ACR Journal February 2016

VOLUME 2 No2 ISSN 2058-4407

Essential Information for the Air Conditioning and Refrigeration Industry

FEBRUARY 2016

Refrigeration & Air Conditioning partnership goes from strength to strength

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02 FEBRUARY 2016

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C O N T E N T S

FEBRUARY 2016

REGULARS

1989-2014

AN N

IVE RSA

Essential Information for the Air Conditioning and Refrigeration Industry

Editor Will Hawkins 01778 392094 willh@warnersgroup.co.uk

6 News

10 IOR News

11 ACRIB Update

Multimedia Account Manager

James Knight 01778 395029 jamesk@warnersgroup.co.uk

Mitsubishi Electric column

Advertising Sales Theresa Geeson 01778 392046 theresag@warnersgroup.co.uk

Editorial Design Ady Braddock

Advertising Design Natalie Reynolds

Production Sue Ward 01778 392405 production@warnersgroup.co.uk

Subscriptions Single copy £3.00; Annual UK subscription £35.00 Overseas £65.00

Publishing/Editor Juliet Loiselle 01778 391067 julietl@warnersgroup.co.uk

PRINTED BY WARNERS 01778 395111

Contents.indd 4

Time for a Change January is the season for a change for many people. Getting a new job or hiring new employees is normal in January. It’s no different for the ACR Journal. Our top two news stories online are about people who have changed jobs. It is also show season. The AHR Expo in the USA will have happened, and The ACR Show in Birmingham will be a matter of days away by the time you read this. Later this year, Chillventa is here again. All of this means we should see some interesting new solutions for the heating, ventilation, AC and refrigeration market. However, the third most popular article online in January is about an old favourite – F-Gas. This topic continues to drive much of the new business in the market. Connected to that is energy efficiency. Lowering energy costs is front and centre of many new business deals. But, I often hear that it is challenging to get the message about considering not just the capital costs but the operational costs of a solution to more senior people in a customers’ business. Given that many businesses rely on refrigeration or air conditioning for their success, is it not time that people in charge of ‘cooling’ in those companies sat on the board? Cooling is as important as IT in many companies. Will Hawkins Editor, willh@warnersgroup.co.uk

Competition – Enter the REFCOM word search to win great prizes

34 Company Profile – Chemours: The new name in refrigerants

42 Changing Faces – Who’s new and who’s moved

48 What’s new – The latest products on the market

52 Chilly Chatter including Chilly Van Competition

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C O N T E N T S

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FEATURES

AIR MOVEMENT

2016

Keeping Up to Date with ERP Regulations Airﬂow

WINNERS ANNOUNCED 28.01.2016

16 Quiet Eﬃcient Air movement ebm papst

30 National ACR and Heat Pump Awards 2016

VRF

20 Mitsubishi Electric Launches Latest Hybrid VRF System

HEAT PUMPS

46 18

VOLUME 2 No2 ISSN 2058-4407

COOLING

36 The future of cold – Toby Peters looks ahead

22 VRF Pump Down Procedures Toshiba

REFRIGERANTS

CHILLERS

39 CRS Saves Energy and Boosts Chiller Control

26 F-Gas: Ten Steps to Best Practice A-Gas looks ahead

28 R404A: Time to Plan Your Move Away from It in 2016 Part2 Climalife

Contents.indd 5

Essential Information for the Air Conditioning and Refrigeration Industry

FEBRUARY 2016

MAINTENANCE

£15 a Year Energy Bills for Home-Owner Stiebel Eltron

Refrigeration & Air Conditioning partnership goes from strength to strength

ELECTRICAL SAFETY

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To Isolate or Not to Isolate Working Dead to Stay Alive Cool Concerns

25/01/2016 12:30

About our front cover: HRP and Danfoss www.hrponline.co.uk

27/01/2016 10:23:13

N E W S

06 FEBRUARY 2016

GERMANY IN EU COURT OVER MOBILE AIR CONDITIONING REFRIGERANTS

Evaporator coil

DAIKIN FACES CORRODING EVAPORATOR COIL ALLEGATIONS

Daikin Applied (formerly known as McQuay International) is being sued by a US woman who alleges the evaporation coils in their HVAC systems are defective. Joanna Park-Kim is suing Daikin Applied in a multi-million dollar class action in which she alleges that the company’s evaporator coils are prone to ‘formicary corrosion’ which leads to microscopic holes forming in the tubing. As a result, she alleges, the coils leak refrigerant and fail to work properly. Park-Kim’s law suit says that Daikin Applied selected the wrong type of alloy for their product, that their manufacturing process is incorrect and that they have filed to ensure the coils perform correctly throughout their lifetime. Daikin has asked for the case to be taken to the federal court because the members of the class action live in different US states (there are over 100 members) and the sum being sought is over $5 million.

