http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/RSS.ashxRA PagesTue, 20 Oct 2009 21:05:42 +0200http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=1http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=1MaKInG ModERn LIVInG PossIBLE SolutionS T R E n d s a n d T o P I C s T H a T I M P a C T I n d u s T R Y EnVisioneering SM A Culture of Innovation » P L u s : d a n f o s s E n V I s I o n E E R I n G sM s Y M P o s I u M C o V E R a G E EnGInEERInG + EnERGY EffICIEnCY + EnVIRonMEnT = EnVIsIonEERInG VoLuME 8 / IssuE 3 / 20092009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=2http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=2MaKInG ModERn LIVInG PossIBLE EnVisioneering Imagination–Action–Solutions. sM engineering innovations flow from the Danfoss passion for technology. Together with our OEM customer partners, we focus every kind of technology on each problem, delivering the best HVACR solutions imaginable. energy efficiency. Because energy consumption has a large impact on total cost of ownership, improving energy efficiency is a priority in every Danfoss solution. environmental responsibility. Danfoss factories, processes, and products are managed for minimal environmental impact. We have a long tradition of concern for our natural surroundings, today and for future generations. To see how EnVisioneering can bring new perspectives to your project, visit www.envisioneering.danfoss.com ENGInEERInG + ENERGY EffICIEnCY + ENVIRonMEnT = ENVISIONEERING2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=3http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=3VoLuME 8 / IssuE 3 Dear readers, “Invention must go from the cool comfort of the laboratory to the cruel crucible of the marketplace.” –Kenneth Morse, founding director, MIT Entrepreneurship Center. as our industry faces some of the most transformational policy on climate change, energy efficiency and security, and the future of refrigerants, we must look forward in our business, industry, and the policy community. Many great technologies exist today to tackle these challenges, but pending climate and energy policy also opens the door for innovation. How do global corporations establish a culture of innovation? In this issue of EnVisioneering Solutions, we sat down with Kenneth Morse of MIT who shared his input and experiences in breeding innovation and in working with danfoss Ventures—a hub for innovation that encourages, vets and incubates promising new businesses. Innovation and collaboration go hand in hand. Through dialogue with industry stakeholders, the danfoss EnVisioneering symposium convened more than 60 HVaC&R industry professionals on July 24 at the u.s. Capitol to discuss new climate change legislation, the role of hydrofluorocarbon (HfC) refrigerants and the new—and rapidly changing – energy landscape. see pages 6–9 for more details. also, in this issue of EnVisioneering solutions we spotlight practical innovative case study projects—Macy’s in walnut Creek, California, and Canada’s first industrial refrigeration ammonia/Co2 project for the food industry. as always, we welcome your suggestions and feedback on this very wide-ranging issue. Robert wilkins, president of danfoss north america, discusses energy challenges at the 11th EnVisioneeringTM symposium. story on page 6. Contents / 2 / from The coVer 2 / driving Innovation from the Inside out 6 / danfoss EnVisioneeringsM symposium addresses Climate and Energy Policy / 14 / cAse sTUDies 14 / Big Box Retailer Goes outside the Box 16 / foodservice Company Pioneers Canada’s first Industrial Refrigeration ammonia/Co2 Brine system PRoduCT HIGHLIGHTs THIs IssuE The editors solutions@danfoss.com world’s smallest Programmable Controller MBs 1900 Range / Performer HCJ series scroll Compressors sPECIaL: aB-QM Valve Helps designers optimize system Performance information contained in the Danfoss EnVisioneering Solutions may be republished only with permission of Danfoss and always with credit to Danfoss enVisioneering solutions. comments, suggestions, and contributions are welcome. This publication should not take the place of appropriate technical or legal advice related to company-specific circumstances. Danfoss enVisioneering solutions does not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication.2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=4http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=4D r i V i N G i N N o V AT i o N fRoM THE 2 InsIdEou corPorATe VeNTUriNG TAKes A sTrATeGic APProAch AND A TAsTe for risK: It took the automobile 56 years to reach 25 percent of U.S. households, the Internet 23 years. Even more than good timing and patience, the key to taking innovation from a spark of brilliance to a profitable business involves collaboration between inventors, sales people, and the market. EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=5http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=5T H I s I s T H E M E s s a G E K E n n E T H M o R s E , founding director of the MIT Entrepreneurship Center, delivers to enterprises as he teaches them how to drive innovation from within. “Invention must go from the cool comfort of the laboratory to the cruel crucible of the marketplace,” says Morse, who launched five successful high-tech companies himself. He notes that 85 to 90 percent of purely technical startups fail. In the end, no matter how ingenious the invention, it’s the business plan and sales team that make or break an innovation. Danfoss takes this message to heart through its approach of investing in innovation with a clear path to commercialization. Danfoss Ventures was established as a hub for innovation that encourages, vets and incubates promising new businesses. “A successful venture requires a complete ecosystem,” says Stig Poulsen, president of Danfoss Ventures. “To begin with, the innovation needs to fit the Danfoss strategy, be linked to its core business, and show high market potential.” Over the years Danfoss has invested in a number of ventures to develop revolutionary technologies outside its core business divisions. This has resulted in a number of new products, such as indoor climate sensors that gauge temperature, humidity and carbon dioxide, AquaZ membrane technology for sea water desalination, and PolyPower, a revolutionary intelligent elastomeric film (see box on page 5). ut Go with your gut “Innovation requires a patient and sustained effort, top-level commitment, and a long-term view of innovation,” says Morse. These are the same traits that have allowed Danfoss to nurture its passion for innovation at all levels. The “Man on the Moon” program was launched by Jorgen