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The Helix: Bold Collaboration & Disruptive Innovation

RajanRajendran2 Rajan Rajendran | V.P., System Innovation Center and Sustainability

Emerson’s Commercial & Residential Solutions Business

When Emerson first opened The Helix Innovation Center, we envisioned it as a catalyst to advance research and drive innovation for the global heating, ventilation, air conditioning and refrigeration (HVACR) industry.

In only a few short years, it has surpassed our best expectations, quickly becoming a place where industry experts can come together and work collaboratively to confront and solve some of the biggest challenges facing not just our industry, but our communities and the entire planet.

A perfect example of this is the work we’ve done at The Helix in regard to sustainable supermarket refrigeration. We recently introduced a new distributed scroll booster refrigeration architecture for retail operators that will help them meet their sustainability goals without introducing unnecessary serviceability complexities.

The Copeland™ scroll booster architecture helps reduce emissions from refrigeration systems by utilizing reduced charges of lower global warming potential (GWP) refrigerants and system design strategies that maximize energy efficiencies. It is designed for maximum application flexibility and optimized for use with a low-pressure refrigerant, R-513A.

This flexible architecture fills an urgent need within the food retail market, which is looking for commercially viable technology and equipment that not only delivers efficiency and simplicity, but also provides a positive impact on the environment. Until now, there has not been a single system architecture that addressed the wide range of sustainability objectives, as well as system cost and long-term serviceability considerations.

The combination of high performance, sustainability and serviceability made the distributed scroll booster an ideal choice for the Gem City Market, a new small-format supermarket that opened this April in a food desert in Dayton, Ohio.

The work being done at The Helix became a focal point for the project as Dayton community members, city officials and commercial refrigeration industry leaders came together to identify a solution that met the market’s configuration of the distributed scroll booster system that met the store’s unique footprint, floorplan and refrigeration requirements.

Special thanks to business partners Chemours and Hussmann, and my own company, Emerson, for donating expertise, resources and equipment for this important installation

This is a great example of why we built The Helix. There is no shortage of great ideas, innovative technology and dedicated commitment in the industry. Our innovation center provides an ideal place where are these elements can come together to achieve great things for our industry and our communities.

 

 

 

Emerson Launches Copeland™ Variable Frequency Drives

Joe Summers | Product Manager,                                                                               Variable Speed & Integrated Solutions
Emerson’s Commercial & Residential Solutions Business

Improving energy efficiencies in heating, ventilation, air conditioning and refrigeration (HVACR) systems is a goal shared by operators in many food retail, commercial building and industrial applications. Variable frequency drives (VFDs) can be applied to various fixed-speed system motors to control their speed and capacity, and in doing so, significantly reduce energy consumption and associated operating costs. Emerson is pleased to announce the launch of its Copeland VFD product lines, which are designed for maximum compatibility with Copeland compression products to reduce the costs and complexities of VFD implementation. You can read our latest E360 Product Spotlight to take a closer look at the improved system efficiencies that can be achieved in certain HVACR applications.

According to research from the Department of Energy (DOE), the commercial building sector accounts for 40 percent of the total energy consumption within the U.S. Among the greatest electricity consumers and energy cost contributors are the motor loads from mission-critical HVACR equipment.

From refrigeration compressors to the evaporator and condenser fans used in parallel rack and/or chiller applications, Copeland VFDs can be added to existing fixed-speed HVACR motors to help operators to quickly retrofit their facilities and achieve:

  • Significant improvements in system performance and reliability
  • Substantial reductions in energy consumption
  • Fast return on investment (ROI)

Available in two platforms and multiple connection options

The Copeland EVM VFD series is intended for chillers, medical refrigeration, display cases, walk-ins, reach-ins and other applications where less control functionality is needed.

  • Covers ½ to 30 HP range
  • Available in single- and three-phase input options
  • Equipped with onboard Bluetooth® capabilities for ease of use

The Copeland EVH VFD series is designed for large centralized racks, including CO2, advanced chillers, and industrial refrigeration applications that require more demanding motor control functionality.

  • Covers 1 to 250 HP
  • Available in three-phase, including 575-volt options
  • Delivers advanced motor control

These product lines offer a variety of connection options, including an onboard web server (available on EVM series only) and a multitude of available onboard communication options:

  • Modbus RTU or TCP
  • BACnet™ MS/TP or IP
  • Ethernet IP/TCP
  • Optional cards such as: CANopen, Dual Ethernet Port and Profibus

Benefits of variable-capacity modulation

Copeland VFDs allow facility operators to reap the benefits of variable-capacity modulation without swapping out their current HVACR equipment. Adding a VFD to a fixed-speed fan or pump motor can result in a 30 to 50 percent reduction in energy costs while allowing capacity to fluctuate from 10 to 100 percent. When added to a semi-hermetic compressor, a Copeland VFD provides a 15 to 30 percent reduction in energy costs while enabling capacity modulation from 40 to 100 percent.

