Utilizing Digital Retrofits to Achieve Capacity Modulatione2%80%8butili… · • Copeland™...
Transcript of Utilizing Digital Retrofits to Achieve Capacity Modulatione2%80%8butili… · • Copeland™...
Utilizing Digital Retrofits to Achieve Capacity ModulationE360 Webinar • September 26, 2017
Chris RaffelLead Application EngineerEmerson
Speaker
2
Chris RaffelLead Application EngineerEmerson
Chris Raffel has spent his entire 33-year career with Emerson. He started with the company in 1984 as a product evaluation/applied mechanics technician. Afterward, he worked as a product evaluation/multi-area technician before moving onto positions such as: project technician/group leader; reciprocating engineering senior project coordinator; new product launch application engineer; lead sales engineer; and lab operations manager before accepting his current role as lead application engineer.
His various experiences within the company have allowed him opportunities to work in: product research and performance testing; field support and training for end users, OEM customers and contractors; and technical and sales support.
He is a graduate of Rets Tech Center in Centerville, Ohio.
Goals for Today’s Discussion
• Digital Operation
• Supermarket Rack Upgrade — Selecting the Right Compressor
• Supermarket Digital Upgrade — Energy Study
• Questions
3
Refrigeration Industry Trends
• Retrofitting existing R-22 and R-404 systems with 448/449
• Merchandising upgrades based on efficiency and flexibility
• Desire to maintain more consistent product temperature
• Pressure to reduce spoilage
• Improve energy efficiency and system reliability
• Shortage of time and qualified technicians to complete retrofit plans
4
What Is Digital?
• Copeland™ digital technology is fundamentally different from inverter-based modulation.
• The capacity modulation of the digital compressor is achieved by averaging the time between a “loaded state” and “unloaded state”.
• It is unique, reliable and very simple to apply.
Digital Discus™Digital Scroll™
5
How Does Digital Discus Work?
6
Digital Valve De-Energized Digital Valve Energized
How Digital Scroll Works
7
Digital valve opens, allowing discharge gas to:
Poll Question
• Have you used digital modulation?
– Yes
– No
8
Supermarket Racks/Foodservice
Walk-in Coolers/FreezersRefrigerated Warehousing
Commercial AC Systems
Process Chillers/Air Dryers
What Types of Systems Can I Upgrade to Digital?
9
Why Include Digital in Your Refrigeration Retrofit and Remodel Projects?
• Reduces compressor cycling
• Increases contactor life/system reliability
• Improves system load match capability
• Improves suction setpoint range
• Improves energy efficiency
• In some cases, suction setpoints are lowered to compensate for swings in suction pressure due to compressor cycling. By increasing the suction setpoint, an energy savings can be achieved.
• For every 1 PSI increase in suction pressure, compressor power is reduced by approximately 2 percent.
• Up to 30 percent more efficient than using hot-gas bypass
10
11
Significant Part-Load Efficiency Improvement With Copeland Scroll Digital
Digital Scroll vs. Hot Gas Bypass Efficiency Comparison
Goals for Today’s Discussion
• Digital Operation
• Supermarket Rack Upgrade — Selecting the Right Compressor
• Supermarket Digital Upgrade — Energy Study
• Questions
12
Poll Question
• Are you specifying modulation on rack selection or remodel projects? If so, what method?
– Not using modulation
– Hot gas bypass
– Digital
– Variable speed
13
Supermarket Rack UpgradeSelecting the Correct Compressor
14
Digital Leads to Paradigm Shift in Rack Design
15 15 8 5 3
6D 6D 4D 3D 2D
46 hp
Rack A, Traditional Configuration – Actual Store
15 12.5 12.5 6
6D 4D4D 3D
46 hp
Digital
Rack A, Configuration With Digital – Actual Store
• 50% capacity unloading• Poor load matching• Significant compressor cycling• High in-rush current
• Increased steps of unloading• Better load matching• More compressors needed• Increased equipment costs
• Variable unloading up to 90%• Excellent load matching• Reduced number of compressors• Lower capital equipment costs
Early Rack Configurations
23 23
46 hp
15
Evaluating Existing Racks for Digital Retrofit
4D 4D 4D 3D
Existing Rack for Digital Retrofit
*Be aware of other compressors sharing the same suction group.
180,000 BTU
180,000 BTU
180,000 BTU
100,000 BTU
4D 4D 4D 3D
Digital Retrofit, No Evaluation
180,000 BTU
180,000 BTU
180,000 BTU
100,000 to10,000
UNL
4D 4D 4D 3D
Digital Retrofit With Evaluation
180,000 BTU
180,000 BTU
90,00090,000
100,000 to10,000
Traditionalunloading creates capacity gaps
Digital retrofitimproperly applied increases cycling
Digital retrofitproperly applied reduces cycling
DGTL
DGTL
16
Supermarket Applications — Digital Upgrade MT Rack
Significant and immediate reduction in compressor cycling
Digital Discus activated
72 psi 8 psi
Digital retrofit
89% reductionin suction
pressure range
2D
3D
6D From 900 starts per day to 12 starts in four days
17
Dairy Case With Discus Digital Activated
Case Temperature Range Narrows Significantly
ProductDegradation
ExcessiveOperating Costs
DigitalProductIntegrity
15 0F
1.25
0F
Case temperature fluctuations reduced
90% to 1¼ 0 °F
Copeland Digital Discus activated
18
Goals for Today’s Discussion
• Digital Operation
• Supermarket Rack Upgrade — Selecting the Right Compressor
• Supermarket Digital Upgrade — Energy Study
• Questions
19
Poll Question
• Have you been involved in energy improvement projects? If so, what were the results?
– Not involved
– Negative results
– Break-even results
– Excellent results
20
Supermarket Digital UpgradeEnergy Study
21
Digital Discus Compressor Upgrade Measurement and Verification
22
Overview:• 20-year-old, 45,000 sq. ft. grocery located in southwestern Ontario
• Medium- and low-temperature centralized rack system
• System (total 164 hp) operates with 10 semi-hermetic Copeland compressors
Objective:• Analyze the energy impact of the medium- and
low-temperature racks of retrofitting one compressor on each to a Digital Discus compressor
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
23
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
24
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
25
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
26
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
27
Questions?
DISCLAIMERAlthough all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated herein or that other measures may not be required.
Thank You!
28