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Posts tagged ‘Ani Jayanth’

New Copeland Scroll™ Compressors Help Address Foodservice OEM Challenges

anijayanth Ani Jayanth | Director, Product Marketing

Emerson Commercial & Residential Solutions

This blog summarizes an article from our most recent E360 Outlook, entitled Less Is More.” Click here to read it in its entirety.

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Foodservice refrigeration equipment manufacturers will have a complex regulatory landscape to navigate in the coming years. In 2018, the Environmental Protection Agency (EPA) will be phasing out the use of R-404A in new remote condensing units for walk-in coolers and freezers (WICF). Then, the Department of Energy (DOE) has proposed the enforcement of its new WICF efficiency mandate in 2020, as measured by the annual walk-in efficiency (AWEF) standard. The challenge for foodservice OEMs is to design new condensing units and stand-alone equipment that comply with both requirements.

Emerson’s new ¾ to 1½ horsepower (HP) offerings extend the existing Copeland Scroll ZF*KA and ZB*KA compressor lines, allowing OEMs to combine compliance into a single design cycle for smaller low- and medium-temperature applications.

With the EPA’s proposed phase-down of hydrofluorocarbon (HFC) refrigerants with higher global warming potential (GWP), new refrigeration platforms must be designed to accommodate the performance characteristics of lower-GWP alternatives. Accordingly, our new fractional HP Copeland Scroll compressors are rated for use with new alternatives R-448A/449-A as well as existing lower-GWP HFCs such as R-407A.

Liquid-injected for low-temperature efficiencies

Walk-in freezers that rely on outdoor condensing units will require compressors that can mitigate the higher discharge temperatures produced when using new refrigerant alternatives in low-temperature applications. The Copeland Scroll ZF*KA fractional HP models utilize liquid-injection technology to cool discharge temperatures and reduce compressor stress. Compared to hermetic reciprocating compressors that will require additional modifications and heat-reduction strategies, Copeland Scroll technology is well-suited for these low-temperature scenarios.

Copeland Scroll ZF*KA fractional HP compressors are the basis of Emerson’s X-Line outdoor condensing unit, enabling it to simultaneously meet both DOE (AWEF efficiency) and EPA (lower-GWP refrigerant) requirements in low temperatures.

Wide applicability in medium temperatures

For medium-temperature, walk-in coolers, the new fractional HP ZB*KA compressors deliver enhanced AWEF efficiencies in WICF condensing units. It’s important to note that incumbent hermetic reciprocating compressors cannot achieve the same efficiencies without modifications to other system components (e.g., coils, cooling fans, etc.). Patented Copeland Scroll technology enables significant efficiency improvements in medium-temperature WICF applications without investments in additional components or incurring engineering, design and development (ED&D) costs.

The new ZB*KA compressors represent an extension of the medium-temperature line of compressors to better serve today’s wide range of walk-in cooler requirements. OEMs can now integrate reliable Copeland Scroll technology into their complete lineup of walk-in refrigeration equipment, while achieving compliance with environmental and energy-efficiency regulations.

By addressing both EPA and DOE compliance requirements, fractional HP Copeland Scroll compressors help simplify the design cycles for foodservice refrigeration OEMs.

[E360 Webinar Recap] Achieving Capacity Modulation With Digital Retrofits

anijayanth Ani Jayanth | Director, Product Marketing

Emerson Commercial & Residential Solutions

 

VIEW our latest E360 Webinar on demand, “Utilizing Digital Retrofits to Achieve Capacity Modulation.”

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The integration of a digital compressor into an existing rack to achieve capacity (or load) modulation is a technique often referred to as a digital retrofit. In our most recent E360 Webinar, “Utilizing Digital Retrofits to Achieve Capacity Modulation,” Chris Raffel explained the principles behind digital technology and its potential benefits.

In theory, digital capacity modulation can improve any system with varying load requirements, including: supermarket and foodservice refrigeration; commercial AC; walk-in coolers/freezers; refrigerated warehousing; and process chillers and air dryers. A recent emphasis on deploying systems with lower global warming potential refrigerants is prompting many supermarket retailers to make changes to their existing refrigeration systems — thus presenting digital retrofit opportunities.

Why go digital?

Digital compression technology addresses many of the challenges of traditional refrigeration systems by enabling the benefits of capacity modulation:

  • Reduced compressor cycling
  • Increased contactor life/system reliability
  • Enhanced system load match capability
  • Tighter suction setpoint range
  • Improved energy efficiency

The relationship between suction pressure and energy efficiency is particularly noteworthy. We estimate compressor power consumption is reduced by approximately 2 percent for every 1 PSI increase in suction pressure. When the suction pressure is held tighter, as is the case in digital retrofit systems, the suction setpoint may also be raised. It’s here where significant energy savings from digital capacity modulation can be achieved.

