E360 Outlook Volume 2 Number 2 1 ⌂ ☰ ✉ F t 4 l ò r G y Volume 2 Number 2 P. 8 Multiplex refrigeration system lays foundation for café’s green mission P. 12 Montreal Protocol commits to HFC management amendment P. 14 Exploring the potential of CO 2 transcritical booster systems Outlook Balancing All Aspects of the Commercial Refrigeration and Air Conditioning Industries Reducing Refrigerant Leaks Environmental and Economic Impacts Force Retailers to Take a Close Look PAGE 2
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E360 Outlook Volume 2 Number 2 1
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Volume 2 Number 2 P. 8
Multiplex refrigeration system lays foundation for café’s green mission
P. 12
Montreal Protocol commits to HFC management amendment
P. 14
Exploring the potential of CO2 transcritical booster systems
OutlookBalancing All Aspects of the Commercial Refrigeration and Air Conditioning Industries
Reducing Refrigerant LeaksEnvironmental and Economic Impacts Force Retailers to Take a Close Look
The relentless pursuit of innovation has always been a staple of Emerson’s business model. We are at our best when we’re asked to solve tough problems and balance customer requirements within the larger context of industry-wide
challenges. With the launch of The Helix Innovation Center in December, our ability to build upon this legacy just got stronger.
Located on the University of Dayton campus in Ohio, this 40,000 square foot facility blends the disciplines of technology and engineering — part academic think tank and part real-world test lab. It’s here where we’ll take a blank slate approach, utilizing a comprehensive suite of flexible resources to tackle current industry challenges and develop the solutions of tomorrow.
To accomplish this, we’ve installed five industry modules that simulate the following real-world environments:
• Residential connected home — 2,000 square foot, fully functional two-story home built to Department of Energy specifications. Capable of simulating global weather and annual performance conditions, from -20 °F to 120 °F ambient temperature and 20 percent to 90 percent humidity.
• Light commercial building — the facility itself serves as the light commercial module, with state-of-the-art HVAC and variable refrigerant flow systems. The facility is LEED certified by the U.S. Green Building Council.
• Foodservice operations — 1,500 square foot restaurant features a fully functioning, licensed commercial kitchen capable of servicing up to 150 diners. Like the residential module, allows for complete control of ambient air and humidity for desired comfort levels.
• Supermarket refrigeration — utilizes a CO2 transcritical booster system for refrigeration, HVAC and heat reclamation for hot water. Simulates a 2,500 square foot supermarket or convenience store retailer.
• Data center — 1,000 square foot module replicates a data center’s precise temperature and humidity control requirements.
Each industry module is a separate entity with isolated power sources to enable discrete measurement of energy consumption in individual modules and their respective equipment. We’ve also equipped the innovation center with three industry learning labs, where we expect to host up to 600 visitors and trainees each year.
The Helix is under the direction of Dr. Rajan Rajendran, vice president of system innovation center and sustainability, and will reflect the collaborative spirit that’s characteristic of our E360 program. Rajan will also be contributing a new column to this publication that will highlight a relevant module, system or project taking place at the center. Look for the first installment of Helix Highlight in this edition, where Rajan takes a closer look at the supermarket module’s CO2 transcritical booster system. We look forward to sharing these stories with you and invite you to make use of this new industry hub of innovation.
F I R S T WO R D
The Helix Innovation Center Is Open for Business
by D O N N E W LO N CO N T E N T S
1 First Word BY DON NEWLON
The Helix Innovation Center is open for business
2 F E ATUR E
Industry Sets Sights on Reducing Refrigerant Leaks BY JOHN WALLACE
Effective leak detection good for retailers and the environment
8 SU C C E SS S TO RY
State of the Art Sustainability Multiplex refrigeration system lays foundation for café’s green mission
12 Rajan on … Refrigerants BY DR. RAJAN RAJENDRAN Montreal Protocol commits to HFC management amendment
14 Helix Highlight BY DR. RAJAN RAJENDRAN Exploring the potential of CO2
transcritical booster systems
16 Solution Spotlight BY BEN PICKER
The evolution of predictive protection
18 Contractor Connection BY TIM UDERMAN Make the upgrade to digital
to report that we have kept our promise.As a company known for our
proactivity and planning, we were already well down the path of formalizing many sustainability initiatives, and the specific commitments we made were aligned with
those objectives. First, we committed to the construction of a global industry-accessible innovation center that would take on the biggest environmental and energy efficiency challenges affecting food retail, foodservice, commercial and residential buildings, and data centers. On December 17, 2015, the Helix Innovation Center opened on the University of Dayton campus, where we are beginning these pursuits toward a next generation of technologies.
