1. KE2 Evaporator Efficiency
Smart Defrost Management
Energy savings through precise evaporator control
True demand defrost initiated by loss of evaporator efficiency
Efficient defrost management and termination
Optional Electronic Expansion Valve control
Communications
Companion Literature B.1.1

2. 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
Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

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

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

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

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

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

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

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

10. LOCATION: Osborne Middle School
No Defrost Control Established (Baseline Data Only)
5/9/2011 thru 5/13/2011

11. LOCATION: Osborne Middle School Ke2Therm Defrost Control Established
3:10 pm
osbourne

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

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

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

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

16. Typical Pump Down Cycle
Pump-Down Control
Liquid Line Solenoid
Pump-Down Control
Periodically, it is necessary to pump the refrigerant system down, evacuating the system for maintenance or removal of any system component. In order to pump a system down, a pump-down solenoid is closed and the compressor is run to fill the receiver with refrigerant. The compressor must run into the vacuum range, upon which time the pressure control automatically shuts off the compressor.
Temperature Control
A TS1 thermostat may be used to cycle a liquid line solenoid to maintain the temperature of a refrigerated case.
Temperature
Control

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

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

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

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

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

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

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

24. New generation electronic evaporator controller
“Wishlist”
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 ??????
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
Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

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

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
Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

27. 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
Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

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
Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

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

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

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

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

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

34. Optional EEV control possible with pressure transducer and suction temperature sensor
Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

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

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

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

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

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

40. Osborne Middle School Test

41. 23 Defrosts in 5 Days, Total Time In Defrost 8.4 Hours
Week One
LOCATION: Osborne Middle School
No Defrost Control Established (Baseline Data Only)
Room Temp +25F
23 Defrosts in 5 Days, Total Time In Defrost 8.4 Hours
Coil Temp +100 F
5/5/2011 thru 5/9/2011

42. 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours
Week Two
LOCATION: Osborne Middle School
No Defrost Control Established (Baseline Data Only)
Room Temp +25F
22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours
Coil Temp +100 F
5/9/2011 thru 5/13/2011

43. 9 Defrosts in 5 Days. Total Time in Defrost 1.7 Hours
Week Three
LOCATION: Osborne Middle School
Ke2Therm Defrost Control Established
Room Temp +10F
9 Defrosts in 5 Days. Total Time in Defrost 1.7 Hours
Coil Temp +50 F
8:28 am

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

46. Osborne Middle School

47. Osborne

48. Osborne

49. Osborne

50. Osborne 26.1% Reduction 11.8% Reduction 84.2% Reduction Compressor
Fans
Heaters

51. Berkmar Middle School Test

52. 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours
Week One
LOCATION: Berkmar Middle School
Room Temp +25F
No Defrost Control Established (Baseline Data Only)
22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours
Coil Temp +100 F
Bermar
10:56 am

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

54. 2 Defrosts in 5 Days, Total Time in Defrost 0.7 Hours
Week Three
LOCATION: Berkmar Middle School
Ke2Therm Defrost Control Established
Room Temp +15F
2 Defrosts in 5 Days, Total Time in Defrost 0.7 Hours
Coil Temp +50 F
June 4 – june 8 1:46 pm

55. 2 Defrosts in 5 Days, Total Time in Defrost 0.5 Hours
Week Four
LOCATION: Berkmar Middle School
Ke2Therm Defrost Control Established
Room Temp +15F
2 Defrosts in 5 Days, Total Time in Defrost 0.5 Hours
Coil Temp +50 F
6/10/11 thru 6/14/11 10:30 am

56. Berkmar Middle School

57. Berkmar

58. Berkmar

59. Berkmar

60. Berkmar
19.4%
Reduction
11.4%
Reduction
94.4%
Reduction