69
Enhanced Refrigeration Solutions [email protected] Director of Marketing, CO2 Business Development CMPX Show Thursday March 19 th ,2014
Enhanced Refrigeration Solutions
[email protected] Director of Marketing, CO2 Business Development
CMPX Show Thursday March 19th ,2014
Enhanced Refrigeration Solutions
Enhanced Refrigeration Solutions
Supermarket Commercial HVAC
C-Stores Data Centres
Customer Pains
1. Profitability 2. Precise Temperature 3. Downtime 4. Energy Cost 5. Predictive Maintenance 6. Sustainability 7. Balancing Inventory/Turns 8. Remote Monitoring 9. Consistency of Suppliers 10. Lack of Skilled Workforce 11. Keeping up with Technology 12. Warranty Cost 13. Need To Differentiate 14. Justify Sell Price 15. Top Line Growth
End User Contractor Wholesaler OEM
4
Agenda-Enhanced Refrigeration Solutions
3
2
1 Compressor Protection and Diagnostics New Optimized Refrigeration Scroll Digital Compressor Capacity Modulation
• HVAC • Supermarket • Commercial Refrigeration
Benefits of Floating Head Pressure Benefits of Low Pressure Systems Vs Traditional Set points
4
5
CoreSenseTM Compressor Protection and Diagnostics
CoreSenseTM Technology “New To The Industry”
What It Is: • Compressor As A Sensor • To Monitor And Interpret Compressor
And System Information • Delivers Advanced Protection,
Diagnostics And Communications • Enhances Performance And
Reliability
Why We Did It: • Differentiation – Added Value • Technology With Real Benefits
Discus w/ CoreSense Protection
CoreSense Technology Is Being Rolled Out Across All Of Our Major Product Platforms
Discus w/ CoreSense Diagnostics
Ref Scroll w/ CoreSense Diagnostics
Outdoor Condensing Unit
CoreSense Diagnostics Module
Service Contactor
Indoor Condensing Unit
A/C Scroll w/ CoreSense Communication
ComfortAlert PerformanceAlert
SecureStart™
* Primarily Used In Supermarket Applications
*
9 Emerson Confidential
Compressor Diagnostics Have Impacted Failure Rates & Will Continue To Improve
Discus With CoreSense Diagnostics Warranty Performance
New
Phase 1 • Oil/Motor Protection • Current Diagnostics
Phase 2
• Advanced Motor Protection
• Voltage Diagnostics • Communication
Phase 3 • Future Enhancements
Electronics Evolution
‘05-’06
‘07-’09
0%
5%
10%
15%
20%
25%
30%
35%
40%
Liqu
id R
efri
gera
nt(F
lood
ed S
tart
Or R
unni
ng)
Hea
t(H
i Com
p. R
atio
, Ret
urn
Gas
, etc
.)
Con
tam
inat
ion
Mot
or B
urn
No
Def
ect F
ound
Filename/Presenter-Topic: 3/11/2014
LED Status Indications for Discus
LED Status Indications
• Green ON And Steady No Faults
• Green Flashing Warning
• Yellow Flashing Trip
• Red Flashing Lockout
Slide 10
New Discus III
Improved Reliability with CoreSenseTM Technology Onboard
Ref K5 Has CoreSense Diagnostics For Improved Reliability, Advanced Monitoring, Protection & Communication Capabilities
CoreSense™ Technology Provides Additional Field Information Through Mobile Applications
CoreSense Communication - Options B) Connect to E2
Controller C) Connect To Computer
1. Modify User Adjustable Features
2. Review/Download Compressor History
3. Use As Data Logger
A) External LED On CoreSense
1. Modify User Adjustable Features
2. Review/Download Compressor History
3. Use As Data Logger
1. Multi-color LEDs indicate type of failure
2. Enables quick troubleshooting
CoreSenseTM For R-410A Commercial Scrolls
Delivers Enhanced Reliability On-Board 20-60 HP R-410A Copeland Scroll Compressors ZP236, ZP296, ZP385,ZP485, ZP725
Protection • Scroll And Motor Temperature Diagnostics • Phase Monitor • Short Cycling • Locked Rotor • Fault History Communications • Modbus Protocol
NEW!
