years of time. e whole fabric of recent modernization has depended on harnessing energy, and to a large extent that has meant burning fossil fuels. We nd ourselves building on an energy infrastructure that was developed during the course of the 20th century on the basis of vast energy availability. at investment had unintended consequences to the environment and is getting old, overused, and unsustainable. Economic development in India, China and elsewhere has shied energy demand sharply upward and as a consequence, there is little excess capacity le anywhere in the system. En Visioneering Solutions You say that many environmental innovations come from management and leadership recognizing that customers demand environmental protection and the prots increase with pollution prevention. . . . Do you think that this attitude is widespread or the exception in todays industry Stephen O. Andersen In an odd way, it is both widespread and the exception. Many industry leaders have recognized that products that help to protect the environment can strengthen a companys market position and add to its bottom line. ere is a genuine demand for sustainable green products, and as energy becomes more expensive, the market forces favoring these products will become stronger. Increasingly one sees technological innovation that is good for the environment and a good investment. e energy savings result in pretty short payback times and an ongoing savings investment grade ROI. In addition, we are understanding the importance of energy independence for national security. But human behavior and energy markets are complex, and sometimes incentives do not align so easily, perceptions dont keep up with technology, and obstructions can come between the producer and the end user. e result can be that environmental protection takes a back seat to shortterm thinking, even when responsible energy use products are more economic within a few years of purchase. ese are things we have to work on. e market forces we spoke of in Industry Genius are strong, and manufacturers nd it pretty hard to compete if they dont keep up and even try to lead, especially in energy eciency. But government has an important role in smoothing the way and educating the market. Government can also set standards, which can have a pretty dramatic eect on transforming markets. Governmentindustry partnerships are one of our most powerful tools. It takes initiative from both sides, but when government and industry decide to work together, the results can be pretty impressive. Kristen Taddonio Look what Wall Street says on this question. According to publications like Business Week magazine and the New York Times, investment in green companies and technologies is at an all time high, and management and stockholders are deciding that environmental protection is a real business opportunity. is seems to indicate that attitudes are changing. If the trend holds, we can expect to see more environmental innovations as a result. En Visioneering Solutions How can EPA help a company like Danfoss and its customers to nd protable markets for environmentally superior technology in a way that has a global impact Stephen O. Andersen Danfoss can contribute to climate protection by increasing its own manufacturing eciency and by helping customers use less energy. Governments can encourage energy eciency by cer2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=75Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM En Visioneering Solutions What are the main issues today facing our industries in terms of the environment Stephen Yurek e biggest issue facing the industry in general is the energy shortage. On the supply side there are limited energy sources to meet the ever increasing demand. At the same time there is the issue of increased energy demand in the developing world, such as in India, China, and Brazil, where they are getting used to the comforts of the developed nations and putting more strain on the limited resources. Also, there are major concerns about climate change and how energy use contributes to that, including burning fossil fuels. En Visioneering Solutions Is the HVACR industry eectively addressing these challenges Stephen Yurek Yes. e industry is developing more ecient equipment for residential and commercial cooling and commercial refrigeration. We are seeing more and more components on the market that achieve higher levels of eciency. On the airconditioning area residential side, one major development has been components that help equipment meet the SEER eciency ratings. Now manufacturers are going beyond the standards and trying to compete to be the one with the highest SEER rating. En Visioneering Solutions Weve known about the problem of demand outpacing energy supply for a long time, what is nally driving the industry to make changes When Energy Costs Hit The Pocketbook, Customers Seek New Technologies Interview with Stephen Yurek, General Counsel for the Air Conditioning and Refrigeration Institute ARI Continued on next page. Manufacturers are going beyond the standards and trying to compete to be the one with the highest SEER rating. It advocates Life Cycle Climate Performance LCCP to minimize the joint greenhouse gas emissions from chemical emissions and from associated energy consumption. Kristen Taddonio Sometimes a technology that minimizes environmental impacts in one area will actually increase environmental impacts in another area. For example, a new refrigerant chemical may reduce greenhouse gas emissions from leakage, but increase greenhouse gas emissions from energy consumption. e challenge is to weigh all of the variables, and select the technology with the fewest overall impacts. En Visioneering Solutions What actions can we expect from the EPA in the future that will help drive energy eciency Stephen O. Andersen EPA is using voluntary partnerships, ENERGY STAR labels, and government procurement incentives to promote both energy eciency and climate protection. We show companies and people how to save money and save the environment and we are open to new initiatives that support global environmental protection. EPA welcomes project suggestions from companies, industry associations, and environmental organizations. Kristen Taddonio EPAs successful Energy Star program is continually revising and upgrading its requirements for the sought aer ENERGY STAR label. ese routine updates keep the bar high and drive energy eciency improvements in many markets. Recently, EPA launched the Clean Energy Environmental State Partnership Program, which encourages state ocials to develop and implement comprehensive clean energy strategies that will lead to public health and economic benets. ese actions can be expected to drive energy eciency in the future as well. For a comprehensive report on EPA energy eciency programs and plans, visit www. epa. govcppd and click on annual reports. n2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=86Vol. 5 Issue 2 Stephen Yurek Consumers are putting the demand on manufacturers, especially larger and more sophisticated consumers put on the pressure in the commercial and industrial