MAKING MODERN LIVING POSSIBLE

EnVisioneering SM

Solutions
Tr e n ds a n d t o p ics t ha t i m p ac t i n d u s t ry

How the Tide is Turning

The future of energy and energy efficiency strategies

E n gi n e e ri n g + E n e rgy Effici e n cy + E n vir o n m e n t = e n visi o n e e ri n g V o l u m e 7 / I ss u e 1 / 2 0 0 8

MAKING MODERN LIVING POSSIBLE

EnVisioneering
SM

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

Volume 7 / Issue 1

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
Jean Lupinacci fields questions from the audience during the
much larger scope as well. Focus on global energy issues has
April EnVisioneering Symposium. Story on page 14.
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. Contents
The tide is certainly turning and the future of energy and energy-
efficiency strategies is evolving. This edition of EnVisioneering / 2 / From the cover
Solutions puts that evolution into context; we believe energy How the Tide is Turning: The future of energy
efficiency eclipses other issues without borders and deserves and energy efficiency strategies
critical examination from the manufacturing industry.
/ 8 / Case Studies
Danfoss is proud of its authority on energy efficiency as well as 8 / The Kennedy Building Project
its products and technologies, which reduce energy consumption
10/ A Case Study in Energy Efficiency: Field test
and emissions that contribute to climate change. In this issue, story on the Universal TR6 valve
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. / 14 / Newsworthy
14 / Baltimore Laboratory Accredited to ISO 17025
As always, your comments are welcome. 16 / The April Envisioneering Symposium

The Editors
solutions@danfoss.com Product Highlights this issue
VSH Variable Speed Compressor / Brazed Plate
Heat Exchangers / VLT HVAC Packaged Drives

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.
 How the tide is
turning
Th e f u t u r e o f e n e rgy a n d e n e rgy e ffici e n cy s t ra t e gi 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.

2 E n visi o n e e ri n g s o l u t i o n s
 T o day, high - p r o fil 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. »

V o l u m e 7 / I ss u e 1 / 2 0 0 8 3
 C o v e r s t o ry c o n t i n u e d

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

38%
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.

The projected increase of
greenhouse gases emitted by the
United States between 1990 and
2025 if aggressive energy efficiency
policies are not implemented.
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
Policy needs to give performance levels set forth for new appliances, automobiles, and other everyday items
steadfast incentives that consume energy. These mandates were a great place to start discovery on energy
for the use of 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
efficient equipment,
insulation, automobiles—and a surplus of consumers who would use them but not for their
not simply mandate a
upfront costs. There are not enough good reasons for them to replace old equipment with
floor on what efficiency something that’s better.
standards new
purchases must meet. 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

4 E n visi o n e e ri n g s o l u t i o n s
 Illusions and Embellishment
Green Marketing May :
Be What’s Worst About
Marketers that can’t ba
ck up their claims with
data to support green empirical
claims drive customers
away from products tha an d goodwill
t are legitimately energ
y effi cie
and have practical busin nt
ess or financial value.
While conventional ma
rketing wisdom advises
confusing consumers, ag ain st
the number of products
“green” does just that— tou ted as
recent research by The
Group, a research firm, Sh eld on
found the number of pe
willing to choose one ho op le
use over another based
efficiency alone fell mo on en erg y offs, not providing pro
re than 16 percent from
2007, with buyers’ mistr 20 06 to
ust of terms like “susta
“eco-friendly” driving tha inable” and
t decrease.
Products from chewing
gum to laptop computer
now touted as being sub s are
stantially more energy
efficient
Energy Efficiency
than others. This “gotch
a”-type marketing discou
the rages
purchase of products or
components that are
legitimately energy-effic
ient.
TerraChoice, a marketin
g firm that specializes
energy efficient produ in
cts and services, released
similar report late last a
year that cites six tactics
when advertising a pro to avoid
duct as energy efficient
so-called “greenwashing or green—
.” These include hiding
tra de-
of, being vague, not rem
relevant, lying, and sta ain ing
ting the lesser of two evi
ls only.
Among the 1,753 produ
cts the firm examined for
study, all but one of the the
m used at least one of
tactics, with 57 percent the se
of those instances being
hiding of trade-offs. the

Market Conditions that Don’t Promote green fatigue:

Use: A Focus on Energy Productivity buyers’ growing mistrust
of overused marketing
Global energy demand will almost surely speed up for terms such as “sustainable”
and “eco-friendly,”
the near-term future, and the contention that the pace of
discouraging them from
increase will strain consumers and economies along with the purchasing products that are
environment is nothing new. What is new is the widening legitimately energy-efficient
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. »

V o l u m e 7 / I ss u e 1 / 2 0 0 8 5
 C o v e r s t o ry c o n t i n u e d

Energy efficiency The MGI report also stated:

might very well
be the cheapest
form of new energy
available, but there
aren’t enough
immediate reasons
to strive for it.
»» 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

17%
infrastructure makes good business sense when done properly.

