http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/RSS.ashxRA PagesTue, 07 Jul 2009 11:17:07 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=1MAKING MODERN LIVING POSSIBLE SolutionS T R E N D S A N D T O P I c S T h A T I M P A c T I N D u S T R y EnVisioneering SM A Climate for Change » P Lu S : T h E 2 0 0 9 c O P E N h A G E N c L I M AT E S u M M I T ENGINEERING + ENERGy EffIcIENcy + ENVIRONMENT = ENVISIONEERING VOLuME 8 / ISSuE 2 / 20092009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=2MAKING MODERN LIVING POSSIBLE EnVisioneer your future today. In seven years, seven Danfoss products have been honored with AHR Innovation Awards, including the 2009 AHR Product of the Year. We built that record by working with our customers to achieve energyefficient engineering innovations that add value to their business. We call it EnVisioneeringSM. Our passion for technology delivers efficient innovations like the Danfoss ApexxTM VSH variable speed scroll solution for air conditioning and our new AKD 102 adjustable frequency drive for commercial refrigeration. Both achievements are recognized with AHR Innovation Awards for 2009 and both deliver higher standards of energy efficiency in a business climate where efficiency matters most. But already, our engineers are taking the next steps. We EnVisioneer for a future of sustained innovation. www.danfoss.us ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=3VOLuME 8 / ISSuE 2 Dear readers, It’s been more than three months since the united States inaugurated a new president, who has tried to tackle everything from the financial bailout to the global economic crisis to a dramatic change in energy strategy. While there are no easy answers, President Obama is making energy policy a top priority for his administration. To better understand the energy challenges and opportunities that lie ahead, EnVisioneering Solutions turned to Robert Sauchelli of the u.S. Environmental Protection Agency’s ENERGY STAR Program. On pages 2-6, Mr. Sauchelli sheds new light on America’s energy situation and helps bridge the gap between energy and business priorities. Also in this issue (pages 7-11), EnVisioneering Solutions provides an in-depth preview to the fifteenth Conference of the Parties under the united Nations Framework Convention on Climate Change (uNFCCC COP15), to be held in December in Copenhagen, Denmark. Ministers and officials from 189 countries will take part in this historic event. Hundreds of industry groups, non-governmental organizations and media will also descend on Denmark’s capital to find out how the world will tackle the complex issues around climate change and the environment. Whether they’re debated in the united States or abroad, energy, climate change and the environment are important issues now – and will be for generations to come. We invite you to engage in the dialogue and, as always, we welcome your suggestions and feedback on this issue. The simple yet elegant design of Danfoss Turbocor delivers maximum results at the NFL Film’s studio complex. Story on page 14. Contents / 2 / from the coVer 2 / Bridging the Gap: Head of EPA’s ENERGY STAR program discusses energy and business priorities 7 / The 2009 Copenhagen Summit brings nations together to solve pressing environmental issues / 12 / case stUDies 12 / Every detail counts at Samsung’s Texas factory 14 / Danfoss Turbocor’s advanced compressor technology delivers reduced energy consumption at NFL Film’s studio complex 18 / Best Practices from auto industry lead to increased efficiency in air conditioning the editors solutions@danfoss.com information contained in the Danfoss EnVisioneering Solutions may be republished only with permission of Danfoss and always with credit to Danfoss enVisioneering solutions. comments, suggestions, and contributions are welcome. this publication should not take the place of appropriate technical or legal advice related to company-specific circumstances. Danfoss enVisioneering solutions does not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication. PRODuCT HIGHLIGHTS THIS ISSuE AK-CS Controller / AHR Expo Award Winners / VLT® HVAC Drives / VLT® Micro Variable Frequency Drives2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=4Brid GING The united States had just entered a period of heightened concern over energy when financial and economic news threatened to overturn the national agenda. T O D AY, M A N Y T H I N K E N E R G Y efficiency technology and correcting today’s economic imbalances are linked. But concerns remain over misaligned incentives, first costs, skepticism about technology, and whether energy efficiency can drive a new economy without solutions to these persistent challenges. To better understand the opportunities, EnVisioneering Solutions turned to robert sauchelli of the U.S. Environmental Protection Agency’s ENErGY STAr Program. The EPA ENErGY STAr organization is well-known for its work bridging energy and business priorities. We spoke with Mr. Sauchelli at his Manhattan office. HEAD OF EPA’S ENERGY STAR PROGRAM DISCuSSES ENER Q: Financial markets remain constricted, business is challenged for growth, and energy efficiency is seen by some as a key to a new economy. In the present situation, what are the prospects for serious progress on energy efficiency? The economy is a challenge for everyone, but there is genuine movement on energy efficiency. i expect the pace to quicken. The marketplace we see is ready for it – for its environmental impact and its financial benefits. Energy efficiency projects pay for themselves and continue to return on the investment. A: 2 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=5RGY AND BuSINESS PRIORITIES GAP M O R E Q & A W I T H R O B E R T S Au C H E L L I the Q: A: Q As you know, there are concerns about slow rates of return on investment in energy efficiency technologies. Such perceptions are cited as market drivers. What, if anything, has changed? Historically the rOi on many energy efficiency technologies has not been slow. But today the returns are coming even faster, and that fact is more widely recognized by corporate decision makers. We have seen this directly through EPA projects with private sector leaders. Technologies typically pay for themselves well within normal investment timeframes, and the return is enhanced by incentive programs – earlier & through A INTER VIEW and WITH ROBERT SAuCHELLI » the utilities, after deregulation, through state government efficiency programs. The returns are sufficiently certain that, at least before financial markets froze, banks were providing financing for energy efficiency investments. » VO VO Lu LM uM EE 87 / / I SIS Su SE uE 21 / / 20 20 09 08 32009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=6COVER STORY CONTINuED Creating new power generation is a major challenge, but energy efficiency is half the cost of new generation and offers the fastest impact on emissions and business earnings. The loans were viewed as low risk and the equipment as essentially self-financing. The ESCO model was built on that insight and has worked well. it will perform even better in the future as its merits are more widely recognized and methodologies are refined. With CEOs and investors working to find pennies per share in growth, energy efficiency is a profit center that warrants attention for business reasons as much as environmental ones. Creating new power generation is a major challenge, but energy efficiency is half the cost of new generation and offers the fastest impact on emissions and business earnings. A properly designed and operating building that has earned the ENErGY STAr – a truly energy efficient building – costs about 50 cents per square foot less to operate than its traditional counterpart. it uses 35 percent less energy and emits 35 percent less carbon. 