sectors. But also residential consumers as they want to reduce monthly bills. And there is also the regulatory pressure pushing the industry toward more ecient equipment. en theres the environmentalists and energy eciency advocates who are trying to entice consumers to buy more ecient equipment. e real struggle is to get consumers to understand the benets of going beyond the minimum equipment requirements. En Visioneering Solutions What will get people to make the changes necessary to help alleviate the energy shortage Stephen Yurek When it hits consumers in the pocketbook thats the fastest way to get to them. ere are also many educational programs out there. ARI and its members, for example, have e Perfect Match, a program to educate homeowners about the importance of choosing an ARI Performance Certied matched airconditioning systems to achieve the maximum level of energy eciency. e Federal government also has promotional campaigns to educate consumers about the value and availability of ecient equipment. ere is the wellknown Energy Star program, so successful it has been adapted by the European Union, Canada and Australia. But when customers see their utility bills go up they really start searching for solutions. For example in the year 2000 in California when they had the major energy crisis, the price of electricity went up considerably and there was a huge spike in purchase of energy ecient equipment, as well as a change in habits. En Visioneering Solutions Is technology up to pace with the need to address the energy shortage Stephen Yurek Technology is ahead of where consumers are and where the market is right now. Manufacturers have been very forwardthinking in using RD to develop technologies that deliver highly ecient refrigeration and air conditioning. A lot of technologies are in the testing stage and not yet perfected for wide distribution, but manufacturers are continually pushing the envelope to make compressors and valves more ecient, for example, and perfecting motors and drives and coils and other things. ARI does precompetitive research with great results. We have been looking at the coil, a big part of the heat transfer, looking at the traditional coil, round copper or aluminum tube. We investigated what would happen if we atten the tube, and what we found out is that using the at tube you have better eciency. is research was just released, and we continue to do this kind of research, which is free and available to the public. En Visioneering Solutions It seems manufacturers could be better recognized for the part they play in helping to reduce energy usage and nding alternative energy solutions. Stephen Yurek is industry needs to get its story out more about how it is very advanced, forwardthinking, and in the forefront in creating technology that is environmentally ecient. n About The Air Conditioning and Refrigeration Institute ARI The Air Conditioning and Refrigeration Institute ARI is the trade association representing manufacturers of more than 90 percent of the airconditioning and commercial refrigeration equipment installed in North America. An internationally recognized leader in developing standards for and certifying the performance of these products, ARI is also a major advocate for the heating, ventilation, airconditioning, and refrigeration HVACR industry both domestically and abroad. For more information visit www. ari. org. Technology is ahead of where consumers are and where the market is right now. 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=97Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM Step Up Cooling Control In Supermarkets About thirty years ago, supermarket evolution accelerated. Stores rapidly increased in size to bring greater variety to a public becoming more sophisticated in tastes and appetites. A proliferation of new products required much more refrigerationmore cooling circuitsto serve the greatly increased variety of products. Back then, in most cases each refrigeration circuit in a supermarket had its own compressor for one or two cases other circuits served storage and workrooms for products including meat, poultry, dairy products, and ice cream, each circuit requiring its own optimum storage temperature for best product life. With single compressors, failures usually resulted in costly product losses. Soon twocompressor twin racks made things a little more failsafe, and were also a big step because their arrival meant that there were three cooling capacities available using 0, 1, or 2 compressors. en came trio racks to provide 4 dierent capacities. A trio might serve half a dozen or more circuits. Fourcompressor racks brought with them the golden age of uneven parallels. e conguration included dierent sizes for example, one 5 HP, two 10 HP, and one 20 HP compressor. Such a conguration could produceby running compressors in dierent combinations, 0, 5, 10, 15, 20, 25, 30, 35, 40, or 45 HP10 capacities from just four compressors. Because of the capacity available, some quads had fourteen or more circuits connected, generally using EPR evaporator pressure regulating valves to provide varying suction pressures for the dierent xture temperatures. AK2SC 255 Variable Frequency Drives2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=10ere was a downside to staging refrigeration with uneven parallels more cycling increased wear. To change from 20 to 25 horsepower was easy turn on one 5 HP compressor. But to drop from 20 to 15, the 20 had to cut o, and a 10 and a 5 had to start up. DRIVES TAKE REFRIGERATION TO NEXT LEVEL In the late 1980s, refrigeration engineers began to design racks with an inverter a variable frequency drive. ese electronic drives, interfaced to an electronic rack controller, could run a compressor from 30 of rated speed to 105. Now a rack could have an innite number of capacity steps. Drive control strategies reacted quickly to load changes. Todays drives are reliable in 24hour operation, easy to program, and have simple, informative displays. Danfoss drives are fully solid state, reliable, and require little eld service by refrigeration technicians. Variable frequency drives VFD take advantage of the fact that rotational speed of an AC motor is proportional to the frequency of the power supplied. Within limits, if the frequency is varied, motor speed changes, and in a compressor, capacity varies proportionally. Chart 1 shows the capacity output of a fourcompressor rack as the load increases. Compressor 1 is a variable capacity compressor. When the rack starts, compressor 1 is at 25 capacity the capacity increases until it is at or near full capacity, then compressor 2 xed capacity comes on line, and the compressor 1 drops to 25. As the load continues to increase, compressor 1 ramps up in response until it reaches maximum capacity, then compressor 3 xed capacity comes on, compressor 1 drops to 25, and so on. e capacity at all times matches the load, and there is no energy wasted. Chart 2 shows capacity output of a rack with four xed capacity compressors of the same size. Note the distance of the load line from the capacity delivered. Usually such racks deliver more capacity than the