http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/RSS.ashxRA PagesThu, 28 Jun 2007 07:39:16 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=1MAKING MODERN LIVING POSSIBLE The Green Light Is On For Investing In Sustainable Technologies 2 An Obsession Increases Efciency At The Operating Engineers Trust Fund Building 5 High Power Drives Bring Efciency To Oregon Vineyard 8 Nobody Does It Like Sara Lee When It Comes To Refrigeration 10 Keeping An Eye On Stacking Saves Goods And Money 12 Product News 142007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=2MAKING MODERN LIVING POSSIBLE ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING Great partners boost energy eciency 60 for Engineer of Engineersthats En Visioneering SM. With expiring caps and increasing demand for electricity, building owners turn to professionals like those from the Operating Engineers Union to achieve greater savings. One of those engineers is Bruce Manning, Chief Engineer for the Operating Engineers Trust Funds, Local 12. He worked with Danfoss Turbocor as an En Visioneering SM partner to slash costs for the Trust Funds 210, 000squarefoot headquarters facility in Pasadena, CA. The solution Two compact, 120ton Danfoss Turbocor compressors with quiet, oilfree magnetic bearings and variablefrequency drive. The result Almost 60 energy reduction due to compressor eciency and fewer DX systemeect lossesplus 50 less maintenance with oilfree Mag Lev operation. See your solution at www. envisioneering. danfoss. com2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=3CONTENTS Volume 6, Issue 1 We are pleased to continue bringing you useful information about the industries you work in through this magazine. e topics of climate change and energy eciency continue to gain in importance around the world, and we are proud to be leaders in developing technologies that reduce energy consumption and emissions that contribute to climate change. Danfoss has been on the cutting edge of environmental sustainability since it was founded. is publication is one of the ways we are showing how we put into practice the principals of En Visioneering engineering innovation, environmental responsibility, and engaging partnerships. In this issue, you will read about solutions in everything from irrigation to supermarkets and food processing. As always your comments are welcome. THE EDITORS, solutionsdanfoss. com The Green Light is on for Investing in Sustainable Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 An Obsession Increases Efciency at the Operating Engineers Trust Fund Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 High Power Drives Bring Efciency to Oregon Vineyard . . . . . . . . 8 Nobody Does it Like Sara Lee when it Comes to Refrigeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Keeping an Eye on Stacking Saves Goods and Money . . . . . . . . . 12 Product News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 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 Design www. Arista Advertising. com Dear Readers, 1 Jeff Duncan North America Motion Controls Jennifer Allison Corporate Communications Jan Petersen 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. MAKING MODERN LIVING POSSIBLE The Green Light Is On For Investing In Sustainable Technologies 2 An Obsession Increases Efciency At The Operating Engineers Trust Fund Building 5 High Power Drives Bring Efciency To Oregon Vineyard 8 Nobody Does It Like Sara Lee When It Comes To Refrigeration 10 Keeping An Eye On Stacking Saves Goods And Money 12 Product News 14 Vol. 6 Issue 1 2007WWW. ENVISIONEERING. DANFOSS. COM2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=42Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING THE GREEN LIGHT A s Jonathan Lash and Fred Wellington report in Competitive Advantage on a Warming Planet, in the March 2007 issue of the Harvard Business Review online, Investors already are discounting share prices of companies poorly positioned to compete in a warming world. Many businesses face higher raw material and energy costs as governments around the globe increasingly enact policies placing a cost on emissions. Consumers are taking into account a companys environmental record when making purchasing decisions. It is not only a matter of the planets future, but of competing in a greener business landscape. With energy prices on the rise and regulatory pressures mounting, we have entered the age of green technologies. With the growing energy needs of developing nations, such as India, China and Brazil, aordable and sustainable solutions are necessary to keep up with the world demand. e Supreme Court ruling in April that the Environmental Protection Agency must consider greenhouse gases, like carbon dioxide, as pollutants put even more heat on the situation. It means those gases will need to be federally regulated. In addition, federal and state regulations continue to push for greater energy eciency and lowering impact on the environment in everything from manufacturing to commercial buildings. To provide viable environmental technologies, Danfoss is constantly developing innovations for energy savings and emissions reductions, and is also involved in renewable energy ventures, such as solar. Matters of climate change, energy conservation, and preserving the ecosystem have gone from interesting to critical. They are driving businesses across sectors to develop solutions that help customers meet their objectives while being costeffective and environmentally responsible. for Investing in Sustainable Technologies 2 COVER STORY2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=53Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING33Vol. 6 Issue 1 2007WWW. ENVISIONEERING. DANFOSS. COM IS ON 2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=64Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING4 Its a Matter of Money Companies in both old and hightech industries, from oil and raw materials to HVAC, IT and robotics, are preparing for a new world in which business and environmental interests must go hand in hand. ey do this with the realization that the costs will be enormous if they dont act. At the same time, investors and consumers are demanding that companies take measures to conduct business responsibly. is has sparked a major increase in investments in the Clean Technology sector, or Cleantech, which refers to the nancial asset value of technologies that diminish impact on the environment, while reducing costs, improving operational performance and eciency and providing other business benets. Clean Technology is making waves with investors. Cleantech Venture Network reported that North American venture capital investment in the cleantech category totaled a record 2. 