35% energy saved by buildings that have earned the enerGY star. Q: In your view, then, the ROI on energy efficiency technology is generally quite certain. But, there are skeptics in the marketplace. How can the skeptics confirm the ROI for themselves? A: The EPA has worked for several years to develop a toolbox of instruments that allow owners, investors, and others to gain a thorough understanding of the energy savings potential of a building and of specific products and technologies that can be used to enhance efficiency. it is important to remember that the EPA focused for quite some time on building partnerships with the private sector. For example, we have an ENErGY STAr partnership program for energy users and also with service and product providers. danfoss Turbocor is one of the over 2000 companies that have partnered with us, helping to develop products and strategies for improving energy efficiency in buildings. We work with them as well to promote their products. in our experience, it is critical to map a route to bring energy users and service and product providers together profitably. it is essential to us that end users be able to confirm results. So in addition to our well-known work through ENErGY STAr on products, and on residential buildings, where we have developed rating systems and technology and behavioral upgrade strategies, ENErGY STAr has also developed commercial building guidelines for energy management. These are a suite of tools to which business has free access and that we want to share with the marketplace. One example is our energy performance rating system available through our Portfolio Manager tool. it is a tool accessible by our partners on the EPA ENErGY STAr website that establishes an energy performance rating on a scale of 1 – 100. it examines twelve types of commercial buildings and incorporates location, use patterns, square footage, monthly bills and an array of attributes. We can rate a given building against a database that normalizes for differences in location, climate, function, and the like. it’s the EPA “miles per gallon” for buildings. Over 83,000 buildings have been rated. The average commercial building rates about 50. Any building at 75 or higher is in the upper quartile and earns an ENErGY STAr. There are about 6200 such buildings. Those 6200 buildings save about $1.7 billion annually on energy use. $1.7 billion money saved annually on energy use by the 6,200 U.s. buildings that have an enerGY star rating of 75 or higher. 4 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=7it also equates to 13 million metric tons of carbon not emitted into the atmosphere. We have been working on this tool for eight or nine years, fine tuning it for various types of buildings, and improving its capacity to normalize for varied conditions. And we have developed best practices for upgrading a building’s rating and re-benchmarking it after improvements are made, so the drive for energy efficiency is an ongoing process. Buildings that have earned the ENErGY STAr typically continue to improve. Q: How can investors, building owners, and tenants assess the difference energy efficiency technology will make for their businesses? A: That is a complex question. First, what is the goal of the owner? When the main goal is return on investment and the building is a cost of doing business, ENErGY STAr has developed a Financial Value Calculator that takes information from the owners’ annual report and its energy performance rating and calculates the energy efficiency potential, its impact on net income, and then on shareholder value. The financial value of energy efficiency can be calculated in dollars and cents per share —language investors appreciate. The value can then be translated into reductions in cost of goods sold—for example, the equivalent sales per square foot in a grocery store. The grocery industry works on narrow margins, and we can help show the direct impact of energy efficiency technology on those margins, and again, back to earnings per share. And grocery stores are a good example of another aspect of the issue —we have been talking about buildings, but there are ENErGY STAr products that can save up to 50 percent of their energy expense over conventional products. Another tool is the Cash Flow Opportunity Calculator, a cash flow optimization tool. With this, the owner can see how and when the investment in an energy efficiency technology project pays for itself. Almost invariably, such projects are net positive cash flow. The banks can therefore offer loans to cover the initial project cost. And since investors are focused increasingly on the free cash generated by the businesses in which they invest, the benefit again is to asset value and to investors. There are other tools that can be found on our website. And we are actively looking for companies that can partner with us on energy efficiency products and services. But the overarching point is that, in demanding economic times, these tools help demonstrate the financial value of energy efficiency, energy efficiency technology, and projects to drive energy efficiency in the commercial built environment. it’s real, visible, and adds value to the building, to the revenue stream, and to the investor’s balance sheet. » The ENErGY STAr Toolbox: ENERGY STAR has developed tools that help quantifiably demonstrate the financial value of energy efficiency, energy efficiency technology, and projects to drive energy efficiency in the commercial built environment. Portfolio manager a tool accessible by partners on the ePa enerGY star website that establishes an energy performance rating on a scale of 1 – 100. financial Value calculator a tool that takes information from the owners’ annual report and its energy performance rating and calculates the energy efficiency potential, its impact on net income, and then on shareholder value. cash flow opportunity calculator a cash flow optimization tool that allows the owner to see how and when the investment in an energy efficiency technology project pays for itself. For more ENERGY STAR tools and resoureces, visit energystar.gov. VOLuME 8 / ISSuE 2 / 2009 52009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=8The energy component of the stimulus package is crafted to capitalize on the heightened awareness and maintain focus on energy efficiency. ENVISIONEERING SOLuTIONS BRIEF Q: ARRA Tax Incentives The recently passed American Recovery and Reinvestment Act includes tax incentives to drive sales of energy efficiency technology in residential and commercial buildings. Some of the key provisions are: The u.S. Government has passed a stimulus package to spur economic growth, and part of the package concerns energy efficiency. What are its main provisions, and how can our readers capitalize on them? » residential consumer federal tax credits for 30 percent of the cost of energy efficient HVAC, water heaters, doors, windows, insulation, and other home efficiency improvements, up to $1,500, through 2010. And 30 percent for some residential renewables— geothermal, solar panels, small wind power, fuel cells, and the like—until 2016, with no dollar limit per home. » tax deductions of up to $1.80 per square foot to owners and designers of new or existing commercial buildings that save at least 50 percent of the heating and cooling energy of any building that meets ASHRAE Standard 90.1-2001. » Partial deductions of up to $.60 per square foot that can be taken for measures affecting any one of three building systems—the building envelope, lighting, or heating and cooling systems. These tax deductions are available for any systems “placed in service” from January 1, 2006 through December 31, 2013. A: The energy component of the stimulus package is crafted to capitalize on the heightened awareness and maintain focus on energy efficiency. it commits over $6 billion to energy efficiency projects, dispersed through states, municipalities, and governments. For states and localities that have adopted the ENErGY STAr rating strategy and are prepared to take advantage, that $6 billion is like air to fire. And some states are well positioned. California has new rules requiring each commercial building sold to disclose its ENErGY STAr rating. Washington, dC now