Slide 14
Ref K5 Scroll
Current Scroll Delta
LT Efficiency 7.8 6.9 13%
MT Efficiency 16.1 13.9 16%
Sound (dBA) 80 86 6 Weight (lb) 135 221 86
Jan 2012
Next Gen 7-15HP Scroll Delivers Unmatched Energy Efficiency & Reliability
$35K
$40K
$45K
$50K
$55K
$60K
Discus Competitor Recip.
K5 Scroll
Annu
al E
nerg
y C
ost
@ $
0.10
/kW
h +$3,830
-$1,654 Baseline
New Digital L.T. Scroll 7–15 HP with Electronic Vapor Injection
Discharge Temp Sensor
Electronic Vapor Injection
CoreSense and Digital Modulation Control
Oil Fill Port
Oil Sight Glass
Discharge Connection
Suction Connection
17 Emerson Confidential
7.1
7.4
6.5 6.7 6.9 7.1 7.3 7.5
ZB75KCE ZB76K5E
20/120 EER
15.6
18.9
0.0
5.0
10.0
15.0
20.0
ZB75KCE ZB76K5E
20/70 EER
7.5
7.9
7.2
7.4
7.6
7.8
8.0
ZF33K4E ZF34K5E
-25/70 EER
High Efficiency Performance AHRI & Optimized at Low Condensing
4.4
4.9
4.0 4.2 4.4 4.6 4.8 5.0
ZF33K4E ZF34K5E
-25/105 EER
+ 11%
+ 5%
+ 6%
+21%
6.9
7.3
6.6
6.8
7.0
7.2
7.4
ZF33K4E ZF34K5E
LT Weighted EER
13.9
16.6
12.0 13.0 14.0 15.0 16.0 17.0
ZB75KCE ZB76K5E
MT Weighted EER
Med
ium
Tem
p Lo
w T
emp
+ 6%
+19%
LT Weighted EER = 0.8*(-25/70 EER) + 0.2*(-25/105 EER) MT Weighted EER = 0.8*(20/70 EER) + 0.2*(20/120 EER)
Digital Compressor Technology, Design and Applications Copeland Scroll Digital™,Discus Digital™ and Variable Speed Compressors
Why Modulation?
Precise Load Matching – When supply and demand are largely different
Better Seasonal Efficiency – Reduced Power Consumption & Running Costs – Lower CO2 Emission – Compliance to Minimum Efficiency Regulation
Standards
Improved Comfort – Precise Temperature and Humidity Control
CO2 Emissions
Comfort
System Capacity Strategies – Refrigeration
Single-Compressor Condensing Unit
Even Parallel Rack
Uneven Parallel Rack
Distributed Systems
VFD and Swing Compressor
Digital Discus Capacity Modulation
Modulation Technologies – A/C Tandem / Trio
– Multiple Std On/Off Compressor • Capacity Variation By Switching Compressors On And
Off
Digital – Mechanical Unloading
• Capacity Variation By Loading Or Unloading Scroll Set
Inverter – Variable Speed Compressor Motor
• Capacity Variation By Changing Motor Speed
Scroll Set Profile
Comprises Two Scroll Parts
Fixed Scroll
Orbiting Scroll
24 24
Loaded (1) Full Capacity
1.0 mm Scroll Separation
Unloaded (0) Zero Capacity
Time (sec)
4
20 40 60
20% Capacity
16 4 16 4 16 4 16
80
Percentage Of Full Capacity
Perc
enta
ge O
f Ful
l Pow
er
ZRD, ZPD, ZBD, ZFD
Copeland ScrollTM Digital Compressor Operation (10 to 100% Capacity Modulation)
0%
20%
40%
60%
80%
100%
0% 20% 40% 60% 80% 100%
Digital Compressors Commercial A/C, Process Cooling
System Challenges Changeover / Bypass (COBP)
As Zones get Satisfied in A/C, cold air is re-circulated back to the unit causing Low Suction Pressure and
Control Issues
Digital Benefit in Rooftop Applications Tight Air Temperature Control
– Comfort Improved Humidity Control
– Comfort Tight Supply Air Flow Control
– Increased Efficiency – Possibilities to reduce air flow to Minimum
Reliability Simple No Oil Return issue No risk of resonance associated as Inverter