9 billion for 2006, representing a 78 percent increase over 2005. Cleantech encompasses everything from water and wastewater treatment, alternative energy, and innovative manufacturing and industrial processes, to energy saving products and applications that support sustainable development. Quiet Technologies Shout Efciency In the meantime our industries heating, refrigeration, airconditioning, and motion control, are helping our customers contribute to the picture with technologies that may not be as well known as solar power, fuel cells and ethanol, but are no less exciting in terms of oering business and environmental benets. Saving energy can oer greater, and quicker, benets than alternative energies. As the Intergovernmental Panel on Climate Change stated in its policymakers report from Bangkok on May 4 of this year, It is oen more costeective to invest in enduse energy eciency improvement than in increasing energy supply to satisfy demand for energy services. Components that greatly reduce the energy consumption of airconditioning equipment are a major success in the market due to legislation that requires increased energy eciency. Highly ecient compressors that operate without oil or use alternative refrigerants, like carbon dioxide, which do not harm the ozone layer, also provide bottomline benets while reducing environmental impact. Motion control variable speed technologies for HVAC systems in green buildings and more ecient industrial processes are also helping to meet more stringent eciency standards. Technologies such as these that reduce the demand for natural resources and put less strain on the energy grid, are ultimately just as important as alternative energy production to the overall solution. e positive outcome of climate change and the energy shortage is that these issues are giving rise to research and development and investment in new and exciting technologies. n THE GREEN LIGHT IS ON COVER STORY2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=75Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING5 If youre a Union Pension Trust Fund that owns real estate and demands the highest level of operating efciency for your buildings, you need to continually implement cuttingedge energy conservation measures. This is done by maximizing the longterm nancial performance of the investment. ose who work for the Operating Engineers Pension Trust, Local 12 out of Pasadena, CA, want to be the best when it comes to HVAC systems optimization and performance. As the chief engineer for this Trust Fund, Bruce Manning admits to being obsessed with nding ways to minimize energy use in the buildings for which he is responsible. One of those sites is the Trust Fund headquarters located at 100 E. Corson St. in Pasadena, California. Mannings obsession is why he is so excited about the performance of the new Danfoss Turbocor technology. e newly installed oilfree compressors in the building have opened the door to additional cooling savings. He predicts these could be as high as 50 to 70 percent versus his older compressors. Danfoss supplies products and technology to increase energy efciency of commercial buildings An Obsession Increases Efciency at the Operating Engineers Trust Fund Building 5Vol. 6 Issue 1 2007WWW. ENVISIONEERING. DANFOSS. COM2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=86Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING6 Compressors Support DX System e fourstory oce building was completed in 1988 and encompasses 210, 000 gross square feet. e heart of the original cooling system was two 120ton, opendrive reciprocating compressors connected to a builtup directexpansion DX coil with sixteen expansion valves. Conditioned air is delivered to four oors of VAV boxes from the centralized penthouse airhandling system with dual, sidebyside DX coils and associated faceo dampers, variablespeed driven supply and returnair fans. e system also features a fully functional 100 percent outside air OA enthalpy controlled economizer system. Manning, a 30year engineering and energy analysis veteran, took over in 1993 and performed extensive maintenance management and energy management evaluations of the entire real estate portfolio, including this facility. Energy Report Card Over time, Manning installed VFDs on the supply and return fans, as well as the cooling tower fans to conserve energy by eliminating the previous constant volume fan operation using inletguide vane control. He then retrotted and overlaid a pointintensive DDC energy management control system on all mechanical equipment and oor VAV boxes. Manning developed his Energy Report Card, which utilizes k Btusq. . as the primary benchmark to evaluate and sustain the energy eciency of his buildings. Aer evaluating all possible plant retrot options for years, he knew that additional eciency improvements were possible, but not at the right costbenet and associated returnoninvestment ratios. He became particularly interested in refrigeration compressor improvements and began studying and tracking a new lowfriction, oilfree refrigeration compressor. is technology was developed by Danfoss Turbocor and was beginning to appear in California. Manning says, I had been following the development of this technology since its inception. I waited until a few local jobs were THE REVOLUTIONARY DANFOSS TURBOCOR family of compressors, the worlds rst totally oilfree compressors, are specically designed for the Heating, Ventilation, Air Conditioning and Refrigeration HVACR industry. The convergence of aerospace and industrially proven magnetic bearing, variablespeed centrifugal compression and digital electronic technologies enables the Turbocor family of compressors nominal 60150 ton capacity range at ARI standard conditions to achieve the highest compressor efciencies for middlemarket watercooled, evaporatively cooled and aircooled HVACR product applications. This technology can possibly revolutionize the compressor industry, while creating a tremendous opportunity for all utility companies to implement and achieve a signicant loadreduction strategy in the communities we serve. 