requires a public disclosure of energy use in buildings. New York City has legislation pending requiring that the ENErGY STAr ratings for buildings of a certain size be provided to the city. Many cities and states are adopting ENErGY STAr rating systems, so it is possible to be quite specific about targeted performance levels, quantification of benefits, documentation of accomplishments, and even celebration of success. Energy efficiency processes are becoming more standardized and routine. The stimulus package fuels that process. it is a reason to be optimistic about the future of energy efficiency. Energy efficiency is a source of profit, not cost. That fact is demonstrable. investors and owners are increasingly drawing the right conclusions. They are even finding creative ways to structure leases to get past the “split incentives” issues in commercial real estate. despite major economic challenges, the economics of energy efficiency is reaching its stride. The stimulus cuts a path through obstacles created by the financial and economic crises. Given the realities of energy efficiency economics, we think it will make an important difference. Helpful Websites » tax credits & incentives: http://www.energystar.gov/index.cfm?c=products. pr_tax_credits » tax credits & incentives on commercial Buildings: http://www.energystar.gov/index.cfm?c=products. pr_tax_credits#s8 6 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=9coPenhaGen sUmmit 2009 brings nations together to solve pressing environmental issues T H I S Y E A R W I L L B E A T u R N I N G P O I N T for the world’s environment. in december, more than 10,000 people will head to Copenhagen for the fifteenth Conference of the Parties under the United Nations Framework Convention on Climate Change (UNFCCC COP15). Ministers and officials from 189 countries will take part. Hundreds of industry groups, non-governmental organizations, and media will also descend on denmark’s capital to find out how the world will tackle the complex issues around climate change and other environmental issues. A top item on COP15’s well-packed agenda will be how to fairly and effectively implement emissions cap-and-trade schemes, carbon taxes, or a combination of both. Other key topics include efficiency standards, subsidies for new environmental technologies, and deforestation. COP15 aims to set a global roadmap for addressing climate change and natural resource conservation the stakes are high With the Kyoto protocol set to expire in less than four years, COP15 aims to forge a new environmental agreement to take effect after 2012. The summit will impact industries and economies around the world. it also will determine whether developed and developing nations can join forces to take major action to stem the impact of greenhouse gases on the global climate. COP15 aims to align the countries that signed the roadmap set out at the 2007 international environmental summit in Bali. The overarching goal is a global agreement to stabilize greenhouse gases in the earth’s atmosphere at a level that prevents dangerous manmade climate changes. The bigger challenge is doing it in a way that enables nations to meet their economic growth targets. The summit also has political implications. A central question is whether the United States is ready to fully embrace a global climate change treaty. The U.S. is a signatory to the Kyoto Protocol, but has neither ratified nor withdrawn from the Protocol, and isn’t bound to its mandates. All eyes are on U.S. President Obama’s administration, which has already positioned itself as a green government by pushing for environmental legislation. »2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=1033.3 42.3 billion trillion “it’s likely that the new administration will approach climate change negotiations from a different perspective than the previous administration did,” says Air Conditioning, Heating and refrigeration institute (AHri) president Stephen Yurek. “Active engagement in the COP15 negotiations might signal to the U.S. that the federal government is preparing to take the lead on a national climate change policy.” To size up the challenge, consider that the U.S. Energy information Administration forecasts that world energy consumption will continue its rapid expansion to 33.3 trillion kilowatt hours by 2030. World carbon dioxide emissions also will continue to increase steadily, to reach 42.3 billion metric tons in 2030. if carbon and other greenhouse gas emissions continue to grow at this rate, scientists confirm, there will be grave consequences and costs. forecasted amount of kilowatt hours of energy consumed globally by the year 2030 cap-and-trade challenges industry to green up Greenhouse gas emissions trading is one of the hottest, and most debated, issues on the table. Businesses across virtually all sectors are preparing for the impacts of a climate change treaty, as well as national environmental legislation. Cap-and-trade schemes involve imposing caps on businesses’ greenhouse gas emissions and gradually decreasing limits, until emissions reach the desired level. The caps could apply to industries, power plants, and vehicles. Focus has been on carbon dioxide, considered the primary greenhouse gas, but other substances known to contribute to global warming are also on the radar. Cap-and-trade allows businesses to obtain permits to emit greenhouse gases, which they can trade in a secondary market. Factories or utilities with low emissions will sell their spare carbon allowances to those who don’t have enough. The idea is to make reducing emissions profitable for businesses, for the government, and for the environment. The government auctions emissions permits to the companies required to reduce their emissions, which would be a major revenue stream. Cap schemes are meant to prompt businesses to take serious measures to reduce harmful emissions. This could include everything from improving energy efficiency in manufacturing, constructing green buildings, using renewable energy, or even rethinking entire business models. Although it challenges manufacturers to make changes, emissions trading would also be welcome news for makers of energy saving and emissions reducing components and equipment. “To the extent that COP15 helps accelerate replacement of the worldwide installed base of air conditioning and heating equipment to a more efficient level, the industry would be supportive,” says Yurek of AHri. Of course, the industry will also look for a treaty that is pro-business. A study released by the Economist intelligence Unit at the 2009 Sustainability Summit in London found, through a global survey of 528 senior executives and in-depth interviews with executives and experts, that many companies would embrace a cap-and-trade scheme, within a limited carbon price. forecasted amount of metric tons of carbon dioxide consumed by the year 2030 cap-and-trade: highly debated strategy that imposes caps on businesses’ greenhouse gas emissions while allowing them to obtain and trade emissions permits 8 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=11the Green Buildings movement will be another important part of reducing energy use and emissions associated with it. Buildings account for about 68 percent of total electricity consumed in the U.s., and for 39 percent of the total amount of carbon dioxide emissions. the U.s. considers cap-and-trade The outcomes of COP15 could influence national and states’ legislation. This, in turn, could spur more technological innovations in product efficiency, emissions control and renewable energy. The refrigeration and HVAC industry is currently preparing for several key rulemakings now underway in the department of Energy (dOE) that will further increase minimum energy efficiency standards for a variety of air conditioning and refrigeration equipment. A global climate treaty is likely to advance efficiency technologies even more. “Ambitious emissions reduction goals offer a significant business opportunity,” says dr. Jürgen Süss, vice president of