M. Clausen, Danfoss board chairman and former CEO. The corporate-wide competition encourages employee teams to conceive new ideas and present them to a panel of judges. The best of the projects can get financed as ventures, and the inventors attend an intensive six-day entrepreneurship course at MIT. Several Man on the Moon projects have been launched commercially in recent years. Poulsen’s job includes evaluating the viability of new ideas and figuring how to make them thrive. Innovations are judged by a long list of criteria, from patent potential and competing technology to investor and market uptake. » Vo VL ou LM uE ME 8 7 / I/s Issu sE uE 3 1 / 2 / 020090 8 3 32009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=6http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=6CoVER sToRY ConTInuEd The most important factors are the people behind it, the value proposition, and the breakthrough potential. –stig Poulsen, president, danfoss Ventures “The most important factors are the people behind it, the value proposition, and the breakthrough potential,” he says. Although each innovation is critically analyzed, Poulsen admits, the final decision to invest often comes down to a “gut feeling.” “We are now moving closer to a major success—a whole new division for the company.” more than one way to breed new businesses Morse says flexibility and open innovation ensure the right people and resources get behind each new technology. Open innovation is a term promoted by Berkeley professor and author Henry Chesbrough. It involves a paradigm that promotes using internal and external ideas and paths to market to push forward new technologies. In his book, Open Innovation: the new imperative for creating and profiting from technology, Chesbrough asserts that all innovation is not created equal. In closed innovation, the approach taken through most of the last century, the innovators must do everything. It is inwardly focused and vertically integrated and occurs without external knowledge and resources. Open Innovation, in contrast, is about finding and connecting with the people who have the knowledge you need, then building upon that. Chesbrough says the world is shifting toward innovation models to keep up with mobility of skilled and knowledgeable workers, faster time to market, global competition, and wider knowledge bases across many sources. Danfoss engages in open innovation regularly with commercial and academic partners. When it decides to embrace an innovation, it might create a wholly owned start-up company, form a joint venture or create a new type of collaboration. “It’s a dynamic way of thinking,” says Poulsen. “It doesn’t matter if the idea is formulated inside or outside the business, whether it’s fully owned, or partially owned. What’s important is that we do what it takes to make it succeed.” It’s also important to know when to let go. Danfoss Ventures stands ready to abort a project or spin it off when the investment begins to outweigh the potential long-term return. open innovation: A paradigm that promotes using internal and external ideas and paths to market to push forward new technologies. read about one product of open innovation, PolyPower technology, on the next page. How does a company maintain a culture of innovation? Morse says entrepreneurship can be taught, including creative thinking and risk taking. He says inventors should respect the sales organization. “They should understand that successful commercialization of your invention is the most effective way to diffuse your innovation.” Poulsen says corporate venturing makes room for the “crazy thinkers,” the inventors who are more suitable for start-up environments than typical corporate life. He adds that Danfoss has nominated 45 ambassadors around the world to promote innovation and seek out new ideas. Companies looking to begin venturing should establish clear objectives, a venture team, and funding sources, says Morse. “Get training, meet with venture capitalists, and invest in a few strategic projects.” Also, be prepared to take some losses before you see the gains—the lemons ripen before the plums. It’s well worth it, says Poulsen. “Companies that are innovating all the time are able to make shifts as markets change.” 4 EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=7http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=7a BRIGHT IdEa PoLYPoWer The idea for an “intelligent artificial muscle” arose in 1995 from Jorgen m. clausen, Danfoss chairman and former ceo. Today, the PolyPower technology has come a long way, and was launched to the market this spring. The invention is based on dEaP (dielectric Electro active Polymers). simply put, electrostatic forces between two electrodes squeeze a polymer and transform electric energy into mechanical work. The result is an elastomeric film with vast potential in the industrial automation, consumer electronics, medical device, automotive, and entertainment industries. “our biggest success so far is the fact that we cracked the nut of how to make dEaP film on volume manufacturing equipment,” says Michael Jorgen Hamann, president of PolyPower a/s, a fully owned danfoss start-up. “This is a paradigm shift that allows for commercial success.” Customer projects are already under development. “from a technical point of view the concept has been proven; now the ongoing hard work of improving performance and lowering production cost remains,” says Hamann. The PolyPower technology was developed by danfoss in conjunction with Risø Research Institute in denmark. some of the technology’s original inventors remain on the team. Examples of applications include smart grippers in robotics that can adapt force and stroke and human-like movements, smart clothing and intelligent textiles, proportional valves with actuators and position sensors in one, wave and wind power generators, medical gloves with finger position sensing, and virtual animation based on clothing sensors, to name just a few. “I won’t give numbers at this point, but the potential is huge,” says Hamann. Living up to the “poly” name PolyPower is extremely versatile technology. It can be used as an actuating mechanism, a sensing element, and/or an electrical generator based on converting mechanical energy. all three modes of operation can be supported in the same device. It’s a technology platform that is lightweight and “environmentally friendly.” The versatility is the result of the elastomeric nature of the devices made from PolyPower. despite the fact that the material is soft, it can be made into shapes and structures that are very strong and capable of doing mechanical work more than 100 times its own