2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=9installed and went to look at and evaluate them. He then discussed the design and performance of the jobs with various contractors, consulting engineers and on site property engineering stas. Oil Free Compressor Seen as Opportunity Manning concluded that the technology with its oilfree design, variablefrequency speed control, oating magnetic bearings, centrifugal compression and digital controls was the ideal replacement compressor for his building. He admits, I was also inuenced by the fact that with only one moving part, no need for lubrication and virtually no major service requirements, both maintenance and energy costs could be very signicantly reduced. Manning turned to ACCO Engineered Systems, a designbuild contractor with a long history, a solid reputation, and experience with the Danfoss Turbocor product. He says, We were determined not to leave any energy savings potential uncaptured. Bill Brown from ACCO was absolutely relentless in looking for energy savings. is focus on energy savings continued through design, installation and system commissioning. Startup without Troubles e new compressors are rated at 120 tons each, or 240 tons total. e installation was done in January 2006 and was completed over a few weekends. Manning says the startup went very smoothly. We did the normal tuning and tweaking to prevent surge conditions on low load and verifying proper motor cooling at the specied compressor amperage at full load. e HVAC system in this oce building has eight electronic expansion valves EXVs on each of the two DX cooling coils to ensure the appropriate ow of refrigerant during varying load conditions. According to Manning, he and Brown spent considerable care in the commissioning stage to ensure that these EXVs were utilized properly in a full face coil feed control strategy. is strategy is used in conjunction with the buildings centralized energy management system and the compressors onboard intelligence. Utility Supported Improvements Perspective e electric utility, Pasadena Water Power PWP, was very supportive of the compressor upgrade, actually providing a rebate for the installation. PWP also worked with the owner to document the eciency improvements. PWP account representative Robert ompson, who coordinated the rebate process, documented and videotaped the performance tests. He recorded the side byside operation of one of the original opendrive reciprocating compressors running simultaneously with one of the new Turbocor compressors. Manning says, At the time of the test and aer balancing the load equally across both compressors at the same time via the DDC control system, we all saw energy reductions approaching 65 to 70 percent for the new compressor. PWPs ompson adds, An ammeter simply doesnt lie. e obvious peak load demand reduction, along with the totalized k Wh reduction potential, is one that is of great interest for the utility company. is technology can possibly revolutionize the compressor industry, while creating a tremendous opportunity for all utility companies to implement and achieve a signicant loadreduction strategy in the communities we serve. Manning feels the most important aspects of the new compressors will be their unparalleled eciency that will nally enable a properly implemented and optimized system to match exactly the required horsepower and associated k W of the entire plant to the connected realtime air conditioning load. Impressed by Energy Improvements Manning is impressed by the eciency improvements in the entire system due to the removal of normal DX system eect losses, reciprocating technology friction losses, oil insulating losses and lowered condensing pressuresfrom 220 psi down to 160 psi. He continues, For the rst time, I have seen a refrigeration system that can be so precisely tuned that there is zero operating slop. He also points out that the strength of the DDC controls on the entire system makes a lot of dierence. Its not just the compressors. Manning also points2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=10AFTER EXTENSIVE RESEARCH to nd the right region for growing quality grapes, including fertile soil conditions and ideal weather, seven entrepreneurs combined eorts and formed Seven Hills Vineyards in Milton Freewater, Oregon. Milton Freewater is located in northeastern Oregon along the Columbia River. is 1265acre site resides just south of Walla Walla, Washington, which has a total of 52 wineries in that area. Seven Hills Vineyards started plotting and subdividing the property into smaller plots to sell to other premier wineries for growing grapes. ey next constructed an elaborate, stateoftheart control system for irrigating the entire 1265 acres. ere are two main wells that will supply water to three large ponds, each of which will hold approximately 10 million gallons. In each pond, there are pump stations to distribute the water to the entire area for irrigation. e electrical control system for Seven Hills was engineered with the help of Doyle Electric, and the comprehensive integrated pumping system package was engineered by Danfoss Drives water distributor, Mitchell Lewis and Staver. Since the Seven Hills Vineyard complex was a new installation, the customer wanted to design all elements, including the irrigation system, with the appropriate exibility and capacity in mind for future development. To ensure the irrigation system could provide proper ow and pressure from the initial installation and beyond, it was determined that all pumps should be controlled utilizing variable speed technology. Besides providing the maximum system exibility, utilizing VFDs would increase system eciency and reliability while returning energy savings. In addition, the application of drives would allow the system to match water ow and pressure to actual demand at any given time, minimizing water consumption. 