research & development for danfoss refrigeration and Air Conditioning. “There are profit and business opportunities in identifying and developing various ways of minimizing greenhouse gas emissions.” An emissions trading approach also might spark greater collaboration between suppliers, equipment manufacturers and installers, and end users to reduce products’ carbon footprint. Süss points out that once a product reaches the customer, the manufacturer no longer has control over the product’s environmental impact. “ideally, HVAC&r installations should apply latest technologies, including smart electronics, ensuring energy efficient operation throughout the entire lifetime as well as a minimal charge of refrigerant with less environmental impact to optimize the overall lifecycle climate performance,” says Süss. He adds that increased understanding of total cost of ownership will further reduce industries’ environmental impact. running up to the summit in Copenhagen, the U.S. will debate a national emissions trading system. The Obama administration’s 2010 budget proposal includes a cap-andtrade system designed to reduce industry emissions and earn the U.S. government $646 billion through the sale of permits. The proposal sends a strong signal about the administration’s desire to reduce emissions, and to profit from it. The proposed measures have been under much debate in Congress. Then, in April, the Environmental Protection Agency declared that along with carbon dioxide, methane, nitrous oxide, hydrofluorocarbons, perfluorocarbons and sulfur hexafluoride are deleterious to the environment. The EPA finding is game-changing and will have significant impact on emissions through regulation or legislation. The state of California is already moving ahead with a comprehensive global warming plan that includes a cap-andtrade program covering 85 percent of the state’s emissions. To design an effective emissions trading scheme, the U.S. will surely look to the European Union’s four-year-old foray into cap-and-trade for lessons learned. The European Union’s emissions trading program has had ups and downs. But a study by the Pew Center on Global Climate Change found that the EU’s scheme has been successful in many ways. “The European Union’s Emissions Trading System in Perspective,” (denny Ellerman and Paul L. Joskol, MiT, May 2008) reports that the EU’s scheme “has established a European-wide carbon price and created an infrastructure for a multi-national trading program.” it also found that European businesses have been prompted to incorporate the price of carbon into their decisionmaking, which is exactly the point of emissions caps. » VOLuME 8 / ISSuE 2 / 2009 92009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=12ThE roAd To EnErgy EffiCiEnCy Three basic ways for businesses to set course towards energy efficiency 2 1 implement the use of more energy-efficient machinery Use existing machinery and equipment more efficiently 3 Use less energy efficiency road blocks: » the current economic crisis » tougher efficiency standards and increased mandates the road to efficiency Energy efficiency will also be in focus in the global discussions. There are basically three ways to save energy—use less, implement the use of more efficient machinery, and use existing machinery and equipment more efficiently. real change requires more companies to incorporate energy efficiency and carbon reduction into their strategies. Companies like Proctor & Gamble, Chevron Corp., Wal-Mart, Mcdonald’s and General Electric prove that green practices also can be profitable. They are among ten companies included in Standard & Poor’s new U.S. Carbon Efficient index, based on the amount of annual greenhouse gas emissions driven by a company’s total revenue. Green buildings, vehicles, and highly efficient operations are some of the ways in which these companies are reducing their environmental impact while advancing their business objectives. COP15 will aim to push more companies in this direction in developing and developed countries. The 2009 Economist intelligence Unit report found that 54 percent of the 500 companies polled have established some kind of climate-change strategy, although most only consider energy efficiency. The economic crisis has put a damper on some efforts, but many are still committed to making progress in energy efficiency. The Green Buildings movement will be another important part of reducing energy use and emissions associated with it. Buildings account for about 68 percent of total electricity consumed in the U.S., and for 39 percent of the total amount of carbon dioxide emissions. innovations such as software for building controls systems and high-performing HVAC systems that improve buildings’ environmental performance will help meet new efficiency standards. Overall, the green building industry is expected to grow at a rate of more than 60 percent in 2009 due to increasing mandates by cities, states and the federal government. the refrigerant industry braces for a new global treaty in addition to efficiency legislation, refrigeration and HVAC industries also grapple with the complex issue of refrigerants. Since the Montreal Protocol mandated phase-out of ozone-depleting substances, including CFCs (chlorofluorocarbons), and HCFCs (hydrochlorofluorocarbons), the industry has been under pressure to find new solutions. This led to development of HFCs (hydrofluorocarbons), which do not deplete the ozone layer, and new equipment to use them. However, HFCs can still have environmental impact and are targeted as greenhouse gases. 10 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=13newsWorThy “We’re hopeful that the Copenhagen delegates will see the wisdom in separating HFCs from the so-called ‘big basket of gases’ so that they get treated separately in any climate change regime instituted,” says AHri’s Yurek. He points out that unlike other greenhouse gases, HFCs are not by-products of combustion or other process. “They’re manufactured for a specific purpose that includes economical, efficient space cooling and commercial refrigeration.” HFCs are not included in the Montreal Protocol, but they are included in the Kyoto protocol. AHri argues that new climate change legislation or treaties should phase down and not phase out HFCs1. “it should include an appropriate initial cap set at actual HFC market demand in tons of carbon dioxide equivalent,” says Yurek. “if HFCs are to be phased down in a climate regime, the industry would like to see a realistic transition period.” The industry also urges climate change initiatives to recognize that not all HFCs result in emissions. And it pushes against constraints for imports of the refrigerants by domestic manufacturers for credits for HFCs destroyed domestically. “Any cap-and-trade program should provide for allocations to be made available to HFC users, importers, and producers,” says Yurek. “Proceeds from the sale of allocations (or a levy) on refrigerant emissions should be used to encourage consumers to purchase products that are energy efficient or contain low Global Warming Potential (GWP)2 refrigerants and to provide for the deployment of low GWP products and technologies.” delegates to COP15 will have plenty to discuss and debate. Whatever the outcomes, danfoss, as a global leading provider of energy efficiency solutions, is positioned to help industries worldwide meet climate change mandates. danfoss CEo Addresses Energy Efficiency in global forum DANFOSS, A GLOBAL LEADER in providing sustainable, energy efficient solutions for refrigeration, air conditioning, heating and motion controls, was industry co-host at the Alliance to Save Energy’s Energy Efficiency Global Forum held in Paris in late April. CEO Niels Bjorn Christiansen joined political, academic and business leaders for the only international energy efficiency forum to advance the dialogue on energy efficient solutions. The leaders skillfully explored the new energy paradigm – from economic stimulus funding in the u.S. to new government mandates in Europe