Principles of digital modulation

Both Copeland Scroll Digital™ and Discus Digital™ compressors work according to a similar principle: varying the percentage of time that the compressor is loaded and unloaded to achieve the desired load requirements. For example, if the required capacity is 50% during a 20-second period, the compressor may be fully loaded for 10 seconds and completely unloaded for the remaining 10 seconds.

Regardless of the load/unload state, the speed of the digital compressor speed remains constant. During the unloaded stage of the compression cycle, the flow of suction gas is completely closed off to the cylinders; no gas is compressed and power consumption is significantly lower. A solenoid valve controls the gas flow; when it is deenergized, the suction gas resumes flow into the cylinders and normal compression resumes.

When to make the move to digital

System redesign, refrigerant changes or a compressor replacement are all viable opportunities to install a digital compressor to act as the lead compressor in a rack. In doing so, retailers will not only significantly improve refrigeration system performance, but also potentially prolong the life of the other compressors on the rack. I demonstrated this concept in the webinar with data that showed a clear reduction in compressor cycling — in one case going from 900 starts per day to 12 starts in four days.

To learn more about digital retrofits with capacity modulation, view this webinar in its entirety

[New E360 Webinar] Time to Retrofit Racks? Go Digital!

anijayanth Ani Jayanth | Director, Product Marketing

Emerson Commercial & Residential Solutions

Join us for our next E360 Webinar, “Utilizing Digital Retrofits to Achieve Capacity Modulation” on Tuesday, September 26 at 2 p.m. EDT / 11 a.m. PDT.

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Many supermarket retailers today are faced with the prospect of retrofitting their existing refrigeration systems to utilize lower global warming potential refrigerants. While complying with regulations and deploying environmentally friendly systems may be the primary reasons for the retrofit, retailers are also seizing the opportunity to upgrade their systems to provide improved energy efficiencies, tighter setpoints and greater reliability. The integration of a digital compressor in an existing rack — known as a digital retrofit — is becoming an increasingly effective way of achieving these objectives.

Our next E360 Webinar, entitled Utilizing Digital Retrofits to Achieve Capacity Modulation, will explore the potential of digital retrofits. Hosted by Emerson’s Chris Raffel, lead application engineer, the webinar will take a closer look at the digital compression technology behind the architecture and explain how it provides the capacity modulation to greatly improve system efficiencies.

This informative webinar will take place on Tuesday, September 26 at 2 p.m. EDT / 11 a.m. PDT. Attendees will learn about the many operational benefits of digital retrofits, including:

  • Reduced compressor cycling for increased system reliability
  • True load matching capabilities
  • Tighter setpoints for precise case temperatures
  • Significantly higher energy efficiencies than other capacity modulation methods

Chris will also present actual case studies of supermarkets whose digital retrofits achieved measurable energy efficiencies, tighter suction pressures and less food spoilage.

To learn how digital retrofits can provide these benefits in your supermarket, register now for this timely E360 Webinar on Tuesday, September 26 at 2 p.m. EDT / 11 a.m. PDT.

R-290 Condensing Units Deliver Refrigeration Efficiencies and Regulatory Compliance

anijayanth Ani Jayanth | Director, Product Marketing

Emerson Commercial & Residential Solutions

This blog summarizes the Product Spotlight column in our most recent E360 Outlook, entitled R-290 Ready.” Click here to read it in its entirety.

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The growing demand for energy-efficient and environmentally friendly commercial refrigeration equipment has led to the resurgence of the natural refrigerant propane (R-290). With a global warming potential of 3, R-290 checks two key regulatory boxes: 1) it is listed as an acceptable refrigerant substitute by the EPA; and 2) it meets the DOE’s call for more energy efficiency in compressors and condensers. To support our OEM customers who are responding to this market demand, Emerson offers a line of condensing units designed to maximize R-290 efficiencies.

As a class A3 (flammable) refrigerant, R-290’s charge limit of 150g has largely constrained its use to smaller, self-contained applications. This makes R-290 an ideal candidate for use in stand-alone, reach-in applications, where the DOE has mandated 30–50 percent reductions in energy consumption as of March 27. This same class of equipment will also be subject to the EPA’s phase-down of commonly used hydrofluorocarbon (HFC) refrigerants in 2019. The disparate timing of these regulations is forcing foodservice OEMs to consider meeting both requirements in the same design cycle. Currently, R-290 is a leading option for accomplishing both objectives.