8 High Power Drives Bring Efciency to Oregon Vineyard Danfoss VFDs provide maximum system exibility, increased system efciency and energy savings for stateoftheart irrigation system. 8Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=119Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING9 Danfoss VLT AQUA Drive series products were selected for the installation, but there was one hurdle that needed to be overcome the installation included an 800 HP pump, which was beyond the current cataloged VLT AQUA Drive product range. is situation however coincided perfectly with a product development activity taking place at the Danfoss Drives North American headquarters in Loves Park, Illinois, to expand the product range to 1. 2 MW. A coordinated eort between Mitchell Lewis Staver and Danfoss sales and RD resulted in allocating one of the early production 800 HP units that were in development. is new power expansion of the VLT series products is modular in design and utilizes technology currently of the 125600 HP VLT series products by paralleling power sections, resulting in increased power capabilities. e modular 800 HP VLT AQUA Drive was assembled in Danfoss Drives Milwaukee facility and was put through the full series of tests and evalutions by Danfoss production and RD departments before being released to the customer. At Seven Hills Vineyard, the two main water supply wells consist of one 350 HP Vertical Turbine Pump and one 800 HP Vertical Turbine Pump. e 350 HP pump can deliver water to the east and middle ponds, while the 800 HP pump can deliver water to all three ponds. Both pumps are controlled with Danfoss VLT AQUA Drives. e pond pump stations are all vertical turbine style pumps of various horsepower ratings. All the pond distribution pumps were supplied with Danfoss Drives and So Starters. e distributor was able to oer a comprehensive integrated pumping system for the customers unique application. is included Danfoss Drives VLT Series products and pressure transducers, as well as the pumps, motors, level sensors, meters, and other required control equipment. ese components were integrated into a central control system which monitors well level, discharge ow and discharge pressure. is total system integration approach, as well as the expertise provided by Danfoss and Mitchell Lewis Staver in order to implement it, was one of the key selling points on the project. Seven Hills Vineyards intends to sell the acreage to premier wineries around the country and provide them with turnkey service that includes crop planting, vineyard maintenance, irrigation and harvesting. Buyers are welcome to handle their own cultivation of the acreage if they desire, but would pay a monthly fee for irrigation services, which are owned by Seven Hills Vineyards. e centralized control system and the VLT AQUA Drives provide the exibility needed to implement this business plan by allowing the system to grow and adapt with the needs of the various wineries it was built to serve. n Thirsty farms turn to irrigation U. S. agriculture relies on extensive irrigation systems. Only 16 percent of all harvested cropland is irrigated, but this equals nearly half the value of all crops sold in the country. Agriculture uses about 80 percent of water consumed in the U. S. The U. S. Geological Survey reports that water withdrawals for irrigation were an estimated 137, 000 million gallons per day, or 153, 000 thousand acrefeet per year, in 2000. 9Vol. 6 Issue 1 2007WWW. ENVISIONEERING. DANFOSS. COM2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=1210 iel is responsible for a 660, 000 square foot ammonia facility that produces all of the frozen pies for Sara Lee Corporation, a global consumer products company with food, beverage, and household and bodycare businesses. His facility has 100, 000 pounds of ammonia refrigerant, 45 F blast cell and up to 70 DX cooler to handle an annual volume of 18 million cases of pies produced each year. It has two holding freezers capable of storing 6, 000 pallets in addition to using osite storage capacity when required. e plant runs two shis, ve days a week, but recently the facility was running seven days a week to keep up with the extremely high demand. Looking to improve eciency, iel decided it was time to retrot the liquid feed from a standard solenoid package to the Danfoss ICM a motorized valve with a digital display. e Danfoss ICM was installed to modulate the liquid ow to a recirculator vessel. e ICAD keeps the liquid feed constant, allowing much more ecient loading, explains iel. FLASH GAS IS ELIMINATED Terry Chapp, Danfoss regional sales manager, explains that one problem Sara Lee had with the old system was excessively large amounts of ash gas. When high pressure liquid expands to form cold liquid, vapor, in the form of ash gas, is also generated. In a traditional feed, the vessel control system is a simple ono rather than modulating. ere is no call for liquid until the liquid level falls to a preset level. Once this occurs, liquid continues to ow into the vessel in large quantities until the high pressure switch determines that there is enough liquid in the vessel. A side eect of this action is generally a large increase in suction pressure. Nobody Does it Like When it comes to Refrigeration What drives a manager whose company is already a leader in its industry and a household name Innovation and Improvement, according to Joe Thiel, project manager for Sara Lee in Traverse City, Michigan. I constantly evaluate new technologies to improve the efciency of our plant. 10Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=1311 Oen, when suction pressure increases, the primary compressor cannot bring the level down fast enough and an additional compressor which means more energy consumption must be brought online, Chapp explains. With modulating control using the ICM, the liquid level within the vessel is kept within much tighter limits. When liquid is now called for, it is generally in a small amount and the magnitude of ash gas that is generated is held in check. e outcome is that the suction pressure is kept under control and usually does not require extra compression to be brought online. With the new solution, the ash gas is greatly reduced. We are able to have constant compressor load because the solenoid is no longer your control mechanism. EASY INSTALLATION Retrotting the system with the new ICM was a straightforward process. We made the whole job easier by incorporating the new ICFintegrated liquid line assembly into the line, explains Chapp. e ICF assembly is similar to a block valve with stop, strainer, solenoid, and modulating valve functions all built into a compact, 2weld assembly. We had to evacuate the system, remove the old valve train, and pipe in the new valve. en we had to bring it back online, program the valve head and it was up and running, iel explained. Programming the valve actuator the ICAD is very easy with the userfriendly design. We saved a lot of time in the setup process because of the modular design of the valve it really saves in welding. GOOD THINGS TO COME My contractor, Advantage Refrigeration, brought this new technology to my attention and we were really intrigued, says iel. We really like to look at new technology. Most of it does not work as advertised, but this valve really delivers on its promise. In fact, this is the third one weve installed and we are planning to make this a standard spec on all future jobs. n New Danfoss ICF integrated liquid line assembly. Vol. 6 Issue 1 2007WWW. ENVISIONEERING. DANFOSS. COM2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=14E nsuring food product integrity and safety is a key topic for the refrigeration industry. Supermarket operators can save signicant costs if the products they oer are stored and displayed in optimum environments. If the systems that maintain the refrigerated environments run eciently, largescale energy savings also accrue. And discovering equipment problems before they become emergencies greatly reduces maintenance expense or energy consumption. Staying informed about food environments and equipment eciency is essential, then, to managing a costecient supermarket. ere is a lot to be saved. Food products, of course. And energy. And broken machinery. ese three can add up to tremendous costs for the supermarket operator costs that can be mostly avoided. Twentyve years ago, the supermarket operators information and reaction needs were met by having store personnel patrol the sales oor and look in on the equipment in the machine room periodically. Today, surveillance is constant. Electronic systems provide for ecient operation and can generate alarms for a myriad of problems in their infancy, so that they can be addressed before they become costly. Among the many problems that can arise, there is a special set of conditions aecting refrigeration systems that are dependent on seasonal changes in weather. Weve just come through a winter that was harsh in many places. During such cold weather, refrigeration systems are oen taxed heavily by stacking, which is the tendency of refrigerant to seek the part of the system where it will be at the lowest potential energy levelin other words, the coldest. e majority of supermarket systems in temperate zones have rooop condensers, which are exposed to the worst of cold weather. By design, they are mounted where airow is best. erein lies a wintertime problem. Stacking eectively increases the amount of refrigerant needed in the system. If a store has less refrigerant charge the amount contained in the entire system than optimal, then when the condenser is always lled, there is not enough refrigerant, or barely enough, to do the cooling job in the display cases, the cutting rooms, and the storage walkins. Temperatures begin to rise. Compressors dont get enough oil, because oil is dispersed in the refrigerant, and not enough refrigerant is reaching the compressors. At the same time, because lack of refrigerant creates low pressures, compressors cycle rapidly on and o short cycling, which makes the oil decit problem worse. At last, compressors fail. As this scenario progresses, repair costs increase exponentially. Keeping an eye on stacking Saves Goods Moneyand Danfoss products and technology help supermarkets eliminate waste, to improve energy efciency, to reduce maintenance and energy costs, and to be environmentally responsible. 1212Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=15All of the eects of stacking are expensive. Emergency maintenance is oen done on overtime. When compressors short cycle, energy bills rise sharply due to the constant increased demand when motors start up, and broken compressors of the size used in supermarkets are very costly to replace. WHY IS THE SYSTEM SHORT OF REFRIGERANT Some engineers suggest that it is a rare supermarket system that doesnt have one or more leaks each year, brought about by high pressures, vibration, refrigerant hammering, and other traumas, including sometimes less than best service practices. Accurate leak detectors are very costly, and it is dicult with a good handheld one to nd a slow, insidious, oen sporadic leak in a huge system with pipe covering a portion of sales oor and work area that may be 20, 000 square feet. Another downside of leaks is the need to replace the refrigerant to keep the system running. Systems contain several hundred pounds of refrigerant costing from 5 to 20 dollars per pound. e environmental damage that can be done by refrigerants escaping into our atmosphere has been greatly lessened by the development of new, more environmentally friendly refrigerants, but the potential for damage to the ozone layer and also for contributing to global warming remains. Oen, when systems become short of refrigerant, they are recharged