The European Commission (EC) has referred Germany to the EU Court of Justice over its failure to apply its directive (2006/40/ EC) the refrigerants used in mobile air conditioning systems. The directive aims to phase out the use of high global warming potential (GWP) refrigerants used in a car’s air conditioning system. Each country is obliged to certify that cars made within their own borders comply with the EU laws on ‘safety, environmental and production requirements’ before they are sold on the open market. The EC believes that Germany has not complied with the EU directive because of allowing Daimler to sell its cars within the EU which don’t comply with the so-called ‘MAC directive’ on refrigerants. Daimler refused to use alternative, low GWP refrigerants in its cars, because it was worried about their safety implications. The company continied to use R134a in its cars, which is banned for new cars. Daimler refused to use R1234yf. From 1st January 2017, all refrigerants with a GWP higher than 150 will be banned in new cars. Daimler was the only car manufacturer worried about using the new refrigerants. Germany’s motor industry trade body, the Federal Motor Transport Authority, and Joint Research Centre of the European Commission were not concerned either, having carried out risk analysis in 2014. The German government, however, took no action against Daimler for continuing to use R134a, which is why the EC has now refereed the case to the court.

(The story originally appeared on the Legal New Line website)

DENCOHAPPEL STOPS PRODUCTION AT HEREFORDSHIRE FACTORY German-owned heat exchanger manufacturer, DencoHappel, is to cease making its products at its factory in Moreton-on-Lugg, Herefordshire due to a restructure within its global business. The company has made heat exchangers in the area since the 1970s and used to employ 250 people. Since moving to its current site in 2012, the number of people employed there has dropped dramatically. DencoHappel informed 23 of its production staff that they would be let go on Christmas Eve. The business has shifted much of its production abroad, particularly to the Czech Republic. The company has factories in Germany, India, Turkey and China. The site will now house the company’s office staff and be used as a warehouse.

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Dr. Dieter Zetsche

25/01/2016 16:33

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25/01/2016 14:38:03

N E W S

08 FEBRUARY 2016

REFRIGERANTS:

BITZER APPROVES R404A AND R507A REPLACEMENTS FOR COMPRESSORS

COOLSUREDOORS KEEPS

COMMISSARY COOL AND EFFICIENT coolsuredoors, the Bedforshire-based refrigerated cabinet doors manufacturer, helped the US Forces Commissary at RAF Lakenheath, become more energy efficient recently. Working with Fridge Systems, who commissioned the project, coolsuredoors refursbished the refrigerated cabinet doors on 21 meat and dairy units in the store. The team had to replace 90 doors over five nights to help the Commissary make shopping easier for customers and save energy. Michael Tucker, managing director, coolsuredoors comments, “The refurbishment and installation of the doors at RAF Lakenheath’s Commissary had to be carried out in an

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extremely tight time-frame for the client. This was achieved by our precise project management and planning. “The addition of Universal doors and LED lights to the refrigerated cabinets has created a warmer, more inviting environment for the shoppers. The retailer is also extremely pleased with the reduction in energy loss and the new look of the store. Overall we have delivered a cost-effective and environmentally friendly solution to suit the updated facility.” The coolsuredoors system allows shopper to easily access produce in the cabinets, and also allowing staff to restock shelves quickly. The doors cut down the energy use of the chiller cabinets.

Bitzer, the German compressor manufacturer, has approved its twostage reciprocating compressors for use with new, low GWP refrigerants. The company announced that it has approved R448A and R449A, the low global warming potential alternative refrigerants to R404A and R507A, for use with its compressors. Each of the alternative refrigerants has a GWP below 1400, which makes them ideal for low temperature applications. All Bitzer twostage reciprocating compressors now work with new alternatives as well as with thermostatic expansion valves. The approval came after Bitzer modified its compressors to work with refrigerants R448A and R449A. They have global warming potentials of 1386 and 1397, respectively. R404A has a GWP of 3922 and its use will be banned in stationary areas after 2020 because of the F-Gas regulations. Bitzer’s tests, using the alternatives to R404A and R507A show that its modified compressors work perfectly well with R448A and R449A, and can be applied in ‘areas are practically identical to those of R407F’, according to the company’s statement. R448A and R449A are ‘transitional refrigerants’ which help to bridge the gap as industry moves towards using low GWP refrigerants entirely.

