E360 Outlook Volume 2 Number 1 1

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Volume 2 Number 1 P. 8The pros and cons for wider adoption of low-GWP R-290

P. 10 Southern supermarket deploys its first CO2 transcritical booster system

P. 14Incentivized efficiency upgrades deliver measurable energy savings for Canadian grocer

OutlookBalancing All Aspects of the Commercial Refrigeration and Air Conditioning Industries

HFC-134a R-407C R-410A

Phased OutEPA Publishes Final Rule on Refrigerant DelistingPAGE 2

2 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 1

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From its inception, our E360 initiative was designed to facilitate a

dialogue in the refrigeration and air conditioning industries to address

the many issues we’re facing. Our E360 Forums and Webinars have

fueled conversations that have helped achieve consensus and gain clarity

on our most pressing questions.

This publication is a product of those important discussions, as the

many concepts, relevant technologies and insights make their way into

these pages.

But we need to create more opportunities for dialogue, and keep

the conversations going long after our scheduled events have ended. To

help make that a possibility, we’ve created a LinkedIn group for E360.

The main objective of the E360 LinkedIn group is to support

ongoing industry discussions throughout the year. In doing so, we’ll be

able to better identify the topics that are most important to you and the

industry. Our objective will be to offer our insights whenever possible

and potentially expand on these topics more fully in future Webinars or

roundtable discussions. In addition, our new E360 LinkedIn group will

serve many purposes:

• Aggregate all social posts related to E360

• Allow all content developed under the E360 umbrella to be shared

within LinkedIn

• Offer needed perspectives and insights on pending DOE and

EPA rulings

• Expand the industry’s knowledge base by inviting experts

to participate

The next few years will be filled with challenges as we come to

terms with the regulations and determine a path forward that works for

all links in the commercial refrigeration value chain.

We hope you’ll join our new E360 LinkedIn group (linkd.in/1J2hXUr), jump

into the conversation and make the most of this opportunity to set a

course for the future of refrigeration.

F I R S T WO R D

E360 Is Going Social

by D O N N E W LO N

CO N T E N T S

1 First Word BY DON NEWLON

E360 is going social

2 F E ATURE

Delist, Delay, Decipher BY DR. RAJAN RAJENDRAN

Coming to terms with the EPA’s rulings

8 The Case for R-290 Reviewing the pros and cons for wider

adoption of this natural refrigerant

10 SU C C E SS S TO RY

National Grocery Store Chain Makes Transition to Transcritical Refrigeration Atlanta supermarket deploys its first CO2 transcritical booster system

14 SU C C E SS S TO RY

A Cool Chunk of Change Incentivized efficiency upgrades deliver measurable energy savings for grocer

16 Regulatory Compliance

BY KURT KNAPKE

Achieving compliance is our top priority

18 Solution Spotlight Variable capacity modulation goes digital

20 E360 Forum and Industry Events

21 E360 Webinar Series

Publisher

Emerson Climate Technologies

Managing Editor

Don Newlon

Email Us

Please email us at e360.climate@emerson.com

with any comments or suggestions. We would

love to hear from you.

Website

EmersonClimate.com/E360

Don Newlon

Managing Editor, E360 Outlook

V.P., Refrigeration Marketing; G.M., Integrated Products Division, Emerson Climate Technologies

For two years, the commercial refrigeration industry has

been reeling from a one-two regulatory punch from the

Department of Energy and the Environmental Protection

Agency. This convergence of aggressive regulations was

unprecedented for our industry.

It has forced us to explore every possibility to engineer the

next generation of refrigeration systems — those that are capable of

achieving new levels of energy efficiency while using an emerging

class of eco-friendly refrigerants.

Not only has this process consumed much of our efforts

here at Emerson Climate Technologies, it’s also been the topic of

discussion and debate throughout the industry. It was partly the

reason why we launched our E360 platform last year: to provide a

forum for these important conversations to take place and help the

industry achieve consensus on our approach to these regulations.

Given the complexity of the industry and the broad range

of segments affected, there’s no question the final rulings are

challenging to digest.

While the rulings do indicate some responsiveness to the

industry’s collective comments and concerns — such as slight timing

delays and some application-specific concessions — the larger time

frame and the targets set forth are still very aggressive.

But now that the rulings are final, the industry begins the

“action” phase of this transition. This is where the rubber meets

the road.

Now’s the time for us to translate our proof-of-concept

designs into tangible courses of action that lead us on the best path

forward. The dialogue will certainly continue, but now it will be

more focused on identifying the specific solutions that will take us

into the future of commercial refrigeration.

More than ever, we will still need the combined input and

knowledge of all industry constituencies. We’ll need to understand

the efforts required by everyone in the value chain and agree on a

direction that works for all parties.

There are still many questions and moving pieces in this

process, and it may take a while for the dust to settle. But from a big

picture perspective, the time to start putting plans into action is now.

The Rubber Meets the Road

By John Rhodes

President, RefrigerationEmerson Climate Technologies

Final rulings signify start of next phase of transition

2 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 3

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HFC-134a R-410A R-407AR-407A HFC-134aR-407C R-410A

2 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 3

Delist, Delay, DecipherComing to terms with the EPA’s refrigerant rulings

Dr. Rajan Rajendran, Vice President of System Innovation Center and Sustainability for Emerson Climate Technologies, is one of the most respected, global authorities on refrigerants, particularly in commercial refrigeration applications. In this article, he explores the implications of the EPA’s final rule on refrigerant delisting and discusses likely replacement alternatives.

4 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 5

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If you’re in the commercial refrigeration

business, you’ve witnessed a turbulent

regulatory environment over the last

few years. Some, me included, have

even referred to it as a perfect storm. The

Environmental Protection Agency’s (EPA)

recent Significant New Alternatives Policy

(SNAP) refrigerant delisting rule (Federal

Register Vol. 80 No. 138, July 20, 2015,

42870-42959) is fresh in our minds,

but it comes within a broader context of

other significant rulings.

At the eye of the storm you’ll find two

primary issues: refrigerants and energy

efficiency. Competing for our undivided

attention are the EPA’s recent SNAP rulings

and the Department of Energy’s (DOE)

energy efficiency mandates — all of which

have major implications to our industry.

The EPA’s moves are just the most

recent steps the agency has made under

the authority of the Clean Air Act (CAA),

a law enacted by Congress in 1970 to

limit air pollutants. Public awareness

of environmental concerns grew in the

1990s when scientific evidence of ozone

depletion brought the dangers associated

with aerosols and refrigerants to light.

The ozone depletion potential (ODP)

of these substances became the subject

of the Montreal Protocol, an international

treaty proposed in the 1990s to phase out

and ultimately ban refrigerants based on

chlorofluorocarbon (CFC) and hydrochlo-

rofluorocarbon (HCFC) compounds. ODP

also became one of the EPA’s criterion

used to evaluate a refrigerant’s potential

risk to the environment.

Today, as environmental focus has

grown to include global warming concerns,

the EPA has also added global warming

potential (GWP) as another important

environmental indicator.

There are many sources of chemicals

and pollutants that could lead to climate

change, but hydrofluorocarbon (HFC)

refrigerants have the greatest impact on

our industry. High-GWP HFCs like R-404A

have been the target of regulations all

around the globe; here in the U.S., the EPA

has spearheaded the effort to reduce the

use of these HFCs.

