mAKInG moDeRn LIVInG poSSIbLe

SolutionSt 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

EnVisioneeringSM

V o L u m e 7 / I S S u e 1 / 2 0 0 8e n G I n e e R I n G + e n e R G Y e F F I C I e n C Y + e n V I R o n m e n t = e n V I S I o n e e R I n G

How the Tide is Turningthe future of energy and energy efficiency strategies

DANFOSS LOCATIONS

BALTIMORE, MD7941 Corporate Drive baltimore, mD 21236 410-931-8250 / Fax: 410-931-8256 www.danfoss.us

Refrigeration & Air-Conditioning »Industrial & Heating Controls »

TALLAHASSEE, FLDanfoss turbocor 1769 paul Dirac Drive tallahassee, FL 850-504-4800 www.turbocor.com

oil-Free Compressors for »Refrigeration and Air-Conditioning

GLENS FALLS, NYDanfoss 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, IL4401 n. bell School Road Loves park, IL 61111 815-639-8600 / Fax: 815-639-8000 www.danfossdrives.com

Drives »

MILWAUKEE, WI8800 W. bradley Road milwaukee, WI 53224 414-355-8800 / Fax: 414-355-6117 www.danfossdrives.com

Drives » nessie High pressure »Water Systems

MISSISSAUGA, ONT6711 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, NJDanfoss Hago, Inc. 1120 Globe Ave. mountainside, nJ 07092 908-232-8687 / Fax: 908-232-7246 www.hagonozzle.com

Components for oil burners »

SOMERSET, NJDanfoss bauer 31 Schoolhouse Road Somerset, nJ 08873 732-469-8770 / Fax: 732-469-8773 www.danfoss.com

Geared motors »

EnVisioneeringSm

Imagination–Action–Solutions.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 = ENVISIONEERING

mAKInG moDeRn LIVInG poSSIbLe

Jean Lupinacci fields questions from the audience during the April enVisioneering Symposium. Story on page 14.

Contents/ 2 / FROM THE COVER

How the tide is turning: the future of energy and energy efficiency strategies

/ 8 / CASE STUDIES

8 / the Kennedy building project

10/ A Case Study in energy efficiency: Field test story on the universal tR6 valve

/ 14 / NEWSWORTHY

14 / baltimore Laboratory Accredited to ISo 17025

16 / the April envisioneering Symposium

pRoDuCt HIGHLIGHtS tHIS ISSue

VSH Variable Speed Compressor / brazed plate Heat exchangers / VLt HVAC packaged Drives

Dear Readers,

We are pleased to be able to bring you relevant content about not only the respective industries you work in, but issues of a much larger scope as well. Focus on global energy issues has grown in volumes, making supply and consumption major parts of world politics, the global economy, and international relations. And the increasing world population, which is growing exponentially, will inevitably drive even greater attention to the industry.

the tide is certainly turning and the future of energy and energy- efficiency strategies is evolving. this edition of EnVisioneering Solutions puts that evolution into context; we believe energy efficiency eclipses other issues without borders and deserves critical examination from the manufacturing industry.

Danfoss is proud of its authority on energy efficiency as well as its products and technologies, which reduce energy consumption and emissions that contribute to climate change. In this issue, you will read about the broad area of energy efficiency as well as features and case studies about products that contribute positively to the environment.

As always, your comments are welcome.

The Editors solutions@danfoss.com

VoLume 7 / ISSue 1

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.

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t H e F u t u R e o F e n e R G Y A n D e n e R G Y e F F I C I e n C Y S t R A t e G I e S

today, discussions about the energy

industry are as volatile as the price

of a barrel of crude oil, and that’s

partially because advocates for the

efficient and responsible use of

energy have grown up. Literally.

How the tide is

TURNING

3

t o D AY, H I G H - p R o F I L e S u m m I t S and policy drive energy efficiency, but it wasn’t always that way.

In the 1970s, air pollution was accepted as the smell of prosperity and cars ran V8 sedans fueled by leaded gasoline. This mix of carelessness and indifference fueled the 70s environmental movement, which saw large protests and public demonstrations that decried poor environmental behavior.

Now, energy-efficiency advocates have moved off the college campus and into the boardroom, and responsibly using natural resources is as much a challenge for big business as it is for consumers—on one side, it influences investments, global trade, and foreign affairs; on the other, gasoline prices and home ownership. And there are more good questions than answers. What is the best way to calculate a carbon footprint? How can policy drive innovation in the private sector? Must going green involve high up-front costs?

A few observations, however, are likely to continue. Mounting tension between the United States and European-Union countries will likely shape energy efficiency into yet more of a geopolitical issue of relative immediacy. Domestically, the correct modifications to public energy policy could mold the global energy sector to the country’s liking.