These efficiencies are achieved via improved load matching, less on and off cycling, softer start-ups and faster temperature pull-downs — which also deliver the following system performance improvements:

  • Precise temperature and humidity control
  • Adaptable capacity for changing loads and weather conditions
  • Controllable noise levels

In addition, Copeland VFDs enhance equipment reliability through proactive motor failure prevention, advanced diagnostics, decreased susceptibility to power issues, and by greatly reducing the number of start/stop events.

Maximum compatibility with Copeland compressors and ease of use

Native software that supports the Copeland VFD platforms is designed to deliver optimal performance when paired with Copeland compressors, including: scroll, semi-hermetic and screw compression technologies. This software also provides the same optimization of the control algorithms found in VFDs designed for competitive compression technologies and general, multi-purpose motors, such as fans and pumps.

The Copeland VFD series provides maximum ease of use for contractors and end-users during installation, servicing and operation. An intuitive startup wizard, quick-start menus and simple connections make set-up fast and uncomplicated, while offering seamless integration with Emerson’s Lumity™ supervisory control platform including the E3 and site supervisor controllers.

Selecting the right model for your applications

To simplify the selection process, each Copeland VFD model is designed to accommodate dozens of general motors and compressor SKUs. In addition, Emerson’s online product information (OPI) tool can help you to determine which VFD is appropriate for your application. Simply locate the motor’s nameplate and then begin selecting and sourcing the best-fit Copeland VFD model for your application. Product catalogs and manuals are also available on our website for easy reference.

It’s also important to remember that sustainability initiatives are driving many U.S. states to offer energy-efficiency incentives to operators who implement variable frequency drives. Where available, we encourage you to leverage these incentives to reduce and/or offset your upfront costs.

Innovative Solutions to Sustain Our Communities

John Rhodes |Group President, Cold Chain
Emerson’s Commercial & Residential Solutions Business

Putting our technologies and knowledge to work in pursuit of a better planet is in our DNA at Emerson. It’s ingrained throughout our culture and reinforced in our Purpose: We drive innovation that makes the world healthier, safer, smarter and more sustainable.

Our newest innovation – a unique refrigeration technology developed at our Helix Innovation Center in Dayton, Ohio – will help the local community, where the concept first came to life.  Gem City Market, a collaborative grocery store with the mission to equip, engage and empower our neighborhoods will be the recipient of our donation which was made in partnership with Hussmann and Chemours who donated additional refrigeration equipment in service of this initiative. We are proud to help through one of our core areas of expertise: providing sustainable refrigeration technology that can help protect food quality and safety.

The location of Gem City Market qualifies as a “food desert,” according to the U.S. Department of Agriculture Economic Research Service. In order to meet the standards of a food desert, more than 40% of the population must have an income of less than or equal to 200% of the federal poverty threshold and live more than a mile from a supermarket or large grocery store.

Food deserts are a persistent problem in many communities, and supply chain barriers to accessing healthy, affordable food contribute to this global issue. Many local and smaller retail stores within distance of underserved communities struggle to get their shelves stocked with local produce and fresh food due to the lack of perceived customer demand, limited technology and the lack of infrastructure to refrigerate these goods properly.

There are alternatives to costly full-scale refrigeration systems typically seen in supermarkets. Our new Copeland™ scroll booster refrigeration technology will help combat the issue of limited infrastructure to properly store perishables at Gem City Market. The first commercialization of technology developed at our Helix Innovation Center in Dayton, the Copeland scroll booster is a new-to-the-world flexible refrigeration architecture. This booster technology enables Gem City to use a lower global warming potential refrigerant to store food at its optimal temperature, helping them meet their sustainability goals and achieve stringent regulatory compliance.

Our scroll booster technology is a new architecture option for those who are in search of sustainable solutions – and is a testament to the power of innovation and collaboration. When committed people come together, we can create options for families to shop for nutritious food in their own communities. And when problem solvers come together in the name of leaving the world a better place, they are truly unstoppable.

 

[New E360 Webinar] Preparing for the Safe Use of A2L Refrigerants in Commercial Refrigeration

RajanRajendran2 Rajan Rajendran | V.P., System Innovation Center and Sustainability

Emerson’s Commercial & Residential Solutions Business

The recent passing of the American Innovation and Manufacturing (AIM) Act is accelerating the phasedown of hydrofluorocarbon (HFC) refrigerants and renewing the search for viable refrigerant alternatives, including those classified as A2L (mildly flammable) and A3 (highly flammable). But while A2Ls are among the leading alternatives capable of achieving regulatory requirements, the safety standards governing their use in the U.S. have yet to be finalized. Our next E360 Webinar — which will take place on Thursday, May 27 at 10 a.m. ET/7 a.m. PT — will feature a panel discussion about how A2Ls have been successfully deployed in regions where they have already been approved.

Around the globe, the phasedown of HFC refrigerants is prompting a transition toward alternatives with lower global warming potential (GWP). While A2Ls and A3 have been approved for use in Europe and are now widely adopted in commercial refrigeration applications there, the development of safety standards is ongoing within the U.S.