load requires. is is a safe but wasteful strategy. e extra capacity delivered requires extra energy, increasing cost of operation. Over a year, or even a quarter of a year, the energy waste cost is signicant in the lowmargin supermarket business. VFDs work well with electronic rack controllers. e Danfoss AK2SC 255 rack controller has optimization code built in for control of Danfoss AKD drives made specically for supermarkets. Energy savings of up to 25 have been measured in supermarket installations and documented for variable capacity racks using electronic drives. Reduced compressor cycling on a variable capacity racks results in longer component and compressor life that saves additional cash for the supermarket operator. Another supermarket application where variable capacity provides several benets is condenser fan control. Not only is energy saved, and head pressure kept at optimum level, but In many supermarkets, much of the heat removed by refrigeration is used to provide heat during cool weather, and hot water. But the problem of heat removal remains a problem in warm periods. The heat is rejected by outdoor condensers with large fans. When fans come on at full speed, there is a lot of noise added to the ambient environment. In more and more jurisdictions, supermarkets with outdoor condensers are subject to noise abatement regulations. Now variable capacity drives are being used to bring fans on at low speed and then ramp them up to required capacity. The gradual buildup in fan speed overcomes the problem of startup noise, and can save the expense of constructing around the condensors architectural noise shields, which may also limit airow. A Better Neighbor Chart 2 Performance model for a rack of xed capacity compressors, each with the same nominal capacity as the corresponding one in Chart 1. The refrigeration capacity exceeds that required for the load almost constantly, resulting in costly waste energy. Chart 1 Performance model for a variable capacity rack and an increasing load. The refrigeration capacity closely matches the load. In real applic2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=11Chart 3 Fan noise for a remote condenser with 1400 RPM fans. Noise level varies with speed. A 50 speed reduction results in a volume of sound that is 16. 5 decibels lower. variable capacity condensers make the supermarket a better neighbor and save construction expense. HOW DOES THE VARIABLE CAPACITY STRATEGY WORK FOR FANS Just as is the case with the compressor rack, variable capacity condensers save energy, perhaps an even greater percentage of their xed speed consumption. Condensers, just like racks, are sized for maximum load, and oen staged in pairs. At xed capacity, a fan stage comes on at full speed whether its full capacity is needed or not. In physics, the fan law states that airow increases with the cube of fan speed. at means that there is quite a lot of condensing capacity variation available when fan motor speed is controlled by a variable frequency drive. And over 85 of the time throughout the year, full capacity of a properly sized condenser is not needed. With a variable frequency drive, fans are generally not staged. Instead, one drive serves all of the fans. ey all come on together quietly at low speed, and ramp up as needed. Much of the time, 50 or less of rated speed is needed. Operating the fans at the capacity needed to reject heat and maintain head pressure at optimum at any given time saves considerable energy, reducing the supermarkets operating cost as do variable capacity compressors. As is the case with variable capacity racks, condensers equipped with variable frequency drives provide energy savings as high as 25 when compared to units with xed speed fans. Condenser fan noise reduction with variable capacity is shown in Chart 3. e chart assumes a typical condenser fan with a rated speed of 1400 RPM. Noise reduction in d BA is given by the formula another law of fan physics shown in the chart to the right of the graph. Note that when speed is reduced by 50, there is a 16. 5 d BA reduction in noise. A 3 d B reduction means that sound volume has been reduced by one half. e 16. 5 d B reduction that results from 50 speed reduction means that only about 15 the noise is generated. In addition it avoids the ono awareness impact of the fans starting and stopping. Chart 3 has been used at zoning authority meetings to demonstrate the eectiveness of variable speed control as a noise abatement measure. Variable frequency drives such as the Danfoss AKD can be retrotted to existing condensers by trained refrigeration technicians. Savings in energy to the supermarket operator are signicant, and the improvement in neighbor relations may well bring an improved business climate. Variable capacity control of refrigeration racks and condensers is a mature but constantly improving technological strategy for todays world of ever increasing energy consciousness and cost. Another recently emerging application is builtup and rooop HVAC systems. But in refrigeration, you will serve your customer by becoming trained in the application, and by recommending variable capacity where it will produce the most savings. n Variable Capacity Hermetic Compressors A relatively recent development is the introduction of variable capacity hermetic compressors for commercial appliances. These compressors have integrated drive electronics, and serve such applications as self contained food cases and walkin coolers, have integrated electronic capacity controls, and various models are suited to temperature ranges from 30F to 45F. 9Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=1210Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING MIXES UP The Danfoss EKC331T, electronic controller, loads and unloads the reciprocating compressor and allows the cranberry juice to be maintained at a 1 temperature differential. DESIGNBUILD FIRM2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=1311Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM Clement Pappas, a large producer of bottled juice and cranberry sauce, is located in Seabrook in southern New Jersey. e facility, a 400, 000plus squarefoot plant, is not only a processing plant, but also a cold storage and bottling facility that produces millions of gallons of juice per year. Time to convert traditional system When Clement Pappas decided to upgrade their existing facility, they turned to Devault Refrigeration, a Design Build contractor located in Colmar, Pennsylvania. e plant was a pre World War II vegetable processing facility that was converted into a juice and cranberry sauce processing facility and cold storage warehouse. Until recently, the operation used an ammonia system with three Frick HDI reciprocating compressors and cooled salt brine solution to remove heat from the processing plant. ere were three heat exchangers between the product and the refrigerant and three cooling mediums R717 to a saltbrine solution, and the salt brine solution to propylene glycol, and the propylene glycol to the product. e brine solution was piped underground to the processing plant. e evaporators were located in the processing