It’s Official: The SNAP Refrigerant

Delisting Is Final

Let’s start with a closer look at the EPA’s

recent SNAP delisting ruling and explore

what it means to our industry. When

the original proposal was published on

August 6, 2014, it created quite a stir in

commercial refrigeration. Among other

things, it proposed changing the status

of three of the most commonly used

refrigerants: R-404A, R-507A and HFC-134a,

all typically found in stand-alone, reach-in

and walk-in units, as well as traditional

rack refrigeration systems.

The industry as a whole responded

with resounding calls for caution via the

EPA’s NOPR (Notice of Public Rulemaking)

commenting process. In addition to

numerous private companies like Emerson

Climate Technologies, industry associa-

tions such as the American Heating and

Refrigeration Institute (AHRI) and the

North American Association of Food

Service Manufacturers (NAFEM) submitted

comments to the public record.

Earlier this summer, AHRI (with me

as a delegate) was invited to discuss the

potential ramifications of this ruling with

the Office of Management and Budget

(OMB) of the White House. They were

well-informed on the complexity of the

issues at hand and listened intently to our

concerns. In addition, Emerson Climate

Technologies and other industry constit-

uents participated in many EPA meetings

leading up to this ruling, and have had

many conversations with policy makers to

voice our concerns and opinions.

Based on the nature of the final ruling,

it’s clear the industry’s collective caution

contributed to a less severe delisting time-

line than what was originally proposed.

High-GWP, HFC refrigerants R-404A

and R-507A are planned for phase-out in

certain end uses, although the timeline is

less aggressive than originally proposed.

For example, in supermarket racks, the

R-404A/R-507A ban was pushed from

2016 to 2017. It’s important to note that

the EPA addresses new and retrofit systems

differently, so be sure to familiarize yourself

with that distinction (see Table 1).

An important distinction of the EPA’s

final rule regarding service of existing

systems is worth noting: “existing systems

may continue to be serviced and main-

tained for the useful life of that equipment

using the original refrigerant.” This is a

very good thing.

Stand-alone applications — which

include low- and medium-temperature,

reach-in and walk-in units — now have

some wiggle room to comply, but aren’t

without complications. In low-temperature,

stand-alone systems, several new (and

natural) refrigerants are approved for use,

including: R-448A, R-449A, R-290 and

R-744 (CO2). HFC-134a is still allowable in

low-temperature systems, although new

refrigerant blends R-450A and R-513A

represent viable alternatives. Some of

these refrigerants have high compressor

discharge temperature issues; others have

low capacity problems.

It is also worth noting that R-448A

and R-449A, while recently SNAP-

approved in most commercial refriger-

ation applications, were not approved

for medium-temperature, stand-alone

applications. Medium-temperature,

stand-alone systems face the challenge

of having to design with low-capacity

refrigerant blends or move to hydrocar-

bons (or hydrocarbon blends), which are

charge-limited flammable gases.

The EPA’s final delisting ruling also calls

for bans on foam-blowing agents, such as

those commonly used in insulation for

commercial reach-in refrigeration units.

Among the plastic-based foams listed include

rigid polyurethane and rigid polystyrene

with a delisting date of 2020. Please see

Table 8 on page 55 of the EPA’s final rule for

a complete listing of all the changes.

New Approved Refrigerant Substitutes

While the SNAP delisting rule is grabbing

all the headlines, the EPA has also finalized

three other SNAP rulings in the past year

that approve new refrigerant substitutes

High-GWP, HFC refrigerants R-404A and R-507A are planned for phase-out, although the timeline is

less aggressive than originally proposed.

Emerson Perspective:EPA FINAL RULE ON DELISTING—Phase-out Candidates*, Likely Alternatives*and Dates

* Abbreviated; see EPA final rule for complete listing.

1 The EPA defines the term “new” as follows: “The date upon which the refrigeration circuit is complete, the system can function, the system holds a full refrigerant charge, and the system is ready for its intended purpose.”

2 The EPA defines the term “retrofit” as follows: “The use of a refrigerant in an appliance (such as a supermarket) that was designed for and operated using a different refrigerant.” Further, the term retrofit “does not apply to upgrades to existing equipment where the refrigerant is not changed.”

Phase-out Refrigerant

Super-market

New1

Super- market

Retrofit2

RemoteCDU New

RemoteCDU

Retrofit2

Stand-alone

MT <2,200 BTU/hr. and not contain flooded evap.

New

MT >2,200 BTU/hr. with or without flooded evap.

New

LTNew

LT and MTRetrofit2

R-404A/507AJan. 1, 2017

July 20, 2016

Jan. 1, 2018

July 20, 2016

Jan. 1, 2019 Jan. 1, 2020Jan. 1, 2020

July 20, 2016

R-410A OK – OK – Jan. 1, 2019 Jan. 1, 2020Jan. 1, 2020

–

R-407A/C/F OK OK OK OK Jan. 1, 2019 Jan. 1, 2020Jan. 1, 2020

OK

HFC-134a OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK

Likely Alternatives

R-448A/449A OK OK OK OK Neither SNAP- approved, nor banned

Neither SNAP- approved, nor banned OK

OK for LT only

R-450A/513A OK OK OK OK OK OK OK OK

R-290 – – – – OK OK OK –

R-744 OK – OK – OK OK OK –

R-717OK

(in primary loop of secondary CO2 system)

–OK

(in primary loop of secondary CO2 system)

– – – – –

Table 1: The EPA’s much-anticipated SNAP ruling on refrigerant delisting is now final. While the nature of the ruling has moderated from the original proposal, the change of listing status will take place between the 2017–2020 time frame — a schedule that still presents significant challenges for the commercial refrigeration industry.

6 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 7

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in commercial refrigeration (see Table 2).

The first two rulings cleared the way for

several approved alternatives having a

GWP ranging from 3 to 675 and include:

R-170 (ethane), R-600A (isobutane),

R-290 (propane), R-441A (hydrocarbon

blend) and R-450A (HFC/HFO blend).

The first three in this list are considered

“natural” refrigerants with very

low GWP/ODP, but are also class

A3 (flammable).

A third ruling, which was recently

approved this summer, introduced

additional class A1 (non-flammable)

refrigerants to the mix: R-448A, R-449A

and R-513A. R-448A and R-449A are blends

of HFC/HFO, and are considered a suitable

replacement in several applications that

traditionally used R-404A and R-507A.

Prior to this announcement, Emerson

Climate Technologies successfully

performed research, development and

testing to prepare our Copeland Scroll™

and Copeland Discus™ compressors for

use with R-448A and R-449A. These units

are now ready for market.

With a GWP of less than 600, R-513A

and R-450A are HFC/HFO blends designed

to potentially replace HFC-134a. While

HFC-134a is an effective refrigerant in

medium-temperature applications, it has

a lower capacity than R-404A and operates

below atmospheric pressure under most

low-temperature conditions — the reduced

capacity results in equipment size increases

up to ~35 percent, and the lower pressure

leads to a greater potential for refrigerant

leak-related issues.

It’s important to note that none of

these new refrigerant alternatives are

“drop-in” substitutes for retrofitting.

Equipment must be specifically designed,

evaluated and tested for use with these

new refrigerants. We recommend that

you check with the equipment and com-

ponent manufacturers before any retrofit

to ensure that all proper guidelines are

being followed.

