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P.1.2 KE2 Evaporator Efficiency Smart Defrost Management Companion Literature B.1.1 1. Energy savings through precise evaporator control 2.True demand.

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Presentation on theme: "P.1.2 KE2 Evaporator Efficiency Smart Defrost Management Companion Literature B.1.1 1. Energy savings through precise evaporator control 2.True demand."— Presentation transcript:

1 P.1.2 KE2 Evaporator Efficiency Smart Defrost Management Companion Literature B Energy savings through precise evaporator control 2.True demand defrost initiated by loss of evaporator efficiency 3. Efficient defrost management and termination Optional Electronic Expansion Valve control Communications Slide P.T2 - 1

2 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P Smart Defrost Management What we will cover:  Background  Factors in buildup of ice  Three typical kinds of defrost control  Understanding evaporator performance  Using latent “free cooling” energy  Defrost heater control – traditional and KE2 control  “Wishlist” for next generation evaporator control  Next generation control - KE2 Evaporator Efficiency (KE2 Evap)  KE2 Evap communication capabilities  Installing the KE2 Evap

3 Factors in the build-up of ice  ice build-up on an evaporator is influenced by a number of factors Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri  The temperature difference (ΔT)  Atmospheric conditions  Product humidity (without packaging)  Coil location  Poor plant design  Air flow

4 The basic kinds of defrost controllers: Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Time Clock Electromechanical or Electronic Time Initiate-Time Terminate Reactive -Time Dependent Micro-Processor Time Initiate-Temperature Terminate Microprocessor controlled pro-active KE2 Evaporator Efficiency defrost 3

5 Slide P.1.2 – 5 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Evaporator capacity decreases with accumulation of frost Understanding Evaporator Performance

6 Understanding evaporator performance Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P Evaporators with high temperature differences between coil surface and discharge air (ΔT) need defrosts sooner

7 Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Understanding evaporator performance For optimum results, defrosts should start when the efficiency of the coil drops to 90%.

8 P.1.2 KE2 Evaporator Efficiency Smart Defrost Management 1. Up or down arrow to desired room set point 2. Select defrost mode Electric Hot Gas Air 3.Select expansion device Mechanical TEV Electric expansion valve Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P.T2 - 8 KE2 Evap – only requires two inexpensive temperature sensors for defrost control

9 Change in ΔT indicates need for defrost Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

10 No Defrost Control Established (Baseline Data Only) LOCATION: Osborne Middle School

11 Ke2Therm Defrost Control Established LOCATION: Osborne Middle School

12 Circle of Concern Valley Park, Mo.  Defrost frequency per average week Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P.T2- 12

13 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P Some examples:

14 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P Some examples:

15 “Free cooling” – Latent energy recovery Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P  Proper fan control during operation provides “free cooling” by sublimating frost to chill room

16 Typical Pump Down Cycle Pump-Down Control Liquid Line Solenoid Temperature Control

17 Latent energy recovery Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P

18 Latent energy recovery - Advantages Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P  Less dehumidification and shrinkage of product  Reduced need for defrost heat  Energy savings  Highest possible cooling capacity  Even room temperature  Optimal performance of unit cooler  Reduced compressor operation time  Longer compressor life  Re-humidification

19 Electric defrost based on time Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri 80% additional heat gain (radiation + convection) due to high heater temperature High coil temperature drives “fog” into the room

20 Consequences of fogging Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

21 Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Consequences of excessive heat

22 P.1.2 KE2 Evaporator Efficiency Smart Defrost Management 1. Up or down arrow to desired room set point 2. Select defrost mode Electric Hot Gas Air 3.Select expansion device Mechanical TEV Electric expansion valve Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P.T KE2 Evap – only requires two inexpensive temperature sensors for defrost control

23 Pulsed defrost heaters Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Ensures lower terminal coil temperature, less energy usage, decreased product heating Only 20% additional heat gain (radiation + convection) due to heater temperature

24  Provide: Responsiveness to need for defrost  Provide: Free cooling using latent frost energy  Provide: close temperature control  Provide: electric expansion valve control  Provide: remote monitoring and ?????? New generation electronic evaporator controller Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri  Minimize defrost duration  Minimize number of defrosts  Minimize fan run time  Minimize defrost heater temperature and run time  Minimize pull down time to temperature setpoint “Wishlist”

25 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P KE2 Evaporator Efficiency Smart Defrost Management Satisfies the “wishlist”, and it is easy to install.