Second, we committed to complete the development of several new products optimized for low-GWP refrigerants, as well as expand upon our efficient and sustainable CO2, propane and ammonia product lines. I am happy to report that we successfully developed new compressors, controls and flow components in 2015, utilizing natural and low-GWP synthetic refrigerants that are viable replacements for traditional HFC applications. We
also advanced our condensing units built around these class-leading core technologies, launching new products that enable significantly higher efficiencies while meeting refrigerant needs.
Our industry witnessed a whirlwind of regulatory activity in 2015, and these rulings are likely to continue throughout the near future. With the Helix Innovation Center open for business, it enhances our capability to collaborate with the entire value chain and respond to these requirements as they emerge. We’ve learned through the development of these products that as an industry of contractors, wholesalers, OEMs and consultants, we are all seeking to better understand how to apply and service new installations and manage the existing installed base of systems.
That is why we are even more committed to accelerating the E360 stewardship and exchange platform. To date, nearly 6,000 industry leaders and professionals have registered for these events. We are dedicated to hosting an objective forum — a place where ideas are presented and the challenges we face throughout the channel can be discussed and solved.
In October of 2015, the White House invited us to a follow-up meeting to report on our progress. While we were extremely pleased to present these accomplishments, we also pledged our ongoing commitment. It is our strong belief that environmental protection, global understanding of these sustainability measures and continued industry participation are all required to meet our shared challenges and objectives. Emerson Climate Technologies is dedicated to continuing its support for these efforts through our commitment to providing innovative products and ongoing industry stewardship.
Progress Report: Sustainability Commitments Met; New Goals Set
By Bob Sharp
Executive Vice President & Business Leader Emerson Climate Technologies
Dr. Rajan Rajendran and Bob Sharp were invited to the White House to participate in a meeting
addressing the environmental impacts of hydrofluorocarbon emissions.
When developing your program, your aim should be to not only establish proper leak detection response protocols, but also institute proactive measures to minimize or eliminate leaks altogether.
the Green Restaurant Association (GRA) evaluated the Green
Sage Café’s environmental profile for certification purposes, they
commissioned RDT to perform an independent, third-party study
on the Eco-Cool system. The results were surprising.
The UL energy study simulated a foodservice application,
comparing a multiplex system (with one Copeland Scroll Digital
compressor servicing six fixtures) to a conventional system. The
study replicated actual foodservice conditions, such as varying
demands and frequent refrigerator door openings and closings. The
data revealed that in 90 °F ambient conditions, the Copeland Scroll
Digital-based Eco-Cool system delivered 48 percent energy savings.
The study demonstrates that as the ambient temperature
rises above 90 °F, the energy savings will decrease slightly. But as
Dyess explained, at temperatures below 90 °F, the potential for
energy savings will continue to rise above the 48 percent mark.
Keeping Cool and Getting Into Hot Water
The multiplex refrigeration system also helped Green Sage Café
owners check other significant items off their sustainability list.
By placing the Eco-Cool unit outside the restaurant and removing
condenser surface areas that are present on each fixture in
conventional systems, they eliminated 53,856 BTUH of heat, or
the equivalent of 4.5 tons of air conditioning. Not only does this
contribute to the café’s eco-friendly footprint, it helps create
a better dining experience for patrons and improved working
conditions for the staff.
Another advantage of the Eco-Cool refrigeration system was
its ability to capture waste heat and divert it into a heat exchanger
that provided heating for the restaurant’s hot water tank.
“We had used solar panels for hot water heating in our
first location, but this heat reclamation system was even more
effective,” Talley explained. “This system takes care of all of our
hot water requirements,” he added.
For the RDT team, the concept of heat reclamation just
makes good environmental sense.
“If our customers see the value in reusing a natural by-product of
the refrigeration system, then we recommend it,” Dyess said. “Green
Sage Café had the vision and commitment to utilize every available
natural resource,” he added.
10
Designed with a Copeland Scroll Digital compressor, the Eco-Cool system from RDT serves as a cornerstone of
the Green Sage Café’s sustainability strategy.
Certifiably Green
With the Eco-Cool refrigeration system as a green foundation, the
Green Sage Café incorporated additional sustainable elements,
including: solar panels, energy-efficient dishwashers and LED
lighting. In recognition of its sustainable, state-of-the-art vision,
the Green Sage Café earned the distinction of being the GRA’s
first four-star certified Green Restaurant in the South.