How the DOE and EPA Rulings Interact

Energy efficiency and refrigerant choice

are highly dependent variables in a refrig-

eration system. One of the biggest chal-

lenges the industry has grappled with is

the close timing between the EPA’s SNAP

rulings and the DOE’s energy reduction

mandates on stand-alone commercial

refrigeration systems (see Table 3). Not

only must we concern ourselves with which

refrigerants to use, we also have to comply

with the DOE’s efficiency requirements.

For example, a medium-temperature,

stand-alone case using R-404A will be

subject to compliance with the DOE’s

energy reduction rule by March 27, 2017.

The same case will also have to transition

to an EPA SNAP-approved refrigerant by

Jan. 1, 2019 (see Table 2).

As an industry, there are several

important questions we need to consider

to approach this challenge. First, how

will we meet the DOE’s energy efficiency

requirements using this new class of

approved refrigerants? To qualify as a

suitable alternative in new self-contained

systems, refrigerants will need to comply

with energy efficiency requirements and

be capable of production on a mass level.

Second, and more importantly, how

can we combine our product evaluation and

qualification efforts to satisfy both sets of

requirements in one step? The last thing we

want is to develop solutions and systems

that meet DOE compliance today, and then

repeat that exercise in 2 to 3 years for the

EPA. This scenario would result in unneces-

sary costs and duplication of efforts.

Finally, are there enough resources at

the component suppliers, equipment man-

ufacturers and test laboratories to handle

the increased workload of the qualification

process? Let us not forget that this process

is linear. We first need the refrigerants to

be made available and components to

become widely produced — only then can

equipment manufacturers begin to test,

approve and place new equipment into

production. To the extent possible, our

objective should be to pursue refrigeration

technologies that achieve both DOE and

EPA regulatory compliance at once. This

will be no small task.

Continued Stewardship Is Needed

If there’s a silver lining to the dark clouds

of this regulatory storm, it’s been the

opportunity for the industry to make its many

voices heard. I mentioned our discussions

with the OMB earlier this summer. It was

our second visit, the first of which took

place last September when the 2014 SNAP

ruling on delisting was in the NOPR phase.

The meetings we’ve been a part of

were well attended by EPA and DOE leaders,

Congress and Senate members, refrigera-

tion industry associations (such as NAFEM

and AHRI) and a select number of represen-

tatives from other private companies.

At the September 2014 meeting, the

White House asked us to develop a list of

action items to demonstrate our commit-

ment to their environmental and energy

efficiency initiatives. Among these was

the development of a new innovation cen-

ter and continued research in CO2-based

refrigeration systems. We will present

our progress to them this October when

Emerson Climate Technologies Executive

Vice President Bob Sharp and I attend the

next White House meeting.

As we navigate the next few years,

ongoing industry participation in regulatory

decisions will continue to be critical — not

only here in the U.S., but in Canada, the

E.U. and the Middle East. Our industry has

many decisions to make in the next few

years about which refrigeration system

technologies will take us into the future.

In this increasingly global marketplace,

we all must play an active role in shaping

refrigeration strategies that meet our

environmental, economic and energy

efficiency objectives.

Table 2: The EPA has approved several new low-GWP refrigerants through its recent SNAP rulings, including natural alternatives and new refrigerant blends. Their intent was to replace recently delisted R-404A and HFC-134a in specific applications. Note that the natural options are classified as A3 (flammable), while the blends are class A1 (non-toxic, non-flammable).

Emerson Perspective: SNAP-APPROVED REFRIGERANT REPLACEMENTS

New Refrigerant Class Replaces Application

R-170 (ethane) A3 n/a Very low-temp refrigeration

R-600A (isobutane) A3 HFC-134a Reach-ins, walk-ins, freezers

R-290 (propane) A3 n/a Reach-ins, walk-ins, freezers, vending machines

R-441A (hydrocarbon blend) A1 HFC-134a Reach-ins, walk-ins, freezers

R-448A (HFC/HFO) A1 R-404A Supermarket (racks), reach-ins, walk-ins (low-temp)

R-449A (HFC/HFO) A1 R-404A Supermarket (racks), reach-ins, walk-ins (low-temp)

R-513A (HFC/HFO) A1 HFC-134a Supermarket (racks), walk-ins, reach-in units

R-450A (HFC/HFO) A1 HFC-134a Supermarket (racks), walk-ins, reach-in units

Table 3: Both DOE and EPA rulings take effect in the 2017–2020 time frame. But, the effective dates of respective rulings don’t necessarily correspond. To avoid a duplication of efforts, OEMs should attempt to satisfy both requirements in one product development cycle.

Emerson Perspective: EPA’S FINAL RULE AND DOE ENERGY REGULATION TIMING

Phase-out Refrigerant

Super-market

New

Super- market Retrofit

RemoteCDU New

RemoteCDU

Retrofit

Stand-alone

MT <2,200 BTU/hr. and not contain flooded evap.

New

MT >2,200 BTU/hr. with or without flooded evap.

New

LTNew

LT and MTRetrofit

R-404A/507AJan. 1, 2017

July 20, 2016

Jan. 1, 2018

July 20, 2016

Jan. 1, 2019 Jan. 1, 2020Jan. 1, 2020

July 20, 2016

R-410A OK – OK – Jan. 1, 2019 Jan. 1, 2020Jan. 1, 2020

–

R-407A/C/F OK OK OK OK Jan. 1, 2019 Jan. 1, 2020Jan. 1, 2020

OK

HFC-134a OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK

DOE Energy Reduction

Compliance

Jan. 1,2020

(Walk-in)March 27, 2017 March 27, 2017

March 27, 2017

Our objective should be to pursue refrigeration technologies

that achieve both DOE and EPA regulatory compliance at once.

This will be no small task.

8 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 9

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The viability of propane (R-290) as a refrigerant is a recurring topic of debate in the commercial refrigeration and air conditioning

industries. In light of the EPA’s recent refrigerant delisting ruling, it’s a discussion that’s likely to return to the forefront.

While the United States has been especially hesitant to adopt R-290, it has gained wider acceptance in Europe, where environmental concerns and stricter regulations are driving the adoption of more eco-friendly alternatives. R-290’s true properties and characteristics are largely unknown to those outside the industry, leading to common misconcep-tions among the public. The purpose of this article is to present an unbiased evaluation of R-290 and establish a factual baseline of understanding.

A Long History in Refrigeration

R-290 is a hydrocarbon that was introduced into the refrigeration industry in the early 1900s. Like other natural refrigerants, it was used through the 1930s until it was replaced by chlorofluorocarbons (CFCs). Since the 2000s, R-290 has been regaining popularity in a wide range of applications. With its increase in capacity and low global warming potential (GWP), R-290 has emerged as an alternative to hydrofluoro-carbons (HFCs) like R-404A and HFC-134a.

Global regulatory actions to ban high-GWP refrigerants have placed renewed emphasis on R-290 and other natural refrigerants. It was officially approved in a recent EPA SNAP ruling, and has been identified as a viable HFC alternative in the E.U.’s F Gas regulations. And, with R-404A and HFC-134a officially delisted by the EPA in many commercial refrigeration

applications, natural refrigerants — including R-290 — are primed for a broader resurgence.

Advantages and Applications

Because of its long history in refrigeration, R-290’s performance efficiencies and thermodynamic properties have been well vetted. In terms of pressure, low back pressure, discharge temperature, volumetric capacity, capacity loss and coefficient of performance (COP), R-290 is very similar to R-22 (even outperforming it in certain characteristics).