Elsewhere, hype surrounding green products and services contribute to what some observers are calling “green fatigue” even as reliable research suggests that capital-saving technologies exists, but certain business conditions discourage consumers and business from using them. This is important to realize since decision-makers even when performing political or business duties, are energy consumers as well. »

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Taking the Temperature of the Energy Industry: Policy and Purchasing Behavior

Recently, Fathi Birol, chief economist at the International Energy Agency, said with its current policies, the greenhouse-gas emissions of the United States will increase by 18 percent between 2005 and 2025, for a cumulative increase of 38 percent between 1990, the benchmark from which emission rates are closely watched, and 2025. However, if more aggressive energy efficiency policies are implemented soon, Birol said, that rate would drop by 15 percent.

Meanwhile, the EU has said it will cut its own carbon pollution by 20 percent by 2020, compared with 1990 levels. However, if the United States follows suit, the EU would deepen its reduction to 30 percent, although such a scenario seems unlikely to most observers. This could either indicate the EU’s commitment to leading this type of reduction or its confidence that the United States will fall short of achieving a competitive decrease in emissions.

Whatever the EU’s expectations might be, one truth holds certain: the United States controls its own destiny with regards to energy policy. Energy use in the home is a growing concern to some policymakers, while others trumpet creating different incentives for utility companies to control capacity and the private sector to innovate.

Right now, one key feature of energy policy in the United States is the minimum performance levels set forth for new appliances, automobiles, and other everyday items that consume energy. These mandates were a great place to start discovery on energy technology, but innovation in design has caught up to the requirements. What’s left is an ample supply of energy-efficient goods—refrigerators, air-conditioning units, home insulation, automobiles—and a surplus of consumers who would use them but not for their upfront costs. There are not enough good reasons for them to replace old equipment with something that’s better.

Instead, policy needs to give steadfast incentives for the use of energy-efficient equipment, not simply mandate a floor on what efficiency standards new purchases must meet. The tax write-offs that come with the purchase of a hybrid automobile is an example of good policy that lawmakers could take to further encourage better use of existing technology. Relatively simple technologies like compact fluorescent light bulbs and programmable thermostats could reduce consumption and pay off quickly.

Another area of concern lies with both public and private utility companies, which largely act as manufactured, controlled monopolies. Utilities have financial incentives to sell more energy—they ought to be motivated to sell less.

Some seemingly drastic options come to mind to address such an imbalance:

revamping the rate-setting process »

creating competition »

decoupling revenue from unit sales »

38%The projected increase of greenhouse gases emitted by the United States between 1990 and 2025 if aggressive energy efficiency policies are not implemented.

C o V e R S t o R Y C o n t I n u e D

Policy needs to give steadfast incentives

for the use of energy-efficient equipment,

not simply mandate a floor on what efficiency

standards new purchases must meet.

V o L u m e 7 / I S S u e 1 / 2 0 0 8 5

Market Conditions that Don’t Promote Use: A Focus on Energy Productivity

Global energy demand will almost surely speed up for the near-term future, and the contention that the pace of increase will strain consumers and economies along with the environment is nothing new. What is new is the widening scope of research that suggests practical strategies for managing that growth.

The McKinsey Global Institute (MGI), a division of consulting firm McKinsey & Co., recently stated that investments in energy productivity, or the levels of output achieved from energy consumed, are “very attractive.” A portion of these investments help companies meet regulatory requirements, but a large percentage boosts energy productivity using technologies that pay for themselves and free up resources for investment or consumption elsewhere.

This is sometimes called cost avoidance, and it echoes sentiment of those who champion incentives granted to consumers and businesses that replace outdated equipment with that which is more energy-efficient. »

green fatigue: buyers’ growing mistrust of overused marketing terms such as “sustainable” and “eco-friendly,” discouraging them from purchasing products that are legitimately energy-efficient

Marketers that can’t back up their claims with empirical data to support green claims drive customers and goodwill away from products that are legitimately energy efficient and have practical business or financial value. While conventional marketing wisdom advises against confusing consumers, the number of products touted as “green” does just that—recent research by The Sheldon Group, a research firm, found the number of people willing to choose one house over another based on energy efficiency alone fell more than 16 percent from 2006 to 2007, with buyers’ mistrust of terms like “sustainable” and “eco-friendly” driving that decrease.

Products from chewing gum to laptop computers are now touted as being substantially more energy efficient

ILLUSIONS AND EMBELLISHMENT: Green marketing may be What’s Worst About energy efficiencythan others. This “gotcha”-type marketing discourages the purchase of products or components that are legitimately energy-efficient.

TerraChoice, a marketing firm that specializes in energy efficient products and services, released a similar report late last year that cites six tactics to avoid when advertising a product as energy efficient or green—so-called “greenwashing.” These include hiding trade-offs, not providing proof, being vague, not remaining relevant, lying, and stating the lesser of two evils only. Among the 1,753 products the firm examined for the study, all but one of them used at least one of these tactics, with 57 percent of those instances being the hiding of trade-offs.