to a level that is too low that will give adequate service in spring and fall, but cause severe stacking problems during winter months and other problems during the summer. Today, many think that the best practice is to charge the system until the receiver is 30 percent full. at will insure that there is always a 20 percent reservoir to feed the refrigerated xtures, even in the dead of winter. is winter, and for some years past, supermarket operators have saved a great amount of damage and cost through electronic control systems that are capable of constantly monitoring refrigerant levels, pressures, compressor run times and cycles, and xture temperatures. e systems generate alarms when any condition exceeds bounds established by the operator. Some store operators have contracted with monitoring centers such as that operated around the clock by Danfoss RETAILCARE. ese centers operate every day of the year, and can oen detect trends and report to store managers before a product loss or machine failure becomes a major problem. Store controllers transmit the alarms to the monitoring center by telephone or via Internet. Some of the largest food retailers, where there are economies of scale, operate their own response centers. Today, these maintain and analyze databases of thousands of alarm conditions, and have learned to identify the most dangerous problems in their infancy, thus saving untold amounts of maintenance and energy dollars, and in some measure protecting our environment by reporting conditions that may indicate leaks. e worries are delayed. But the monitoring centers, the store operators, and their contractors have only eight to ten weeks before changing gears to face the hot weather problems to come. OUT OF SIGHT, OUT OF MIND An important objective of good maintenance and monitoring practices is that the systems, their refrigerants, and their controls be entirely transparent to the stores customers, for whom providing a comfortable, convenient shopping experience is of paramount concern. For instance, customers cant buy what they cant see, and when it is necessary to unload one of the refrigerated cases to nd a leak, sales are lost and customers are unhappy that they have items they cant cross o their shopping lists. Because of the importance of seasonal variations in the behavior of refrigeration systems, training of service technicians and monitoring personnel has become a continuing process, with factories, engineers, and consultants contributing to ensure that a best eort using best practices is put forth to eliminate waste, to improve energy eciency, to reduce maintenance and energy costs, and t2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=1614Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING14 PRODUCT NEWS New Electronically Controlled Bypass Package Danfoss Drives introduces Electronically Controlled Bypass ECB packages. ECB integrates into a single package a plethora of the most desired bypass system control features as standard, including Automatic Bypass, Common Start Stop in drive or bypass modes, and Advanced Fireghts Override that works in coordination with the drive and bypass for improved protection. All features are easily programmed through the drive keypad. By combining the advanced features of the VLT HVAC Drive with the advanced performance of ECB packages, Danfoss is making available a complete HVAC solution with truly advanced performance previously unheard of and currently unrivaled in the HVAC market, says Ed Smith, HVAC product manager. ECB packages provide improved protection and operation through a rstofits kind bypass 24VDC switch mode power supply. Contactor operation is unaected in harsh conditions, and drive operation can be maintained at reduced output with input as low as 70 percent of nominal voltage, or even with one input phase missing. is signicantly improves operation when compared with standard transformer power supplies, or power supplies that only operate o of two legs of input power. e ECB power supply acts as a backup power source to the drive logic when power is removed from the drives input terminals. is allows operation of all drive and bypass control features in less than ideal operating environments and situations. Packages are available in either two contactor or three contactor congurations, from HP through 350HP at 460 600VAC, or HP through 60HP at 208 and 230VAC. NEMAUL Type 1 or Type 12 enclosures are available for all package congurations, and in many cases the physical size of the packaged solution remains constant even with enclosure rating changes. All packages include driveonly input fusing. A wide range of optional power features are available including dual motors operation, contactor motor selection, input reactors, d Vdt lters, and selection between input disconnect, fused disconnect or circuit breaker. For more information, contact 8006218806 salesinformationdanfoss. com www. namc. danfoss. com. n Pressure Transducers for performance under pressure For heavyduty applications like o road hydraulic and construction equipment, and for industrial heating, air conditioning, and ventilation, Danfoss type MBS 1200 and MBS 1250 pressure transducers perform under the most demanding and rigorous conditions. ese transducers are accurate in ambient conditions up to 257F, and can be supplied for extreme conditions up to 302F. ey have a wide pressure range from 145 to 8700 psi. in lm technology, ensures exceptional accuracy and longterm stability, while a unique, patented integral pulsesnubber protects against cavitation and liquid hammering. All welded parts are of stainless steel. With complete customization capabilities, Danfoss can deliver the right pressure transducers and right solutions for any heavyduty or industrial application. For more information, contact 4109318250. n Product Highlight2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=17The VLT AQUA Drive from Danfoss Water and Wastewater Danfoss Water Wastewaters highly popular VLT AQUA Drive is now available in a IP66 enclosure solution. This enclosure is rated for indoor or outdoor use and protects