At Emerson Climate Technologies’ test labs, we’ve found R-290 capable of high-performing, efficient operation. Compared to the refrigerants it will likely be called upon to replace — like the recently delisted R-404A and HFC-134a — R-290

yields more capacity with lower wattage consumption (see Table 1). We’ve developed a full line of Copeland hermetic compressors to be compatible with R-290.

In terms of achieving regulatory compliance, R-290 is very appealing. First, its global warming potential (GWP = 3) is well below the global threshold of 150 GWP, which places it in an elite class of refrigerants from the standpoint of minimal environmental impact. And, its high-efficiency characteristics also qualify it as a candidate for meeting the Department of Energy’s (DOE) energy reduction rules that take effect in 2017.

Because of its small charge limit of 150g, R-290 is typically used in smaller commercial applications, such as: beverage coolers, frozen drink machines, ice machines, small ice-cream freezers and small reach-in

8

The Case for R-290Reviewing the pros and cons for wider adoption of

this low-GWP, natural refrigerant alternative

units. As such, select national foodservice chains recently began installing ice machines designed with R-290.

The applications of R-290 in large food retail applications are more limited. Even in cases where it has been used with special permission to allow for 300g of charge, more compressors are needed to generate the capacity required to meet the refrigeration load. Most supermarkets currently consider this a deterrent for installing an R-290-based refrigeration system.

It’s also important to note that R-290 is not to be considered a “drop-in” refrig-erant. As with the majority of refrigerants, equipment and components must be specifically designed for use with R-290 — it requires a different compressor that will not always directly match the capacity or cost of existing HFC models.

Challenges and Misperceptions

While the upside of R-290 may not be readily apparent to the industry outsider, the negative perceptions surrounding it are fairly well-entrenched. It’s a common perception shared by the industry and governing bodies. The apprehension stems from the fact that R-290 is classified as an A3 refrigerant — meaning it’s considered extremely flammable.

Unfortunately, this negative perception may be somewhat unfounded. Most confuse propane, the domestic “cooking gas” commonly used in backyards for

grilling, with propane the refrigerant. They are not the same compound, the former being a class 4 fire hazard. Anyone who’s used a match to start a gas grill understands that inherent risk. Misunderstandings like these may very well be feeding into the misperception of R-290.

The 150g charge limit for R-290 in commercial refrigeration amounts to little more than half a cup of liquid. Larger charges up to 300g have been used in the U.S., but these applications require special approval and certification.

In the U.S., specifying an R-290-based refrigeration application can be challenging. End user projects are subject to state and municipal governments for fire and building code approval. Failure to gain the requisite approval, particularly in multiple locations throughout the country, is often a roadblock for R-290 adoption.

Compared to traditional A1-based equipment, specifying R-290-based equip-ment typically requires an incremental investment in the business infrastructure where the equipment is installed. Building and fire code approvals are also required at OEM production facilities as well, with expenses that typically exceed $100,000.

But for environmentally forward- leaning companies, R-290 and other natural refrigerants are becoming an increasingly attractive option.

Finally, there are safe-handling considerations for R-290 applications. Both

technicians and carriers along every step of the refrigerant supply chain will require proper training and certification.

Careful Risk-Reward Analysis Is Needed

R-290 has tremendous potential in com-mercial refrigeration. It is eco-friendly, highly efficient and high-performing. It could effectively eliminate EPA compliance concerns for the foreseeable future. But, despite its potential, R-290 has yet to achieve mass appeal. Public perceptions and an absence of an industry-wide safety infrastructure continue to curb its wider adoption.

While the EPA’s recent refrigerant delisting may have cleared the way for wider R-290 adoption, there’s no telling if a new class of acceptable alternatives could push R-290 out of the picture again. New mildly flammable A2Ls such as HFO-1234yf offer similar performance and environmental characteristics. HDR-110 shows similar promise but will likely need some equipment system level adjustments. These continue to be tested and are not EPA SNAP approved at this time.

It remains to be seen if the industry and the public will embrace R-290 as a viable natural alternative, or if the analysis taking place throughout the industry is leaning in its favor. No doubt, there are numerous business models and cases with specific benefit being developed; R-290’s ability to satisfy these criteria will determine its level of adoption.

R-290 has obvious application benefits and well-known

drawbacks. Its many benefits include:

• Hydrocarbon-based, non-synthetic substance

• EPA-approved in commercial refrigeration applications

• Very low environmental impacts; GWP = 3, ODP = 0

• Relatively affordable

• High-efficiency, high-performance, reliable

• Safe when proper protocols and procedures are followed

R-290 suffers from some drawbacks as well:

• Class A3 refrigerant that is flammable

• Globally mandated low charge limits of 150g restrict the

application range

• Difficulty getting approved in fire and building codes

• Requires special handling requirements/certifications

• Lack of trained and certified field technicians

R-290 at-a-Glance

Table 1: Results from Emerson Climate Technologies test labs, comparing the EER of R-404A to R-290 in medium back pressure (MBP), show a significant

improvement when using R-290.

1⁄2 HP

45 / 130

R-404A

5 / 131 50 / 131

1 HP0

2

4

6

8

EER

10

1⁄2 HP 1 HP 1⁄2 HP 1 HP

R-290

7.1

8.7

7.6

9.4

4.2

5.1

3.64.5

7.6

9.3

8.1

9.8

MBP R-404A v. R-290Energy Efficiency Ratio (EER) Comparison

10 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 11

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National Grocery Chain Makes Transition to

Transcritical RefrigerationPhoenix-based grocery chain deploys its first CO2 transcritical

booster system in Atlanta store

SU C C E SS S TO RY

10

In “Hotlanta” ambient temperatures routinely rise above 87.8 °F. That’s the critical point temperature for the

emerging natural refrigerant CO2 (R-744). When the temperature outside approaches this point, CO2-based

commercial refrigeration systems begin to experience declining efficiencies. That’s why CO2-based refrigeration

architectures are more common in cooler climates. And why CO2 transcritical booster systems — which rely

entirely on CO2 — are not considered an obvious solution in places like Atlanta.

However, with increasing regulations prompting a shift toward sustainable alternative refrigerants, retailers

are looking more closely at CO2 transcritical booster systems to anchor their refrigeration operations, even in

warmer climates.

With more than 200 U.S. locations, Sprouts Farmers Market, a healthy grocery chain that offers fresh,

natural and organic foods, is among the first retailers in North America to do just that. They opened their first

store in suburban Atlanta in July 2014, and when they did, they set out to prove CO2 transcritical booster

systems aren’t only for cool climates.

But Sprouts had clear business objectives for their CO2 pilot program, as well. Their senior leadership

wanted to reduce the company’s carbon footprint and mitigate regulatory compliance concerns. The forward-

thinking grocery chain wanted to push the envelope and establish a sustainable refrigeration alternative in their

new fleet of southern stores.

Going Green and Keeping It Fresh

When you’re a grocery chain focusing on selling

fresh foods, fresh is the fundamental ingredient.

That means your refrigeration system design has to

be—above all else—reliable.

Like many food retailers, Sprouts has historically

employed more traditional refrigeration systems based

on common hydrofluorocarbon (HFC) refrigerants.

These HFC systems operate with what’s traditionally

seen as acceptable temperatures and pressures.