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C o V e R S t o R Y C o n t I n u e D

Average internal rate of return for investing in newer, energy efficient equipment and technologies.

cost avoidance:investments in energy productivity using technologies that pay for themselves and free up resources for investment or consumption elsewhere

The MGI report also stated:

Such investments average an internal rate of return of 17 »percent and could generate energy savings of nearly $900 billion annually by 2020.

energy productivity is the most cost-effective way to reduce »global emissions of greenhouse gases

Capturing a high level of energy productivity could go halfway »toward keeping the long-term concentration of greenhouse gases in the atmosphere from encountering a significant increase in mean temperature

This alone is ample proof for some to consider energy efficiency not just for its environmental sensibilities, but for its business benefits as well. The report states expenditures across the board for energy efficiency hover around 1.6 percent of global fixed capital investments, or 0.4 percent of aggregate GDP. So upping investments in energy-efficient infrastructure makes good business sense when done properly.

However, current conditions discourage businesses from making larger investments in these strategies and investors from pouring money into energy efficiency. Fuel subsidies, for example, directly discourage productive energy use, but the International Energy Agency estimates that, on average, an additional $1 spent on more-efficient electrical equipment, appliances, and buildings avoids more than $2 in future investment in electrical supply.

Conversely, fuel taxes directly encourage conservation, but are extremely unpopular in the US, even if offset by other tax cuts.

Written another way: Energy efficiency might very well be the cheapest form of new energy available, but there aren’t enough immediate reasons to strive for it.

Chiefly among the report’s recommendations are implementing energy-efficiency standards for appliances and equipment, upgrading building efficiency and automation, raising corporate standards for energy efficiency, and investments in energy intermediaries like energy services companies.

17%

Energy efficiency might very well be the cheapest

form of new energy available, but there

aren’t enough immediate reasons

to strive for it.

Danfoss Introduces brazed plate Heat exchangers

Danfoss, a global leader in supplying components, controls, compressors and solutions for air conditioning and refrigeration, introduced earlier this year the newest extension of its product portfolio, brazed plate heat exchangers.

the exchangers are tailored for refrigeration and air conditioning systems, can be customized for specific application requirements, and offer an environmentally responsible solution for a wide range of applications. each brazed plate heat exchanger is engineered to add value over its lifetime, providing superior performance and cost-effectiveness.

each exchanger consists of a series of thin, corrugated metal plates that are brazed together to improve heat transfer efficiency. the plates are compressed together

in a rigid frame to create an arrangement of parallel flow channels, in which one high-viscosity fluid travels through the odd-numbered channels, and the other high-viscosity fluid flows through the even-numbered channels.

“We are continuously striving to develop and provide environmentally friendly and energy-efficient products,” says peter J. D’Ambrosio, strategic global marketing manager-heat transfer, Danfoss Inc. “our brazed plate heat exchangers are space-saving, offer a highly flexible design for manufacturing, and require less use of refrigerants.”

“With our entire range of heat exchangers, we offer our customers an opportunity to define both the capacity and connections they need for their specific application,” D’Ambrosio says. “As an added benefit to the customization

Danfoss brazed plate heat exchangers are tailored for refrigeration and air conditioning systems, can be customized for specific application requirements, and offer an environmentally responsible solution for a wide range of applications.

options, the brazed plate heat exchangers, because of their high heat transfer performance, contribute to an increase in overall cooling capacity. this not only reduces energy consumption, but it provides the best value over the longest period of time as well.”

Danfoss offers 15 brazed plate heat exchanger models. each model is compactly designed and combines high efficiency with energy-saving qualities.

model b3-048 is designed with a special patent of different corrugation depth on the same plate. With a capacity of 30 – 80 kW, this model allows a larger water flow rate, lower pressure rate drop and lower refrigerant charge. model b3-260 is the ideal choice for HVAC and chillers, while Danfoss makes 10 different models for boilers and chillers. And, for air

driers and chillers, Danfoss recommends models b3-014, b3-027 and b3-136. the entire range of brazed plate heat exchangers can also be used for heat pumps, economizers, de-superheaters and numerous other applications.

Danfoss brazed plate heat exchangers perfectly fit applications in the food, beverage, pharmaceutical and chemical process industries, in indirect and direct air compressors, and in commercial refrigeration applications such as supermarket systems, ice making machines, beverage cooling and more.

FoR moRe InFoRmAtIon:

contact 410-931-8250

baltimore@danfoss.com

www.danfoss.us

p R o D u C t H I G H L I G H t

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t H e K e n n e D Y C e n t e R for the Performing Arts is an imposing place. Located on 17 acres overlooking the Potomac River in Washington, D.C., it is America’s living memorial to President Kennedy as well as the nation’s busiest arts facility, presenting more than 3,000 performances each year.

Even without the gravity lent to the building by its namesake, it boasts an impressive history of guests over the years who have been drawn to the majesty of the venue. Much of the building’s grandeur comes from its cavernous interior spaces, which also recently made it a prime candidate for renovation of its HVAC systems.