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VRF: BOSCH ENTERS THE MARKET Bosch Commercial and Industrial, the German-owned heating and hot water equipment manufacturer, entered the UK air conditioning market in January with the news that it has a new variable refrigerant flow (VRF) range. Its VRF systems deliver simultaneous heating and cooling for domestic and commercial properties. The Bosch Climate 5000 VRF systems comes in three types, namely the SDCS series, its inverter heat pump range; the RDCI series, an all DC inverter heat recovery system; and the MDCI series, the company’s mini VRF heat pump, which is suitable for small domestic, commercial and small retail properties. Bosch is confident that its VRF range is efficient and easily controllable through its Bosch VRF Intelligent Manager (BVIM) solution. Geoff Hobbs, Business Development Director at Bosch Commercial and Industrial said: “Consultants, contractors, architects and specifiers within the building services industry are increasingly faced with the challenge of recommending and installing flexible heating and hot water systems with the ability to maximise efficiency. With this in mind, we’ve taken the decision to introduce a VRF system which offers maximum heating and cooling comfort efficiently, and on a large scale.” It is a bold move by Bosch to enter the UK market. It has a strong brand name in the heating sector through its Worcester Bosch business where it is well established. The air conditioning market has two dominant manufacturers with several companies competing hard to be number three in the UK. However, the company has deep expertise in developing a strong partner network and using high profile marketing to grow its business. The new player in the air conditioning market will intensify the competition which will be good for end users. www.bosch-industrial.co.uk

News.indd 9

CARRIER WINS TRANSPORT REFRIGERATION DEAL FROM ASDA Carrier Transicold, the transport refrigeration units manufacturer, has won a deal to supply its trailer units to UK supermarket, ASDA. In late 2014, Carrier won a deal to supply 20 of its Vector 1950 MT refrigeration units to Walmart-owned ASDA. The success of that deal was significant in their latest bid to supply more of the same to the supermarket chain. Not only were their trailer units important in winning, but also their service delivery standards for over 700 refrigeration units already used by ASDA. Carrier did a good job in maintaining the fleet and helping their client to comply with F-Gas regulations. Sean Clifton, senior manager, National Fleets at ASDA said: “Environmental performance, cold chain protection and fleet uptime are three of the biggest considerations when specifying new fridge units for our fleet. The Vector systems deliver in all of these areas; put simply, they don’t give us any issues.”

DEARMAN HIRES FIRST ENGINEERING APPRENTICE FOR CLEAN COLD TECHNOLOGY Dearman, the company that invented the Dearman Engine, has taken on its first engineering apprentice, Cameron Douglas. Cameron will work for the ‘clean cold technology’ business for four days a week and will spend a day a week at Kingston College in Surrey. Dearman’s new apprentice will work on development, testing and machining. Dearman recently announced a further £16 million investment to help bring its Dearman Engine technology to market. Cameron is part of the company’s plans to quickly develop its business and to attract young talent to help it grow.

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I O R

N E W S

FEBRUARY 2016

EN378 REFRIGERATION SAFETY STANDARD UPDATE It was reported at the IOR Technical Committee this month that after seven years of discussion and debate the process for the updating of EN378 is nearly complete.

Andy Pearson

his length of time might seem difficult to defend in a time when refrigerant requirements are changing very rapidly, but the task has been complex and required the balancing of numerous competing requests for change (or in some cases no change). It is difficult to see how the process could be significantly shortened without thoroughly exploring the technical implications of all viewpoints.

Too complicated and stringent?

The current version might be considered by some to be still too complicated and not 100% suitable for all circumstances. In particular the increased use of ﬂammable refrigerants, whether they are class A3 hydrocarbons or class A2L HFOs, is likely to lead to a need for further reﬁnements to the standard as “real-world” experience of

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implementation is gained over the next few years. In some cases some may call for the most stringent guidelines to be relaxed or simpliﬁed and in other ways it may be necessary to tighten up some requirements. No doubt over time we can expect to see extension of strategies currently only permitted “for human comfort” to other systems and a general rationalisation of the requirements. In particular the wider use of A2Ls in supermarkets, chillers and other small to medium-sized systems will lead to further work by the International drafting teams to make the standard is easy to use while still ensuring high safety levels.

Will it mean system design changes?

The way in which companies do their system design will not fundamentally change with this revision of EN378 however. If designers choose to use mildly ﬂammable refrigerants, they must still

follow all of the legal and safety standard requirements associated with flammability. This goes beyond the scope of EN378, which is not harmonized with those regulations. It does not mean that all electrical equipment needs to be “flameproof” of the type found in petrochemical plant, but it does mean that if the safety data sheet for the refrigerant has the hazard phrase H220 or H221 then a risk assessment conforming to the requirements of DSEAR must be completed and must cover maintenance and service activity as well as normal operation and standstill. A guidance note on the use of DSEAR for ammonia systems is being prepared by the Food Storage and Distribution Federation with input from the IOR, and a version of this for hydrocarbon and possibly for HFO refrigerants may be called for in the future. The main issues that designers may find with this revision of the European safety standard do not lie with the text of the standard itself, but in the other regulations which will apply if companies are encouraged by the introduction of the new flammability class to adopt the new “lower flammability” refrigerants. This does not make their use impossible, but it is an extra layer of difficulty to be overcome.