personnel against incidental contact with enclosed equipment while protecting the drive from falling dirt, rain, sleet, snow, ice, windblown dust, splashing water, hosedirect water, and corrosion. Available power sizes in the IP66 enclosure include 560 HP in 230VAC and 10125 HP in 480 and 600VAC. The VLT AQUA Drive is also available with a NEMAUL Type 1 or NEMAUL Type 12 IP5455 enclosure. Engineered with specially designed software for water and wastewater applications, the VLT AQUA variable frequency drive provides seamless installation, commissioning, operation and system maintenance in the water and wastewater industry. A streamlined and compact design enables easy integration into even the tightest installation spaces. The new VLT AQUA Drive signicantly improves system efciency in applications such as water supply, treatment, distribution, pressure and level control, irrigation, and wastewater applications such as pumps and blowers where speed, pressure andor level control are critical. Its modular design offers the highest exibility in option selection with fast delivery of a fully factory tested, customized drive with a number of additional plugandplay options available for simplied upgrades as application needs evolve. Additionally, the VLT AQUA Drive offers 98 operating efciency along with automatic sleep mode functionality, automatic energy optimization and ow compensation resulting in considerable energy savings to the user. For more information, contact 8006218806 salesinformationdanfoss. com www. namc. danfoss. com. n 15 e Universal TR6 oers homeowners the opportunity to increase the eciency of older airconditioning units and heat pumps, regardless of the manufacturer, and reduce energy costs without investing in more expensive 13 SEER or higher equipment. For a low investment, a TR6 retrot can boost system eciency between 10 and 15 percent on older equipment, depending on the age and capacity of existing systems. Operations research has demonstrated that a thermostatic expansion valve oers the most timely, most cost ecient and least risky method to regulate refrigerant ow and increase the eciency of older residential airconditioning systems, said Mark White, aermarket business development manager at Danfoss. Danfoss provides the TR6 thermostatic expansion valve in congurations and sizes for residential units. Were committed to meeting the huge increase in demand for these valves created by the recent EPA ruling that requires a minimum Seasonal Energy Eciency Ratio of 13 for newly manufactured airconditioning and heat pump systems. Using temperature and pressure sensors to open or close the diaphragm as needed, the TR6 precisely meters refrigerant ow to maintain proper gas saturation in the coil. An internal check valve, adjustable superheat and adaptable inlet and outlet ports make it easy for contractors to install the valve aer selecting the refrigerant, tonnage and connection type. e TR6 valve ts Aeroquip, Chatli and a variety of other connections. Appropriately named the Universal TR6, the new valve is available in six models that cover original equipment manufacturer OEM airconditioner and heat pump designs in a wide range of applications, from one to six tons in R22 and R410A systems. is feature simplies stocking and inventory by eliminating the need for service technicians to carry several dierent OEM valve designs on their trucks. e Universal TR6 thermostatic expansion valve includes a number of additional features to ensure a long life of ecient service. e sensing bulb charge is carefully optimized for residential air conditioning. e power element, containing the sensitive valve diaphragm that operates the valve, is laser welded to preserve the integrity of the diaphragm, and a new bulb str2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=1816Vol. 6 Issue 1 2007ENGINEERING ENERGY EFFICIENCY ENVIRONMENT ENVISIONEERING PRODUCT NEWS 16 e VLT Micro Drive includes a number of features that provide real, tangible benets to users in water applications, says Tom Momberger, product manager for Danfoss Drives. e drive eliminates the need for an external controller, and oers true sidebyside mounting without any derating due to its compact bookstyle design. An Automatic Energy Optimizer function allows the drive to consume less energy while the Automatic Motor Adaptation feature leverages the motors full operating potential. Users will also benet from up to 150 percent more torque for up to a full minute, eliminating the need for a bigger drive, he says. e extremely compact VLT Micro Drive provides IP20 protection even without the terminal cover. It is available in cabinet sizes as small as 2. 75 in. wide x 6 in. tall x 6 in. deep, and can be commissioned in minutes to perform even complex operations. Approximately 100 parameters can be set to optimize energy eciency and operation. A ying start feature provides more uptime while an electronic thermal relay eliminates the need for external motor protection. A builtin RFI lter saves on cost and space. e VLT Micro Drive also features a smart logic controller a simple yet clever way to seamlessly integrate the drive and motor for optimum application performance. is feature allows users to program the controller to react on virtually any event, oen eliminating the need for a PLC. Additional features include builtin AC and DC brake functions that help the drive transform kinetic energy from the application into braking power, intelligent heat management and coated electronics for maximized drive reliability and life, and the ability to copy settings via a local control panel LCP to easily set up multiple drives. VLT Micro Drives are available in singlephase 200 240 VAC 0. 25 2 HP threephase 200 240 VAC 2 HP and three phase 380 480 VAC 0. 