CO2’s low critical point temperature and high

operating pressure (around 1,500 psig) are character-

istically not found in traditional HFC-based refrigeration.

These are the primary reasons for the reluctance to move

toward CO2. But, with advances in system technology

and architecture, CO2 can be a game changer for retailers seeking to improve energy efficiencies, achieve sustainability

targets and cross the finish line on regulatory compliance.

Changing their refrigeration philosophy and moving to a CO2 transcritical system architecture was a giant step

for Sprouts, especially for this store in the hot, humid climate of Atlanta.

To pull this off, they turned to OEM partner Hillphoenix, whom the company partnered with to earn an

EPA GreenChill platinum certification in 2011. And Hillphoenix, seeing the challenge presented by installing a CO2

transcritical booster system in a warm climate, turned to Emerson Climate Technologies.

Transcritical Technology in Action

Emerson Climate Technologies, Hillphoenix and Sprouts all shared the same goal: show the industry it’s possible

to operate an efficient refrigeration system in higher ambient temperatures using CO2 exclusively.

A key enabling feature of the CO2 transcritical booster system is an adiabatic condenser, which was

designed to operate in high ambient temperatures. Adiabatic condenser cooling is the process of spraying water

Hillphoenix warm climate CO2 -based transcritical booster system installation utilizing

Emerson Climate Technologies components

12 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 13

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into the air supply of an air-cooled condenser to pre-cool the air and improve refrigeration efficiency. The goal of

this condenser technology is to keep the CO2 below its critical point, thus maximizing system efficiencies.

Hillphoenix’s rack refrigeration system featured four Copeland™ semi-hermetic transcritical CO2 compressors

and three Copeland Scroll™ ZO compressors. Both models were designed for CO2’s high-pressure requirements

and benefit from its thermal properties.

Emerson’s E2 Facility Management System was installed to oversee the CO2 transcritical booster system,

manage nearly 50 electronic case control units and optimize the facility’s overall energy management profile.

The E2 system helps improve performance in multiple ways:

1) Controls the variable speed of the fans on the adiabatic condenser in response to operating conditions

2) Optimizes compressor coefficient of performance by regulating system discharge pressures via Emerson’s

high-pressure CO2 controller

3) Provides complete oil management control of all CO2 refrigeration compressors

4) Communicates with and captures information from individual case control units

5) Provides complete control of building HVAC and refrigeration systems, and supports the retailer’s energy and

maintenance reduction strategies

The E2 system also allows Sprouts operators to run diagnostics, monitor the system remotely through

Emerson’s ProAct™ Service Center and, if necessary, shut down the system components before failure.

The condenser manages both low- and medium-temperature refrigeration requirements on the same

system using only CO2 as the refrigerant, another unique aspect to the transcritical booster system. Running

both requirements from the same condenser enhances the efficiency of the system across the store.

Easing Concerns

CO2 transcritical booster systems have been used in Europe for nearly a decade. Adoption by the U.S. refrigeration

industry has been slower due to a general apprehension about new (and, to many, unknown) technology.

It’s understandable why stateside end users are hesitant to switch to CO2 transcritical booster systems.

Concerns over operating pressures, maintenance levels and energy have prompted careful and steady evaluations

to understand the true cost of ownership for their enterprises.

Emerson technology helped ease those concerns for Sprouts. Their Atlanta-area store is operating efficiently

and effectively on the transcritical system.

12

The pilot CO2 transcritical booster system designed for

Sprouts’ Atlanta store utilizes multiple Emerson Climate

Technologies components, including:

1. Copeland Scroll ZO compressors — for low-

temperature refrigeration requirements (freezers)

2. Copeland semi-hermetic transcritical CO2

compressors — for medium-temperature

refrigeration requirements (dairy, produce and meat

cases); includes variable frequency drives to prevent

the compressors from cycling on and off too frequently

3. CoreSense™ technology for Copeland

compressors — advanced compressor diagnostics,

protection and communications technology that

allows technicians to make faster, more accurate

decisions, resulting in improved compressor

performance and reliability; present on all

store compressors

4. E2 Facility Management System — provides

complete CO2 transcritical booster system

optimization and facility-wide energy management

5. High-pressure CO2 controller — optimizes high side

pressures and liquid quality to the cases

6. XM Series case controls (pulse-width modulated) —

integrates with the E2 system to maximize operating

efficiencies through tighter temperature controls;

present on nearly 50 cases

Discharge air controller (not shown) — operates in

unison with the E2 system and is capable of controlling

heat and cool stages, fans, dehumidification devices

and economizers using on-board I/O

Emerson Climate Technologies equipment portfolio

Transcritical CO2 booster system

14 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 15

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A Cool Chunk of Change

Incentivized efficiency upgrades deliver measurable energy

savings for Canadian grocer

SU C C E SS S TO RY

In an effort to offset rising energy costs, a leading supermarket

chain commissioned a detailed energy analysis and performed

a series of energy efficiency measures (EEMs) on a typical

grocery store in its fleet: a 45,000 square-foot, 20-year-old

unit in southwestern Ontario.

The grocer also sought to take advantage of the Independent

Electricity System Operator’s (IESO) — formerly Ontario Power

Authority (OPA) — saveONenergy Incentive Program, using

the Equipment Replacement Incentive Initiative (ERII) to offset

investment costs. To do so, they engaged Renteknik Group

(www.renteknikgroup.com) — experts in energy optimization

and management, and an experienced consultant with the

saveONenergy incentive programs — to lead the effort.

To start the project, Renteknik installed its ClimaCheck

(http://home.climacheck.com) data collection and analyzing

system, gathering extensive baseline data on the system operation

and identifying preliminary EEM opportunities. Renteknik then

looked to Emerson Climate Technologies for real-world ways to

improve efficiencies in the store’s legacy refrigeration system.

The store in question utilized a common refrigeration architec-

ture, consisting of low- and medium-temperature parallel rack sys-

tems running on 10 Copeland™ semi-hermetic compressors. With

a cooling capacity of 1,000,000 BTU, the system had historically

consumed approximately 950,000 kWh of electricity per year.

Toward the end of 2012, Renteknik began the meticulous

process of establishing an energy consumption baseline from

which to evaluate refrigeration system efficiencies — a critical

first step for launching a Measurement and Verification (M&V)

program and demonstrating efficiency gains which could later

qualify for the saveONenergy incentives.

14

Stepped M&V Process Culminates in Equipment Upgrades

Renteknik employed a stepped approach toward achieving

efficiency improvements through a series of EEMs. The first step

was to fine-tune the system as it stood. This meant optimizing

every set point in the supermarket, cleaning condensers and

replacing any damaged components — without making any

material changes to the system itself.

Renteknik performed these basic EEMs for 11 months, while

closely monitoring system performance through the real-time

ClimaCheck online portal. When any piece of the refrigeration

system drifted outside of desired efficiency ranges, Renteknik’s

monitoring system detected it and alerted the store on how

to restore efficiency. Using these adjustments alone, the store

achieved an 18 percent reduction in energy costs in the refrigera-

tion system and qualified them to receive saveONenergy incentives.

These preliminary EEMs, while impressive, did not represent all

the achievable energy savings associated with system improve-

ments and minor capital upgrades that would meet the Simple

Payback threshold required and maximize, for the long-term,

sustainable energy efficiency improvements.