weight. “In five years I envision that the first commercial products with PolyPower will have been on the market for two to three years, and may have won significant market shares within the respective niches,” says Hamann. “In 10 years I see PolyPower as a recognized technology broadly applied to a range of products.” VoLuME 8 / IssuE 3 / 2009 52009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=8http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=8enVisioneeringsm SyMpOSIuM 11th danfoss EnVisio Addresses Cli2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=9http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=9more than 60 hVAc&r industry professionals convened in the U.s. capitol in Washington, Dc, on July 24 at the 11th Danfoss enVisioneering symposium to discuss new climate change legislation, the role of hydrofluorocarbon (hfc) refrigerants and the new—and rapidly changing—energy landscape. ioneering symposium sM mAte & energy PoliC y Kateri callahan K E Y n o T E s P E a K E R K aT E R I C a L L a H a n, president of Alliance to Save Energy, stated, “Energy efficiency offers enormous potential for savings in all sectors. By capturing the potential available from existing technologies with an internal rate of return of 10 percent or more, we could cut global energy demand growth by half or more over the next 15 years. In other words, global energy demand in 2020 would decline by an amount equal to almost 150 percent of the entire U.S. energy consumption today.” Callahan also pointed out, “The federal economic stimulus package has dedicated $65 billion in spending related to energy efficiency.” And according to Callahan, the funding is based on sound public policy: research, development and deployment (RD&D), education and outreach, incentives, standards and codes, and government “leadership by example,” such as federal high-performance green buildings. robert Wilkins In his opening remarks, robert Wilkins, president of Danfoss North America, summed up the challenges facing the HVAC&R industry. “The issues today are important and complex,” he said. “Energy prices have moderated a bit, but the trend continues upward. We have seen the effects of supply interruptions with traditional energy sources, especially those in sensitive or critical parts of the world, and along the U.S. Gulf Coast. “We know change is coming, and that it is required as our nation faces strategic issues related to energy and climate change. The challenge is that change should be well informed, and that we should be well informed about where it will take us, so we can adapt and achieve our business goals.” » VoLuME 8 / IssuE 3 / 2009 72009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=10http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=10CoVER sToRY ConTInuEd Energy efficiency offers enormous potential for savings in all sectors. By capturing the potential available from existing technologies with an internal rate of return of 10 percent or more, we could cut global energy demand growth by half or more over the next 15 years. –Kateri Callahan, president, alliance to save Energy climate change and hfcs: What’s on the horizon? Several symposium speakers expressed optimism that the U.S. Congress will finalize new climate change law before December. The House narrowly passed its version, known as the American Clean Energy and Security Act of 2009 (the Waxman-Markey bill) on June 26. Now, five different Senate committees are drafting pieces of legislation that should come together in a bill by September 28. The bill would then reach the Senate floor in October. On the Senate side, there is strong support for separating control and reduction of HFCs from waste byproduct gases in order to keep costs low and encourage development of alternatives. The Senate energy/climate bill is expected to include a tax title to offset the high cost of energy caused by cap-and-trade. On the international front, industry experts expressed strong belief that the Montreal Protocol may take control of HFCs due to its experience and record of performance in controlling ozone-depleting gases. Because the protocol is focused on production/ consumption, HFCs could still be measured in the “big basket” of gases. Thus countries could get credit for HFC reductions, but HFCs would be administered by the protocol. (Note: on September 15 the U.S. Department of State announced a joint North American proposal between the Governments of the United States, Canada, and Mexico to phase down the use of hydrofluorocarbons (HFCs) under the Montreal Protocol on Substances that Deplete the Ozone Layer). Climate change legislation is important to the HVAC&R industry because it will set guidelines for reducing greenhouse gas emissions and regulating the production and use of refrigerants, including HFCs. Some experts aren’t so sure that Congress can finalize a climate change bill before an international climate change conference scheduled for December in Copenhagen, Denmark. Kevin fay, president of Alcalde & Fay, Arlington, VA, and executive director of the International Climate Change Partnership, noted that 45 senators are believed to be supportive of climate legislation similar to the Waxman-Markey bill. Fifteen more must endorse it to gain passage in the Senate. He pointed out that the Waxman-Markey bill provides a model for international consideration to reduce HFC emissions. For example, it mandates a 33 percent reduction in HFCs from 2005 levels by 2020. If the Senate adopts Waxman-Markey in its entirety, it is projected that the HFC portion of the bill would achieve 16-25 billion tons of CO2e reductions between 2012 and 2050 in the U.S. alone. If this approach were applied globally, Fay believes the HFC portion would achieve a reduction of 3 to 13 billion tons of CO2 per year. 33% 8 senate committee expects investment in clean energy The Senate Energy & Natural Resources Committee’s American Clean Energy Leaders Act (ACELA), now under discussion, would establish a new Clean Energy Deployment Administration. An entity within the Department of Energy, this administration would be responsible for a transmission grid upgrade, an energy efficiency title (both residential and commercial), and a demonstration project for carbon capture and storage technology. In the process, the administration would double the investment in clean-energy research and development. The Waxman-markey bill mandates a 33 percent reduction in hfcs from 2005 levels by 2020. EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=11http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=11u.s. Energy and Environment Legislation climate change and energy