Find out more at the IoR Annual Conference

Those interested in ﬁnding out more about changes in the proposed new standard can attend a more detailed talk being given by the IOR Technical Committee Chairman, Andy Pearson, as part of the IOR Annual Conference on 18th February 2016 in Birmingham. The revised standard itself is still going through an international approvals process and at the earliest is expected to be available for use in spring 2016.

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A C R I B

U P D A T E

11 acrjournal.uk

F-Gas Developments It appears to have been fairly quiet on the F Gas Regulation front in recent months but there have been some developments behind the scenes.

PEE – the European Partnership for Energy and the Environment is conducting a useful study on how the regulation is being implemented across Member States and this is throwing up a number of issues, which will be fed back to the European Commission.

The latest figures available from the Environment Agency on the numbers of individuals having achieved the required minimum qualifications and companies including sole traders obtaining their F Gas Certifications are encouraging: ₀ Nearly 35,000 individuals have obtained full certification to City & Guilds Cat. 1/CITB J11 ₀ 530 are qualified to work only on equipment under 3kg of HFC refrigerant City & Guilds Cat. 2/CITB J12 ₀ Recovery of end of life equipment only - City & Guilds Cat. 3/CITB J13 – 1,000 ₀ Leak checking only - City & Guilds Cat. 4/CITB J14 – 2,105 ₀ Company/Sole Trader F Gas Certifications are now just under 7,000 In the meantime the European Commission published three new implementing Regulations relevant to air conditioning, refrigeration and heat pump sectors, in November 2015.

Labelling

The first of these outlined the format for new labels for products and equipment containing fluorinated greenhouse gases, which must be in place from 1st January 2017. Known as Implementing regulation (EU) 2-015/2068, this replaces Regulation (EC) No 1494/2007 and article 12 (14) of Regulation (EC) No 842/2006. It defines the exact wording of the information to be included on labels referred to in Article 12 (1) of Regulation (EU) No 517/2014 and sets out requirements ensuring visibility and readability of such labels with regards to their layout and replacement. New labelling requirements will apply to all products containing fluorinated greenhouse gases including equipment and containers, drums, road and rail tankers from 1st January 2017. The wording is similar to existing labels but includes additional requirements such as CO2 equivalent values.

Harmonisation of certification across different Member States

The second sets out the format for Member States to notify the Commission of any additional training and certification programmes. Known as Implementing Regulation (EU)

ACRIB.indd 11

2015/2065, this replaces article 10 (13) of Regulation (EC) No 842/2006 and repeals Commission Regulation (EC) No 308/2008. It specifies essential information required to allow the authentication of a certificate or attestation to ensure it complies with the minimum requirements. This should be reassuring for those employing individuals who have gained their certificate in another Member State.

Minimum requirements for individual certificatioN

The third updates the minimum requirements and conditions for the certification of technicians and companies in the stationary air conditioning, refrigeration, heat pump equipment and extends these to refrigerated trucks and trailers containing fluorinated greenhouse gases. This is Implementing Regulation (EU) 2015/2067, and replaces Article 10 (12) of Regulation (EC) No 842/2006 and also repeals Regulation (EC) No. 303/2008. It clarifies new obligations for refrigerated trucks and trailers, concerning certification of companies and individuals, that have now been included in the new Regulation. It also formalises the requirements for the content of certification programmes to contain information on relevant technologies to replace or reduce the use of fluorinated greenhouse gases. This new requirement was included in UK certifications from January 215, but the Implementing Regulation applies only from 1st July 2017 to allow other Member States time to adapt their existing certification programmes. It should be noted that existing Certificates issued under the original Regulation 842/2006 remain valid and re-certification is not required, unless the certificate issuer has put an expiry date on it. If you wish to download copies of the new Regulations there are links on the www.acrib.org.uk website, where the latest information on F Gas is added regularly. ACRIB is participating in the implementation study being conducted by EPEE (mentioned above) and would be pleased to feedback any issues and concerns that individuals or companies implicated by the new F Gas Regulation may have. All such issues and concerns are also shared with DEFRA and the Environment Agency as deemed appropriate. We are also advised that DEFRA is proposing to host an F Gas stakeholder meeting in March to keep industry informed of the latest developments. ACRIB will report on the outcomes of that meeting in the future.