To take the store to the next level of energy efficiency,

Renteknik recommended compressor upgrades on two weaker

units that it had detected — one on the low-temperature side and

the other on the medium-temperature rack. They selected two

Copeland Discus™ digital compressors because of their ability

to retrofit refrigeration systems with precise variable-capacity,

load-matching capabilities.

But before engaging the new compressors’ full digital potential,

Renteknik needed to measure the improvements to the system

with the compressors alone (without engaging their variable

capacity capabilities). Using the established energy baseline from

the preliminary EEMs, they were able to demonstrate a 4 percent

energy improvement just by swapping compressors.

The last step of the EEM was to engage the new compressors’

digital retrofit capabilities. In this configuration, each digital

compressor serves as the lead compressor in the parallel rack. Their

ability to vary capacity to precisely match the refrigeration load

provides ongoing energy efficiency gains while reducing compressor

cycling and associated wear and tear. Renteknik determined that this

final step netted an additional 12 percent savings. Combined with

the initial 4 percent energy improvement from the new compressors,

this qualified the store for additional saveONenergy ERII incentives.

The Proof Is in the Payback

After three months of M&V on the variable capacity Copeland

Discus digital compressors, Renteknik verified a reduction in

annual energy consumption of 122,965 kWh as shown in Table 1 —

a 16 percent reduction in energy costs — and an annual savings of

$17,215. At the saveONenergy incentive rate of $0.10 per kWh,

the reduction also translated into an incentive payout of $12,297.

Combined incentives on the entire EEM efforts surpassed $30,000

and produced in excess of $40,000 in annual energy savings at the

current electricity rate.

Table 2 demonstrates the project costs and the return

on investment (ROI) with (and without) the saveONenergy

incentives. At a projected annual savings of $17,215, the simple

payback without incentives is 1.4 years, including Renteknik’s

energy consulting and M&V costs. The additional saveONenergy

incentives cut the ROI time in half. Renteknik’s M&V program

clearly demonstrates the energy savings potential of Copeland’s

variable-capacity digital compressor retrofit.

The supermarket chain is currently deploying the digital

compressor retrofit approach in other stores. Because of

the success of this trial, whenever a compressor needs to

be replaced, they will upgrade their system with a Copeland

Discus digital compressor.

ItemEnergy Savings

kWh/YearOPA

IncentiveAnnual Savings

Rate $0.10/kWh $0.140/kWh

LT 47,390 $ 4,739 $ 6,635

MT 75,575 $ 7,558 $ 10,580

TOTAL 122,965 $ 12,297 $ 17,215

Table 1: Summary of energy savings, OPA incentives and annual operating savings

Table 2: Summary of project costs, OPA incentives, annual operational savings and ROI calculations

Total Project Cost $ 24,592

OPA Incentive (Max 50% of Costs) $ 12,296

Net Project Cost $ 12,296

Estimated Annual Savings $ 17,215

Simple Payback With Incentives 0.7 Years

Simple Payback Without Incentives 1.4 Years

16 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 17

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systems are increasing in popularity around the globe. And, in our R-290 performance testing, we’ve seen more than a 10 percent efficiency improvement. We’ve released several compressors that utilize these natural alternatives, including:

• Copeland semi-hermetic transcritical CO2 compressors

• Copeland Scroll compressors for subcritical CO2 applications

• Copeland hermetic compressors for R-290 to be used in small reach-in systems where the refrigerant charge is less than 150g

A2L RefrigerantsWe’ve also invested in compressor evalua-tions using A2L (mildly flammable) refrig-erants like HFO-1234yf and HFO-1234ze. While A2Ls are not EPA SNAP-approved at this time, we are preparing for their likely introduction into commercial refrigeration applications. As a general rule, we typically make these investments with emerging refrigerants at least 2 to 3 years before compressors could potentially be moved into production.

It’s important to note that from a refrigerant perspective, we’re not changing our core technology to achieve compatibility. We are continually improving our designs to adapt to new refrigerant alternatives.

DOE — Walk-in and Reach-in Compressor Development

With respect to the DOE’s energy reduction requirements on walk-in and reach-in units, we’ve been pursuing major technology extensions to our compressor platforms.

First, we’re expanding our Copeland Scroll line to include smaller displacements and capacities that are more applicable for walk-in (and potentially reach-in) applications — capitalizing on scroll’s known efficiency benefits in these smaller displacements. Second, we’re evaluating our existing vapor-injected scroll technology, specifically to address the challenging annual walk-in efficiency factor (AWEF) standard for low-temp, walk-in applications.

Medium-temperature Walk-ins and Reach-ins

For medium-temperature, walk-in appli-cations, we’re extending the Copeland Scroll ZS*KAE platform by reducing the horsepower (hp) range down to ¾ hp. At this reduced size, it may also be suit-able for large reach-in units.

Low-temperature Walk-ins

Low-temperature, walk-in applications represent the most challenging segment in which to achieve regulatory compliance. The reasons are two-fold: 1) the new class of approved refrigerants has a high

heat of compression, requiring discharge temperature monitoring and control in low-temperature applications, and 2) the AWEF standard for the DOE’s requirements is especially a challenge to comply with.

To address these challenges, we’re evaluating the use of the enhanced vapor injection capabilities of the Copeland Scroll ZF*KVE line, a platform that has been successfully deployed in food retail in small, distributed systems.

Reach-in System EvaluationIt’s important to note that with the walk-in standard, the performances of condensing unit, unit cooler, panels and doors are able to be self-tested and self-qualified. However, on the reach-in applications, the system efficiency is evaluated as a whole, including: insulation, walls, doors, compressor, fans, etc. If you’re an OEM and have begun the process of evaluating and making system changes to qualify with the DOE mandates, now is a good time to check with your Emerson Cli-mate Technologies sales representative to determine how much efficiency can be gained from different compressor options. We can provide guidance on compressor technologies, and even do a complete system evaluation through our Design Services Network to alleviate your engineering load.

Expanded Testing Capabilities

Emerson Climate Technologies has made significant investments to help us better evaluate the performance of new refrigerants and system technologies. We thoroughly test the heat transfer characteristics and thermodynamic properties of each refriger-ant to predict system performance based on theoretical models of heat transfer across the evaporator and the condenser.

Calorimeters — test the performance of various refrigerants in the compressor at specified conditions. By knowing the appli-cation, we can combine our knowledge and test history of that application to run a selection of performance tests. We can then compile those results to predict how that refrigerant will perform across the entire year of running in that application and compare it to today’s refrigerant options.

Life-test stands — test the reliability and robustness of com-pressors by simulating very harsh compressor conditions. With up to 2,000 hours of simulation, we have compiled a compre-hensive database to predict and evaluate compressor wear.

System simulations — designed to evaluate compressor performance inside an entire system in real-time applications (walk-in, reach-in, supermarket rack or ice machine):

• A1, A2L and A3 refrigerants for reach-in and walk-ins

• A1 refrigerants in supermarket module in our Sidney, Ohio, lab

• CO2 in a transcritical booster supermarket module to be housed at The Helix Innovation Center Emerson is opening later this year in Dayton, Ohio

The question we’ve been asked most often over the past year is this: “What is Emerson Climate

Technologies doing to prepare for future regulations?” Between the Environmental Protection Agency’s (EPA) multiple significant new alternatives policy (SNAP) rulings on refrigerants and the Department of Energy’s (DOE) energy reduction mandates, complying with these regulations has been a primary concern for our customers.