conservation are global issues, but proposed measures require action at the national level, such as the new legislation that has passed the U.s. house of representatives and is being worked on in the senate. Below are a few significant developments in U.s. legislation since the clean Air Act. » in 1990 the u.s. Congress enacted the Clean air act amendments. This law defines EPa's responsibilities for protecting and improving the nation's air quality and the stratospheric ozone layer. Legislation passed since then has included several changes. » in 2001, President George w. Bush rejected the Kyoto Protocol to the united nations framework Convention on Climate Change (unfCC), which called for legally binding commitments by developed countries to reduce their greenhouse gas emissions. Instead, the Bush administration decided to focus on reducing the greenhouse gas intensity. » in August 2005, President Bush signed the Energy Policy act of 2005. The act establishes a voluntary national program designed to accelerate demonstration and deployment of less-carbon-intensive technology to encourage voluntary reductions in greenhouse gases. » in January 2006, the department of Energy’s 13 sEER manufacturing standards went into effect. The standard requires that all newly manufactured residential air conditioning units must achieve a seasonal Energy Efficiency Ratio (sEER) of 13 or higher. This is 30 percent higher than the previous 10 sEER standard. » in 2007 Bush signed The Energy Independence and security act of 2007. The purpose of the act is to move the united states toward greater energy independence and security, increase production of renewable fuels, increase energy efficiency of products, buildings, and vehicles, promote research on and deploy greenhouse gas capture and storage, and improve energy performance of the u. s. federal Government. The American energy and security Act of 2009 The u.s. House of Representatives passed the american Clean Energy and security act of 2009 (aCEs), on June 26 by a narrow vote. aCEs includes comprehensive national climate and energy legislation to establish measures to reduce greenhouse gas emissions, a cap-and-trade system and other measures to address climate change and work toward a clean energy economy. now that the House has passed the aCEs, it is in the u.s. senate for consideration. VoLuME 8 / IssuE 3 / 2009 92009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=12http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=12T H E R o a d T o C o P E n H a G E n montreal to fROm 1989 moNTreAL ProTocoL Aims To sToP ozoNe DePLeTioN The Montreal Protocol on substances That deplete the ozone Layer focuses on protecting earth’s protective layer in the stratosphere. The treaty phases out production of numerous substances that cause ozone depletion, including CfCs and HCfCs. It went into force on January 1, 1989. To date, 195 united nations member states have ratified the original Montreal Protocol. 2005 KYoTo ProTocoL focUses oN GreeNhoUse GAses The Kyoto Protocol is a protocol to the united nations framework Convention on Climate Change (unfCCC). This international treaty focuses on stabilizing greenhouse gas concentrations in the atmosphere at a level to prevent dangerous human interference with the climate system. The Kyoto Protocol was adopted at CoP3 in 1997. It requires countries to reduce their emissions, on average, 5.2% below their 1990 baseline through 2012. In all, 183 countries accepted the protocol. The u.s. is a symbolic signatory, but has not ratified Kyoto. 10 EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=13http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=13: a T I M E L I n E ( 1 9 8 9 – 2 0 0 9 ) copenhagen 2009 roAD To coPeNhAGeN Running up to The unfCCC Copenhagen Climate summit (CoP 15) in december, climate change negotiations were held in Bonn, Germany, March 29 to april 8. The Bonn discussions centered on what industrialized countries should do to cut greenhouse gas emissions and quantify emissions reductions. one more session will be held in Bangkok in september–october. additional meeting time before Copenhagen might be made if necessary. In July, 2009, delegates from about 190 parties of the 2007 Montreal Protocol met in Geneva, switzerland, to discuss limiting the use of HfCs. although a proposal for phasedown of HfCs was put on the table, many parties were reluctant to support it, because HfCs are included in the basket of greenhouse gases being considered under the upcoming climate negotiations in Copenhagen. The parties to the Montreal Protocol plan to meet again in Egypt in november. The aspiration for The Copenhagen Climate summit (unfCCC CoP15) in december 2009 includes greater global alignment on a new protocol to take effect after Kyoto ends in 2012. UNiTeD NATioNs cLimATe chANGe coNfereNce iN BALi The united nations Climate Change Conference took place in Indonesia, in december 2007. Representatives from over 180 countries attended. The Bali conference included meetings of several bodies, including the 13th Conference of the Parties to the unfCCC (CoP 13), the 3rd Meeting of the Parties to the Kyoto Protocol, and other bodies and a meeting of ministers. a meeting of environment ministers and experts held in June called on the conference to agree on ”The Bali Roadmap,” a timetable and concrete steps for the negotiations to work towards an agreement in Copenhagen in 2009. VoLuME 8 / IssuE 3 / 2009 112009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=14http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=14A p p l i c At i o n H i g H l i g H t AB-QM Valve Helps Designers optimize System performance You wouldn’t think that the topic of control valves would elicit much discussion or thought these days. After all, control valves have been around for a long time. there are many rules of thumb on how to apply them, and the engineering is well understood. So why would a control valve be perceived as “new and improved?” When the HVAc industry started broadly applying variable speed drives to pumps, application guidance on control valves and balancing wasn’t as well understood as it is today. the additional controls and function of a pump’s speed drive subtly changed control system operation, making attached heating and cooling systems less controllable—and often negatively impacting their energy efficiency. the Danfoss AB-QM control valve solves these problems and helps substantially restore control, comfort and energy efficiency back to variable speed, variable-flow pumping systems used in HVAc. Historically, conventional control and balancing valves relied on a number of design calculations