As a result of their success, many other restaurants in the
Asheville area have taken on the green mantel. And with the help of
grants from the state of North Carolina, 17 restaurants (including the
first two of the Green Sage Café’s three locations) are now offering
sustainable, natural food-based fare in Asheville. The city has become
such a bastion of green culinary principles that it was recently named
the country’s first Green Dining Destination by the GRA.
Energy Consumption Comparison: Copeland Scroll Digital Compressor vs. Conventional System
“If our customers see the value in reusing
a natural by-product of the refrigeration system,
then we recommend it.”
— Brent Dyess, RDT
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Energy Consumption (watts/hr)
Temperature (°F) 90 95 100 105 110
Conventional System 3,571 3,712 3,849 4,143 4,142
Digital Compressor 1,852 2,275 2,508 2,648 2,756
Delta 1,719 1,437 1,341 1,495 1,386
Energy Saved (%) 48% 39% 35% 36% 33%
An independent UL study of RDT’s Eco-Cool unit compares a conventional compressor system with the Copeland Scroll Digital compressor. At 90 °F ambient temperatures, the digital scroll compressor saves 48 percent on energy.
14 E360 Outlook Volume 2 Number 2 E360 Outlook Volume 2 Number 2 15
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Welcome to the first installment
of a new column that will
focus on the technologies,
emerging products and research projects
taking place at our recently opened Helix
Innovation Center. In this edition, we will
place the spotlight on the CO2 transcritical
booster system that, among many other
things, is providing refrigeration to our
supermarket industry module.
We installed a CO2 transcritical
booster system to anchor our supermarket
module for several reasons. It has the
potential to provide an efficient, eco-friendly
refrigeration source for medium- and
low-temp display cases, walk-ins and
freezers. But that’s only the beginning.
We designed our CO2 transcritical booster
system to not only meet the entire air
conditioning and heating needs of the
supermarket module, we’re also reclaiming
its exhaust heat for the facility’s hot water
and snow melt system beneath the sidewalks.
We also chose CO2 because we feel it
has the potential for much broader appli-
cations than what is commonly thought in
the industry today. Our system is designed
with the flexibility to demonstrate and
exploit these possibilities.
Real-World Simulation Evaluates the Viability of CO2 in Warmer Climates
CO2 transcritical booster systems have
gained wide acceptance in northern
climates throughout the world. As a
natural refrigerant with near zero global
warming potential, CO2 is becoming a
preferred option for retailers seeking to meet
sustainability goals and take regulatory
compliance out of the equation. But with a
critical point of 87.8 °F, special measures are
required to keep CO2 systems operating at
high efficiencies above this temperature.
This is the reason very few retailers
have attempted to deploy CO2 systems in
warmer regions. It’s also one of the limitations
with CO2 transcritical booster systems that
we are determined to eliminate.
One unique aspect of The Helix is its
environmental control chamber, located
just outside the facility. This chamber
serves each of the five industrial modules
on-site and is capable of simulating
operating temperatures between -20 °F
and 120 °F. So, if we want to measure how a
Exploring the Potential of CO2 Transcritical Booster Systems
The Helix Innovation Center utilizes a CO2 transcritical booster system that’s designed to accommodate medium-
and low-temperature requirements in the supermarket. The medium-temperature suction group is based on three
Copeland™ CO2 semi-hermetic compressors (Copeland 4MTLS), supplying cooling to the store’s refrigerated cases,
walk-in cooler and air conditioning.
For the low-temperature group, three Copeland Scroll™ CO2 compressors (Copeland Scroll ZO) — including one
Copeland Scroll Digital™ compressor (Copeland Scroll ZOD) to enable varying capacity modulation for the group —
supply cooling to the store’s frozen food cases and walk-in freezer.
CO2 Transcritical Booster System Profile for the Supermarket Module
CO2 transcritical booster system performs
in the middle of summer in a supermarket in
Miami, we can do that.
The great thing about our facility is
that we have the flexibility to control every
variable that contributes to refrigerated
system performance. This allows us to
simulate a year’s worth of performance in
one week from any location in the world.
And, we can use this space to solve problems
with rapid prototyping and evaluation of
new ideas.
For example, if we want to test one of
the available methods for increasing CO2
transcritical booster system performance
in hot weather, we have several options.
First, we have ample space left in our
medium-temperature suction group to
add a compressor and test it in a parallel
compression configuration. We could
install an ejector device to evaluate its
effectiveness in the CO2 refrigeration cycle
in real-world conditions. Or, we could
retrofit our gas coolers with adiabatic pads
to measure their ability to keep the CO2
system below its critical point.