Our answer as a company is unequiv-ocal: nearly every internal development program we’ve undertaken in commercial refrigeration has been geared toward achieving compliance. From participating in the meetings on the Hill — where the scope of the rulings were debated — to making significant investments in research, development and testing, our approach has been all-encompassing.

Individually, the DOE’s and the EPA’s rulings present significant challenges. Combined, they become increasingly more difficult to address. Until the EPA announced its final delisting ruling in July, there was wide speculation about how aggressive the refrigerant ruling would be, and what its impact on the DOE’s already-final

rule on energy reductions would be. While the EPA’s final refrigerant delisting

ruling has slightly delayed their phase-down stance of hydrofluorocarbons (HFCs) R-404A, R-507A, R-407A and HFC-134a in various applications, compliance is still a near-term inevitability. Even though the DOE’s energy reduction mandates on stand-alone commercial refrigeration equipment (such as reach-in and walk-in coolers and freezers, and automatic commercial ice makers) are still looming in the 2017–2018 time frame, we expect a fair amount of industry pushback to the DOE’s timeline to continue. So, even though both rulings are final, there’s still a real sense that the industry is waiting for the dust to settle.

Proactive Pursuit of Energy-Efficient, Eco-Friendly Technologies

As a component manufacturer, we don’t have the luxury of waiting to see what is going to happen next. And as a company, we strive to maintain a proactive posture by relentlessly pursuing a multitude of potential solutions. So our approach to this challenge has remained consistent throughout: to rigorously engineer and evaluate component performance against worst-case regulatory scenarios. As a

result, we can confidently say we are prepared to address both the EPA and DOE compliance challenges.

EPA SNAP Rulings — Refrigerant Preparation

New HFOs and Associated BlendsThe majority of our compressor platforms have been validated for use with the EPA’s newly approved A1, hydrofluoroolefin (HFO) blends, such as R-448A, R-449A, R-450A and R-513A. This includes both our Copeland Scroll™ and Copeland Discus™ semi-hermetic compressor lines. We’re also in the process of following up our validation efforts on these refrigerants in our Copeland™ hermetic compressor lines, which we’ll be finalizing in 2016.

Natural Refrigerant OptionsBecause of their extremely low global warming potential (GWP), the industry is taking an even closer look at CO2 (R-744) and propane (R-290). While these natural options have their own challenges, they take original equipment manufacturers (OEMs) and operators to the finish line on EPA com-pliance. But, they also should be evaluated on their impact to system efficiencies and their viability in terms of meeting DOE energy regulations. CO2-based refrigeration

R EG U L ATO RY CO M P L I A N C E by K U RT K N A P K E

Achieving compliance is our top priority

18 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 19

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A Perfect Match

Although relatively new to commercial

refrigeration, digital compressors have

already earned a reputation as an

invaluable alternative to traditional rack

refrigeration and mechanical modulation

methods. At Emerson Climate Technologies,

we’ve pioneered this technology (or

approach) into our Copeland Scroll™ and

Copeland Discus digital compressor lines

that deliver unprecedented temperature

precision and energy efficiencies.

Each compressor platform achieves

these benefits through a digital modu-

lation capability that allows for infinite

capacity adjustments within specific

modulation ranges — in our Copeland

Scroll Digital and Copeland Discus digital

lines, that range is 10 to 100 percent.

This means that instead of having to

cycle on and off to match capacity, the

compressors are capable of adjusting

their output to precisely match the load.

It’s a revolutionary concept that offers many

advantages in commercial refrigeration

applications.

Digital Technology Advantages

Precise temperature control — Digital modulation allows tempera-

tures to be controlled within +/- 0.5 degrees Fahrenheit. In today’s

increasingly competitive foodservice, supermarket and transport

industries, this provides the assurance that operators are maintaining

the highest quality of perishable food items. Precise temperature

and pressure control also allows for a true steady state of operation,

better enabling the benefits of lowering condensing temperatures

to improve the efficiency of the entire system when combined

with an electronic expansion valve.

Bottom line: Precise temperature control reduces food

shrinkage, preserves brand reputations and improves the

operator’s profit margins.

Reduced power and energy consumption — By matching the

refrigeration load requirements from 10 to 100 percent, digital

compressor technology consumes only the energy needed to

meet the load. Reduced compressor cycling saves energy from

in-rush startup currents and persistent consumption from running

at full capacity. This also enables operators to increase the set

point, resulting in minimized defrost cycles. Compared to other

methods of modulation, digital compression is much more

energy efficient and less costly to implement.

Bottom line: Operators can expect as much as 10 percent

energy reduction (up to 30 percent compared to hot gas-bypass

systems).

Increased system reliability — Digital modulation greatly reduces

cycling rates, which results in significantly less refrigeration system

wear and tear. This not only extends the life of compressors but

also reduces component failure points in rack systems such as

tubes and contactors.

Bottom line: Digital compression technology provides up to

50 percent reduction in compressor start/stop cycling in parallel

rack applications, allowing for reduced maintenance costs and

improved system reliability.

Digital retrofit capability — One digital compressor can be used

as the lead compressor when paired with fixed capacity scroll or

semi-hermetic compressors on a parallel rack. Digital modulation

fills in the gaps on uneven parallel rack applications, allowing

refrigeration system capacity to fluctuate to meet the load

requirements in a supermarket. This supplements the existing

rack to dramatically improve the system’s load matching capability.

Bottom line: Operators can experience the benefits of digital

compression by installing a single compressor on a traditional

rack system. Digital technology allows stores to dramatically

reduce compressor cycling, from cycling frequencies in the

hundreds to the teens.

Meet energy targets in foodservice — The DOE is imposing signifi-

cant energy reductions on walk-ins, reach-ins and ice machines by

2017 and subsequent years. In multiplex refrigeration designs, a

digital compressor can be used to run multiple fixtures throughout

a restaurant or convenience store. Applications that traditionally

require multiple compressors can be reduced to one or two digital

compressors (perhaps one for medium-temperature and one for

low-temperature applications) using a much lower refrigerant

volume. Digital modulation has enough capacity to match the

load of each fixture and/or allow the number of fixtures running

to match the load requirements of the store at a given time. This

intelligent, lean refrigeration architecture can be further optimized

with electronic expansion valves to lower the condensing tempera-

tures, reduce compression ratios and save energy.

Bottom line: Foodservice operators can lower their

compressor investment and achieve energy efficiency targets

with digital compressors.

New refrigerant friendly — Digital technology is available for

the emerging class of refrigerants: new A1 refrigerants (such

as recently approved R-448A and R-449A); R-744 in subcritical

applications; and new blends as they become available.

Bottom line: Emerson has worked, and will continue to

work, to ensure compatibility with the next generation

of refrigerants.

One of the biggest challenges food

retailers and foodservice operators

face is precisely matching com-

pressor capacity to the actual refrigeration

load required. Poorly matched refrigeration

systems lead to many problems, including:

food degradation due to wide fluctuations

in temperatures; high energy consumption

due to high in-rush currents from excessive

compressor start/stop cycles; and increased

maintenance and replacement costs due

to unnecessary wear and tear.

In traditional supermarket rack refrig-

eration systems, multiple compressors are

centralized in a parallel rack design that

circulates refrigerant throughout

the store. To produce the necessary

refrigeration load on a typical day, these

compressors are subject to hundreds of

start/stop cycles.