applied by engineers. For example, when control valves operated, reducing flow, the pumps that provided the required water flow either stayed at the same pressure or increased slightly. to an engineer, examining the pump characteristic curve implied how the control valves worked and interacted. Wide application of variable speed drives on pumps in the 1990s led to a number of technical debates about system operation, with many opinions on hydronic system operation. it was clear that things didn’t work the way they used to— before the drive was applied. As control valves reduce flow, the drive slows the pump speed, lowering system pressure as a result. that’s opposite of the former pump and valve operation. the change in system pressure alters how a temperature controller regulates the valve. in constant-speed pumps with standard valves, the controller “thinks” that as it opens and closes the valve, it always has a linear proportion of heating or cooling. Fifty percent open would mean 50 percent of the total capacity for heating or cooling the “old” way. When a variable speed drive is connected to the pump, the amount of heat transfer controlled through the valve changes for each pump-speed adjustment. the temperature controller needs extra functionality to restore the heat transfer response to the same level it was in the constant-speed pump. the AB-QM solves this problem by integrating a differential pressure control regulator with a temperature control valve in the same body. this simple feature stabilizes pressure to the control valve, restoring the predictable nature back to the valve, regardless of pump speed. the pump only needs to produce the minimum required pressure for the valve to operate, just as pumps are currently controlled with variable speed drives. in addition to allowing the temperature controller to work as intended, the unique user adjustment of the ABQM valve allows it to control2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=15http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=15aB-QM VaLVE Vs. ConVEnTIonaL VaLVE PERfoRManCE the exact flow required for each individual coil. This is the balancing feature that requires a separate balancing valve in other system designs. while the aB-QM replaces the balancing valve, thereby reducing system cost, it provides differential pressure control—something the separate balancing valve cannot provide. The aB-QM also enhances functionality. Because it works over a specific flow range, it’s easy for commissioning personnel to reset the valve flow rate. It’s also much easier for commissioning personnel to tune their temperature controls as they know exactly what flow they’ll get for every volt of their output control signal. Bottom line, a control valve is a simple device that requires a lot of engineering skill to be properly applied. To an owner or an occupant, all they want is to remain comfortable—and keep their utility bills as low as possible. using an aB-QM temperature control valve gives designers the assurance and functionality they need to make their system perform in the most optimal way. That makes a hydronic system using the valve, coupled with variable speed pumps using danfoss drives, a tremendous technique for saving energy and being green. owners will be happy, too, because the “green” they’ll see is the color of money saved. 45% 50% 58% 9 1/2" d 9" 8 1/2" 55% 120 30% 40% 63 % 58 % 60 % 58 % 55 % 100 dIffEREnTIaL PREssuRE (fEET of HEad) 80 8" 7 1/2" 60 7" 11 /2 hP 50 P 3h % P 5H 40 P 2H 20 1/4 HP 0 0 20 40 60 80 100 120 140 160 180 fLow RaTE (GaLLons PER MInuTE) 100% LoAD (Control signal) fLoW reQUireD coNVeNTioNAL VALVe AB-Qm needs 10 GPM 10 GPM 10 GPM 10 GPM 74% LoAD (Control signal) fLoW reQUireD Gets coNVeNTioNAL VALVe AB-Qm needs Gets 4 GPM 3 GPM 4 GPM 4 GPM 37% LoAD (Control signal) fLoW reQUireD coNVeNTioNAL VALVe AB-Qm needs Gets 1 GPM .4 GPM 1 GPM 1 GPM foR MoRE InfoRMaTIon: contact 905-285-2050 www.ABQM.us How the AB-QM affects the operation of the system can be seen by looking at how the pump (grey line) works with the system (red line) to save energy and keep control. As pump speed reduces, horsepower is reduced (blue line) saving energy. The AB-QM does this while giving the precise flow necessary for control. A conventional valve, though, does not reduce the flow in the manner called for by the controller. At 74% Load, the controller needs to get 4 GPM, and the valve can only deliver 3 GPM. When that happens, the controller will begin to cycle looking for the right flow and will start endlessly opening and closing the valve. This wastes energy and affects comfort control.2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=16http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=16CasE sTudY onE a C R E aT I V E R E T R o f I T » uses oil-free danfoss Turbocor compressor » re-uses existing components for significant cost savings » conversion from ozone-depleting R-22 to non-ozone depleting R-134a oUTsiDe The Box M a C Y ’ s R E C E n T LY C o M P L E T E d a major store remodel in Walnut Creek, California, that merged three independent buildings into a single new facility. While the new department store looked great, the existing R-22 reciprocating compressors had become an unreliable maintenance and energy expense—negatively impacting the profitability and performance of this otherwise revitalized retail outlet. Macy’s consultants proposed traditional replacement options that ranged from new rooftop package units to an expensive chilled water central plant. However, a down economy and an already tight retail market encouraged one of America’s oldest, most famous retailers to explore new, cutting-edge air conditioning solutions instead. Big box retailer goes system Variety is a challenge Each original building had a separate air conditioning system, and different sites had different air conditioning loads—some equipment was evaporative-cooled and some was air-cooled. The only common denominator was that all of the HVAC units were direct expansion (DX) units operating on a common refrigerant. On the surface, replacement seemed to be the only available option—but the Danfoss Turbocor retrofit specialists at American Chiller Services, from Rancho Cordova, California, knew better. old hVAc systems Yield New opportunities When American Chiller’s design team arrived at the Walnut Creek Macy’s, they found that the center building was air conditioned by an 80-ton rooftop evaporative-cooled DX packaged unit, the building to the north was air conditioned 14 EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=17http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=17by two 30-ton