Currently, several industry working groups are evaluating A2Ls and A3s in equipment and field applications, including UL 60335-2-89 (the equipment standard based on IEC 60335-2-89) and ASHRAE-15 (the application standard updated for commercial refrigeration based on ISO 5149) — both of which are approaching the final phases of approval.

Our upcoming E360 Webinar will explore one European retailer’s sustainability journey from HFCs to low-GWP A2L refrigerants. As part two of the Air-Conditioning, Heating, and Refrigeration Institute’s (AHRI) webinar series, How to Not Only Survive, but “Win” the Refrigeration Industry HFC Phasedown, this webinar will provide an opportunity for the U.S. to learn from their experience and prepare for a future with A2L refrigerants.

The webinar will include the following experts and practitioners:

  • Helen Walter-Terrinoni of AHRI
  • Lauren MacGowens of AHRI
  • Tim Anderson of Hussmann Corporation
  • Stephen Spletzer of The Chemours Company
  • Brian Churchyard of ASDA (a European retailer)

Attendees will learn about the key points of the European retailer’s journey:

  • Defining sustainability goals and objectives — and meeting them
  • Transitioning from A1s (HFCs) to A2Ls
  • Applying A2L systems in a safe and effective way
  • Understanding the impacts on store and equipment design, training and maintenance
  • Imparting lessons learned along the way

To learn more about the status of U.S. safety standards and how to use A2L refrigerants safely and effectively in retail applications, register for this informative webinar.

 

[Webinar Recap] Explore the Next Generation in Supervisory Controls

Katrina Krites | Marketing and Business Development

Manager, Food Retail

Emerson’s Commercial and Residential Solutions Business

Building management and refrigeration control platforms have become essential tools of the trade in food retail operations. From providing visibility to key systems, faults, statuses, and alarms to fine-tuning performance with advanced algorithms, building control strategies and network connectivity, these platforms give operators and technicians the information they need to maintain efficient store operation. In a recent webinar, co-hosted with Sam Smith, Emerson’s director of product management for digital solutions, we explored the next-generation capabilities of Emerson’s new Lumity™ E3 supervisory control.

Unified control platform for E3 and site supervisor

Earlier this year, Emerson launched the Lumity brand with the goals of providing our customers with data-driven insights to inform operational decision making while helping them ensure food safety and quality. The E3 is among the first products to be launched under the Lumity umbrella. Built upon the foundation of the Lumity supervisory control software platform, the E3 shares the same software with site supervisor. Thus, end-users only need to learn one software platform. Any enhancements made to the software will be available in all available control devices and accessories.

Familiar form and fit with enhanced functionalities

The E3 was designed to provide a true drop-in hardware replacement of the E2, offering the same familiar form and fit, but with greatly enhanced functionalities. The back of the E3 enclosure is designed to fit into existing panels to eliminate the need for new wiring while reducing installation costs and headaches via:

  • Identical wiring holes, mounting points and vents
  • Fits into existing panel cut-out
  • Total of four COM ports for connected devices with two isolated COM ports
  • Fully backward compatible with MultiFlex and IONet boards

The front of the device features an integrated 10-inch, touch-screen display that provides on-site access to the software interface. Web-enabled capability supports online remote visibility from a web browser or mobile device, delivering the same user-friendly experience, regardless of how it is accessed. Compared to the E2, the E3 processing power is 12 times faster and includes 16 times the built-in memory for faster response time and increased storage capabilities. Several models are available, depending on the type of control needed:

  • Building control (BX)
  • Refrigeration control (RX)
  • Combined building and refrigeration controller (CX)

Whether operators prefer a distributed or centralized control architecture — or some combination of the two — the E3 has the built-in flexibility to communicate to upstream and downstream devices. Data integration protocols include: Rest MQTT and SOAP, which allows the E3 to serve as a gateway of communication throughout the network to deliver insights into every aspect of store operation.

Empowering decisions with insights

The E3 is designed to empower stakeholders of all disciplines and skill levels to take decisive actions through a variety of intuitive features. Store operators can manage day-to-day performance while technicians can take a much deeper dive to optimize system performance, perform detailed analyses, and fine-tune facility controls.

  • Floor Plans: Access 2D/3D views of store floor plans to monitor each device, locate active alarms, and streamline your team’s prioritization and response.
  • Graphical Scheduling: Easily update, set, and duplicate schedules via simple click-and-drag functionality and a graphical interface.
  • Smart Alarms: Review straightforward alarm notifications — not cryptic or confusing codes — to detect, prioritize, troubleshoot, and resolve issues.
  • Performance Meter: Monitor refrigeration asset performance from one dashboard to verify refrigeration fixtures and equipment are performing as expected.
  • Site Aggregator: Bring the entire control network into a consolidated view — includes connectivity to legacy Emerson devices (such as E2 controllers) as well as third-party devices.

To learn how you can leverage the power of the new Lumity E3 supervisory control and software platform in your facility, view this free webinar.

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