and storage rooms. is was not an optimum control strategy for several reasons. Fiyve hundred pounds of ammonia were used to cool 30, 000 gallons of brine, which cooled the glycol, and glycol then cooled the cranberry juice. Clement Pappas wanted to eliminate ammonia from the system because the plant is in a residential area and an ammonia leak can be dangerous to employees or surrounding neighbors. Also the system was highly inecient. Prior to the upgrade, the system was consuming approximately 250, 000 k Wh per month. We couldnt afford to sacrice anything. Cranberry juice is like red golda drum is worth thousands of dollars, said Tom De Thomas, director of engineering for Clement Pappas, a leading producer of fruit juice, fruit drinks and cranberry sauce, as he explained why the facility installed a new process chiller Precise temperature control is essential to production, so we needed to upgrade our 1930s chilling technology to guarantee reliability. We also knew our facility was consuming too much energy. EFFICIENT SOLUTION FOR JUICE MAKER Tom De Thomas of Clement Pappas stands in front on the production line where cranberry juice is produced. MIXES UP2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=14Designbuild Firm Drums Up Unique Solution Bil Sauer, sales engineer and project manager at Devault Refrigeration, a UGI company that has provided a full range of HVAC and refrigeration solutions for over 100 years, worked with Deomas and his engineering sta to design a solution for replacing the system with a new propylene glycol, R22, process chiller. Devault designed and built a customized package chiller on a skid that contained a Frick screw compressor and a Vilter reciprocating compressor. An evaporative condenser was located remotely, and a plateframe heat exchanger was used to chill the cranberry juice to precise temperature with propylene glycol. By eliminating the brine and its associated heat exchanger, the system has less pumping loss and less leak potential, and less energy is consumed. is system is basically a miniengine room on skid. It can be moved relatively easily if the customer expands his operation or moves location, Sauer points out. We had some very interesting challenges with this project, explains Bil Sauer of Devault. Juice plants are unique because shelflife considerations, design changes and many of the parameters are variable. e customer runs three lines, and in 8 hours they can produce 50 dierent labels and 15 dierent formulas of juice or cranberry sauce. Accurate temperature control is paramount in processing juices. e juice must be held at 34F. e product is batched, then it is pasteurized and bottled. Pasteurization is a critical control point where the product needs to be heated, lled and cooled immediately. e bottle temperature must be brought down from 182F to 100F very quickly in order to preserve juice quality. Under Control Because it is batch processing, the raw juice processing plant can be idle or it can be producing at a rate of 35gpm gallons per minute. We essentially used two dierent manufacturers compressors to handle the load, explains Sauer. In order to design the system within the budget specications, a screw and a reciprocating compressor were both used on the package. e Frick screw compressor is the lead compressor on the job. When the glycol pump turns on, it activates the screw compressor. If the screw compressor is in antirecycle delay mode and unavailable to turn on, or if additional cooling capacity is required to achieve the target temperature, a Danfoss EKC331T electronic controller will signal the Vilter reciprocating compressor to turn on. The mobile skid package system was delivered to Clement Pappas on a at bed truck. The system was designed so it could be moved if the facility is expanded or relocated. Tom De Thomas, corporate engineer of Clement Pappas Bil Sauer, project engineer of Devault Refrigeration Bill Carrington, installation technician for Devault and Brian Davis, vice president of Industrial Refrigeration for Danfoss, in front of the skid package system. 12Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=15e EKC331T will then load and unload the reciprocating compressor in steps of 100, 75, 50, and 25. A Danfoss AKC21W temperature sensor monitors the glycols leaving temperature to determine when the compressors need to run. e system was designed with no ywheel eect, which means the entire volume of glycol is turned over in 8 minutes, remarks Sauer. ere is very little reserve glycol in the system, so tight refrigerant control is crucial. ere was only one other compressor sequencing with the screw, and it was a reciprocatinga microprocessor sequencing panel did not t within our project budget, so the Danfoss EKC was an ideal solution. For a fraction of the cost, we were able to achieve the same result. According to Brian Davis, vice president of Danfoss Industrial Refrigeration, this application was ideal for the Danfoss EKC331T. We were able to provide the link between the screw and the reciprocating compressors to achieve stable control and system eciency. e controller works harmoniously with the other Danfoss valves and sensors that were also installed on the package. Smooth Startup e mobile skid package system was delivered to the Clement Pappas facility on the back of a atbed trailer and started up on March 22, 2005. Bill Carrington and Tim Schrauger were part of the startup team who were onsite when the system arrived. I can put it on paper, but theyre the ones who make it work, says Sauer of his installation and startup team at Devault. is was the rst project Devault had done using Danfoss controls, and they were very pleased with the results. e blackbox EKC331T was a very costeective solution and it works, says Schrauger. Bill Carrington, who was instrumental in carrying out the design, commented further that the EKC331T allowed them to maintain a 1 temperature dierential on the product with the reciprocating compressor a critical factor since the application requires such precise control. Dramatic Payback For Business And The Environment According to Deomas, once the skid package was started up, Clement Pappas noticed eciency improvements immediately. We are using 25 less energy in the processing than with the old reciprocating units that had been in place. e energy cost of cooling the juice was reduced to approximately 1 cent per gallon. Signicant energy reduction is a benet to both Clement Pappas and the environment. But the ecological impact goes beyond energy consumption. Eliminating the external watercooled condenser means Clement Pappas was able to reduce water consumption by approximately 20 as a result of the new skid package design. Along with the savings in water consumption is the reduction in waste water purging. Our disposal of wastewater is reduced by approximately 300 gallons per minute, stated Deomas. A Solution That Protects The Red Gold We always strive to stay current on the latest technology so we can help solve our customers unique challenges, said Bill Sauer. And thats exactly what we were able to do on this project by working with Danfoss. eir controller