The Kennedy Center was designed in the mid 1960s and opened to the public in September of 1971. During

its conception, the issues relating to energy prices and sustainability weren’t even on the radar. But they certainly are today.

Before undergoing major renovations a few years ago, the buildings were completely electric and very expensive to operate. Today, Danfoss VLT drives help keep patrons, musicians and other artists comfortable while using less energy.

Danfoss’ customer, Johnson Controls, put together a broad solution for lighting, heating and cooling systems in the facility. Danfoss VLT Series drives became embedded in the new variable volume air handling solutions, replacing the old constant volume motor starters. The drives are an important part of the converted VAV air-handling system

C A S e S t u D Y

Danfoss keeps things in tune at the

KENNEDY CENTER

C A S e S t u D Y o n e

p R o J e C t H I G H L I G H t S

25 air handlers installed in multiple zones »

larger VLt drives used for the Center’s »1200 Rpm fan motors

vertical configuration of drives allowed for »installation in tight spaces

V o L u m e 7 / I S S u e 1 / 2 0 0 8 9

As buildings age and energy conservation becomes increasingly relevant, there will be many opportunities for implementing new and better technology in installations around the world to promote more efficient use of diminishing resources.

for the facility, and are used to control hot water pumping systems. The VLT drives were also installed on the secondary pumps in fan pumping systems. The application was complex, with about 25 air handlers in multiple zones.

Chip Aranowski, sales manager for Danfoss, said he knew Danfoss could solve the challenges Johnson Controls faced for this application. The fans were driven by 1200 RPM motors, which require a larger drive. These motors start up more slowly and place a greater strain on the system than 1800 RPM motors, which are more typical in these applications. 1200 RPM motors are rare, and it is especially unique to see so many in one application. The application had to be reassessed in the middle of the project to compensate for the motor type.

A second challenge: In existing buildings, the mechanical or electrical equipment room is often very short on empty wall space. The traditional drives package requires drives to be mounted in horizontal, side-by-side cabinets that take up a large area. At the time, there were few, if any, drive manufacturers other than Danfoss that offered a narrow vertical configuration for drive installations. This unique capability was a prime consideration in choosing Danfoss, which produces tall and skinny integrated drive packages that fit where side-by-side configurations wouldn’t.

As buildings age and energy conservation becomes increasingly relevant, there will be many opportunities for implementing new and better technology in installations around the world to promote more efficient use of diminishing resources. Variable frequency drives can be a major part of the solution, partly due to the ease with which they can be retrofit into existing applications. Conservation must be a prime component of any responsible energy policy, and more and more applications are showing that drives can offer something in the form of greater efficiency that is relatively simple and cost-effective to implement.

The Kennedy Center was designed in the mid 1960s and opened to the public in September of 1971. During its conception, the issues relating to energy prices and sustainability weren’t even on the radar.

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C A S e S t u D YC A S e S t u D Y t W o

n o Lo n G e R J u S t a dire prediction, budget-breaking energy costs have arrived in the US, long fortunate to have among the world’s very lowest utility costs. Though the winter just past was relatively mild in many areas, consumers were still beset by utility bills increased by fifty percent and more over prior years. Further increases will likely arrive during the summer cooling season if predictions are “on the money.”

Pressed by federal regulations to improve energy efficiency by a measurable 30 percent, air conditioning system manufacturers redesigned the hundreds of units in their product offerings to meet the new requirement.

In 2001, five years before the requirement was to go into effect, Danfoss began development of an expansion valve, type TR6, designed specifically to improve the efficiency of new residential air conditioning systems. Testing of the new valve on OEM systems in both Danfoss and OEM laboratories showed that the improvement in efficiency over the fixed orifice devices previously in use was significant and would be a major contribution to meeting the SEER 13 requirement. With the TR6, and with further work by Danfoss and OEM partner engineers, compliant new systems could be offered by the 2006 deadline at more reasonable prices than had been expected. One reason was the inclusion by Danfoss in the TR6 of a patented internal

Upgrade existing air conditioning systems and achieve up to 40%

ENERGY SAVINGS

t H e u n I V e R S A L t R 6 V A L V e

retrofits to all air conditioning units »

easily installed by technicians in the field »

thermostatic expansion valve allows for »maximum efficiency

pays for itself in about 9 months »

V o L u m e 7 / I S S u e 1 / 2 0 0 8 1 1

check valve. Check valves are essential in heat pump systems when the refrigerant flow reverses in the system to provide heating rather than cooling.

The advantage of a thermostatic expansion valve like the TR6 over the traditionally used fixed orifice regulation is that the fixed orifice device constantly delivers the same amount of refrigerant to the system, regardless of the amount of cooling needed for the living space. When the temperature inside has been brought to the desired level, then rises a bit, the system comes on and delivers the same maximum cooling that was required for a large temperature drop. The compressor runs full out, using maximum energy, usually for its fixed minimum run time.

