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Digital X-Line Series and Lumity™ E3 Supervisory Control Earn Awards

Carmem Valle Pereira | Product Manager – Condensing Units,

             HVACR Technologies

Emerson’s Commercial and Residential Solutions Business

Two of Emerson’s refrigeration technologies were honored with recognition by the 2021 Dealer Design Awards program sponsored by The Air Conditioning, Heating & Refrigeration (ACHR) News magazine. The Copeland™ digital outdoor refrigeration unit, X-Line Series was awarded a gold rating in the Refrigeration and Ice Machines category. The Lumity™ E3 supervisory control took home a bronze award in the Commercial Controls category.

Now in its 18th year, the Dealer Design Awards program recognizes exceptional manufacturing of HVACR technology as well as product designs that benefit HVACR contractors. This year, the awards program received 117 entries, which were judged by an independent panel of contractors.

For the gold: The Copeland digital outdoor refrigeration unit, X-Line Series

Designed specifically for small-format operations, the digital X-Line Series is a compact condensing unit solution that provides refrigeration for multiple fixtures while delivering precise temperature control and significant energy savings. With 20 to 100% capacity modulation, proven Copeland digital scroll technology, large-capacity condenser coils, variable-speed fan motor control and smart controls, the digital X-Line Series is a superior solution for convenience stores (C-stores), small-format food retailers and restaurants.

Standard features include multiplexing capabilities, onboard diagnostics, connectivity, installation flexibility, ultra-quiet operation and corrosion resistance. In addition, expanded refrigerant approvals provide operators with multiple options for selecting a lower-global warming potential (GWP) refrigerant that helps them to meet their sustainability and operational objectives. Many of the X-Line unit’s innovations — including faster, simpler setup, more diagnostics and better communication capabilities that improve reliability and reduce equipment downtime — are the result of direct customer feedback.

Bringing home the bronze: The Lumity E3 supervisory control

Launched in February, the Lumity E3 controller is the next generation in facility management and refrigeration controls. The E3 controller is powered by Emerson’s Lumity supervisory control software to provide food retail and foodservice operators with comprehensive control of critical facility systems. In addition to an intuitive, user-friendly and web-accessible interface, it offers customizable graphs and summary pages; smart alarms to detect, prioritize, troubleshoot and resolve issues; and a performance meter to fine-tune the performance of refrigeration fixtures and equipment.

The Lumity E3 controller’s simplicity provides operators with powerful control to manage and optimize energy use throughout a facility via built-in algorithms which support demand response, curtailment and load shedding programs. The E3 controller was designed to empower contractors and operators across a wide range of skill levels, helping them to work more efficiently, decisively and tackle the challenge of skilled staff shortages. And finally, the E3 controller is engineered for adaptability, providing operators with greater flexibility to revamp their store designs or expand their operations.

Our commitment to innovation

Both the digital X-Line Series and the Lumity E3 controller embody Emerson’s commitment to helping our customers attain greater temperature stability and certainty, improve food quality and safety, minimize equipment failures, curb energy use, and achieve regulatory compliance. The awards underscore our causes to lead our customers through complex technical, regulatory and economic challenges and deliver sustainable solutions that improve efficiency, reduce emissions, and conserve resources.

We are honored to be recognized by the 2021 Dealer Design Awards program and will continue to engage with contractors and end-users to identify ways to further improve our products and solutions.

Multiply the Advantages of Multiplex Refrigeration Systems

Julie Havenar | Director of Integrated Marketing, Cold Chain
Emerson’s Commercial & Residential Solutions Business

The challenges that drive refrigeration system requirements in supermarket and restaurant applications have evolved significantly over the past several years. As operators respond to changing consumer behaviors and a shifting regulatory environment, multiplex refrigeration systems — where one condensing unit services multiple fixtures — are emerging as a refrigeration system of choice. In an article recently published in RSES Journal, I discussed the many advantages that multiplex refrigeration systems offer, including lower operating costs, improved temperature control and greater potential to satisfy environmental initiatives.

Building the business case for multiplex systems

In today’s ever-expanding selection of refrigeration technologies and architectures, supermarkets and restaurants have no shortage of options to choose from. However, not all strategies are created equal. As operators confront new and dynamic competitive pressures, their business requirements need to be carefully paired with a refrigeration strategy that can best meet their current and future needs.

