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On Balance:Heat Rejection Controla Packaged Solution

Echelon Americas Channel Partner ConferenceMarch 11, 2005

Presented by

Doug ScottVaCom TechnologiesLa Verne, California

2

Opportunity

An integrated packaged control with:Broad applicabilityValue to end usersValue to integratorsOpen systems benefits

3

Description

One-box integration of:Variable speed drivesBypass controlsControllerUser interfaceEnergy efficiencyCommunications

4

Application

Any type of heat rejection to ambient:Air-cooled condensersEvaporative-cooled condensersFluid coolers (evap or air-cooled)Cooling towers

5

Value to Owners

Lower installed costLower operating costsReliabilityServiceabilityEasier life-cycle cost maintenance

6

Value to Integrators

Higher delivered value to ownerDifferentiation with life cycle cost

Save cost and time vs. custom buildNew business

Retrofit previous projectsFirst opportunity for new customersLeverage utility incentives

7

Add to Open Systems Value

Subsystem control example:Integrate subsystem elementsBuilt-in energy efficiency optimizationPush intelligence closer to end-use

Information = service opportunityManufacturers monitor during warrantyThird party service and monitoring

Flexibility: integrate now or later

8

Energy Background

Concepts Vapor compression cycleLift and floating head pressureVariable speed – affinity lawsSystem balance

9

Vapor Compression Cycle

CompressorPower

Compressor

Low-pressure

Vapor

Evaporator

Condenser

Low-pressureLiquid

LiquidHigh-pressure

Expansion Valve

Low-pressureVapor

Heat source (Cooling)

BASIC CONCEPTS

Energy is conserved -- energy in equals energy out.

Compressor pumps vapor; refrigerant has the cooling effect: Lb/Hr X BTU/Lb= BTU/Hr

High-pressure Vapor

10

Cooling System “Lift”

Evap

orat

or /

Con

dens

ing

Tem

p

-20

100

70

20Lo

w T

empe

ratu

reFi

xed

Hea

d

Low

Tem

pera

ture

Floa

ting

Hea

d Med

ium

Tem

pFi

xed

Hea

d

Med

ium

Tem

pFl

oatin

g H

ead

Fixed

Floating

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Fixed vs. Floating Head Pressure

20

30

40

50

60

70

80

90

100

Jan Feb Mar Apr May Jun Jly Aug Sep Oct Nov Dec

Tem

pera

ture

, F

Ambient Fixed Setpoint Floating Setpoint

12

Variable Setpoint Control

40

50

60

70

80

90

100

Ambient Temperature Condensing Temperature Setpoint

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Floating Head Pressure –Impact on capacity

30

40

50

60

70

80

90

5060708090100

Condensing Temperature, F

Capacity, Tons

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Floating Head Pressure –Impact on capacity and power

30

40

50

60

70

80

90

5060708090100

Condensing Temperature, F

Capacity, Tons Power, kW

15

Floating Head Pressure –Net effect on efficiency

0

0.2

0.4

0.6

0.8

1

1.2

5060708090100

Condensing Temperature, F

Efficiency, kW/Ton

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Variable Speed Fan Control Third power relationship

0 %

1 0 %

2 0 %

3 0 %

4 0 %

5 0 %

6 0 %

7 0 %

8 0 %

9 0 %

1 0 0 %

0 % 1 0 % 2 0 % 3 0 % 4 0 % 5 0 % 6 0 % 7 0 % 8 0 % 9 0 % 1 0 0 %

F an S p eed %

Fan

Pow

er %

Capacity varies directly with change in

airflow

Fan power varies with

cube of change in airflow

80% speed = 51% power

50% speed = 12% power

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Part Load PerformanceVariable speed vs. fan cycling

50% capacity 50% power

80 BTUH/Watt

50% capacity 12% power

330 BTUH/Watt

On On Off Off

50% 50% 50% 50%

Specific efficiency increased by 300% with variable speed

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Energy SavingsEnergy Savings come from:

Lower head pressureLower fan power

Variable speedVariable setpoint

System stabilityOverall: optimum system balance

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Early ExperienceSuccessful supermarket trial

Vons Controls Retrofit -- Four Store Summary

0

200

400

600

800

1000

1200

1400

Jan Feb Mar Apr May Jun Jly Aug Sep Oct Nov Dec

Mon

thly

kW

h, T

hous

ands

1995 kWh

Cumulative Savings

92 - 94 Average kWh

Savings Target

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Case Study

Cold storage warehouse in StocktonEvaporative condenserBase case = fixed SCT at 85 FOptions

Float SCT using fixed setpointAdd variable setpointAdd variable speed with fixed setpointAdd variable speed with variable setpoint

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Results

FHP FSP VSP VFD Savings Payback NPV

X X 6,400$ 0.3 63,500$

Control Options

Annual Energy, mWh

0 250 500 750 1000

Base

Option 1

Compressor Condenser

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Results

FHP FSP VSP VFD Savings Payback NPV

X X 6,400$ 0.3 63,500$

X X 8,400$ 0.6 80,300$

Control Options

Annual Energy, mWh

0 250 500 750 1000

Base

Option 1

Option 2

Compressor Condenser

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Results

FHP FSP VSP VFD Savings Payback NPV

X X 6,400$ 0.3 63,500$

X X 8,400$ 0.6 80,300$

X X X 9,100$ 4.4 52,900$

Control Options

Annual Energy, mWh

0 250 500 750 1000

Base

Option 1

Option 2

Option 3

Compressor Condenser

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Results

FHP FSP VSP VFD Savings Payback NPV

X X 6,400$ 0.3 63,500$

X X 8,400$ 0.6 80,300$

X X X 9,100$ 4.4 52,900$

X X X 21,600$ 2.1 175,300$

Control Options

Annual Energy, mWh

0 250 500 750 1000

Base

Option 1

Option 2

Option 3

Option 4

Compressor Condenser

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Example System

75 Ton condenser for two glycol chillers with four

separate high sides

Estimated first cost savings:

$3,000 savings in reduced custom programming

$2,500 savings in reduced on-site electrical installation cost and MCC hardware

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Typical Panel

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Controller I/O

Analog inputsAmbient DBTAmbient RHDischarge pressures

Digital inputsFan enablesVFD statusOverride statusPump proofDefrost monitor

Digital outputsVFD enableVFD auto bypassPump enableEmergency spray

Analog outputsVFD speed

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Controller Functions

CapabilityUp to four separate pressures or temperature inputsTwo VFDs per controller

VFD controlAuto, bypass and service modesAutomatic restartsAutomatic bypass

Control logicFixed setpoint Variable setpoint using DBT or WBTPID controlSCT calculation for different refrigerants

Other featuresEmergency spray controlRun time and cycle monitoring

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Communications Interface

i.LON100 used for:Initial setupCurrent statusSetpointsAlarms and datalogging

Use web browser for setup, setpoint adjustments and current status

http://63.110.57.69/forms/main.htm

37

Performance Monitoringusing EnergyDashboard™

Remote efficiency monitoringReal time, continuous performance analysisWeb based results presentation

High level performance metrics Energy efficiency: kW/Ton, $/Ton-HrMaintenance indicatorsTrends (e.g. refrig. level, inventory)

42

Questions?

Doug ScottVaCom Technologies(909) 392-6704dscott@vacomtech.com