Competitive Applied Costs
Higher Average Evaporating Temperature – Increased Efficiency
Filename/Presenter-Topic: 3/11/2014 28 Emerson Confidential
Emerson’s Capacity Modulation Solution Precise System Control From 10 to 100%
EC3-D72 Synchronization
Controller
Electronic Valve (10 to 100%)
Digital Scroll (10 to 100%)
Filename/Presenter-Topic: 3/11/2014 29 Emerson Confidential
Valve/Controller for Digital Applications EC3-D72
Copeland Scroll
0-10V Cooling Demand For EC3-D72
Temperature Sensor
Pharmaceutical Process
End User Benefits • Eliminated Downtime • Production efficiency increased • Product quality; never better • Temperature within +- 0.5C • Humidity within +- 0.5% RH
30
Customer Pain • Downtime due to poor temperature and humidity control
during the manufacturing process of codeine pills • Temperature swings 5 to 6F • Humidity Swings 15 to 20% RH
Execution • 1 Digital Tandem Unit with ZPDT360 • 1 EX6-EC3-D72 kits to control 2 evaporators
Copeland Digital Scroll™ Launch Package, Page 31
June 2012
Closed Loop Digital Controller (XC643) for Copeland Digital Compressors
Copeland Discus Digital™
Copeland Scroll Digital™
Digital Scroll Controller for Multi Room
XC643
1 Digital, 1 Fixed
Use of a Copeland Digital™ will maintain a higher average suction pressure in the system.
Converting “Open” to “Closed” Cases
End User Benefits • 60%+ Reduction in Energy (Verified with M & V) • Utilities Rebate • Tight Temperature Control • Improved Product Quality • Increased Shelf Life • Warmer Isles, Increased Dwell Time in Isles
Contractor Benefit • Working on Securing an Additional 160 Stores potential
Customer Pain • High Energy Bills on 36’ of Dairy Case • Large Temperature Swings in Cases • Latent Pain, Product Quality & Shelf Life
Execution • Added Doors to 36’ of Dairy Cases • Replaced 10HP Fixed Capacity compressor with 5HP Copeland Digital Scroll • Added XC634 Digital Scroll Controller
Open
Closed
Digital Compressors For Supermarkets Or Commercial Racks
35
Unloading Range Comparison
0%
20%
40%
60%
80%
100%
Copeland 3D Digital
10%
Capacity
66%
Capacity
Variable
Unloading
up to 90%
33%
Capacity
Increments
40-100%
6 cylinder
2 banks
Typical SH
VS
36
1. Enters Compressor 2. Passes Through Body 3. Into Valve Plate 4. Compressed by Pistons 5. Exits Compressor
Discus Digital Refrigerant Gas Flow
Loaded
Unloader pistons allows suction gas flow into valve plate
Valve assembly routes suction gas above unloader pistons
37
Discus Digital Refrigerant Gas Flow
1. Enters Compressor 2. Passes Through Body 3. 4 Unloader Pistons Block Gas
Before Entering Valve Plate
Unloaded
Unloader pistons block suction gas flow into valve plate
Valve assembly routes discharge gas above unloader pistons
Copeland Discus DigitalTM Continuous Capacity Modulation
From On Copeland Discus Compressors
– 3D - 10%-100% Capacity – 4D (55-100%) & 6D (40-100%)
Applicable On New & Potentially Existing Discus Compressors
Patented Technology
Time Tem
pera
ture
Tightens Temperature Control
Digital Control Module
Time (sec)
10 10 10 10 10 10
0 20 40 60
50% Capacity
System
Needs 50%
Capacity