In contrast, an expansion valve has a sensing bulb that constantly monitors the evaporator and varies the flow of refrigerant so that the evaporator is used with maximum efficiency. This means that when the requirement for cooling is reduced, about 70 percent of the time, there is less flow, the compressor does not work as hard, and considerable energy is saved.

Designed with its patented features specifically for residential air conditioning, the Danfoss TR6 valve is a very efficient solution. It provides air conditioning manufacturers significant help gaining the efficiency improvement needed to meet the impending federal regulations for new equipment. And the new efficiency will be greatly appreciated by homeowners as utility rates increase.

But there are many more homeowners, not limited to those in the United States, with existing systems manufactured before 2006 that are working very well. Through regular seasonal checkups and maintenance, it could be expected that these older systems could give service and comfort for many more years. The cost of continuing operation, though, would be painful. On the other hand, the cost of a new highly efficient system was for most homeowners prohibitive. Could the new TR6 expansion valve help these customers? In the spirit of EnVisioneering, Danfoss turned its attention to finding an answer.

The answer was “Yes.” Retrofit of an expansion valve to an existing residential installation was possible. Danfoss performed laboratory tests to demonstrate that the valve installation procedure could be accomplished by a technician in the field.

The problemThere was one problem: the variety of air conditioning systems, some twenty years old or more, many newer, used three different and incompatible styles of connection. That meant that three valve models would have to be made in each capacity, and that service technicians would have to carry them all as truck stock.

The solutionDanfoss engineers, marketing, and sales professionals, working with contractor customers, developed a solution in early 2006, realizing that a single valve kit with all three types of connections found on existing residential air conditioning systems was a possibility.

For years, Danfoss had been selling fitting adapters for certain models of its expansion valves, so that a single model could serve where either brazed connections or flare »

thermostatic expansion valve:regulator with a sensing bulb that constantly monitors the evaporator and varies the flow of refrigerant accordingly, ensuring that the evaporator is used with maximum efficiency

[The TR6 valve] provides air conditioning manufacturers significant help gaining the efficiency improvement needed to meet the impending federal regulations for new equipment.

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C A S e S t u D Y C o n t I n u e D

27.8%

4.5

9

Average number of hours taken for a field technician to install the Universal TR6 valve

Average saving of kilowatt hours after installation of the Universal TR6 valve

Calculated months of operation it would take for the valve to pay for itself in utility savings

t R 6 F I e L D t e S t I n G

the numbers

connections were needed, thus cutting in half the number of different valve models that a technician needed to carry. Now the same principle was applied to expansion valves for upgrading serviceable systems.

A sound propositionFor the homeowner, an upgrade that saves considerable energy is a very sound proposition both economically and environmentally. For the contractor, being able to offer the energy-saving Universal TR6 upgrade presents the opportunity for an additional sale, and one whose benefit is apparent.

There were many questions about the new Universal TR6 kit. Contractors wanted to know how much could be saved and, most importantly, how long it would take a technician to install and adjust the valve.

To answer these questions, Danfoss application engineers undertook a field test to provide the needed data about actual savings from a Universal TR6 upgrade, to determine how much time a field technician would need to install the Universal TR6 upgrade, and also to study best practices for the installation.

For the test, homes of average size (2300 square feet) were chosen, with air conditioning and heat pump systems in service over a wide range of time periods and in a range of sizes. To isolate savings to the TR6 valve installation, each system was checked for other factors that might influence results: indoor airflow and filter cleanliness; indoor and outdoor coil cleanliness; proper refrigerant charge; proper sizing of the system for the residence; and that customers were, overall, satisfied with system operation and comfort provided.

Universal TR6 valves were installed, with best practices for an efficient installation being noted by the application engineers for all three types of connections—solder, Aeroquip, and Chatleff. Then, using the power monitoring capabilities of a Danfoss AK2-SC 255, power consumption for each system was recorded before and after valve installation. Indoor temperature and humidity as well as mechanical system temperatures and pressures were also recorded. Data were adjusted for degree days.

The results of the field test showed a remarkable average savings in kilowatt hours of 27.8 percent. Using the best practices followed by Danfoss application engineers for the installations, about 4.5 labor hours were required, and at prevailing average labor rates and utility rates, it was roughly estimated that the homeowners utility savings would pay for the upgrade in 9 months of operation (which in the Chesapeake region would be less than 2 air conditioning seasons). In addition, indoor comfort was better, with lower humidity, using the Danfoss valve.

Development of the Universal TR6 expansion valve, its effect on efficiency and our environment, shows how Danfoss EnVisioneering often extends development of a product from one application to a related one, with a profound effect on modern life.