to the potential role of energy efficiency in the climate negotiations scheduled for the united Nations Framework Convention on Climate Change in Copenhagen in December 2009. “What we need is the political awareness and the relevant legislation to drive energy efficiency change around the globe,” Christiansen said in his address, “Improving Energy Efficiency: How Danfoss Meets the Challenge.” “A lot of attention and money are being directed toward renewable energy sources such as wind power, and for very good reasons. But if we get a similar push for improving energy efficiency, the payback will be attractive.” Christiansen added that industries need to apply existing technologies more broadly to improve energy efficiency across the board. “The relevant technologies are available,” he said. “There are companies in most industries that possess the competencies and have the products – today.” Danfoss is one of those companies, Christiansen noted. Danfoss has a 75-year history of effectively reducing energy consumption in the heating, refrigeration, air conditioning and industrial controls markets. “It all boils down to improving energy efficiency, because one kilowatt hour saved is one kilowatt less that needs to be produced,” Christiansen concluded. 1 ahri’s proposed reduction schedule for hfcs to reach an 80 percent reduction by 2046 includes: 1 percent of the initial baseline per year between 2012 and 2020; 2 percent of the initial baseline per year between 2021 and 2025; 3 percent of the initial baseline per year between 2026 and 2046. 2 th2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=14CASE STuDY ONE Danfoss V LT D R I V E S » help to maintain the high indoor air quality for clean room environments » are used in normal and critical exhaust systems » remove fumes and gases from the acid scrubber process at Samsung’s Texas factory M O D E R N L I F E has come to depend heavily on semiconductors, which today are used in everything from computers to automotive controls and appliances. Samsung, the world’s leading electronics company, is also one of the largest semiconductor suppliers globally. One of the company’s manufacturing complexes is located in Austin, Texas, where two huge factories cover a combined 2.4 million square feet. Here, semiconductor wafers are made for a multitude of products that we use every day. eVerY DetaiL coUnts an ingot of crystal. This ingot is then ground to a uniform diameter and cut into very thin wafers. Each wafer is then processed through a series of machines, where it is ground smooth and chemically polished. All of this requires a precisely controlled manufacturing environment, including clean room indoor air quality with precise contaminant and humidity control. Not only does the process demand precision, but it’s also remarkably unforgiving. Uptime is of paramount importance as any interruption in the numerous steps results in a significant loss. Whereas most other manufacturing processes measure the cost of downtime in hours, the stakes are considerably higher at Samsung. They estimate that mere minutes of downtime would measure in the millions of dollars. “The factory must run 24/7 for 365 days of the year, without exception,” says Kevin Judd, Master Facilities Technician for Samsung in Austin. control for critical precision The manufacture of a semiconductor chip is a meticulous process requiring absolute perfection at each of the 672 steps necessary from beginning to end. in the first phase of this process, silicon is heated to a molten liquid and a tiny bit of solid silicon, called a “seed,” is placed into it. A small amount of the liquid rises with the seed and cools, forming 12 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=15The first of the two buildings that make up the Samsung plant in Austin opened in 1996. during the construction of the 760,000 square foot facility (referred to as “FAB1” by Samsung), variable frequency drives from a number of manufacturers were installed in its various applications. Over the next several years, the performance and reliability of these various drives were monitored. Based on the service the danfoss solution provided, as other drives failed over the years, they have been replaced by danfoss drives. When construction started in 2006 on the Austin complex’s second manufacturing facility, “FAB2,” danfoss VLT Series drive units were installed throughout the new 1.6 million square foot facility. Currently there are about 150 danfoss VLT® Series drives in new and retrofit installations throughout the Texas Samsung factory complex. This includes drives ranging from 5 HP units installed on fuel pumps for backup diesel generators to 100–250 HP units utilized in the environmental control and automation applications throughout the manufacturing process. danfoss VLT Series variable frequency drives help to maintain the high indoor air quality necessary for the clean room environment that is so crucial to Samsung’s manufacturing reliability. The drives are used in normal and critical exhaust systems, cooling tower fans, pure water system pumps, positive pressure control systems to prevent contamination, and systems to remove fumes and gases from the acid scrubber process. For Samsung, the use of variable frequency drives provides both efficiency and a higher level of control over their processes. “The variable frequency drives replaced numerous mechanical controls,” explains Mr. Judd. “For example, in the environmental control of the clean rooms, positive pressure is required to keep contaminants out of the facility. The system was originally designed with fixed speed fans and mechanical dampers and vents. Now, variable speed control of the fans provides more accurate pressure control, reduced energy consumption and longer life expectancy of the fan motors. it also eliminates mechanical control of the dampers and vents, reducing the maintenance requirements.” The decision to use danfoss VLT Series drives in both new and retrofit applications was primarily based on the reliability that Samsung has experienced since the original VLT units were installed in “FAB.” Since uptime control over process for samsung, variable speed control of the fans provides more accurate pressure control, reduced energy consumption and longer life expectancy of the fan motors. it also eliminates mechanical control of the dampers and vents, reducing the maintenance requirements. is so crucial to Samsung’s business, the ability of VLT Series drives to ride through disturbances on the AC line was a significant advantage. The plant occasionally experienced voltage sags ranging from 30 to 70 percent over a period of 6–10 cycles of the AC line. VLT units proved to be superior in this area over competitive VFd units. Other features that were of particular importance included user-friendliness, low harmonics, and operation in high ambient temperatures. dean Sniatecki, Facilities Technician, added, “in addition, we have found that the ability to perform online programming while the VLT unit is in operation and the Hand-Off-Auto functions that allow for optimal operation without interrupting manufacturing processes have been a huge advantage.” more to come Samsung is currently proceeding with bringing phase 2 of the new “FAB2” factory online, which will result in the full utilization of its 1.6 million square feet of space. The construction of the “FAB2” facility has already been recognized for its accomplishments by garnering an award from Texas Construction Magazine. Phase 2 of the plant incorporates the latest technology in the VLT product line, the VLT Automationdrive. Samsung was impressed with advancements in the VLT Automationdrive’s local control pa2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=16CASE STuDY T WO Danfoss TuRBOCOR TECHNOLOGY » oil-free centrifugal compressor technology for better energy efficiency » self-running, ultra-quiet and vibration free » requires no special resting foundation or other installation procedures danfoss Turbocor’s advanced compressor technology delivers