Here is How
to Deliver
50% Capacity
Not Needed With ISD v2.x
Results In Narrow Operating Temperature Range
Inverter Technology
Filename/Presenter-Topic: 3/11/2014 40 Emerson Confidential
Copeland Scroll Variable Speed • Compressor (1800 to 7000 rpm)
– 3T (ZPV36), 5T (ZPV60)
– UL Recognized As A Matched Set
• Over-Speed In Heating Improves HSPF • Meets Energy Star EER Requirements • Turndown In Cooling Enhances
Comfort And Improves SEER
Pd (D
isch
arge
Pre
ssur
e)
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
Ps (Suction Pressure)
0.0
-0.1
0. 0 0. 1 0. 2 0. 3 0. 4 0. 5 0. 6 0. 7 0. 8 0. 9 1. 0 1. 1 1. 2 1. 3 1. 4 1. 5
45 ~ 70s-1
30s-1
25s-1
20s-1
C/R: 7.5
15s-1
C/R: 1 + 0.2
C/R: 2
90s-1
120s-1
60, 125
20, 114
20, 70
60, 137
18, 126
60, 82
60, 150
31, 143
40, 126
13, 121
20, 110 2, 107
-20, 80
-20, 70
-1,118
-10,105
-20,90
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
-25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Con
dens
ing
Tem
pera
ture
(F)
Evaporating Temperature (F)
ZPV36K1E-1E9 Operating Envelope: SH20⁰F, SC15⁰F, Amb95⁰F 230Vac Drive Input
1800 rpm, Minimum Speed 2700 rpm, Heating or Cooling Speed 2900 - 4500 rpm, Heating or Cooling Speed 6000 rpm, Heating Only Speed 7000 rpm, Maximum Heating Speed 6000 rpm, 5DegF SH 7000 rpm, 5DegF SH
Emerson Climate Technologies Confidential Emerson Climate Technologies Confidential Emerson Climate Technologies Confidential Emerson Climate Technologies Confidential
49,70
Copeland Digital Scroll™ Launch Package, Page 42
R407C
Digital Scroll Operating Envelope
Conventional Supermarket Rack
Newlon – 041130 End User Presentation 43
44
Digital Discus
Medium Temp Rack-Suction Pressure Rack suction pressure range narrows significantly with Digital Discus
Product Degradation
Excessive Operating Costs
Digital Precision
39 p
si
6 ps
i
Digital Discus Activated
Suction Pressure Narrows by 85% to 6 psig
5 Compressor Rack With Discus Digital Activated Compressor Cycling Reduced By 56% With Discus Digital
3DS3R17ML-TFE-A23 (08E03844R)
3DB3R12ML-TFE-A23 (08E01922R)
3DB3R12ML-TFE-A23 (08E03087R)
3DB3R12ML-TFE-A23 (08E03088R)
3DSDR17ML-TFE-A23 (08E03845R)
Digital Retrofit
Before Digital After Digital
Comp 1
Comp 2
Comp 3
Comp 4
Comp 5
Compressor Cycling:
56% Reduction
Floating head
48 Emerson Confidential
Low Condensing Considerations • Increased Capacity
– Digital Modulation Prevents Excessive Cycling – Electronic Expansion Valve Ensures Precision
Superheat Control Across Entire Capacity Range
• Low Pressure Ratio – Copeland Compressors Approved To Operate At:
• 50°F Min. Cond. Temp. For Medium Temp. Applications*
• 40°F Cond. Temp. For Low Temp. Applications
– Electronic Expansion Valve Operation Not Affected By Low Pressure Differentials
• Flash Gas In Liquid Line
– Adequately Size Expansion Valve To Digest Flash Gas Or Design To Ensure Liquid At Expansion Valve
Compressor Cycling
Digital Installed => 56% Cycle Reduction
25°F
50°F
75°F
100°F
125°F
150°F
-50°F 0°F 50°F
Con
d. T
emp.
Evap. Temp. *Refrigerant Specific
Compressor Operating Envelopes
Med. Temp.
Low Temp.
High Temp.