System reliability will always be a primary requirement for any refrigeration system. But changing consumer behaviors are putting pressure on profit margins and driving demand for greater flexibility. And environmental regulations, combined with corporate sustainability goals, are creating urgency for greener technologies.

Multiplex refrigeration systems are rapidly emerging as a leading option that can satisfy all of these requirements. Multiplex systems are refrigeration systems that use minimal outdoor condensing units (OCUs) to provide cooling for multiple fixtures, including display cases, walk-in coolers, freezers and ice-making heads. Instead of the traditional one-to-one relationship of OCUs to refrigeration fixtures, multiplex systems expand this relationship to one-to-many, providing operators with greater flexibility in terms of system design.

Emerson’s Copeland™ digital outdoor refrigeration unit, X-Line Series is designed to allow operators to multiply the advantages of multiplex architectures. Many operators experience a variety of refrigeration challenges that multiplex systems are particularly well-suited to address, including:

  • A need to scale back refrigeration fixtures and/or refrigeration loads
  • Refrigeration units or loads that are oversized for the application
  • Excessive compressor cycling that negatively affects system performance
  • The imperative to improve food quality and extend shelf life by maintaining tighter temperature control
  • Constraints that prevent the installation of multiple fixed-capacity OCUs

And when the multiplex system is designed to use digital compression technology — like the Copeland™ digital scroll compressor — these advantages quickly add up:

Greater energy efficiency: Digital compression technology allows for variable-capacity modulation to precisely match individual load requirements. Whereas traditional fixed-capacity condensing units run at 100% all the time, digital compressors regulate capacity from 20–100% to meet true energy demand. This is a tremendous energy- and cost-saving benefit for busy foodservice and grocery store applications, where demand can vary throughout the day.

Reduced refrigerant charge: In addition to improving energy efficiency, multiplex systems reduce a system’s overall refrigerant charge by as much as 50%. Modern systems also support the use of lower global warming potential (GWP) refrigerant alternatives. As a result, multiplex systems can help operators to reduce their total equivalent warming impact (TEWI), which is a plus for attaining regulatory compliance and bolstering corporate sustainability initiatives.

Improved temperature control: Digital compression technology allows for tighter control of suction pressures and eliminates large pressure swings while maintaining setpoint temperatures at a much tighter tolerance. Even with the frequent opening of refrigerator, freezer and case doors, temperatures remain constant, thus safeguarding food quality and safety.

Enhanced reliability and protection: With digital compression technology, variable-capacity modulation can take place without cycling the compressor on and off. This limits the in-rush of currents that drive up energy use while reducing the wear and tear of short cycling. With fewer OCUs to commission and maintain, operators can expect to make fewer service calls.

Advanced visibility: Building management and supervisory platforms have become foundational to maintaining operational efficiency and reducing the risk of food loss. Modern multiplex systems have built-in controls to seamlessly connect with these platforms to enable real-time monitoring, remote diagnostics and supervisory functions. In addition to simplifying commissioning, this gives operators and contractors the ability to make system changes (such as changing a setpoint or accessing fault codes) on any web-enabled devices, rather than on the face of the controller.

Smaller footprint, bigger savings

The ability to support multiple fixtures with fewer OCUs provides operators with greater flexibility to do more within a smaller physical and environmental footprint. And with digital compression technology, operators can reduce the risk of catastrophic system failure and extensive food loss.

Emerson is committed to helping food retailers and restaurants get more from their refrigeration strategies. From our next-gen Copeland digital X-Line series to our Lumity™ E3 supervisory control, we provide the technologies to optimize operations, increase equipment uptime, safeguard food quality and safety, achieve sustainability goals, and decrease operational and maintenance costs.

 

Copeland™ Scroll Booster Architecture Balances Sustainability, Serviceability and Flexibility

Andre Patenaude | Director – Solutions Integration,

Emerson’s Commercial and Residential Solution’s Business

As refrigerant regulations continue to progress rapidly, commercial refrigeration stakeholders are looking for refrigeration solutions capable of balancing their sustainability, serviceability and equipment lifecycle goals. Emerson recently completed the development of a new distributed system architecture called Copeland scroll booster. It is designed specifically to help food retailers achieve these goals while providing the flexibility to accommodate a wide range of low- (LT) and medium-temperature (MT) applications.