However, current conditions discourage businesses from making larger

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
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.

6 E n visi o n e e ri n g s o l u t i o n s
 Pr o d u c t H ighligh t

Danfoss Introduces
Brazed Plate Heat
Exchangers

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.

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
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
 C as e S t u dy o n e
Danfoss keeps things in tune at the
kennedy center
Th e K e n n e dy 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
8 E n visi o n e e ri n g s o l u t i o n s
Pr o j e c t highligh t s
»» 25 air handlers installed in multiple zones
»» larger VLT drives used for the Center’s
1200 RPM fan motors
»» v ertical configuration of drives allowed for
installation in tight spaces
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
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. The Kennedy Center was designed in the mid 1960s and opened
to the public in September of 1971. During its conception, the
Conservation must be a prime component of any
issues relating to energy prices and sustainability weren’t even
responsible energy policy, and more and more applications on the radar.
are showing that drives can offer something in the form of
greater efficiency that is relatively simple and cost-effective
to implement.

V o l u m e 7 / I ss u e 1 / 2 0 0 8 9
 C as e S t u dy t w o
Upgrade existing air conditioning
systems and achieve up to 40%
energy savings
N o l o 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.
10 E n visi o n e e ri n g s o l u t i o n s
Th e U n iv e rsal T R 6 V alv e
»» retrofits to all air conditioning units
»» easily installed by technicians in the field
»» t hermostatic expansion valve allows for
maximum efficiency
»» pays for itself in about 9 months
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
check valve. Check valves are essential in heat pump systems when the refrigerant flow thermostatic
reverses in the system to provide heating rather than cooling. expansion valve:
regulator with a sensing
The advantage of a thermostatic expansion valve like the TR6 over the traditionally used bulb that constantly
fixed orifice regulation is that the fixed orifice device constantly delivers the same amount monitors the evaporator and
of refrigerant to the system, regardless of the amount of cooling needed for the living space. varies the flow of refrigerant
accordingly, ensuring that
When the temperature inside has been brought to the desired level, then rises a bit, the
the evaporator is used with
system comes on and delivers the same maximum cooling that was required for a large maximum efficiency
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 problem
[The TR6 valve]
There 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
provides air
that three valve models would have to be made in each capacity, and that service technicians conditioning
would have to carry them all as truck stock. manufacturers
significant help
gaining the efficiency
The solution improvement
Danfoss engineers, marketing, and sales professionals, working with contractor customers, needed to meet the
developed a solution in early 2006, realizing that a single valve kit with all three types of impending federal
connections found on existing residential air conditioning systems was a possibility. regulations for
For years, Danfoss had been selling fitting adapters for certain models of its expansion new equipment.
valves, so that a single model could serve where either brazed connections or flare »

V o l u m e 7 / I ss u e 1 / 2 0 0 8 11
 C as e S t u dy c o n t i n u e d
T R 6 fi e ld T e s t i n g
the
numbers
4.5
Average number of hours taken
for a field technician to install the
Universal TR6 valve
27.8%
Average saving of kilowatt hours
after installation of the Universal
TR6 valve
9
Calculated months of operation
it would take for the valve to
pay for itself in utility savings
12 E n visi o n e e ri n g s o l u t i o n s
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 proposition
For 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 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.
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.
Pr o d u c t H ighligh t
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.
For more information:
contact 800-621-8806
salesinformation@danfoss.com
www.danfossdrives.com
 NewsWorthy
R ece n t n ews a n d updates f rom D a n f oss

ISO-Certified Application
Laboratory: another service
for our customers
For 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
ISO certification means that the Danfoss Commercial Refrigeration
be made of any contemplated change and its effect on every
Laboratory can be relied upon to produce impartial, accurate reports
factory practice. based on testing methods compliant with ISO standards.

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.

14 E n visi o n e e ri n g s o l u t i o n s
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 Before changing any part of a product,
authority. A strong year-long effort put forth by the application manufacturers need to take every possible step
engineering department and the laboratory staff, with the to ensure a very high probability of success
support of Danfoss management, was proven effective when with the new design, because any variation in a
the Danfoss Commercial Refrigeration Laboratory received
product’s design could necessitate changes in
official ISO 17025 certification in April 2008.
manufacturing techniques, resources, assembly
The Danfoss Commercial Refrigeration Laboratory was created procedures, and logistics.
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
Learn more about Danfoss North America and keep up-to-
make. Like many Danfoss efforts, the ultimate benefit is to date on the latest news about Danfoss products and your
the end users of those products with longer life and better industry at www.danfoss.us
efficiency, and to those users’ customers in turn.