See how to install a Universal TR6 valve on an existing HVAC system at http://www.envisioneering.danfoss.com/trvalves.aspx

Danfoss Drives has introduced VLT® HVAC Packaged Drive Solutions, new designs for Electronically Controlled Bypass (ECB) and Electro-Mechanical Bypass (EMB) systems.

eCb packages allow the user to program advanced bypass control features directly from the VLt HVAC drive keypad, including automatic bypass, advanced firefighter’s override, coordinated run-permissive in both drive and bypass, and serial control while in bypass operation. the emb packages are designed for users that prefer the traditional control provided through selector switches and pilot devices.

“by combining the advanced features of the VLt HVAC Drive with the advanced performance of these packaged Solutions, Danfoss is uniquely positioned to provide complete, advanced solutions to the HVAC market that to date have simply been unavailable,” says ed Smith, former HVAC product

manager. “All packages allow the customer to match the capabilities of the packaged Solution with the specific needs of the application,” he says.

each package provides improved protection and operation through a first-of-its-kind bypass 24VDC switch mode power supply. Contactor operation is maintained in harsh conditions, and drive operation can be maintained at a reduced output with an input voltage as low as 70 percent of nominal voltage, or with one input phase missing. this improves operation over standard transformer power supplies or power supplies that only operate off of two legs of input power. Additionally, the unique power supply acts as a backup power source to the drive logic for eCb packages when power is removed from the drive’s input terminals. this allows operation of all control features to remain active in drive and bypass modes.

packages are available in either two contactor or three contactor configurations, from ½ Hp through 350Hp at 460 & 600VAC, or ½ Hp through 60Hp at 208 and 230VAC. nemA/uL type 1 or type 12 enclosures are available for all package configurations, and in many cases the physical size of the packaged solution does not change with the enclosure rating. All packages include drive-only input fusing. A wide range of optional power features are available including contactor motor selection, input reactors, dV/dt filters, and selection between input disconnect, fused disconnect or circuit breaker.

p R o D u C t H I G H L I G H t

FoR moRe InFoRmAtIon:

contact 800-621-8806

salesinformation@danfoss.com

www.danfossdrives.com

Danfoss Introduces new packaged Solutions to optimize and Simplify HVAC operations

Combine with popular VLT® HVAC Drives to provide unparalleled flexibility, performance and protection in HVAC applications.

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NewsWORTHyR E C E n T n E W S A n D U P D AT E S f R O M D A n f O S S

ISO-Certified Application Laboratory: another service for our customersFor a manufacturer, changing components in a product can improve its performance, appearance, efficiency, and overall quality. these variables are often affected by what seems to the end user to be a relatively simple change.

but before changing any part of a product, manufacturers need to take every possible step to ensure a very high probability of success with the new design, because any variation in a product’s design could necessitate changes in manufacturing techniques, resources, assembly procedures, and logistics. there are other important considerations, too: from quality control procedures to packaging. Clearly a thorough study must be made of any contemplated change and its effect on every factory practice.

to ease the process, to benchmark, and to possibly provide additional solutions, Danfoss has established at baltimore a certified application laboratory for refrigeration equipment.

Initiation of a performance test, or the acceptance process for a design change using Danfoss components or subassemblies, starts with an inquiry from an oem partner working with a Danfoss sales engineer to Danfoss application engineering. the contribution of the Danfoss component is studied, modeled, and estimated. When the potential is strong, tests are designed.

the first tests are of functionality, determining that the Danfoss product integrates well into the oem design. Always working through the Danfoss sales engineer and with the oem’s design staff, the laboratory staff and application engineers often suggest additional modifications that will help to produce a more efficient, appealing product.

Very often, Danfoss is called upon to prove its suggestions, and indeed Danfoss has been performing laboratory tests on oem equipment for many years, with the tests being verified

in oem facilities. most, however, of the Danfoss laboratory facilities were in europe, and testing facilities here in north America were in need of expansion and enhancement as a growing customer base sought Danfoss refrigeration and air conditioning expertise to improve their products. thus Danfoss took the giant step of creating an ISo-Certified Commercial Refrigeration Laboratory at the north American Headquarters in baltimore. A certified laboratory would give Danfoss the ability to develop solutions on a larger scale, and to expand and solidify partnerships with customers who manufacture appliances for refrigeration and freezing, ice production and storage, bottle cooling, vending, frozen carbonated beverages, and other applications.

Customers find the Commercial Refrigeration Laboratory a welcome addition to Danfoss services. not only is the lab able to prove the proposition of redesign using a Danfoss product, but customers use the lab to validate the results of their own testing.

ISO certification means that the Danfoss Commercial Refrigeration Laboratory can be relied upon to produce impartial, accurate reports based on testing methods compliant with ISO standards.