reduced energy consumption at nfL fiLms stUDio comPLex F O R B u I L D I N G O W N E R S , nothing generates complaints faster than the failure of the HVAC system. However, when the building owner is NFL Films, the failure can cause a lot more than discomfort—it can be catastrophic. The 200,000 square-foot NFL Films studio complex houses the world’s largest sports film library. To keep the films preserved, the temperature in the vault needs to be maintained at 54°F. in addition, cool temperatures are critical during the production of television programs at the complex. Under the hot studio lights, if the air conditioning fails, the show’s hosts and their makeup can quickly melt. For NFL Films, a reliable air conditioning system is a lot more critical than for a conventional office building. reliability problems » No one knows this better than John Rauch, Operations Manager, of Marubeni Sustainable Energy, the company that provides building operations services for the NFL Films headquarters complex in Mount Laurel, NJ. When one of the two chillers (owned by Marubeni and leased back to NFL Films) began having problems, rauch quickly sought a resolution. His mechanical contractor suggested replacing one part and then another. “We did not, however, have a high confidence level in their ability to understand what the problems were,” said rauch. 14 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=17Looked for a new contractor » At about that time Marubeni was beginning to solicit bids from other mechanical contractors, as the maintenance agreement on the chillers was about to expire. Tustin Mechanical Services of Hammonton, NJ, was one of the contractors. “i liked what they had to offer,” said rauch. “i asked them to give me a second opinion on what our current contractor was saying was wrong with the machine.” While Tustin was evaluating the problem chiller, rauch said he was so impressed with their ability to understand the problem—and with their maintenance staff—that he signed them up for the contract. energy efficient the smardt chillers utilize oil-free centrifugal compressor technology, which boosts energy efficiency and cuts operating costs. effects of a catastrophe » Shortly after Tustin came on board, a catastrophic failure occurred in the HVAC system. “We lost 60 percent of our capacity and we were going into the summertime,” said rauch. “We needed an immediate temporary solution before we could even begin to make a decision on whether to repair the machines or buy new ones.” Tustin installed a temporary chiller on site. “We spent 12 months using the temporary chiller while trying to repair the old chiller,” said rauch. “during those 12 months, we began researching the latest in chiller technology. That’s when we came upon Smardt chillers, which feature a completely different technology than the chillers we were using.” new chillers are highly energy efficient » When it was eventually determined that Marubeni couldn’t be 100 percent confident in repairing the old chiller, the decision was made to replace not one, but both, machines with Smardt chillers. “The Smardt chillers utilize oil-free centrifugal compressor technology, which boosts energy efficiency and cuts operating costs,” said rauch. “it provides much better efficiencies than the conventional oil-lubricated compressors on our old machines. Since we’ve installed the new chillers, we’ve realized a 10-12 percent reduction in the consumption of electricity on a monthly basis. The NFL Films complex uses a lot of electricity—about 11 million kWh per year with the old machines. With these new machines, we should be under 10 million kWh this year, resulting in a 10 percent reduction. simple design enhances reliability » The two 450-ton chillers have five Danfoss Turbocor compressors on each machine. “it’s an amazingly simple design,” said rodney Moore, General Manager, at Tustin Mechanical Services. “With magnetic bearings and inlet guide vanes, the oil-free design translates into enhanced reliability and reduced maintenance.” The chiller design includes variable frequency control. “This means that the machine consumes only the level of electricity that’s required to meet the cooling need at a particular point in time,” he explained. “Conventional machines have a big motor that’s always running. With the danfoss Turbocor technology, you modulate the vanes for the refrigerant in order to achieve the level of cooling you need so you don’t have the motor running all the time.” » “it’s an amazingly simple design,” said rodney Moore, general Manager, at Tustin Mechanical Services. “With magnetic bearings and inlet guide vanes, the oil-free design translates into enhanced reliability and reduced maintenance.” VOLuME 8 / ISSuE 2 / 2009 152009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=18CASE STuDY T WO CONTINuED Conventional machines have a big motor that’s always running. With the danfoss Turbocor technology, you modulate the vanes for the refrigerant in order to achieve the level of cooling you need so you don’t have the motor running all the time. Quiet running » Another feature of the Danfoss Turbocor compressor technology is that it enables the machines to run quietly. “They are significantly quieter,” says Moore. “You can actually stand next to the machine and hold a normal conversation. Conventional machines are required to have vibration isolators. These machines don’t require that. They are self-running, ultraquiet and vibration free.” remote monitoring » The building automation system is tied into the chillers and can access all the data from the machines. “From a workstation, you can look at the data and analyze performance,” said rauch. “A mechanic can log into one specific compressor, while the other four are running, and perform diagnostics to find what, if anything, is wrong. if there is a problem with one of the compressors, it doesn’t shut down the whole machine. The fact that you can replace a compressor on the machine while the other four are running was an important factor in our decision to go with the Smardt chillers.” Less capacity per compressor reduces impact of failure » “On the old chillers, we had four compressors, two on each machine, with 25 percent of our capacity on each compressor,” said rauch. “With the new chillers, we have 10 compressors, five on each machine. Now, instead of 25 percent capacity on each compressor, we have 10 percent per compressor so the impact of a failure on the operation is a lot less.” easy installation » No special foundation was required for installation of the chillers. “They just sit on the floor,” said Moore. “it is incredible how simple the installation was from that standpoint.” Tustin did all the piping and startup. “Marubeni allocated one week per machine to get them in and started up,” said Moore. “However, the installation went much faster than expected. By day two, we had the first machine on line producing chilled water. The installation of the second chiller was just as fast.” 10% eligible for rebate » Because the oil-free, high-efficiency nature of the Danfoss Turbocor technology is environmentally attractive, NFL Films was eligible for a rebate offered by the state of New Jersey through its SmartStart Buildings® program. “The manufacturer submitted performance data,” said rauch. “SmartStart inspectors visited the site before and after the installation of the chillers. They saw how many kW of power were being used, calculated the efficiency of the machines, and validated that the machines do what the manufacturer says they do at different levels.” instead of 25 percent capacity on each compressor, the nfL films complex has 10 percent per compressor, so the impact of a failure on the operation is greatly reduced. Best of both worlds » Marubeni’s goal was to acquire reliable, energy-efficient this article has been re-published courtesy of the tustin Group, www.thetustingroup.com chillers that would last 25 to 30 years. “With the Smardt chillers and their danfoss Turbocor technology, we believe that it’s the best investment we could have made,” concluded rauch. “And with Tustin on board to maintain the machines, we believe we’ve got the best of both worlds.” 