Benefits of Floating Head Pressure
Filename/Presenter-Topic: 3/11/2014 50 Emerson Confidential
Low Condensing Introduction
Floating Head Pressure with 70ºF min SCT
Temperature Variation
Condenser TD = 15ºF
40°F
50°F
60°F
70°F
80°F
90°F
100°F
0 4 8 12 16 20 24
Tem
pe
ratu
re
Time (hrs)
Energy Saving Opportunity
Fixed Head Pressure set
at 100ºF
Ambient
Energy saving • Capacity and power input
Capacity and power input at +40°F evaporating temperature
10
11
11.5
12
12.5
13
13.5
85 105 125
Condensing temperature °F
Cap
acity
TO
NS
6
7
8
9
10
11
12
13
14
Pow
er in
put k
W
Q P
Condenser
Compressor
1 lb
Greater Capacity, Less Power Achieved By Reducing Compression Ratio
Low Temperature System
Med Temperature System
High Temperature System
Evap
orat
ing
/ Con
dens
ing
Tem
p
110ºF
70ºF
40ºF
20ºF
0ºF
-20ºF
270 psig 270 psig 270 psig
150 psig 150 psig 150 psig
16 psig
60 psig
85 psig
16 psig
60 psig
85 psig
Floating Head
Floating Head
Floating Head
∆254 psig
∆134 psig
∆210 psig
∆90 psig
∆185 psig
∆65 psig
R-404A System Pressures
System Dynamics
Vancouver, BC 91% of the year < 60°F Ambient
Saskatoon, SK 87% of the year < 60°F Ambient
Calgary, AB 90% of the year < 60°F Ambient
Winnipeg, MB 84% of the year < 60°F Ambient Toronto, ON 80% of the year < 60°F Ambient
Filename/Presenter-Topic: 3/11/2014 54 Emerson Confidential
Removing Headmaster for VFD
Variable Frequency Drives for 3 phase Motors
Three Phase Motors
0102030405060708090
100
0 10 20 30 40 50 60 70 80 90 100
% Speed
% H
P a
nd
To
rqu
e
HPTorqueFlow
At 80% Speed (Flow), theoretical Power consumption is 50% of rated.
Existing Designs
Benefits of Emerson’s Electronic Valve Gate Port Design
Flow
(cap
acity
)
Stroke / Steps
100%
100%
50%
50% 80%
10%
Emerson EX – Valve
Gate Port Design
Valve Capacity Range Travel Time EX4 = 0.5 - 5T, 750 Steps / 1.5 Seconds EX5 = 1.5 - 14T, 750 Steps / 1.5 Seconds EX6 = 3 - 34T, 750 Steps / 1.5 Seconds EX7 = 9 - 94T, 1,600 Steps / 3.2 Seconds EX8 = 25 - 250T, 2,600 Steps / 5.2 Seconds 8
EC3 and EX Valves Superheat Controller and Electronic Valve
Replaces: – Liquid Line Solenoid Valve – TXV – Crankcase Press Regulators
System Challenges: – Wide Load Variations – Floating Head Pressure – Inconsistent Liquid Quality – Large Evap. Performance – Cryogenics (Ultra Low)
9
+35°F Cooler, R-404A (25°F SST)
59 Emerson Confidential
Energy-Efficient System Electronic Control + Digital Modulation
Conventional System Energy-Efficient Solution
Disable/Remove 1. Head Pressure Control Valve 2. Liquid Line Solenoid Valve 3. Hot Gas Bypass Solenoid Valve 4. Hot Gas Regulator 5. TXV 6. Crankcase Pressure Regulator
Add 1. Electronic Expansion Valve 2. Digital Modulation
1
3
5
1
2
The Energy-Efficient System Enables • Low Condensing Operation • Enhanced System Performance
6
2
4
Low Pressure Drop System Benefits
• Reduce Energy Usage • Precise Temperature Control • Precise Humidity Control • Reduced Defrost Time • Increased System Capacity • Reduce Refrigerant Charge • Reduced Leaks • Reduced Downtime • Complete Capacity Modulation • Improves Profitability • Improved Product Quality • Prevents Floodback with EX when Evaporator Fan Motors burns out
Simplified Efficient Solution
Cold Storage Warehouse takes Advantage of low Ambient Temperatures
Customer Pain • High Energy Bills (108HP of Equipment 4 x 27HP Units) X 2 • 100,000 lb of Turkeys, pull down 4°C down to -25°C. • 72 hours Required to Pull and Hold • Production maxed out