25/01/2016 17:09

M I T S U B I S H I

E L E C T R I C

FEBRUARY 2016

A BRAZEN REMINDER Ben Bartle-Ross, technical trainer at Mitsubishi Electric asks for feedback on installer support for controls

he factories that produce our air conditioning systems have some of the most robust quality control procedures in the industry, so if we do ever get products returned from a job, then you can be sure that we investigate thoroughly to identify any issues. From analysis of returns, it would appear that occasionally we come across an engineer who has simply forgotten the basics and not taken adequate care of any brazing on the system. I don’t believe this is a major problem throughout the industry, especially looking at the numerous engineers I come across in my role as a trainer, but for us as manufacturers, and perhaps more importantly, for the customers of the air conditioning systems being installed, it can lead to added costs and delays. With legislation such as F-Gas now in place, this should also be the most basic thing we all look at, if only to make sure the systems are installed to run as eﬃciently as designed. It sounds simple and you will forgive me appearing to teach everyone how to ‘suck eggs’.

It’s therefore worth reminding ourselves of one of the ﬁrst ﬁrst things we are all taught – Use OFN! ₀ Check and double check the penetration of the brazing before pressure testing the full system (Remember cutting through the pipes during training and what you were looking for?). ₀ Always use oxygen-free nitrogen when brazing to stop oxidisation inside the pipework ₀ Also use OFN when pressure testing the system to appropriate pressures ₀ Always ensure you get a proper vacuum to avoid any moisture which reacts with the refrigerant, making it acidic However, when we look at why any of our systems are returned, this does come up as a potential reason for a majority of the time – Ben Bartle-Ross, Technical Trainer and it should be the easiest to avoid.

Don’t know what to do with your recovered refrigerant oil? 10-litre oil disposal containers are available from A-Gas wholesalers today! Contact A-GAS on 01275 376600 for more information Mits Column.indd 12

25/01/2016 15:37

Refrigerants

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“Our customers see Opteon™ low GWP refrigerants as the new industry standard” Mark Hughes Business Development Manager OpteonTM Refrigerants EMEA Chemours UK

Our strength is our service Quality engineering products for NH3, CO2 and other refrigerants from leading European manufacturers • Open Refrigerant Pumps • Hermetic Pumps NH3/CO2 • Pressure Vessels • Surge Drums • Liquid Receivers • Economisers • Oil Recovery Systems • Chilled Water/Brine Chillers • Ammonia Spray Chillers • High Pressure Floats • Stop Valves NH3/CO2 • Ball Valves

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11.01.16 12:22 27/01/2016 10:27:16

A I R

M O V E M E N T

FEBRUARY 2016

KEEPING UP TO DATE

WITH ERP REGULATIONS I n many instances, upgrading fans to an electronically commutated (EC) centrifugal model is the most cost-effective method of ensuring that a ventilation system is Ecodesign and ErP compliant. In many instances, upgrading fans to an electronically commutated (EC) centrifugal model is the most cost-effective method of ensuring that a ventilation system is Ecodesign and ErP compliant.

Here, Clive Greenstreet, Category Product Manager at Airflow Developments explains. The 2015 update to the Energy-related Products Directive (ErP) requires all industrial fans and motors to comply with stringent energy efficiency requirements. This is because the European Union is committed to reducing its CO2 emissions by at least 20 percent by 2020. To achieve this, the Energy-related Products Directive (ErP), was to be introduced in two stages. The first stage in 2009 replaced the 2005 Energy-using Products Directive (EuP) to improve the efficiency of high energy-consuming building services such as heating, hot water and ventilation systems. The second stage came into force in January 2015. This encompassed an even higher level of legislation regarding the energy efficiency of industrial fans. ErP covers all types of industrial fans (axial, centrifugal, mixed flow) and motors, with an input power of between 125W - 500Kw.

Replace your entire ventilationÂ system?

However, those who are responsible for the upgrade of ventilation systems, should not automatically assume that they need to replace their entire ventilation system.

EC double inlet fans

Airflow.indd 14

The reality is that in virtually all instances, upgrading the fan to an electronically commutated (EC) centrifugal model is the most costeffective method of ensuring Ecodesign and ErP compliance. There are a number of innovative ventilation solutions on the market that can not only save the capital outlay of a new system but also help to reduce longterm building operation and maintenance costs. For example, as well as consuming up to 80% less energy than conventional AC motors units, the new EC fans offer significant noise reduction, variable speed control and remote monitoring options.

Fan choice

For example, Airflow Developments introduced a range of EC fans and enhanced its AC fan options, resulting in a full range of compliant fans. It is important to select a product that is fit for purpose and there are a number of options to be aware of. Single inlet EC direct drive

EC Single inlet fans

centrifugal fans offer noteworthy benefits in performance and pressure development for applications where space availability for an air-moving device within equipment is limited. This type of fan is ideal for compact cooling in electronics cabinets, lighting, and smaller air conveying systems. Double inlet EC fans are designed for low noise and high efficiency applications such as general ventilation, industrial warm air movement, VAV boxes, air handling units, telecommunications and transmitter cabins. This range offers high airflows specifically suited for this type of application.