V o l u m e 7 / I ss u e 1 / 2 0 0 8 15
 NewsWorthy c o n t i n u e d

Danfoss-Sponsored Panel
Gives Answers to Energy-
Efficiency Questions
E n e rgy l e ad e rs 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 More than 30 representatives from the federal government, energy
box and incorporate new energy-efficient technologies.” utilities, foreign embassies and the HVAC&R industry attended the
seventh Danfoss EnVisioneering Symposium April 4 in Washington, DC.
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
energy technologies. He noted that renewable energy, as a
agencies, engineering firms, end users and others—to consider
percentage of annual new energy capacity additions, increased
and, potentially, implement. Thompson’s goal, he said, is
from 2 percent in 2004 to 22 percent in 2006.
to put energy savings first and costs second, a seemingly
counterintuitive prospect for his utility counterparts. The panel also discussed at length the decoupling of electric
utility revenues from KWH sales and the creation of incentives
Thomas Hartman, president of The Hartman Company,
to upgrade old, inefficient equipment.
echoed similar sentiments. “The power of utilities needs to be
redirected. … For utilities, it’s a change from selling energy to Robert Wilkins, president of Danfoss Inc. (U.S. and Canada),
managing energy.” summed up the symposium, noting that all stakeholders can
and should make valuable contributions to the global energy
Darrell Beschen, chief economist for Energy Efficiency and
challenge.
Renewable Energy, U.S. Department of Energy, said the
Department will continue to research and develop renewable “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.
A video of the symposium can be viewed at
http://www.envisioneering.danfoss.com/2008.aspx New ideas and solutions—and new ways to apply them—come
to the forefront at every event.”

16 E n visi o n e e ri n g s o l u t i o n s
 Pr o d u c t H ighligh t

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
 Danfoss Locations

Baltimore, MD
7941 Corporate Drive
Baltimore, MD 21236
410-931-8250 / Fax: 410-931-8256
www.danfoss.us
»» Refrigeration & Air-Conditioning
»» Industrial & Heating Controls

Tallahassee, FL
Danfoss Turbocor
1769 Paul Dirac Drive
Tallahassee, FL
850-504-4800
www.turbocor.com
»» Oil-Free Compressors for
Refrigeration and Air-Conditioning
www . da n f o ss . u s
Glens Falls, NY
Danfoss Flomatic Valves
15 Pryun’s Island Drive
Glens Falls, NY 12801
800-833-2040 / Fax: 800-314-3155
E-Mail: flomatic@flomatic.com
www.danfossflomatic.com
»» Water Controls

2008 Calendar of Events LOVES PARK, IL

4401 N. Bell School Road
Loves Park, IL 61111
815-639-8600 / Fax: 815-639-8000
June 2008 September (Continued) www.danfossdrives.com
» EnVisioneering Symposium: » RETA: Refrigerating Engineers »» Drives
“The Owner Nexus” and Technicians Association
June 21, 2008 September 24–26, 2008 MILWAUKEE, WI
8800 W. Bradley Road
Denver, Colorado Hershey Lodge and Convention
Milwaukee, WI 53224
Center, Hershey, PA 414-355-8800 / Fax: 414-355-6117
» Sensors Expo & Conference www.danfossdrives.com
June 9–11, 2008 »» Drives
October 2008
Donald E. Stephens Convention »» Nessie High Pressure
Center, Rosemont, IL » WEFTEC: Water Environment Federation Water Systems
Technical Exposition & Conference
October 19–22, 2008 Mississauga, ONT
September 2008 6711 Mississauga Rd., Suite 410
McCormick Place, Chicago, IL.
» Comfortech Visit Danfoss booth #21015 Hall B
Mississauga, Ontario L5N 2W3
905-285-2050 / Fax: 905-285-2055
September 10–13, 2008
www.na.heating.danfoss.com
Georgia World Congress Center, » HARDI: Heating, Air-Conditioning and »» Heating Controls
Atlanta, GA Refrigeration Distributors International »» Motion Controls
October 25–28, 2008
» RSES Annual Conference JW Marriott Desert Ridge Resort Mountainside, NJ
September 16–20, 2008 Danfoss Hago, Inc.
and Spa, Phoenix, AZ
Hilton Hotel, Indianapolis, IN 1120 Globe Ave.
Mountainside, NJ 07092
» Johnstone Supply Annual Meeting 908-232-8687 / Fax: 908-232-7246
and Trade Show www.hagonozzle.com
September 19–21, 2008 »» Components for Oil Burners
Chicago, IL
SOMERSET, NJ
Danfoss Bauer
31 Schoolhouse Road
Somerset, NJ 08873
732-469-8770 / Fax: 732-469-8773
www.danfoss.com
Keep up-to-date on the latest news about Danfoss products and your industry at www.danfoss.us »» Geared Motors
To find out more about Danfoss North America, contact us via email: solutions@danfoss.com