5 3 HP power range congurations. For more information, contact 8006218806 salesinformationdanfoss. com www. namc. danfoss. com. n Danfoss Drives Introduces the VLT Micro Danfoss Drives introduces the VLT Micro Drive a genuine VLT variable frequency drive with unsurpassed reliability, user friendliness and condensed functionality that is extremely easy to commission. Users simply connect the motor and power cables, turn the control knob, and watch the motor speed change. The VLT Micro Drive is a general purpose drive designed for rugged and reliable, outofthebox, plugandplay control of AC motors up to 3 HP. There are plans to extend the horsepower range through 10 HP later this year Product Highlight2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=19Danfoss announces new Variable Capacity Solutions, combining the latest technology in variable speed scroll compressors, variable speed drives, electronic expansion valves and controls. Variable Capacity Solutions includes the rst commercially available variable speed scroll compressors of their kind for lightcommercial and commercial airconditioners rooop units and chillers, according to Mogens Rasmussen, application development engineer at Danfoss Refrigeration Air Conditioning, North America. In addition, Danfoss has developed dedicated speed drives, controls and electronic expansion valves as part of the total integrated solution. Our variable speed compressors have an operating range from 30 to 90 Hz, providing impressive continuous capacity range from 4 to 37 tons with only four compressor models, Rasmussen said. In addition, Variable Capacity Solutions oer many integrated functions such as a builtin crankcase heater, advanced motor protection, so start to reduce inrush current, builtin power factor correction and protection against voltage imbalance. For OEMs, the key benets are the highest energysaving performance at the lowest system cost and optimal system control, including exact load matching. For end users, benets include increased comfort, lower utility bills, less downtime and noise, and lower maintenance costs. e projected energy cost escalation makes Variable Capacity Solutions a perfect t for both OEMs and end users alike. Variable Capacity Solutions can generate substantial annual energy savings and reduced electrical peak demand compared to conventional ono compressor alternatives. e exact savings depends on multiple factors, including load prole. Variable speed compressors can also be combined with xed speed compressors to form a hybrid solution. By combining a single, variable capacity compressor with one or more xedcapacity compressors, an OEM design engineer can provide continuous variable capacity over a much wider capacity range, for decreased costs. Whats more, the Danfoss variable capacity compressor allows engineers to design compact light commercial and commercial units with fewer manifolds. Simply put, Variable Capacity Solutions give engineers more options, Rasmussen said. Keep in mind that chillers and rooops in air conditioning applications run on partial load approximately 90 percent of the time and on peak load only 510 percent of the time. Adding variable speed to the condenser fans yields even greater system savings. is results from the large periods of operation where the condenser is running under partload condition and is matched precisely with a slower overall fan speed, consuming signicantly less power. Using Variable Capacity Solutions is just one more example of En Visioneering in action. e rst of the new Variable Capacity Solutions models will be released by the end of 2007, and the hybrid solution by the end of 2008. For more information contact 4109318250. n EKC for Compact Refrigeration Control The EKC 202 is a UL approved compact refrigeration xture control that can ensure energy efcient operation of cooling, defrost, compressors, fans, and xture lights. With large, bright numerals, the EKC 202 allows inspection of food storage temperature easily from a stores sales oor. The control is easy to program using its three buttons. Three temperature sensor connections, along with four onoff relays, allow a variety of control strategy options. Flexible onoff inputs provide functions such as door monitoring, a switch to allow alarm suspension for case cleaning, dual temperature operation, and others. Echelon communications capability makes the EKC 202 compatible with many host controllers including the Danfoss AK2SC 255. This control has been adopted by convenience stores and small markets as a means of complying with Food Code requirements as well as saving energy. For more information contact 4109318250. n Variable Capacity Solutions from Danfoss Provide Optimal Energy Saving Perform2007-06-28T07:39:16+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsv612007/?Page=20June 2007 5th Danfoss En Visioneering SM Conference June 5, 2007, Westin Hotel, Long Beach, CA. August 2007 World Energy Engineering Congress August 5116, 2007, Georgia World Congress Centre, Atlanta, GA. Food Engineerings Process Technology Xchange August 2629, 2007, e Lodges at Deer Valley, Park City, Utah. September 2007 70th RSES Annual Conference September 11 15, 2007, Crowne Plaza at Riverwalk, San Antonio, TX. HVAC Comfortech 2007 September 2629, 2007, Americas Center, St. Louis, Missouri. October 2007 RETA 98th Annual National Convention October 25, 2007, Double Tree Hotel Riverside, Boise, Idaho. The NAFEM Show October 1113, 2007, Georgia World Congress Center, Atlanta, Georgia. Visit Danfoss booth 6665 WEFTEC Conference Exposition October 1317, 2007, San Diego Convention Center, San Diego, California. November 2007 National Association of Convenience Stores NACS November 79, 2007, Georgia World Congress Center, Atlanta, GA. Visit Danfoss booth 1924 2007 CALENDAR OF EVENTS 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. com 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 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 6711 Mississauga Rd. , Suite 410 Mississauga, Ontario L5N 2W3 9052852050 Fax 9052852055 www. na. heating. danfoss. com Heating Controls Motion Controls SOMERSET, NJ Danfoss Bauer 31 Schoolhouse Road Somerset, NJ 088731212 7324698770 Fax 7324698773 www. danfoss. comdrivesus Gearmotors TALLAHASSEE, FL Danfoss Turbocor 1769 Paul Dirac Drive Tallahassee, FL 32310 8505044800 www. turbocor. com Oil Free Compressors for Refrigeration and Air Conditioning 2007-06-28T07:39:16+02:00