allowed us to provide a unique control strategy and they provided excellent support during the entire process. Deomas was very pleased with results of the project. Devault was able to design a system that met my budget and our specic needs. I was able to save money with the reciprocating compressor and the controller, but I didnt sacrice anything in the control processing side, says Deomas. Since installing the new system, Clement Pappas overall energy consumption dropped by 25 and they no longer require 5500 pounds of ammonia or 30, 000 gallons of salt brine solution. Best of all, the customer has compressor redundancy to protect the red gold n 13Vol. 5 Issue 22007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=16Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING With energy costs on the rise, its no wonder theres increasing demand from builders and building managers for energy analysis tools. Costs and payback time are the main concern, but legislative actions and rising environmental concerns are also stepping up needs for accurate energy data. Energy represents 30 percent of a typical oce buildings costs and is a propertys single largest operating expense. at consumption can be cut by 25 percent or more through retrots, improved operation, and energy savings technology, including installation of variable frequency drives VFDs. Energy analysis to develop ecient designs also greatly benets new construction. Calculating how much energy a building consumes and how to reduce energy use, however, requires the right soware tools. Manufacturers of HVAC heating, ventilation, and air conditioning equipment oen provide energy analysis programs to help customers nd solutions to rising utility costs. From a customer perspective, there is a need to identify what kind of actual savings hell achieve if he installs a variable frequency drive on a fan or pump, says Ken Fonstad, Danfoss HVAC training manager. Danfoss constantly develops its own energy analysis tools to provide the most accurate picture of HVAC system energy use. e latest release, VLT Energy Box, incorporates high levels of exibility and userfriendliness for users around the world. Keith Kempski, Danfoss global application specialist, explains, We test each soware release to ensure that it meets the global needs of customers. SOFTWARE WITH A HISTORY AND A FUTURE Fonstad developed the rst version of the soware about two decades ago, and since then has worked on the soware to include more features to meet customers demands. Estimates until now havent taken into consideration all the factors, such as what it takes to maintain the equipment over several years, what it takes to install the device, and so on, he explains. is soware gives a more accurate picture. e latest version of VLT Energy Box allows the customer to make a simple analysis or a more complex one, depending on the kind of output he needs. e program also takes into account the complete system control curve and allows the user to customize the fan or pump curve to accurately model specialized types of equipment. e program takes the user through a simple 7 step process to calculate energy savings. e sowares capabilities will soon expand even more with the launch of the new VLT HVAC Drives later this year. e program will communicate directly with the drive, explains Mark Hansen, director business development for HVAC Danfoss Drives. When used with the new drives, it will also be possible to do a postanalysis of the VFD performance. Customers get payback info from Energy Analysis In A Box 14Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=17NINEMONTH PAYBACK FOR GEOTHERMAL SYSTEM e VLT Energy Box soware has proven to be an eective tool for determining payback time on investment in VFDs, and also to determine energyloss points in a system. One university used the VLT Energy Box soware to determine how installing VLT Series variable frequency drives could increase the energy eciency of a watersource heat pump. A multistory building, rst constructed in 1979, had gone through several expansions and renovations. e university decided to analyze energy use in this building, which includes health science classrooms, laboratories, oces and two libraries. Watersource heat pumps eciently heat and cool the building by using geothermal energy heat transferred between the buildings HVAC system and deep wells in the earth. A 75 HP constant speed pump is used to continuously circulate water so that it is always available to meet the buildings heating or cooling demands. An analysis of the system showed that a pressure of 75 feet of water is required to provide the ow in the system. However, the pump provides 115 feet of pressure when it is run at full speed. e pressure delivered to the system was reduced from 115 feet to 75 feet by partially closing a throttling valve. is pressure drop and the continuous ow caused a signicant energy loss. Although the pumps capacity could be reduced by trimming its impeller, this would require shutting down the system, disassembling the pump, machining its impeller, and reassembling the pump. Trimming the impeller also reduces the eciency of the pump and makes it dicult to later increase the capacity of the pump. An analysis was made using VLT Energy Box to determine if it would be more economical to open the valve fully and use a VLT 6000 Drive to control the speed of the pump and thus the ow from the main circulation pump. is would eliminate the need to introduce a 40foot pressure drop across the valve, since the drive would simply slow the pump so that it produced the required pressure and ow. e program also provides a place to enter the 40foot pressure drop that will be removed from the system when the throttling valve is replaced by a drive. While analyzing the system, power measurements indicated that the motor produced 65. 3 HP at the pumps sha. e program allows the sha power to be entered directly so that it can take into account any eciency losses that result from running the motor at less than full load. Even when including installation and startup costs for the drive system, the payback period in this case will be less than 9 months. e VLT Energy Box soware is freely available and used by customers and consultants in conjunction with Danfoss sales and application engineers. e program is not only useful for preselling VFDs and helping the customer to determine the energy savings he will achieve, but it can also help the customer to troubleshoot energy losses, adds Hansen. n 15Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM Customers get payback info from Energy Analysis In A Box2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=1816Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING Advanced Motion Control Solutions THE USE OF VARIABLE FREQUENCY DRIVES VFD for control of electric motors brings many advantages, as a result of precise speed or torque control, and the advanced functionality of motion controller devices, which when added to the converters, transform the ensemble into socalled servo systems. rough its VLT Drives and synchronizing positioning features, Danfoss provides advanced solutions for