Variable speed control

All EC fans offered by Airflow Developments incorporate variable speed control with EC high efficiency motors and balanced forward curved tablock constructed impellers. Duplex Fans have a dual shafted motor positioned between two impellers. It is designed to provide air across a large discharge footprint at high volume but having a small physical profile. Offering excellent

27/01/2016 10:28:56

15 acrjournal.uk

XP40

Refrigerant (R-449A)

Problem solved with low GWP Opteon™ XP40 • Excellent efﬁciency and performance • Quick and easy replacement for R-404A • ASHRAE A1, non-ﬂammable • One third the GWP of R-404A

Duplexvent FLEXI air velocity and pressures for applications such as: electronic cabinet cooling, air curtains, fan coil units, fume cupboards, plastic manufacturing procedures and medical applications. The end result is a compact direct drive fan, designed for handling air within ‘space critical’ equipment, which can offer significant benefits in performance and pressure development over other fan designs. A range of high temperature, direct drive fans designed for handling hot air from gas burning appliances where temperatures of up to 250C through the fan are required. These are ideal for overhead radiant tube heating, domestic and commercial ovens, boiler / heater flue fans, gas fire flue boosters, hot air extraction and UV lamp cooling for printing. Flue Gas Dilution fans offers an opportunity for flexibility in designing when positioning a boiler or water heater within a property, allowing low level discharge of burnt gases and removing the need of unsightly external, expensive chimney flues. Fan ratings make them suited to boilers with maximum boiler input ratings of between 80 and 650Kw. Remember fans that are compliant with the ErP Directive can be identified by the CE symbol and the efficiency data placed on the product. However it is advisable to consult a professional to help select the right fan for your requirements. For more information visit: www.airflow.com

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• Widely available and supported by component manufacturers

“Opteon™ XP40 – the best solution for my customers” David Wilkinson General Manager GEA Refrigeration UK Ltd

www.opteon.com

Overmatter

25/01/2016 16:59

A I R

M O V E M E N T

FEBRUARY 2016

QUIET EFFICIENT AIR M E

uropean commitments to reduce energy usage by 2020 have set demanding limits through the ERP directives for energy consumption and noise. If an air movement system is perceived as being noisy it will be inefficient. Whilst the amount of primary energy converted to noise in an air movement system is very small, the cause of the noise will have the greatest impact on the energy consumed. Combining high efficiency drive motors with aerodynamically efficient design requires intelligent thinking coupled with numerical modelling techniques. ebm-papst has used these tools to analyse the performance of their product range and has developed a number of innovations that optimise the passage of air through the fan. When air is on the move it does not react well to sharp changes in direction, high velocities caused by restrictions or turbulent eddy currents. In air handling systems laminar flow is a goal that is achieved by minimising the air velocity in the system, using rigid ductwork, swept or curved bends / splitters and guide vanes where possible. Areas where turbulence occurs can reduce the effective area of a duct resulting in increased air velocities. Turbulence consumes energy in its creation and the increased velocity at these points requires greater dynamic pressure causing a greater load on the fan. These principals can equally be applied to the fan as the air passes into and through the impeller.

Backward Curved Motorised Impeller

In developing this backward curved fan, flow analysis identified four areas of turbulent flow through the existing impeller design. At the interface between the rotor hub and impeller back plate and the exhaust of the fan, there was a circulation of low pressure air. At the top of the rotor there was an area of low pressure recirculating air and a high velocity seen at the outer diameter of the rotor head.

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Each ach of these points effectively reduced the working area of the impeller blades resulting in an increased velocity and turbulence induced noise. Using numerical modelling techniques, the impeller was developed to eliminate turbulence and promote laminar flow across the full width of the impeller blade. Increasing the working area of the impeller blade resulted in an increase in performance and efficiency and facilitated a reduction in noise levels. This impeller range is designed for low to medium pressure applications in sizes from 133 to 630mm diameter.

Backward Curved Motorised Impeller â&#x20AC;&#x201C; Aerofoil blade design

For medium to high pressure ranges, this backward curved fan range already benefits from rotating diffuser technology, allowing air passing through the impeller to equalise in pressure as it reaches the exhaust. Coupled with an optimally selected EC motor and matched variable speed electronics, the system delivers real world efficiency improvements that are realised in practice and lead to low power consumption. A further improvement in efficiency has been achieved by the addition of an aerofoil blade design which provides a highly stable, low loss performance with a wider peak efficiency operating range. The inclined trailing edge of the blade reduces exhaust flow turbulence as well as reducing the tonal effect of the blade passing frequency. This development has also allowed the motor to be positioned optimally to maximise the working area of the impeller. The total improvement in efficiency is in the region of five to eight per cent with a reduction in noise level of over 3dB at the same operating point.