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A typical scenario is this: the testing process begins with a customer request. next, an agreement is executed that binds the Laboratory to strict confidentiality. only the oem, his Danfoss sales representative, the involved application engineer and the laboratory technician directly involved have knowledge of the brand and model of product being tested, or that the test is underway. test reports are strictly guarded as confidential, in accordance with ISo Standard 17025. Specific tests are agreed to in the document and methodology. Documentation is specified, and importantly, the reports to be issued are described in detail. When the customer product arrives at the Danfoss north American laboratory, the first step is benchmarking performance, which establishes a baseline for comparison. then, the product is tested strictly according to the test specification. photographs are taken throughout the process. the lab’s calibrated environmental chamber is used in many tests to determine how the product performs under various carefully controlled ambient conditions. these tests are made during benchmarking as well as with the Danfoss solution. Finally, the reports are made, checked, and delivered to the customer. Frequently, Danfoss returns suggestions for additional improvements to the product that will enhance performance or make manufacturing a more efficient process.

the certification process for laboratories is conducted according to ISo Standard 17025. Like other ISo certifications, the demands are rigorous, requiring documented procedures for the types of tests performed, calibration of instruments, and documentation of the results, and specific programs for continuous improvement, all demonstrated during initial and periodic audits by an independent and impartial certifying authority. A strong year-long effort put forth by the application engineering department and the laboratory staff, with the support of Danfoss management, was proven effective when the Danfoss Commercial Refrigeration Laboratory received official ISo 17025 certification in April 2008.

the Danfoss Commercial Refrigeration Laboratory was created through the efforts of many Danfoss people, and certified to ISo Standards with one goal: to serve Danfoss oem customers by providing additional value to the products that those customers make. Like many Danfoss efforts, the ultimate benefit is to the end users of those products with longer life and better efficiency, and to those users’ customers in turn.

Learn more about Danfoss North America and keep up-to-date on the latest news about Danfoss products and your industry at www.danfoss.us

Before changing any part of a product, manufacturers need to take every possible step to ensure a very high probability of success with the new design, because any variation in a product’s design could necessitate changes in manufacturing techniques, resources, assembly procedures, and logistics.

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NewsWORTHy C o n t I n u e D

Danfoss-Sponsored Panel Gives Answers to Energy-Efficiency Questionse n e R G Y L e A D e R S A n D policymakers convened in Washington, D.C. April 4 and generated observations and predictions to proverbial power issues that have surrounded energy efficiency for some time.

the Danfoss enVisioneering Symposium, “Is the tide turning on energy efficiency Strategy?”, attracted more than 30 representatives from the federal government, energy utilities, foreign embassies, and the HVAC&R industry. the day-long event featured presentations from five energy experts followed by an interactive discussion of specific ways to address the global energy challenge and specific recommendations for public policy change.

“the tide is turning, but we need to change our respective approaches,” said Robert thompson, project manager of Commercial energy efficiency programs for pasadena (Calif.) power and Water. “For example, utilities need to go outside the box and incorporate new energy-efficient technologies.”

With thompson’s leadership, the utility created and now organizes an annual energy fair, where industry presents its best energy-efficient technologies for stakeholders— government agencies, engineering firms, end users and others—to consider and, potentially, implement. thompson’s goal, he said, is to put energy savings first and costs second, a seemingly counterintuitive prospect for his utility counterparts.

thomas Hartman, president of the Hartman Company, echoed similar sentiments. “the power of utilities needs to be redirected. … For utilities, it’s a change from selling energy to managing energy.”

Darrell beschen, chief economist for energy efficiency and Renewable energy, u.S. Department of energy, said the Department will continue to research and develop renewable

energy technologies. He noted that renewable energy, as a percentage of annual new energy capacity additions, increased from 2 percent in 2004 to 22 percent in 2006.

the panel also discussed at length the decoupling of electric utility revenues from KWH sales and the creation of incentives to upgrade old, inefficient equipment.

Robert Wilkins, president of Danfoss Inc. (u.S. and Canada), summed up the symposium, noting that all stakeholders can and should make valuable contributions to the global energy challenge.

“energy-efficient technologies are available right now, and they’re making an impact in the u.S. and abroad,” Wilkins said. “but we still have a long way to go to make those technologies universal. that’s why these symposia events are so valuable. new ideas and solutions—and new ways to apply them—come to the forefront at every event.”

More than 30 representatives from the federal government, energy utilities, foreign embassies and the HVAC&R industry attended the seventh Danfoss EnVisioneering Symposium April 4 in Washington, DC.

A video of the symposium can be viewed at http://www.envisioneering.danfoss.com/2008.aspx

Danfoss Introduces World’s First Commercial Variable Speed Scroll Compressor for Air Conditioning with R-410A

The new Danfoss ApexxTM VSH compressors are the first high-capacity, R-410A, variable speed scroll compressors for air conditioning and heat pumps.

In January of this year, Danfoss introduced the ApexxTM VSH series compressors: the first R-410A variable speed scroll compressors for commercial air conditioning and heat pumps. Compared to conventional systems, users can realize energy savings of more than 20 percent when using a Danfoss VSH compressor.