16 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=19PRODuCT HIGHLIGHT AKD 102 ahr expo Award Winners Danfoss captured two AHR Innovation Awards at the 2009 International Air Conditioning, Heating and Refrigerating Exposition held in Chicago in January. The apexxtm Vsh compressor was named Product of the Year, while the aKD 102 variable-speed drive earned the top honor in the refrigeration category. The Apexx VSH compressor and drive package is the world’s first high-capacity, variable-speed scroll solution for commercial R-410A air conditioning and heat pumps. Danfoss has now won seven AHR Innovation Awards in as many years, a record unmatched by any other company in the HVAC&R industry. ApexxTM VSH compressor Danfoss introduces New Feature on VLT® HVAC Drives VLT® HVAC Drives are now available with a dual motor selection feature. Available as a factory-installed option on new VLT HVAC drives, these individual motor overloads and fuses allow users to run two motors simultaneously from either the drive or the bypass. users no longer need to purchase two drives to control two motors, resulting in reduced up-front costs, a smaller solution footprint, and elimination of start-up and commissioning costs associated with a second drive. The dual motor selection option is rated for use in temperatures up to 104°F, and is available with BACnet, Siemens APOGEE™ FLN, Johnson Controls Metasys® N2 and LonWorks serial communications capabilities. Danfoss Launches New VLT® Micro Variable Frequency Drives VLT® Micro Variable Frequency Drives are now available in an M4 frame size covering the three-phase 380-480 VAC, 15-20 HP range. The M4 is just 9.8 in. (250mm) tall (11.5 in., or 292mm with flange) x 4.9 in. (125mm) wide x 9.5 in. (241mm) deep. The drives feature conformal-coated PCBs per IEC 60721-3-3, class 3C3, and provide serial communication via RS 485 Modbus RTu and FC protocols. A detachable Local Control Panel (LCP) with or without a potentiometer and an LCP copy function, as well as a panelfront mounting kit for the LCP, all facilitate ease of use.2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=20CASE STuDY THREE MICROCHANNEL HEAT ExCHANGERS » highest heat transfer and energy efficiency attainable » use less refrigerant than alternative products » result in significant reduction in carbon footprint and less environmental impact Best Practices S O M E T I M E S M A J O R A D VA N C E S are made possible by adapting manufacturing systems and design technologies from one industry to another. This is happening today to great advantage as engineers developing residential and light commercial air conditioning systems apply microchannel heat exchanger technology, which has long been used in automotive air conditioning. Microchannel heat exchangers are now used as evaporators and condensers in air conditioning units for homes and small commercial buildings, making possible more compact units that require significantly less refrigerant and save considerable energy. from auto industry lead to increased efficiency in air conditioning The development of microchannel heat exchangers, their success in the automotive industry, and their later application in stationary air conditioning and refrigeration equipment is a case study in cross-industry application. When the era of automobile air conditioning began, the systems were an option in high-priced luxury sedans and limousines. Automotive air conditioning systems were miniaturized versions of the systems used to cool buildings, and took quite a while to cool down a car that had been sitting in the sun. The answer to that problem was to make air conditioners with more capacity—and that meant bigger compressors, more refrigerant, and larger heat exchangers as well as evaporators and condensers. When the compressor started, the increased load on the engine was easily felt. 18 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=21http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=21in the mid-1960s, though, automotive air conditioning began to move down to medium-priced cars. Style dictated that the cars have longer front ends, and the cars’ width increased, so there was more room in the engine compartments of mid-priced cars. Gasoline was cheap, and consumers were demanding more comfort. Air conditioning became an option that had to be offered by competitive manufacturers in all their models except the very smallest. Such compact cars made in America, and the small imports that were appearing in larger numbers, were deemed too small for air conditioning; they simply did not have space for a compressor, condenser, evaporator, and piping. in hot weather, their owners drove with the windows open. the situation began to change in the mid-1980s. Air conditioning systems began to appear commonly in smaller cars, and as more and more equipment was mandated for emissions control and fuel efficiency, luxury sedan manufacturers welcomed markedly more compact air conditioning equipment. if the equipment was more fuel efficient, that was a welcome bonus. Thus the automobile industry began to provide much smaller systems with equal or greater capacity than those they replaced. To bring about the solution, engineers moved from the traditional fin and tube heat exchangers to evaporators and condensers with more surface area for transferring heat from a car’s interior to the outside air. The new devices were called microchannel heat exchangers, and were made with a large number of flat tubes. These had more and smaller refrigerant channels. The greater surface area meant that a more efficient heat movement could be accomplished in a much more compact component. That in turn meant that less refrigerant was required, then only a cost-saving benefit—environmental concerns were yet to come. in recent years, spurred by its success in the auto industry, microchannel technology has been applied to domestic air conditioning, and has given us smaller, more efficient units. The smaller refrigerant charge these systems use is now seen as a distinct advantage, as environmental protection becomes more and more important, and the cost of refrigerant soars. There are other important advantages to microchannel technology. There is less restriction of refrigerant flow (engineers call it pressure drop). Because refrigerant flow is “easier,” the compressor need not work as hard. Compressor lifetime is lengthened, lowering maintenance cost for the consumer. Less compressor work also decreases an air conditioner’s energy requirement; as a result, less fuel is needed, whether in a car or in a building. in designing the MCHX series of microchannel heat exchangers, danfoss engineers chose to use all aluminum, avoiding the electrolysis and other problems that can arise when copper tubes are joined to aluminum fins. Should an exchanger be damaged in the field, it can be repaired with a two-part epoxy. » fin-tube process: the traditional fin-tube heat exchanger has served industry well for many years, and continues to be used in many applications. But the increased surface area and improved airflow offered by the microchannel heat exchanger, provides improved heat transfer, greater energy efficiency and less compressor wear. in the traditional fin-tube design, flow around the tube in both directions causes turbulence, pressure drag, lower heat transfer and noise. MCHX process: the microchannel heat exchanger provides a smoother path without turbulence. heat transfer is superior because of the greater number of refrigerant channels and increased fin surface area. VOLuME 8 / ISSuE 2 / 2009 192009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=22http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=22CASE STuDY THREE CONTINuED during development of the design, constant testing determined optimum fin thickness and spacing, and it was found that the pitch, or angle, of the fins affected heat transfer