motion control. ere are two types of applications in the servo universe, which are widely used in a number of processes positioning Absolute and Relative and Touch Probe and synchronization Speed, Position, CAM. is article explains each one of the distinct types of application and their basic concepts, in addition to the use of VFDs for controlling conventional motors. Positioning Applications involving positioning usually work with an actual physical path represented by physical positions which are directly related to a given motion type vertical, horizontal, circular or a combination thereof. erefore, the motion is measured in displacement units over the path at issue. e servo systems interpret such units as usually being the positive and negative sides of the encoder pulses quad counts or the position numeric values sent by absolute encoders installed directly or indirectly via mechanical reduction on the application axle. A positioning is absolute when its origin is xed and dened on a path. A relative positioning is when the current motion origin is not xed, but dened as the last position before the positioning command. A Touch Probe positioning takes place when the origin is xed and determined over the path, and Conventional asynchronous electric motors are used extensively on industrial machines for advantages such as low maintenance, high robustness, and ease of use and installation, compared with other mechanical, hydraulic or pneumatic systems. For Industrial Processes Asynchronous Electric Motors The asynchronous motor, also called the induction motor, is an AC motor which comprises a rotor and a stator like the DC motor, but the AC motor does not need current to ow through the armature. The current owing in the eld coils forces the rotor to turn. However, it does have to have a three phase supply, i. e. one where AC has three conductors, each conducting at a point one third into the normal cycle period. 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=1917Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM Typical Synchronizing Positioning System with Mark Correction VLT RFC 300 Flux closed loop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Sensor Mark 1 Sensor Mark 2 Typical system of synchronization of velocity MCO 305VLT RFC 300 Synchronization Flux closed loop Load Motor Enconder Slave Enconder Master Typical Synchronizing Positioning System VLT RFC 300 Flux closed loop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Typical synchronizing positioning system using Danfoss VLT Drives MCO 305 Positioning Enconder Motor Load VLT RFC 300 Flux closedloop CAM Movement Figure 1 shows a typical positioning system using Danfoss VLT Drives. Palletizer using an absolute and relative positioning. the motion controller takes over as a reference for the positioning command when an outside signal is sent and the positioning is performed from the current position. See Figure 1. On this application are two Danfoss Drives VLT Automation Drive MCO 305 or VLT 5000 Sync Pos performing the control of two linear motions. e vertical motion of the box collector and the horizontal motion of the box collector. e machine cycle starts with the ascending and absolute vertical motion, already with the sixbox package duly collected. When the motion upper position is reached, the VLT units controlling vertical motion informs the horizontal motion VLT drive by means of a digital signal and this, in turn, starts the horizontal motion which is also absolute, properly positioning the box package on the stack to be formed. Upon completing this positioning, the horizontal motion VLT unit informs the vertical motion VLT, and starts the descending with relative positioning until the right pallet height is reached based on the last relative position. is motion should always consider the box stack height on the pallet, and the next set of boxes should consider the motion origin and ending, as being the last relative position reached, in view of such height. e motion on the pallet stack could also be Touch Probe if sensors detecting the pallet height are installed. e VFDs restart the cycle by returning to the initial positions and communicating via digital IO. is application uses all the positioning concepts. Synchronization Applications involving synchronization always refer to two systems and two motions. e rst system is called master and the second system is called slave. e master motion is transformed into electric signals via an encoder absolute or incremental and sent to the slave. e slave system VLT Automation Drive MCO 305 or VLT 5000 Sync Pos receives the signals from the master encoder and compares them with the feedback signals from the slave encoder usually installed on the controlled motor axle. By means of an internal PID controller the error is determined and the correction is performed on the basis of the synchronization PID gains. e result is the accurate synchronization of the slave relative to the master. Typically there are four synchronization types speed synchronization the slave follows the master speed, position synchronization the slave is referenced to the position of the master, position synchronization with mark correction eliminates cumulative errors by marks, CAM synchronization. 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=20See Figure 2. On this application the speed control accuracy is important as the speed dierence between the cylinders determines a precise material stressing and stretching. e feed cylinder on the le turns at a lower speed than the second cylinder and thus successively up to the sixth cylinder on the right. e need for synchronization occurs because the speed dierence should remain constant throughout the machine operating range. On the system at issue a Virtual Master is used, which is generated by one of the Danfoss VLT Drives. is Virtual Master signal simulated encoder signal will be the reference for all the VLT units, minimizing error accumulations, should it be a cascading reference system. In addition, the VLT drives are connected on Load Sharing load sharing through the unied DC bus in order for the power regenerated by the lowerspeed drive motor to be used by the greater speed drive motor. See Figure 3. is application is a pipe saw. It is a highly dynamic and precise application. e pipe is produced on a continuous basis and moves at a constant speed. e main task is to cut the moving pipe without disrupting the saw, on a length previously determined by the user. A master encoder is installed directly on the continuous pipe surface. e signal is sent to the VLT drive. e VLT controls the circular saw up and down motion by means of a digital output associated with a pneumatic system which moves the saw vertically. e VLT also controls the motor coupled with a worm thread system which performs a parallel motion of the saw relative to the pipe. A slave encoder directly coupled with the slave motor axle sends the saw position signal to the drive and this, in turn, synchronizes the cutting point in place, lowering the circular saw while the pipe moves, performing the pipe cutting. Upon completing the cutting, the VLT