Execution • New Equipment with Copeland Discus III (575V) 27 HP LT. • New Electronic EX Valve on each Evaporator • VFD Condenser fan control down to 60°F SCT Minimum (old system was set for 110°F SCT)
End User Benefits • Calculated Energy Savings $240,000 / year
• Start up Occurred Spring 2012
• Pull Down Time 48 hours ( 33% faster) • Increased Capacity by 33% • Two Months After Opening, Power issue (208V) to the Facility took out all Evaporator Fan Motors….and Rack Cycled off on Low
Pressure rather than Liquid Slugging Compressors • End User is Thrilled with Increased Profitability
Indirect Impact (kg CO2) 50,000 <---Energy x Life x Conversion Factor
Direct Impact (kg CO2) 32,019 <---%Leak x Life x Charge x GWP TEWI (Metric Tons of CO2) 82.0 <--- (Indirect + Direct) x 1 tonne/ 1,000 kg
Environmental Impact
Equivalent to take 16 passenger Vehicles off the road for 1 year
Taking Advantage of Low Ambient
Standard System
Condenser
Compressor
Evaporator
6DP3F93KE
60F Condensing During 50% of the Year
Floating Head System
6DP3F93KE
Double the Energy Efficiency Ratio
62% More Capacity
Enhanced Supermarket Solution
Alarm Resolution
Energy & Maintenance Reports
Setpoint Management
Smart Dispatch
Demand Response
Site Administration
64 Emerson Confidential
Enhanced C-Store Solution
Alarm Resolution
Energy & Maintenance Reports
Setpoint Management
Smart Dispatch
Demand Response
E2 Controls
Diagnostics Distributed Controls
Variable Speed Drives
Belts & Sheaves
Scroll Compressors
Site Administration
65 Emerson Confidential
End User Comments after 2 Month Pilot C-Store
66 Emerson Confidential
HVAC Control
Humidity monitoring & control
Indoor Air Quality monitoring
Refrigeration Condenser
Systems
Power Monitoring / Demand Shed
Interior & Exterior lighting control
Exhaust fan control
Heater control
Refrigeration Control & Temperature Monitoring
Enhanced Restaurant Solution E2 -The core of a comprehensive, integrated site management system, providing intelligent monitoring & control of HVAC, refrigeration, lighting, plus many other devices & systems
Remote interface enables easy integration With Remote Software & Services
Enhance Data Centre Solution - Retrofit
End User Benefits • Excess of 30% in Energy Savings (Calculations) • Remote Adjustment & Monitoring • Centre Can implement at other Data Centers
OEM Wholesaler Contractor End-User
3 2 1
Customer Pain • Active Pain High Energy Cost • Latent Pain Lack of Equipment Connectivity
Execution • Floating Head Strategy – 28 EX valve Kit Opportunity
• Suggested CoreSense for ZR300 • Suggested Control Technique VFD for Cond. Motors • Suggested E2 Controller for Valve, CoreSense and
VFD Connectivity
68 Emerson Confidential
Using Data Monitored Across Enterprise To Identify Opportunities And Improve Performance C
ritic
al R
ack
Alar
ms
Enterprise-Level Monitoring
Using Store-Level Data Across Enterprise To Improve TCO
Maintenance & Energy Perspective: • Maintenance Savings Via Remote
Troubleshooting • Identify Worst Performing Stores &
Focus Improvement • Establish Benchmark & Best Of Class
Enhanced Refrigeration Solutions
[email protected] Director of Marketing, CO2 Business Development
Contractor Business Development Managers [email protected] (Ontario) [email protected] (Quebec/Maritimes) [email protected] (Western Canada)
Application Engineering [email protected] (Manager of Technical Services) [email protected] (Application Services)