Like every industry module in The
Helix, the supermarket is an entity unto
itself, meaning that the power coming
into the module is completely isolated.
This allows us to measure the power
consumed by the store on its own, while
further isolating the energy consumption
of any one piece of equipment. Because
everything is within this controlled
environment, we’re able to evaluate the
performance of the CO2 transcritical
booster system in the supermarket and
the larger building envelope.
What all this means to our customers
is that you now have a real-world test lab
for designing the ideal refrigeration system
for your supermarkets, simulating the
conditions and environments that are most
challenging without risking product loss
or potential damage to your brand. While
today the system is CO2 based, we have the
ability to change the refrigerant as well as
the system architecture. We hope that this
opportunity will only spawn new ideas and
open the doors to further innovation.
H E L I X H I G H L I G H T by D R . R A J A N R A J E N D R A N
Medium-Temp Compressor Suction Group Equipment Served
Copeland transcritical CO2 compressors• 4MTLS11ME-FSD (with VSD)• 4MTL82KE-FSD (qty: 2)
Total BTUs: 225,000
• Floral case with three doors• Cake case• Upright dairy (qty: 2)• Upright produce (qty: 2)• Upright deli (qty: 2)• Upright meat (qty: 2)• Walk-in cooler• Air conditioning
Low-Temp Compressor Suction Group Equipment Served
Copeland Scroll CO2 compressors• ZO34K3E-TFD• ZOD34K3E-TFD (Copeland Scroll Digital)• ZO21K5E-TFD
• Frozen foods with three doors (qty: 3)• Ice cream with three doors (qty: 2)• Walk-in freezer
18 E360 Outlook Volume 2 Number 2 E360 Outlook Volume 2 Number 2 19
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The use of a digital compressor as the lead compressor in a fixed capacity refrigeration rack is becoming a preferred method for supermarkets seeking to meet varying refriger-
ation loads. With the ability to modulate capacity from 10 to 100 percent, a digital compressor gives operators many benefits:
• Precise matching of capacity to changing refrigeration loads
• Tight control over suction pressures
• Improved case temperature precision
• Reduced compressor cycling (on/off)
Digital compressors have proven so effective in providing capacity modulation that this strategy is being written into the design specifications of many big-box retailers.
Digital Upgrade Kit for Traditional Rack Systems
This option is also available as an upgrade to existing refrigeration systems that are based on traditional parallel rack architectures. Many technicians are being called upon to retrofit these systems with a digital compressor upgrade kit. Although there are some newer technologies and electronic controls involved with the transition, the upgrade process is relatively straightforward.
The typical scenario for a digital compressor upgrade is fairly predictable:
a) The supermarket operator has likely made several attempts to
improve control of product temperature or reduce compressor cycling. It’s common in these scenarios to see cycling rates in the hundreds per day with as much as 15 °F fluctuations in case temperatures.
b) Modifications to the equipment (typically via the rack controller) were unsuccessful: adjustments to narrow suction pressure resulted in excessive compressor cycling; adjustments to reduce compressor cycling produced a wide range of suction pressures and unacceptable fluctuations in temperatures.
These operating conditions present an ideal opportunity for a digital compressor upgrade:
a) Identify the compressor — the technician’s first order of business is to identify the fixed capacity, semi-hermetic or scroll compressor in the rack that is the best candidate for replacement. Ideally, the fixed compressor capacity needs to be equal to or larger than the next compressor in the stage sequence to prevent capacity gaps between compressor cycling.
b) Verify the system controller — the system controller must be capable of providing an analog signal to the digital controller. Most modern rack controllers are capable of providing analog output.
c) Choose the correct upgrade model — once the replacement compressor has been identified, Emerson Climate Technologies
CO N T R AC TO R CO N N EC T I O N by T I M U D E R M A N
Make the Upgrade to Digital
offers an upgrade kit per specific model (Copeland Discus Digital™ or Copeland Scroll™). Note: for semi-hermetic compressors that are less than four years old, technicians can perform a head modification to convert the compressor to digital.
d) Select the digital controller — the new digital compressor necessitates an additional interface controller to tie into the rack system’s master controller. Emerson offers controllers for these specific applications.
e) Install upgrade kit — often the greatest apprehension about the upgrade process is the wiring required to tie into the interface controller, even though the process is fairly straightforward. The length of time required to install depends on the technician’s experience and electrical familiarity.