drive commands the saw pneumatic system to go up, and then nalizes the cycle by returning the circular saw to the cutting origin position at high speed, saving time on the machine cycle. e cycle repeats. On this application we used a combination of position synchronization and absolute positioning. We synchronized the cutting cycle in place, and positioned returning the circular saw to its origin. Another synchronization strategy variation is to use the CAM synchronization. is type of position synchronization is a synchronization where the slave follows predened positions for all the master position. e cutting and returning motion, on the saw application, can be performed by a CAM curve. See Figure 4. See Figure 5 ere are two conveyor belts in this application. One for boxes and the other for teddy bears. e box conveyor is the master system. ere is a xed speed motor and an encoder coupled with its axle, sending the master position signal to the VLT drive. e drive controls the conveyor motor moving the bears, which also has an encoder coupled with its axle. e physical motion is converted into an electric signal and sent to the VLT unit. e slave position is under the complete control of the VLT. ere are two sensors one installed on the master conveyor and the other on the slave conveyor. A sensor detects boxes, and the other senses the position of the bears. ese sensors send the socalled marks to the VLT unit so the drive knows exactly the distance between the marks. When the boxes sensor is enabled, the VLT waits for the signal from the bears sensor. At the time the bears sensor is enabled, the VLT drive determines accurately the position dierence between the box and 18Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING Typical Synchronizing Positioning System with Mark Correction VLT RFC 300 Flux closedloop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Sensor Mark 1 Sensor Mark 2 Typical system of synchronization of velocity MCO 305VLT RFC 300 Synchronization Flux closed loop Load Motor Enconder Slave Enconder Master Typical Synchronizing Positioning System VLT RFC 300 Flux clo2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=21http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=21the bear, correcting the bear position, accelerating or decelerating the slave conveyor, in such a way that the bear falls exactly inside the box. Marks are also used in order to eliminate what we call a cumulative error, normally originated by mechanical inaccuracies that are impossible to be actually eliminated. Functions of a small PLC e Danfoss Sync Pos and MCO 305 Motion Control systems can also be used in order to replace small PLCs in many applications where a Positioning or Synchronization is not necessarily required. e optional Sync Pos and MCO 305 are fully programmable by means of a programming language which is familiar to users of servo systems. Such programming language is quite similar to Basic, with all the conditional structures, subroutines, mathematical operators, and tenths of functions such as timers, counters, logic and analog comparators, customizable PIDs, in addition to global and local internal variables. ese are two options which, when installed on the Danfoss VLT Drives, extend the number of the drive digital inputs and outputs, besides allowing for a total control of the VLTnative digital and analog inputs and outputs. e application programs may be written, edited and saved on a PC by means of a program running on a Windows environment. n Article courtesy of Marcos Mori, Danfoss Latin America applications manager. 19Vol. 5 Issue 2 Typical Synchronizing Positioning System with Mark Correction VLT RFC 300 Flux closed loop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Sensor Mark 1 Sensor Mark 2 Typical system of synchronization of velocity MCO 305VLT RFC 300 Synchronization Flux closedloop Load Motor Enconder Slave Enconder Master Typical Synchronizing Positioning System VLT RFC 300 Flux closedloop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Typical synchronizing positioning system using Danfoss VLT Drives MCO 305 Positioning Enconder Motor Load VLT RFC 300 Fluxclosedloop CAM Movement Figure 5 shows a typical Position Synchronization system with mark correction. WWW. ENVISIONEERING. DANFOSS. COM Typical Synchronizing Positioning System with Mark Correction VLT RFC 300 Flux closedloop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Sensor Mark 1 Sensor Mark 2 Typical system of synchronization of velocity MCO 305VLT RFC 300 Synchronization Flux closedloop Load Motor Enconder Slave Enconder Master Typical Synchronizing Positioning System VLT RFC 300 Flux closedloop MCO 305 Synchronization Enconder Master Enconder Slave Motor Load Typical synchronizing positioning system using Danfoss VLT Drives MCO 305 Positioning Enconder Motor Load VLT RFC 300 Fluxclosedloop CAM Movement Figure 4 shows an example of CAM motion. The limitation is not electronic but mechanical. When a servomotor is compared with a conventional asynchronous motor, there are physical differences inertia, magnetization that, on applications requiring a highly dynamic response or torque, the conventional Asynchronous motors cannot respond to. However, VFDs can be used, as they provide Permanent Magnet Motor Control Algorithms, which are nothing but Servomotors. The stateof theart Danfoss VLT Automation Drive combined with the MCO 305 Motion Control module, controlling an AC Permanent Magnet Servomotor, is a very high performance solution and dynamic response which replaces conventional servo systems and brings about all the benets to the machine manufacturing customer and the end user. n VFD or Servomotor Solutions With the advancement of processors and technologies for controlling conventional asynchronous motors, many applications that were previously performed only with Servomotor systems are today fully feasible using VFDs. 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=22http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=22Danfoss Drives VLT Automation Drive variable frequency drives are now available in the 40 60 HP power range. is power extension covers NEMAUL Type 1 IP21 and NEMAUL Type 12 IP55 rated enclosures in the voltage range 380 480500 V. Additionally the VLT Automation Drive is available to satisfy power demands from fractional to 10HP 200 and 600VAC class units. Manufacturing process demands for motor control can vary from simple speed control to highperformance positioning, responsiveness and accuracy. Traditionally, this required the production facility to install numerous drive types from several suppliers, posing problems in maintenance costs, production eciency, and user complexity. e VLT Automation Drive can handle every specic motor control requirement with a single product platform. is exibility allows users to take advantage of motor control performance for any industrial process application while keeping costs down. e VLT Automation Drive monitors, analyzes and takes action to make sure production continues to run smoothly. e user can program it to adapt to complex operations at various points in the line using the builtin Smart