evaporative-cooled rooftop DX packaged units, and the south building was air conditioned by three rooftop air-cooled package units totaling 80 tons. The total installed capacity for the original equipment serving all three of the sites was 220 tons. There appeared to be no conventional design approach that could consolidate this collage of HVAC equipment into a single system in a costeffective manner. A down economy and an already tight retail market encouraged one of America’s oldest, most famous retailers to explore new, cutting-edge air conditioning solutions. were fitted with new high-efficiency variable frequency drives (VFDs), compatible fan motors, and new digital controllers. Each digital controller was tied into a central energy management system (EMS) that controls the operation of the new variable refrigerant flow central plant, located on the roof of the middle building. As the air conditioning load increases or decreases, the Danfoss Turbocor compressors either increase or decrease the refrigerant flow to precisely meet the requirements of the new integrated system. Going outside the Box In this case, a down business environment and an emerging new “green economy” led to some out-of-the-box thinking. After several brainstorming sessions, a truly innovative system design began to take shape. The engineers at American Chiller Services discovered that this variety of HVAC systems could be linked with a unique retrofit design, using the DX refrigeration systems common to all of the newly connected buildings, and the energy-efficient Danfoss Turbocor compressor as a centerpiece. The new system would consist of a central station Variable Refrigerant Flow plant that would pump non-ozone depleting R-134a refrigerant to the existing units, which could now remain in place. creative retrofit Provides Unique Benefits The key ingredient in this unique retrofit prescription was the Danfoss Turbocor compressor—its oil-free design opened the door to a previously impossible retrofit solution. Some additional benefits of this project included: » significant cost savings through the reuse of existing components. » Conversion from ozone-depleting R-22 to non-ozone depleting R-134a. » successful completion of the project without major prolonged cooling disruptions. » substantial savings in both maintenance and repair costs due to the central plant design and the oil-free danfoss Turbocor compressors. » Quiet, vibration-free operation due to magnetic levitation compressor technology. » Readily accessible operational documentation and energy savings by the Energy Management system using the compressor’s on-board software. Variable refrigerant flow (Vrf) Macy’s Corporate Energy Manager completed a peak load analysis for the new facility based upon reduced loads that were the product of re-lamping and other energy measures incorporated into the remodel project. That study determined that the new cooling load had been reduced from 220 to 180 tons. All of the existing compressors were removed and the 80ton evaporative-cooled package unit that was located on the middle building was modified to become the central refrigerant plant while retaining its ability to cool the middle building. It was retrofitted with two Danfoss Turbocor TT-300/R-134a compact 90-ton compressors in the space currently occupied by two 40-ton reciprocating compressors. The existing evaporative condenser was replaced with a larger 180-ton unit, while headers fashioned with stub-outs were piped to the two outer buildings, which would provide refrigerant flow to the north and south air conditioning units. All of the existing package units were modified to become DX air handling units. The existing thermal expansion valves were converted to new-age electronic expansion valves, to insure precise refrigerant control at the coils. All of the air handlers macy’s realizes major savings The new variable refrigerant flow system is being eagerly monitored by the loca2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=18http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=18CasE sTudY T wo aMMonIa/Co2 BRInE sYsTEM » provides 200 tons of refrigeration affordably and efficiently » offers the efficiency of an ammonia-based system with the safety of pumping cooled Co2 » easy to install and program iNDUsTriAL refriGerATioN AmmoNiA/co2 BriNe sYsTem E x Pa n s I o n B R I n G s w I T H I T o P P o R T u n I T I E s and challenges—opportunities to grow and provide better customer service, and the challenge to do so affordably and in a way that does not significantly impact the environment. The people at Flanagan Foodservice, Inc. should know. The broad line foodservice distributor recently completed a 65,000-square-foot expansion of its Kitchener, Ontario, Canada, facility, increasing the size of the structure by 50 percent. Most of the 65,000 square foot expansion is a state-of-the-art freezer that uses technology developed and implemented in Japan, but never before built in Canada. Flanagan Foodservice caters primarily to restaurants, including quick-serve restaurants, fine-dining establishments and everything in between. Its list of more than 5,000 customers also includes bakeries, donut shops and healthcare and institutional facilities. Flanagan’s 32-year history is matched by 32 consecutive years of growth. “With a track record like that, it’s natural to anticipate continued growth,” said Rick Flanagan, executive vice president at the company. “However, we were at capacity in our old facility and unable to add new customers and new product lines in our building footprint. In order to continue to grow and invest in our future, we needed additional warehouse space.” Foodservice Company pioneers Canada’s First 16 EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=19http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=19The expanded warehouse opened in April and brings the facility to 200,000 square feet. Because much of the company’s business is in the frozen food area, the addition was used to double the size of the facility’s freezer space to 50,000 square feet, including 45,000 square feet of regular freezer space and 5,000 square feet of ice cream freezer space. An additional 10,000 square feet of cool dock and 5,000 square feet of refrigerated storage completed the expansion. The original facility relied on a Freon-based system to provide 163 tons of refrigeration and maintain temperatures as low as 4 degrees Fahrenheit in the regular freezer and minus 20 degrees Fahrenheit in the ice cream freezer. “As we considered a system that would serve a new, larger facility, the low initial first cost of the Freon system certainly appealed