Energy-efficient condensing units

Copeland™ M-Line condensing units provide all the technological improvements needed to help OEMs achieve regulatory compliance while giving end users optimal performance in low- and medium-temperature applications. Designed to deliver energy improvements up to 30 percent, M-Line condensing units are built on the following improvements:

  • Latest generation of Copeland hermetic compressors
  • Electronically commutated fan motors (an optional feature)
  • Condenser coil tubing design that enables additional coil rows

Next generation compression technology

Emerson has been testing alternative refrigerants for years to help OEMs make the transition to DOE- and EPA-compliant compression technology. Emerson offers A*E and R*T compressors rated for use with R-290 and available in fractional horsepower options to serve as the basis of Copeland M-Line condensing units. Designed with OEM and end user concerns in mind, these compressors deliver the following benefits:

  • Minimal sound output for quiet operation
  • More than 20 percent energy-efficiency improvements compared to R-404A
  • Little to no environmental impacts

Wider adoption of R-290 is evidence that the commercial refrigeration industry is becoming more comfortable with the natural refrigerant alternative. While OEMs and operators alike have accepted its 150g charge limit, even incremental charge increases would enable significant advances in system design and efficiencies. This charge limit is currently under review by building codes and standards makers. If (and when) charge limits are increased, Emerson will be prepared to make the necessary updates to our compression technology.

This blog summarizes the Product Spotlight column in our most recent E360 Outlook, entitled R-290 Ready.” Click here to read it in its entirety.

Simulation Model Breaks the Ice on Meeting Efficiency Targets

anijayanth Ani Jayanth | Director, Product Marketing

Emerson Commercial & Residential Solutions

This blog is a summary of the article Simulation Model Breaks the Ice on Meeting Efficiency Targets from our recent edition of E360 Outlook. Click here to read the article in its entirety.

System simulation models have been widely used for decades to help commercial refrigeration equipment manufacturers test the impacts of various components and design options. By simulating the steady-state operation of the vapor-compression cycle, these models have served as the basis of predictive evaluation in many modern refrigeration applications. Engineers rely on these virtual models to expedite the design process and test prototypes before proceeding with physical equipment development. This has not been the case with ice machine simulation models … until now.

The transient nature of ice machine operation — continually cycling between ice formation and harvest modes — presents challenges in simulating the effects on the system during these transitions. That’s why developing a usable simulation model for the evaluation of ice machines has been historically problematic. It’s also why our engineering team at the Helix Innovation Center decided it was time to tackle this challenge head-on.

The release of this simulation model has timely implications for automatic commercial ice maker (ACIM) manufacturers. In 2015, the Department of Energy (DOE) revised its efficiency standards for machines that produce 50–4,000 pounds of ice per day. The ruling will take effect on Jan. 1, 2018, requiring ACIMs manufactured after that date in the United States to reduce energy consumption by 10–15 percent1.

Since ACIMs are produced in a wide range of capacities and used in restaurants, hotels, convenience stores and hospitals, compliance to the new standard has broad industry implications. The ruling affects the two primary classes of ACIMs: batch ice machines (aka “cubers”); and continuous ice machines (aka “flakers” and “nuggets”).

With the new DOE standard taking effect in a little more than a year, many ACIM manufacturers have either already begun or are planning to kick off the engineering design cycle. Our new ACIM simulation model is available to help our customers meet this fast-approaching deadline.

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Rapid prototyping

The ACIM simulation model will enable engineers to perform rapid “what if” analyses, allowing them to quickly evaluate the impact of a variety of system design options, including:

–    The size of the air-cooled condenser and finned surfaces
–    Changes in air/water flow rates, as well as ambient air and inlet water temperature
–    Compressor capacity and/or efficiency during freeze and harvest cycles
–    Evaluation of alternative refrigerants
–    Suction/liquid line heat exchanger
–    Thermal expansion valve properties

To verify the validity of simulation data, results from the model were compared with the experimental data of a standard 500-pound capacity ice machine, operating under various ambient air and water inlet temperatures. Key measures of the ice machine’s performance include: cycle time (duration of freeze and harvest cycles); energy input per 100 lb of ice; and energy usage during a 24-hour period. Against these measures and in a variety of operating conditions, the model achieved accuracy levels within 5 percent.

Now that it’s established, the ACIM simulation model enables the prediction of component performance, evaluation of loads under different operating conditions and assessment of system design changes — all within a virtual environment. We’re looking forward to working with our ACIM OEM partners to help them achieve the efficiency levels set forth by the DOE.

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