Digital Technology Yields Indisputable Results
A single digital compressor with 10 to 100 percent capacity mod-ulation enables continuous variable unloading that delivers imme-diate and significant benefits. While results vary per application, operators can expect improvements in three major categories:
• Reduced compressor cycling — the average compressor cycling is reduced up to 50 percent, but some scenarios have seen cycle counts go from 900 starts per day to 12 starts across a four-day span. This increases equipment reliability by reducing contactor wear and tear due to the infrequent cycling. It also saves energy from reduced in-rush, start-up currents and persistent consumption from running at full capacity.
• Improved temperature control — digital modulation is capable of temperature control within +/- 1 °F, giving operators the assurance that they are minimizing food loss while maintaining the highest quality of perishable items.
• Tighter suction pressure control — operating suction pressure ranges are significantly reduced, moving from double-digit suction pressures (psig) to single-digit levels. In some systems, operators have experienced as much as 89 percent improve-ment in suction pressure.
These results make an open and shut case for a digital compressor upgrade. As awareness of this option becomes more well-known, many supermarket operators will opt for capacity modulation using this relatively simple upgrade to their existing rack systems.
Other Methods of Capacity Modulation
The challenge of modulating capacity in centralized rack refrigeration systems is not a new one, and system designers have made several attempts to solve the problem. Though none are as effective as digital capacity modulation, technicians still frequently encounter these systems:
• Uneven rack — one potential solution is to design an uneven rack made up of compressors of varying capacities. But
this still results in high cycling (on/off) rates and provides insufficient temperature control.
• Variable speed drives — known to provide effective capacity modulation, but is often considered cost-prohibitive technology.
One digital compressor per suction group can provide precise capacity modulation from 10 to 100 percent. The results are up to 50 percent reduction in compressor cycling, improved equipment reliability and precise temperature control.
Capacity modulation made possible through digital compressor upgrade kit
AHRI Public Policy SymposiumWillard InterContinental HotelWashington, DCMarch 15–16ahrinet.org/site/412/News- Events/Meetings-and-Events
2016 IIAR Industrial Refrigera-tion Conference & ExhibitionCaribe Royale All-Suite Hotel and Convention CenterOrlando, FL — March 20–23iiar.org/IIAR/WCM/Events/ IIAR_Events_2015-2016.aspx
AHRI Board of DirectorsHyatt Regency RestonReston, VA — May 2ahrinet.org/site/412/News- Events/Meetings-and-Events
AHRI Spring MeetingHyatt Regency RestonReston, VAMay 2–4ahrinet.org/site/412/News- Events/Meetings-and-Events
NRA Show 2016McCormick PlaceChicago, ILMay 21–24show.restaurant.org/Home
2016 ASHRAE Annual ConferenceAmerica’s Center Convention Complex and Renaissance St. Louis Grand HotelSt. Louis, MOJune 25–29ashraem.confex.com/ashraem/ s16/cfp.cgi
Forum
Emerson Climate Technologies is excited to take our educational
platform on the road; we’ll be coming to Atlanta on February 18.
Once again, this daylong event will feature prominent
industry authorities as well as Emerson’s own internal experts.
Our Dallas E360 Forum, held this past September, offered timely
discussions on top-of-mind industry concerns, such as the EPA
delisting ruling aftermath. More than 120 foodservice and retail
leaders gathered and conversed about our shifting industry.
The E360 Forums give attendees an opportunity to participate
in the conversations shaping the commercial refrigeration industry.
We hope to see you at an E360 Forum in the future.
E360 Forum Schedule
Atlanta, GA Marriott Atlanta Airport Gateway Feb. 18, 2016
Toronto, ON CN Tower March 15, 2016
Dayton, OH Dayton Marriott/The Helix May 9–11, 2016
Additional 2016 venues to be announced
Visit EmersonClimate.com/
E360-Event-Registration to register.
What was the most meaningful takeaway from today?
Some of the biggest takeaways were
learning about the changes happening in the foodservice
industry, and how energy and environmental challenges
are playing huge roles. Seeing how these things are
interconnected was an eye-opening experience.”
— Bryan Tonn, engineering manager, H&K International
Would you recommend the E360 Forum?
With respect to the E360 Forum, I would
absolutely recommend it to anybody in the industry. It has
applications regardless of the type of company you have
— whether you’re an OEM manufacturer, a wholesaler
distributor, a contractor or a consultant.”
— Tom Richgels, director of sales, RefPlus
What do the E360 Forum attendees have to say about the event?