to us,” recalled Flanagan. “But a Freon-based system is neither ozone-friendly nor efficient, and it doesn’t last long. We also discovered that as the system ages, leaks occur, making an already inefficient system even more expensive to operate.” So, the search was on for an alternative refrigeration system that could provide as much as 200 tons of refrigeration—and do so efficiently, affordably and in an environmentally responsible way. An ammonia-based system offered the efficiency the company sought. But Flanagan was concerned with the risk of a leak or an accident. Instead, the company turned to what Flanagan described as “an exciting new technology that represents the best of both worlds”—a dual-temperature ammonia/CO2 brine refrigeration packaged system supplied by Mycom Canada, the Canadian arm of Japanesebased Mayekawa, which supplies compressors to the industrial refrigeration market. “However, as a large equipment manufacturer, we do more than that,” explained Len Puhacz, manager of green technology projects for Mycom Canada. “We provide solutions that help food producers and others in the industrial market meet their refrigeration needs.” The solution Mycom offered Flanagan uses ammonia in two large, insulated compressors that are isolated in an enclosed space. The compressors cool CO2, which is then pumped into those areas of the building that require refrigeration, significantly reducing the ammonia charge the warehouse holds. “As a result, Flanagan enjoys the cost benefit derived from the efficiency of ammonia and feels comfortable knowing they are pumping CO2, and not ammonia, into their building,” said Puhacz. Before the Canadian B52 code was amended (even prior to the system design and commissioning), it allowed CO2—as long as the system was designed to ambient condensing pressures of 1,100 psig, which is not practical in industrial refrigeration. Mayekawa designed a system that could safely operate at a maximum of 600 psig, which satisfied Canadian authorities. Critical to the success of this new system is a solution from Danfoss. Danfoss supplied the ICF valve stations that feed CO2 to the evaporators, flooded shell and the tube » VoLuME 8 / IssuE 3 / 2009 172009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=20http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=20CasE sTudY T wo ConTInuEd ammonia/CO2 exchangers. Danfoss also supplied variable frequency drives (VFDs) and pressure transmitters that run the NH3 assembly. The single, one-piece ICF valve station provides ports for up to six function device modules that are configured specifically for a customer’s application and shipped to a jobsite as a complete subassembly, ready for installation into the jobsite piping or into the OEM’s products. “It’s really quite simple to install, requiring just two welds,” said Hernan Hidalgo, key account manager for Danfoss. “Without the ICF valve station, you would need to use individual components, requiring multiple welds and additional installation time— sometimes as much as five times longer. As a result, instead of a one-hour installation, you’re looking at a job that takes as much as a day to complete when individual components are used. And because the ICF is a factory-ready block, it reduces the potential for leaks that occur as the result of flanges or welds, and improves system reliability.” The valve station also features a high-design working pressure of 754 psig, making it suitable for use with high-pressure refrigerants like CO2. “In fact, we used the ICF valve station for both the ammonia feed and the CO2 feed,” said Puhacz. “The ability of the module to adapt to both configurations is amazing.” The Danfoss VFDs in the ammonia/CO2 system are equally impressive. Danfoss provided four 100 HP, 575-volt drives that vary the speed of each of the compressors. “When you vary the speed, you can achieve significant energy savings,” said Hidalgo. “Additionally, the drives are easy to program and interface with the local programmable logic controller.” Quinn Vo, Mayekawa corporate engineer, agreed. “The programming is very user-friendly,” he said. “The keypads are transferrable from drive to drive, so once you program one, you can move the keypad to another drive and download the settings, saving time in the process.” Vo, Puhacz and others at Mayekawa are familiar with these and other advantages Danfoss brings to their solutions. The two companies share a history that spans at least 12 years of successful partnering. “We’ve got faith in Danfoss. The company offers a good product, and this is certainly important to us,” said Puhacz. “But just as important are the knowledge and experience they bring to a project. With Danfoss, we get both a quality product and quality support.” Meanwhile, Flanagan receives a system that meets its needs for efficiency and affordability while operating in a safe, environmentally responsible way. “We’re looking at a payback for this system of about 6.6 years thanks to the energy savings it offers,” said Flanagan. “And it’s an environmentally friendly system that will reduce our carbon footprint and eliminate safety risks to our employees and the products we warehouse. When you put all of that together, it’s definitely clear that the ammonia/CO2 system is a win for us.” Because the ICF is a factory-ready block, it reduces the potential for leaks that occur as the result of flanges or welds, and improves system reliability. 18 EnVIsIonEERInG soLuTIons2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=21http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=21PRoduCT HIGHLIGHT World’s smallest Programmable Controller The mcx controller provides ultimate software control for a wide range of industrial and hVAc&r applications. The open standards-compliant controller adds a new level of flexibility and control for application designers, allowing them to adapt electronics to the application and not vice versa. as a result, system performance can be tailored to exact requirements. The MCX controller provides ultimate software control for a wide range of industrial and HVAC&R applications. The easy-to-program unit uses a “C”-like programming language, providing unique versatility and freedom compared to proprietary systems. with the standard software libraries, designers can focus on the application, their intellectual properties and time to market. In addition, the MCx controller features a high-end design with a flexible graphical display. foR MoRE InfoRMaTIon: contact 410-931-8250 baltimore@danfoss.com Danfoss customers help shape new MBs 1900 Range The Danfoss mBs 1900 is a direct result of listening and responding to specific