efficiency. in routine maintenance of installed systems, one way that efficiency is kept at a high level is to make sure that the fins are not clogged or obstructed by dirt or debris. Testing of microchannel heat exchangers has shown that their all-aluminum construction is stronger, making possible fin cleaning with high-pressure water, thus removing dirt more effectively and in less time. System manufacturers will benefit in many ways that will mean a better experience for their customers. requiring a smaller compressor allowed building a more compact unit, with a longer warranty life for other components, and a reduction in net unit cost. reduced refrigerant volume again reduces expense (especially as refrigerant prices continue to increase), allows faster charging of the system with reduced labor cost and creates a positive environmental impact, which is more and more becoming a selling point. System manufacturers also increase system capacity in the same unit footprint. Weight is reduced, handling is easier and logistics is less costly. danfoss microchannel heat exchangers range in size from about a square foot up to more than 4 by 6 1/2 feet in high-capacity models. today, advanced technology at danfoss provides microchannel heat exchangers with the highest heat transfer efficiency and energy efficiency attainable, that use less refrigerant than alternative products and have significant life cycle benefits. From the manufacturing process through end use and recycling, the efficiencies result in a significant reduction in carbon footprint and less environmental impact. Testing of microchannel heat exchangers has shown that their all-aluminum construction is stronger, making possible fin cleaning with high-pressure water, thus removing dirt more effectively and in less time. sub-assemblies Like the automotive industry, the air conditioning industry has great success with the use of sub-assembly systems. car makers have enjoyed the advantages of out-sourcing sub-assembly manufacture for more than thirty years, allowing them to focus on their core business —the design and assembly of automobiles. thus whole interiors, fuel induction systems and electrical wiring harnesses, to name only a few sub-assemblies, are out-sourced and arrive at the automobile plant in time for integration into finished vehicles. in the same way, liquid line sub-assemblies and compressor functions made to oem specifications by Danfoss are delivered ready for the finished unit, saving the oem labor, simplifying logistics by reducing the number of parts stocked and the number of vendors, and improving system reliability. 20 ENVISIONEERING SOLuTIONS2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=23http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=23PRODuCT HIGHLIGHT new Danfoss Controller Delivers Better Bottom Line Profit to Retailers The AK-CS is a user-friendly, comprehensive control and monitoring solution for convenience store managers, facility managers, maintenance personnel and energy managers. Danfoss introduces the aK-cs, a revolutionary new controller designed specifically for small food retail facilities. Ideal for convenience stores, restaurants, small warehouses and institutional cafeterias, the AK-CS controller can significantly reduce a facility’s operating costs by 10-15 percent through energy savings, reduced maintenance costs and food loss. The AK-CS controller is a suitable replacement for mechanical controls or older electronic systems in small food retail facilities. It controls and monitors all major energy-using systems, including refrigeration, heating, ventilation and air conditioning (HVAC) and lighting. The controller uses an Echelon® communications link coupled with modular input/output (I/O) boards or stand-alone smart controllers. “The AK-CS is a user-friendly, comprehensive control and monitoring solution for convenience store managers, facility managers, maintenance personnel and energy managers,” said David Hebel, business development manager at Danfoss. “Costs for electricity alone can range from $20,000 - $50,000 per year, and we have seen the average size of a store grow from 2,000 square feet 10 years ago to almost 3,000 square feet today. In addition, the facilities are becoming much more mechanically complex. There are significant opportunities for cost savings by installing a central control and monitoring system.” central monitoring: The AK-CS monitors a facility’s energy use with a kWh meter installed on the main power service. kWh meters can also be installed on sub-systems such as refrigeration and lighting. By using a central EIS (Energy Information System), a retailer can look at the energy usage across all store locations, and create energy baselines for each facility or system. The EIS creates an alarm when a store’s energy usage is above its baseline allowing the facility operator to take corrective actions. The AK-CS provides logs of all I/O points and alarms for critical systems. The logged data can be saved and accessed for one year or more. What’s more, the AK-CS features a full Web browser for remote access and a uSB port for software loading/saving functions. The controller can be connected to a facility’s Wide Area Network and viewed or programmed by any Web browser accessing an on-board Web server. xML protocol is provided to allow access to data from third-party software. FOR MORE INFORMATION: contact 410-931-8250 baltimore@danfoss.com www.danfoss.us/foodretail2009-07-07T11:17:07+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=24http://danfoss.ipapercms.dk/refrigerationandairconditioning/ra/solutions/us/solutionsvol8issue22009/?Page=24Danfoss Locations BaLtimore, mD 11655 Crossroads Circle Baltimore, MD 21220 410-931-8250 / Fax: 410-931-8256 www.danfoss.us » Refrigeration & Air Conditioning » Industrial Controls » Heating Controls: 443-512-0266 Fax: 443-512-0270 taLLahassee, fL Danfoss Turbocor 1769 E. Paul Dirac Drive Tallahassee, FL 32310 850-504-4800 / Fax: 850-504-0280 www.turbocor.com » Oil-Free Compressors for Refrigeration and Air Conditioning GLens faLLs, nY Danfoss Flomatic Valves 15 Pryun’s Island Drive Glens Falls, NY 12801 800-833-2040 / Fax: 800-314-3155 E-Mail: flomatic@flomatic.com www.danfossflomatic.com » Water Controls W W W . D A N F O S S . u S 2009 Calendar of Events JuNE 2009 » Boma international conference & office Building show June 28-30, 2009 Pennsylvania Convention Center, Philadelphia, PA » engineered systems Webinar: LoVes ParK, iL 4401 N. Bell School Road Loves Park, IL 61111 815-639-8600 / Fax: 815-639-8000 www.danfossdrives.com » Drives miLWaUKee, Wi 8800 W. Bradley Road Milwaukee, WI 53224 414-355-8800 / Fax: 414-355-6117 www.danfossdrives.com » Drives » Nessie High Pressure Water Systems mississaUGa, ont 6711 Mississauga Rd., Suite 410 Mississauga, Ontario L5N 2W3 905-285-2050 / Fax: 905-285-2055 www.na.heating.danfoss.com » Heating Controls » Motion Controls moUntainsiDe, nJ Danfoss Hago, Inc. 1120 Globe Ave. Mountainside, NJ 07092 908-232-8687 / Fax: 908-232-7246 www.hagonozzle.com » Components for Oil Burners somerset, nJ Danfoss Bauer 31 Schoolhouse Road Somerset, NJ 08873 732-469-8770 / Fax: 732-469-8773 www.danfoss.com » Geared Motors Greenhouse Gases, Climate Change and R-22: What’s the Next Phase June 2, 2009 online at http://webinars.esmagazine.com Featured speakers: Dr. Jürgen Süss, Danfoss Vice President R&D and Jeffrey Staub, Danfoss Application Engineering Manager Securing Our Water Supply saturday, June 13, 2009 JuLY 2009 » enVisioneering symposium: » enVisioneering symposium: San Diego, CA Carbon Neutral, Energy Positive friday, July 24, 2009 Washington, DC SEPTEMBER 2009 » hVac comfortech » ace09: 128th american Water Works association’s annual conference and exposition June 14-18, 2009 september 24-25, 2009 Nashville Convention Center Nashville, TN San Diego, CA sUBscriBe to Solutions to stay up-to-date on the latest news abdout Danfoss products and your industry. To subscribe, email solutions@danfoss.com W W W . D A N F O S S . u S2009-07-07T11:17:07+02:00