27/01/2016 10:32:45

A I R

M O V E M E N T

17 acrjournal.uk

MOVEMENT

By Dan Hopkins, Technical Manager at ebm-papst Inlet Flow Straightener

It is not always possible to manufacture air moving equipment according to design ideals due to space constraints or cost. In some cases this can result in undesirable turbulence induced noise and amplify the tonal noise content of the fan. After modelling a number of applications where space was at a premium it was found that there were stable vortices forming at the inlet of the fan. As one of the impeller blades passed through one of these vortices an acoustic pressure pulse was observed. The speed of operation (rotational frequency) and the number of fan blades combine with these vortices to create a distinctive tone at the blade passing frequency.

performance can be used to reduce the speed of the fan to match the operating point, saving on energy and reducing the overall noise level of the equipment.

The air straightener breaks up the formation of these vortices, significantly reducing the blade passing frequency tone by up to 12dB. The straightening effect also reduces the overall broadband noise level by up to 3dB. Fitted on the inlet of the fan, it can be a quick and simple noise control method at source and is an alternative to other absorptive or resonant attenuation measures.

Aerofoil blade designs are available in sizes from 250mm to 560mm diameter.

Addition of a Diffuser

The addition of a diffuser to the hybrid design axial impeller ranges recovers static pressure from the exhaust side of the impeller blade. The diffuser reduces the exit velocity whilst straightening the exhaust flow, thus improving the static efficiency and performance of the fan. The subsequent reduction in turbulence losses also reduces noise and provides a quieter, more efficient fan system. This improved performance can provide extra airflow capacity in times of extreme demand. Alternatively, the extra

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Available for 710, 800 and 910mm diameter hybrid design axial fans, the diffuser can reduce power consumption by up to 22%; reduce noise level by over 7dB or increase the performance capability of the fan by up to 12 per cent.

In summary, whether it is by aerodynamic design of impeller geometry or by studying and mitigating system effects using product enhancements, the effects of turbulence, high velocity airflows and excessive noise can be overcome by innovative design.

26/01/2016 12:14

C O M P E T I T I O N

18 FEBRUARY 2016

DECEMBER/JANUARY16 WINNERS Winner of the the view from The Shard with 2 course lunch and Prosecco for two in the November issue was Nathan Capps , VPMC. The runner-up for the Harrods Cream Tea Experience for two was Mel Rose , from Wolseley.

Welcome to our new Retreat competition, sponsored by Refcom. The law now requires stationary RAC companies to have obtained full F-Gas Certiﬁcation. If you’ve missed the deadline don’t risk prosecution, get registered now at www.refcom.com To demonstrate your commitment to best practice, you can also join voluntary registration scheme Refcom Elite. There are some BRILLIANT competition prizes this month from Refcom, the UK’s leading F-Gas register.

Simply find the 10 words we’ve hidden in the word search for your chance to win. A

AIR HANDLING

AUDIT

COOLING

ENFORCED

FEBRUARY

GASES

GLOBAL

INSPECTION

REFRIGERANT

WARMING

The winner of this month’s competition will win: Overnight Getaway with Dinner for Two.

One runner-up will win: Deluxe Afternoon Tea for Two. Prizes may vary from that pictured.

CLOSING DATE IS 16th FEBRUARY 2016 Send your entry to: Competitions Department, ACR Journal, Warners Group Publications, The Maltings, West Street Bourne, Lincs, PE10 9PH or complete online: www.w2u.en/RefcomComp Name ...................................................................................................................................... Company .......................................................................................................................... Job Title .................................................................................................................................. Business Address ........................................................................................................... ........................................................................................................................ Post code ...................................... Tel ...................................................... Daytime/evening (please circle) .............................................................................. Company email address ..................................................................................................................................................................... Please sign here if you wish to receive or continue to receive a regular

FREE copy of The ACR Journal

FREE e-newsletter

Signed ........................................................................... Date ................................................................... In relation to air conditioning and refrigeration products, please tick the most relevant box below. Purchase Specify Use Install Maintain Manufacture None of these Do you: Warners Group Publications plc will automatically provide you with relevant direct mail and/or telephone information. If you do not want to receive this information tick here . We may also e-mail you with information about relevant products/services. If you do want to receive e-mail please tick here . Warners Group Publications plc will occasionally allow selected third parties to contact you about their products/services. If you do not want to receive relevant direct mail and/or telephone information from third parties please tick here . If you do want to receive relevant email from third parties please tick here . All prizes are subject to availability and may change.