26 Advantages of KE2 Evaporator Efficiency technology  Defrosting at optimum time  Energy saving during defrost  Evaporator fan management  Field proven operation  No parameters to set  And NO Adjustments are required Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

27 Slide P Advantages of KE2 Evaporator Efficiency technology  Minimal heat gain through convection and radiation  Insignificant fog formation during defrost  No icing around evaporator  Reduced moisture loss and product shrinkage  Low or no heating of stored products  Quickest possible cooling at end of defrost Energy cost savings approx. 40 to 50% of the defrost energy. This represents nearly 10 to 15% of plants total energy use

28 Advantages of KE2 Evap Efficiency defrost control  Defrost starts at optimum time  Self-learning algorithm maintains efficiency under changing conditions  Ensures consistent performance of the refrigeration systems Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

29 Adaptive algorithms sense efficiency loss Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P By sensing temperature difference (∆T) across evaporator efficiency loss is used to initiate defrost

30 Example: Circle of Concern Defrost frequency per average week Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Before Conventional Time Controlled Defrost After KE2 Evaporator Efficiency

31 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P Some examples:

32 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P Some examples:

33 KE2 Evap – only requires two inexpensive temperature sensors for defrost control Slide P Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

34 Slide P Optional EEV control possible with pressure transducer and suction temperature sensor

35 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P KE2 Evap provides control & communication

36 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri Slide P TCP/IP enabled

37 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri 37 Good Eats #1234

38 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri 38 Location: Good Eats #1234 Good Eats #1234

39 Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri 39 Location: Good Eats #1234

40 Osborne Middle School Test

41 LOCATION: Osborne Middle School No Defrost Control Established (Baseline Data Only) Room Temp +25F Coil Temp +100 F 23 Defrosts in 5 Days, Total Time In Defrost 8.4 Hours Week One

42 No Defrost Control Established (Baseline Data Only) LOCATION: Osborne Middle School Room Temp +25F Coil Temp +100 F 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours Week Two

43 Ke2Therm Defrost Control Established LOCATION: Osborne Middle School Room Temp +10F Coil Temp +50 F 9 Defrosts in 5 Days. Total Time in Defrost 1.7 Hours Week Three

44 Ke2Therm Defrost Control Established LOCATION: Osborne Middle School Room Temp +10F Coil Temp +50 F 3 Defrosts in 5 Days. Total Time in Defrost 1.0 Hours Week Four

45

46 Osborne Middle School

47 Osborne

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50 11.8% Reduction 26.1% Reduction 84.2% Reduction CompressorFansHeaters

51 Berkmar Middle School Test

52 0 LOCATION: Berkmar Middle School No Defrost Control Established (Baseline Data Only) Week One Room Temp +25F Coil Temp +100 F 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours

53 LOCATION: Berkmar Middle School No Defrost Control Established (Baseline Data Only) Week Two Room Temp +25F Coil Temp +100 F 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours

54 LOCATION: Berkmar Middle School Ke2Therm Defrost Control Established Week Three Room Temp +15F Coil Temp +50 F 2 Defrosts in 5 Days, Total Time in Defrost 0.7 Hours

55 LOCATION: Berkmar Middle School Ke2Therm Defrost Control Established Week Four Room Temp +15F Coil Temp +50 F 2 Defrosts in 5 Days, Total Time in Defrost 0.5 Hours

56 Berkmar Middle School

57 Berkmar

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60 19.4% Reduction 11.4% Reduction 94.4% Reduction


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