customer requirements. Recognizing product shortcomings, upgrading existing products and designing new product ranges help build an attractive product portfolio. and in today’s highly competitive business environment, being a worldwide business partner to major oEM customers requires a solid portfolio of quality products. business sectors. These new products have now passed all design, validation and production requirements – and a number of key oEMs around the world are currently putting the MBs 1900 range to the test. More importantly, following the recent, full production release of the product range, advance orders for MBs1900 are now being fulfilled. so what makes the MBs 1900 pressure transmitter range so good? for one, it’s designed to meet the demanding performance criteria of two key applications – air and water. also, because the technical design is based on tried and tested technology, it works. Key components have been in use in other product series for many years, so typical risks associated with new product launches are significantly reduced. and with a unit price that makes it very competitive, it can’t be overlooked. The danfoss portfolio also includes other products of great interest to air and water customers, such as temperature sensors, solenoid valves, heat exchangers and on/off products. The mBs 1900 story The MBs 1900 range is specifically designed to meet the demanding technical and commercial requirements of key oEM players in these strategically important foR MoRE InfoRMaTIon: contact 410-931-8250 baltimore@danfoss.com2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=22http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=22PRoduCT HIGHLIGHT Danfoss introduces new scroll Compressor series Danfoss introduces the new Performer HCJ Series scroll compressors for light-commercial and commercial air conditioning applications. This new range of compressors is designed with several patented features, making them the lightest, most compact scroll compressors in their capacity range, and the most compact compressors in the industry. These features include: » A patented hybrid wrap scroll that allows more capacity in less space » Ductile iron scrolls and a patented carbon main bearing for enhanced reliability » A patented lower bearing ring and integrated stamped oil pan that contribute to the lowest compressor vibrations of any comparably sized compressor “The new compressors provide the best value in terms of both cost and energy efficiency for manufacturers and end-users,” says Manohar Reddy, global marketing product manager for Danfoss. “We decreased the weight and size of the equipment to reduce costs for the manufacturer; and we made the compressor even stronger and more reliable.” » An optimized motor design that offers the competitive performance to address needs for increased energy efficiency The Performer HCJ series scroll compressors are suitable for any R-410a air conditioning application and are available in 7.5 TR, 9.0 TR and 10.0 TR capacities in all global voltages. foR MoRE InfoRMaTIon: contact 410-931-8250 baltimore@danfoss.com2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=23http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=23suBsCRIBE subscribe today by emailing solutions@danfoss.com to Solutions Today, technology is facing higher energy, environmental, and application demands that are putting pressure on how products and systems are designed and manufactured. In turn, engineering is being called upon for new concepts, technologies, and solutions, often provided by teams working collaboratively across disciplines and across geographic boundaries. EnVisioneeringsM Solutions tracks the latest innovations and provides up-to-date industry news. Subscribe to EnVisioneering Solutions by sending your full name and address to solutions@danfoss.com ENGInEERInG + ENERGY EffICIEnCY + ENVIRonMEnT = ENVISIONEERING2009-10-20T21:05:42+02:00http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=24http://nozebra.ipapercms.dk/Danfoss/RA/Solutions/US/SolutionsVol8Issue3/?Page=24DANfoss LocATioNs BALTimore, mD 11655 Crossroads Circle Baltimore, Md 21220 410-931-8250 / fax: 410-931-8256 www.danfoss.us » Refrigeration & air Conditioning » Industrial Controls » Heating Controls: 443-512-0266 fax: 443-512-0270 TALLAhAssee, fL danfoss Turbocor 1769 E. Paul dirac drive Tallahassee, fL 32310 850-504-4800 / fax: 850-504-0280 www.turbocor.com » oil-free Compressors for Refrigeration and air Conditioning GLeNs fALLs, NY danfoss flomatic Valves 15 Pryun’s Island drive Glens falls, nY 12801 800-833-2040 / fax: 800-314-3155 E-Mail: flomatic@flomatic.com www.danfossflomatic.com » water Controls LoVes PArK, iL 4401 n. Bell school Road Loves Park, IL 61111 815-639-8600 / fax: 815-639-8000 www.danfossdrives.com » drives miLWAUKee, Wi 8800 w. Bradley Road Milwaukee, wI 53224 414-355-8800 / fax: 414-355-6117 www.danfossdrives.com » drives » nessie High Pressure water systems mississAUGA, oNT 6711 Mississauga Rd., suite 410 Mississauga, ontario L5n 2w3 905-285-2050 / fax: 905-285-2055 www.na.heating.danfoss.com » Heating Controls » Motion Controls moUNTAiNsiDe, NJ danfoss Hago, Inc. 1120 Globe ave. Mountainside, nJ 07092 908-232-8687 / fax: 908-232-7246 www.hagonozzle.com » Components for oil Burners somerseT, NJ danfoss Bauer 31 schoolhouse Road somerset, nJ 08873 732-469-8770 / fax: 732-469-8773 www.danfoss.com » Geared Motors w w w . d a n f o s s . u s 2009 Calendar of Events sEPTEMBER 2009 » remodeling show » NecA september 12–15, 2009 washington state Convention and Trade Center, seattle, wa Visit Danfoss at booth #727 services conference september 13–16, 2009 Hyatt Grand Champion Resort & spa Palm springs, Ca october 28–30, 2009 Indiana Convention Center Indianapolis, Indiana october 31–November 3, 2009 Jw Marriott orlando Grand Lakes, orlando » hArDi 2009 » fmi energy & Technical noVEMBER 2009 » Ahri Annual meeting oCToBER 2009 » WefTec 09 November 15–17, 2009 washington dC state of the industry November 18, 2009 october 10–14, 2009 orange County Convention Center orlando, florida october 13–16, 2009 Monterey Conference Center Monterey, Ca Visit Danfoss at booth #418 october 27–30, 2009 Hilton Minneapolis/st Paul airport Mall of america Hotel Minneapolis/st. Paul » enVisioneering symposium: » reTA 2009 dECEMBER 2009 » construct canada » rses Annual conference December 2–4, 2009 Metro Toronto Convention Centre Toronto, Canada Visit Danfoss at booth #820 Keep up-to-date on the latest news about Danfoss products and your industry at www.danfoss.us To find out more about Danfoss North America, contact us via email: solutions@danfoss.com2009-10-20T21:05:42+02:00