Logic Controller for essential control functions or an optional MCO 305 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. e 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. e VLT Automation Drive handles safety challenges with a variety of enclosure grades, builtin protection against electrical disturbances, and conformal coating for printed circuit boards. A Safe Stop function 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 eective heat management design for the units power components has been incorporated. e user interface for the VLT Automation Drive is simple to operate. e intuitive Local Control Panel LCP has total display capabilities, including graphs, 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 springloaded terminations for control wiring. For more information, contact 800 4326367. n Danfoss Drives Popular VLT Automation Drive Now Available In 40 HP to 60 HP Range Innovative modular design handles every motor control requirement with a single product platform PRODUCT NEWS Product Highlight 20Vol. 5 Issue 2ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=23http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=23Universal Thermostat from Danfoss Answers Contractor, User Needs Danfoss is offering the Universal Thermostat UT 72 to the North American Market WE WANTED A THERMOSTAT THAT WAS EASY TO READ, ADJUST, AND INSTALL for the North American market. Thats why we are introducing the type UT here, said Jeffrey Douglas, Danfoss vice president of aftermarket sales in North America at a recent conference at his Baltimore headquarters. Instead of adjustment screws, the UT is easily and accurately set with the large knob on the front of the control, with large, easytoread scale numerals. The UT 72 is available for wall or panel mounting for applications including cold rooms, beverage coolers, ice cream makers, display xtures, airconditioning systems, and heat recovery systems. With a capillary tube length of 10, the UT 72 thermostat is suited to both short and long reach applications. A highimpact rustproof enclosure and adjustment knob make the control suitable for damp environments. Setting range for the UT 72 is from 20F to 85F. The scale shows both Fahrenheit and Celsius ranges. Reset is automatic, and differential is xed at 4. The UT 72 has SPDT changeover switching capability with contact loads. For cabinet mounting, AMP quick connectors may be used with the UT thermostat. Danfoss thermostats are produced in factories certied ISO 9001 and ISO 14001, assuring high quality standards throughout the design and manufacturing process. For more information contact 4109318250. n Awardwinning Danfoss VLT HVAC Drive Danfoss is pleased to introduce the newest generation of Danfoss VLT Series HVAC variable frequency drives. It is built on Danfoss new modular plugand play platform and dedicated to HVAC applications is an intelligent part of the intelligent building. VLT HVAC Drive, the FC 100 Series, gives the lowest cost of ownership and makes VLT HVAC operation pure childs play. Danfoss was recently awarded a 2006 AHR Expo Innovation Honorable Mention in the building automation for the VLT Series HVAC Drive. Danfoss HVAC Series variable frequency drives for HVAC applications feature a modular design that allows users to buy precisely what they need for their specic application. All drives are congured and tested to customer specications at the factory. With enhanced HVACspecic capabilities and custom programmability, including integral cascade control, fan control and compressor control features, each drive is ready for outof thebox operation. Integrated fuses and disconnect capability are included in each drive enclosure. VLT HVAC Drive Series units also feature open communications, enabling them to speak and understand any HVAC language. An enhanced user interface provides an intuitive, Englishlanguage menu with an available graphical readout for easy operation. Enhanced PC tools such as HVAC Energy Box an energy analysis tool, MCT 10 drive conguration and setup soware, and a USB port interface further enhance user friendliness and ease of use. For more information, contact 800 6218806. n 21Vol. 5 Issue 2WWW. ENVISIONEERING. DANFOSS. COM Danfoss Introduces a High Efciency Compressor for Commercial Freezer Applications Danfoss has added a new, high eciency 34 hp hermetic LBP compressor to its oering. e SC18CLX. 2 is optimized for R404A. Danfoss SC compressors are available for 60 Hz operation at 115Vac and 230Vac, with a wide voltage range tolerance making them insensitive to unstable electric power supplies. ey have an extensive application range covering ice merchandisers, commercial freezers, and laboratory and scientic equipment. Operation in high ambient temperature conditions is made possible by a design with improved internal breathing, oil and surface cooling, and integrated winding protection. e high eciency design of the SC18CLX. 2, incorporating improved internal breathing, yields a high EER that oen allows a smaller compressor than would otherwise be necessary in a given application, and ensures energy savings for the end user. High 2007-07-03T12:47:02+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=24http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv522006/?Page=247941 Corporate Drive Baltimore, MD 21236 September 2006 FMI Energy September 1013Wigwam Resort. Phoenix, AZ. Johnstone Supply Annual Members Meeting September 2022Caesars Palace. Las Vegas, NV. NRWA September 2427Hyatt Regency Reunion. Dallas, TX. Visit Danfoss Booth 120 October 2006 RETA 2006 October 46Arlington Convention Center and Wyndham Hotel. Arlington, TX. Visit Danfoss Booth 108 RSES October 57Omni Hotel. Atlanta, GA. NACS October 911Las Vegas Convention Center. Las Vegas, NV. Visit Danfoss Booth 5216 WEFTEC October 2225Dallas Convention Center. Dallas, TX. Visit Danfoss Booth 3631located in Hall C November 2006 AVS November 1416Moscone West. San Francisco, CA. Visit Danfoss Booth 1409 International Work Boat Show November 29December 1 Ernest N. Morial Convention Center. New Orleans, LA. Visit Danfoss Booth 866 2006 CALENDAR OF EVENTS Please mention that you read about the event in Danfoss En Visioneering SM Solutions HOW TO CONTACT DANFOSS BALTIMORE, MD 7941 Corporate Drive Baltimore, MD 21236 4109318250 Fax 4109318256 www. danfoss. com North America Refrigeration Air Conditioning Industrial Heating Controls Components for Oil Burners DORVAL, QUEBEC Danfoss Turbocor 1850 Trans Canada Hwy Dorval, Quebec H9P 2N4 Canada 5144210523Fax 5144214277 www. turbocor. com Oil Free Compressors for Refrigeration and Air Conditioning GLENS FALLS, NY Danfoss Flomatic Valves 15 Pruyns Island Drive Glens Falls, NY 12801 8008332040 Fax 8003143155 EMail omaticomatic. com www. danfossomatic. 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 088731212 7324698770 Fax 7324698773 www. danfoss. comdrivesus Gearmotors For More Information Keep updated on all the latest news about Danfoss products and your industry at www. envisioneering. danfoss. com To nd out more about Danfoss North America, contact us viaemail at solutionsdanfoss. com2007-07-03T12:47:02+02:00