Capacity of the new VSH compressor series varies continuously to match the system load, with an operation range from 30 Hz to 90 Hz. Danfoss offers three VSH packages that cover a 90 Hz design capacity range from 11 to 23 tR (R-410A). Delivered capacity is from 3.5 to 23 tR, depending on the load. the drive in each VSH package is designed specifically to match its compressor.

“Compressors in traditional commercial system designs are sized for most efficient operation under peak load conditions,” said Greg Johnson, strategic marketing manager at Danfoss in baltimore. “these compressors, without

unloading capability, will deliver excess capacity under the part-load conditions that exist 85 percent or more of the time. the penalty is significant and costly energy waste.”

traditional systems address part-load conditions with multiple compressors or with unloading techniques such as hot gas bypass or digital compressor technologies. these unloading techniques are inefficient either because high compressor efficiency cannot be maintained at part load or because load-matching capability is limited.

“In contrast, the Apexx VSH compressor is designed to maintain high isentropic efficiency at part load, and it has the inherent benefit of precisely and continuously matching the load,” Johnson said. “In addition, continuous operation means less cycling and system stress, higher reliability and longer lifetime.”

With Apexx VSH compressors, the power factor remains above 0.90, regardless of the load, and can result in lower utility charges. Also, drive controller logic ensures a

soft start that reduces in- rush current and adds to energy savings.

VSH compressors offer greater comfort as a result of tighter temperature control and the ability to cool or heat rapidly on demand by instantly increasing speed. there is significant noise reduction, particularly at part-load conditions. this is important at night, when loads are typically lowest and a VSH compressor cycles at its lowest (and quietest) speed.

Customized drive software protects the compressor and provides multiple control options supported by I/o capability for communication, control and monitoring. electromagnetic compatibility filters are built into each drive and comply with the stringent en 55011 standard, virtually eliminating electrical interference.

Smaller than a fixed-speed compressor of similar capacity, the VSH compressor enables designers to create more compact designs and take advantage of new opportunities that eliminate

hot-gas-bypass piping, avoid manifolds, and reduce circuits. Contactors are not required.

the reliability built into the VSH series begins with advanced motor protection that includes protection from short-cycling, current measurement of each phase, high discharge temperature protection, oil management, reverse rotation protection, high tolerance of voltage imbalance, and a built-in crank case heater.

the Apexx VSH series includes a user-definable closed-loop pID capacity controller, load monitoring, and an innovative pack controller for hybrid units that have both VSH and fixed-speed compressors. An optional graphic display and keypad, with onboard memory, can be used for parameter changes and commissioning.

FoR moRe InFoRmAtIon:

contact 410-931-8250

baltimore@danfoss.com

www.danfoss.us

p R o D u C t H I G H L I G H t

SolutionS

June 2008» EnVisioneering Symposium:

“The Owner Nexus” June 21, 2008 Denver, Colorado

» Sensors Expo & Conference June 9–11, 2008 Donald e. Stephens Convention Center, Rosemont, IL

SeptembeR 2008 » Comfortech

September 10–13, 2008Georgia World Congress Center, Atlanta, GA

» RSES Annual Conference September 16–20, 2008 Hilton Hotel, Indianapolis, In

» Johnstone Supply Annual Meeting and Trade Show September 19–21, 2008Chicago, IL

SeptembeR (ContInueD)» RETA: Refrigerating Engineers

and Technicians Association September 24–26, 2008 Hershey Lodge and Convention Center, Hershey, pA

oCtobeR 2008» WEFTEC: Water Environment Federation

Technical Exposition & Conference October 19–22, 2008 mcCormick place, Chicago, IL. Visit Danfoss booth #21015 Hall b

» HARDI: Heating, Air-Conditioning and Refrigeration Distributors International October 25–28, 2008 JW marriott Desert Ridge Resort and Spa, phoenix, AZ

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.com

DANFOSS LOCATIONS

BALTIMORE, MD7941 Corporate Drive baltimore, mD 21236 410-931-8250 / Fax: 410-931-8256 www.danfoss.us

Refrigeration & Air-Conditioning »Industrial & Heating Controls »

TALLAHASSEE, FLDanfoss turbocor 1769 paul Dirac Drive tallahassee, FL 850-504-4800 www.turbocor.com

oil-Free Compressors for »Refrigeration and Air-Conditioning

GLENS FALLS, NYDanfoss 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, IL4401 n. bell School Road Loves park, IL 61111 815-639-8600 / Fax: 815-639-8000 www.danfossdrives.com

Drives »

MILWAUKEE, WI8800 W. bradley Road milwaukee, WI 53224 414-355-8800 / Fax: 414-355-6117 www.danfossdrives.com

Drives » nessie High pressure »Water Systems

MISSISSAUGA, ONT6711 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, NJDanfoss Hago, Inc. 1120 Globe Ave. mountainside, nJ 07092 908-232-8687 / Fax: 908-232-7246 www.hagonozzle.com

Components for oil burners »

SOMERSET, NJDanfoss 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

2008 Calendar of Events