Mechanical Modulation Methods

Attempts to modulate compressor capac-

ity to match load have been successful to

varying degrees, but each method

presents inherent challenges. Uneven rack

systems are designed to better match the

refrigeration load using compressors with

varying capacities (20K, 40K, 60K BTU/

hr), but this method still results in high

cycling rates and does not offer the desired

temperature precision.

A second capacity modulation

option is to change the system’s tubing

and install a hot gas-bypass system that

fluctuates with evaporator pressures and

temperatures. However, this is not as

energy efficient and often unreliable.

Manufacturers have even combined

variable speed drives and compressor

technology to achieve the desired level

of modulation. While this is an effective

form of capacity modulation, variable

speed technology may be considered

cost-prohibitive. And since the solution

includes both the variable drive and

the compressor, replacement costs can

be a concern.

Variable Capacity Modulation Goes Digital

S O LU T I O N SP OT L I G H T by P H I L M O E L L E R a n d J A S O N P R E N G E R

Copeland Scroll Digital™ and Copeland Discus™ digital compressors deliver precise matching

of capacity with refrigeration load

20 E360 Outlook Volume 2 Number 1 E360 Outlook Volume 2 Number 1 21

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Since early 2013, Emerson Climate Technologies

has produced Webinars as part of a series

known as Making Sense. We have recently

renamed this series E360 Webinars to include this

educational effort in the E360 platform which also

includes the E360 Outlook and E360 Forums.

The most recent E360 Webinar provided insights into

the EPA ruling, including:

• Which specific refrigerants were delisted

• An emerging class of likely refrigerant alternatives

• The unique impacts per application

• An updated compliance timeline

• Next steps for OEMs, operators, refrigerant

manufacturers and contractors

• How the DOE’s energy reduction ruling impacts

the EPA’s final rule

Archived Webinars can be found at EmersonClimate.com/E360-Webinars

Recently Archived Webinars

Find archived Webinars at EmersonClimate.com/E360-Webinars

EPA Final Refrigerant Ruling: Its Impact on Your Business August 18, 2015

Seven Keys to Servicing CO2 Systems July 14, 2015

Meeting Future Refrigeration Energy Regulations With Today’s Technology Alternatives March 17, 2015

Staying Ahead of DOE 2017 Walk-In Cooler and Freezer Energy Efficiency Ratings October 21, 2014

Staying Ahead of Rulemaking Proposals on Acceptable Refrigerants August 26, 2014

Improve Refrigerated Marine Container Management With Pervasive Connectivity July 8, 2014

Making Sense of Natural Refrigerants May 20, 2014

I N D US T RY E V E N T S

Comfortech 2015America’s Convention Center ComplexSt. Louis, MOSeptember 15–17comfortechshow.com/ct15

FMI Energy and Store Development ConferenceSheraton San Diego HotelSan Diego, CASeptember 27–30fmi.org/forms/meeting/ Microsite/ESD2015

RETA 2015Milwaukee, WISeptember 29–October 2reta.com/?page=conference

World Energy Engineering ConferenceOrange County Convention CenterOrlando, FLSeptember 30–October 2energycongress.com

2015 RSES Conference and HVACR Technology ExpoEmbassy Suites Chicago- O’Hare/RosemontRosemont, ILSeptember 30–October 3rses.org/conference.aspx

IFMA’s World WorkplaceDenver, COOctober 7–9worldworkplace.ifma.org

AHRI Board of Directors MeetingHyatt Regency Coconut PointBonita Springs, FLNovember 15ahrinet.org/site/412/News- Events/Meetings-and-Events

AHRI Annual MeetingHyatt Regency Coconut PointBonita Springs, FLNovember 15–17ahrinet.org/site/412/News- Events/Meetings-and-Events

Forum

Emerson Climate Technologies is excited to take our educational

platform on the road — this time to Dallas, Texas, on Septem-

ber 3. Once again, this daylong event will feature prominent

industry authorities as well as Emerson’s own internal experts. Our

February E360 Forum in Anaheim, California, was a huge success,

with more than 120 foodservice and retail leaders gathering for

in-depth discussions on important industry issues.

The E360 Forums give attendees an opportunity to participate

in the conversations shaping the commercial refrigeration industry.

We hope to see you at an E360 Forum in the future.

E360 Forum Schedule

Montreal, QC (In French) La Toundra Oct. 29, 2015

Atlanta, GA Marriott Atlanta Airport Gateway Feb. 18, 2016

Toronto, ON TBD Mar. 15, 2016

Dayton, OH Dayton Marriott/The Helix May 2016

Additional 2016 venues to be announced

Visit EmersonClimate.com/

E360-Event-Registration to register.

What was the most meaningful takeaway from today?

Some of the biggest takeaways were

learning about the changes happening in the foodservice

industry, and how energy and environmental challenges

are playing huge roles. Seeing how these things are

interconnected was an eye-opening experience.”

— Bryan Tonn, engineering manager, H&K International

Would you recommend the E360 Forum?

With respect to the E360 forum, I would

absolutely recommend it to anybody in the industry. It has

applications regardless of the type of company you have

— whether you’re an OEM manufacturer, whether you’re

a wholesaler distributor, or a contractor, a consultant.”

— Tom Richgels, director of sales, RefPlus

What do the E360 Forum attendees have to say about the event?

“

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E360 Outlook Volume 2 Number 1

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Emerson Climate Technologies1675 West Campbell RoadP.O. Box 669Sidney, OH 45365-0669

PRSRT FIRST CLASSU.S. POSTAGE

PAIDPERMIT #1315DAYTON, OH

Thank you for reading the fourth edition of E360 Outlook! At Emerson, we

believe the challenges faced by the refrigeration industry cannot be solved in a

vacuum. Only through collaboration and a commitment to innovation will we

discover answers to the difficult questions before us.

We hope the information provided here will spark conversations and open

all of our eyes to new perspectives. But for that to happen, we all need to contribute.

And that starts with you. Feel free to contact us with your feedback, questions

and insights. We look forward to hearing from you.

We’d like to hear your feedback.

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2015 Emerson Electric Co.

Emerson Climate Technologies Copeland Brand Refrigeration and A/C CompressorsSidney, OH

Emerson Climate Technologies, Retail SolutionsFacility ServicesKennesaw, GA

Vilter Manufacturing, LLC Compressors for Industrial Refrigeration and Oil & Gas CompressionCudahy, WI

Emerson Businesses

Fusite Seals, Feedthroughs and Precision Metal ProductsCincinnati, OH

White-Rodgers ThermostatsSt. Louis, MO

Air Comfort ProductsCeiling FansSt. Louis, MO

Control Techniques Variable Speed Drives and MotorsEden Prairie, MN

Therm-O-Disc Electronic SensorsMansfield, OH

Control ProductsCustom Electronic ControlsChanhassen, MN

Design Services NetworkDesign and Testing ServicesSidney, OH

Educational Services HVACR Training ProgramsSidney, OH

InSinkEratorWaste Disposal for Residential and Commercial UsesSturtevant, WI

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EmersonClimate.com/en-us/Pages/RSS_News_Feeds.aspx

youtube.com/user/EmersonClimateTech

@EmersonClimate

E360 LinkedIn Group: http://linkd.in/1J2hXUr

linkedin.com/company/Emerson-Climate-Technologies

EmersonClimateConversations.com

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Transcritical CO2 booster system