When searching for viable and sustainable commercial refrigeration strategies, stakeholders often find themselves weighing the pros and cons of many different system types. Systems that use alternative refrigerants with a global warming potential (GWP) below 150 typically introduce increased service complexities and lifecycle costs. Other systems may not quite achieve sustainability targets but offer serviceability improvements. And when you consider the ever-expanding diversity of system designs needed to address modern commercial refrigeration requirements, system selection becomes even more complex.

Much of the work taking place at Emerson’s The Helix Innovation Center is focused on solving this industry-wide challenge, and the Copeland scroll booster architecture is a key outcome of these efforts.

Leveraging a new refrigerant alternative

Regulatory mandates are driving significant changes within commercial refrigeration system designs to minimize environmental impacts. Many operators are seeking alternatives to traditional centralized direct expansion (DX) refrigeration systems, which utilize large charges of high-GWP hydrofluorocarbon (HFC) refrigerants and are prone to leaks. This has led to an increasing variety of distributed refrigeration approaches — which offer smaller refrigerant charges, lower-GWP refrigerants and wider application flexibility.

Although natural refrigerants CO2 (R-744) and propane (R-290) have the lowest possible GWP ratings, they also come with high operating pressure (R-744) and flammability (R-290), introducing operational complexities and design limitations that many food retailers may not be prepared to address. Newer refrigerant blends — such as the A1 hydrofluoroolefin (HFO) refrigerant R-513A — deliver excellent performance characteristics, much lower GWP than HFCs and zero flammability. Offering the lowest possible GWP (573) among non-flammable refrigerants, R-513A has low-pressure characteristics that provide a familiar operating envelope and require no special training, certification or safety mitigation measures.

Mechanics of Copeland scroll booster

The Copeland scroll booster system is designed to use R-513A for both LT and MT refrigeration loads. Its distributed architecture offers an efficient and environmentally friendly alternative to large centralized systems. System configurations can scale from small, low-charge condensing units to larger distributed racks charged with several hundred pounds of refrigerant.

This innovative technology overcomes the typical challenges of operating a low-temperature system, including requiring compressor cooling via liquid injection and lowering compressor lifespan due to high compression ratios and discharge temperatures. This straightforward architecture leverages the advantages of R-513A’s low-pressure, high-efficiency and key system components to significantly lower discharge temperatures and compression ratios.

This flexible architecture is comprised of one or more MT scroll compressors coupled with one or more LT scroll compressors, where MT compressors can either be placed in a condensing unit or within a typical rack configuration. Condensers may be located remotely or integrated into the system and placed indoors or outdoors. To help reduce refrigerant charge, piping and associated costs, the LT scroll compressors can be placed near the LT evaporators, i.e., directly on top of or beside the case or remotely near the load.

The “booster” design strategy provides significant performance improvements by discharging (or boosting) the LT compressor directly into the nearest MT compressor’s suction line. The lower discharge temperatures of the LT scroll compressor minimize the suction gas temperature of the MT unit and allow the MT compressors to operate within their design limits without the need for additional cooling. The net result is an overall system efficiency gain while greatly minimizing the mechanical loads on the LT compressors.

Simplifying operational complexities

The innovative use of a low-pressure, low-GWP refrigerant within a simple, distributed architecture that’s based on familiar operating principles fills an urgent need within the larger food retail market. The Copeland scroll booster system helps operators to meet their sustainability goals without introducing unnecessary serviceability complexities. Offering the design flexibility to service store formats of varying sizes, its benefits check many key boxes on the list of modern supermarket refrigeration priorities:

  • Lower-GWP, A1 refrigerant (i.e., R-513A)
  • Reduced refrigerant charge
  • Lower leak rates due to lower-pressure system
  • Lower utility costs
  • System familiarity with technicians and end users
  • Low total cost of ownership (TCO) from lower annual energy consumption and lifecycle climate performance (LCCP)
  • Secure remote facility monitoring capabilities

Proof of concept and future evolution

Emerson has conducted successful trials of this technology in various applications and climates. This year, a distributed scroll booster system was installed at Gem City Market, a new small-format supermarket built in Dayton, Ohio. The project involved collaboration among the surrounding Dayton community, city officials and commercial refrigeration industry leaders — including Hussmann and Chemours — who donated their respective expertise and resources to the project. In the future, when even lower-GWP refrigerants (such as A2Ls) are approved for use by applicable codes and standards, a distributed scroll booster system can be adapted for use with these ultra-low refrigerant alternatives (less than 150 GWP).

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.

[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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