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27/01/2016 10:39:50

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25/01/2016 14:57:40

V R F

20 FEBRUARY 2016

MITSUBISHI ELECTRIC LAUNCHES

LATEST HYBRID VRF SYSTEM Mitsubishi Electric revealed the latest version of its Hybrid VRF air conditioning system recently, which provides simultaneous heating and cooling.

itsubishi Electric released the first version of its Hybrid VRF (HVRF) (Variable Refrigerant Flow) air conditioning system in September 2013 in the offices of Working Environments Ltd, a company based in Southampton. Mitsubishi Electric released the first version of its Hybrid VRF (HVRF) (Variable Refrigerant Flow) air conditioning system in September 2013 in the offices of Working Environments Ltd, a company based in Southampton. One major benefit of the system then was that it used no refrigerant within the office building, using water instead to distribute heating or cooling within the system. Its challenge, however, was that it had a limited range of indoor units (only eight) which meant it was too expensive as viable heating and cooling solution. Two years on, Mitsubishi Electric has overcome the challenges with its first generation Hybrid VRF system with the release of its second version. The hybrid system uses the best of its existing VRF and chiller systems to deliver what the UK air conditioning market is demanding, namely efficient, simultaneous heating and cooling for office spaces, hotels and other non-industrial workspaces. Over 75% of the VRF market uses heat recovery within the system, as opposed to heat pumps.

Air Conditioning Market Conditions

Furthermore, the market conditions have changed since bringing out the ﬁrst generation Hybrid VRF. Overall, VRF sales in the UK are back to where they were before the big, ﬁnancial meltdown

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in 2008. Chiller sales have remained stable throughout. In addition, F-Gas regulations have had an impact on cooling equipment manufacturers. They have had to adapt their systems to use low-GWP (global warming potential) refrigerants to meet the ever-tightening rules on carbon and greenhouse gas emissions.

BS EN378

Another concern for property owners is the challenge of keeping in line with refrigerant leak detection regulations (BS EN378, in fact). This means that any air conditioning system used in a building has to have leak detection systems installed if they have refrigerant being pumped around it. That’s an additional cost which some properties customers don’t like.

Large AC Applications

For small air conditioning systems, Mitsubishi Electric, for example, is now using R32 refrigerant in its AC systems in Japan. However, larger applications need a diﬀerent approach, namely using either chillers or VRF to deliver the heating and

cooling needs in buildings. The gap in the market for larger capacity heating and cooling systems in the UK which Hybrid VRF ﬁlls. Therefore, it looks like the timing is right to being out the next version of its product.

The Innovative Step

Given that Mitsubishi Electric already has its YLM VRF series, and recently introduced its e-series chillers into the UK market which are part of the ‘Hybrid VRF’ system, what has changed? The innovative step in the hybrid system is the new ‘Hybrid Branch Controller (HBC)’. This is the part of the product which makes the HVRF unique. The HBC is a self-contained unit in either 8 or 16-port versions with pumps, an all-in-one flow control valve block and plate heat exchangers. The valve block maintains the flow rate and chooses between providing hot water or cold water into the two-pipe system. Because the flow control valve is selfcontained too, it makes designing and maintaining the system very simple. The HVRF uses the same control systems as existing Mitsubishi Electric VRF, such as the remote and centralised controls. The range of HBCs is bigger now too, as is the range of indoor units, which makes HVRF a viable option for customers to consider.

25/01/2016 15:39

V R F

21 acrjournal.uk

Leak Detection?

One of the huge advantages of the HVRF is that the system only uses refrigerant in the outdoor units. The two-pipe system uses water to move heating and cooling around inside the building. This means there is no need to ﬁt leak detection systems internally. That saves on costs, false alarms and hassle. BS EN378 stipulates the use of leak detection systems where refrigerant is present. When there is no refrigerant used inside the building, leak detection is less of a challenge.

What about efficiency and comfort?

The HVRF is efficient too. And HVRF system using one HBC has an ESEER of 6.3. With two HBCs in a system that rises to over 7, according to Mitsubishi Electric. The company has tested its own systems in their Hatfield office for over a year now. Their engineers switched the system between using the regular VRF one month and the HVRF the next month, and monitored the feedback from staff (who didn’t know which system was in operation).

ONE MAJOR BENEFIT OF THE SYSTEM THEN WAS THAT IT USED NO REFRIGERANT WITHIN THE OFFICE BUILDING, USING WATER INSTEAD TO DISTRIBUTE HEATING OR COOLING WITHIN THE SYSTEM”

The feedback was that they felt the HVRF atmosphere was more comfortable. What are you going to need to learn to be able to install HVRF? The first and most obvious skill you are going to need to work with HVRF is understanding the ‘wet side’ aspect of fitting copper pipework for the water. Tony Williams from Cool Solutions has already installed an HVRF into the offices of consultants, Hoare Lea in Wales. His refrigeration engineers learnt from their heating engineers about working with ‘wet side’ pipework. It was not a tough learning curve, he said. The wet side pipework size is different to refrigerant, but they quickly adapted. Engineers are going to need to learn about the HBC, of course. However, Mitsubishi Electric designed the HVRF to be simple to design, install and commission. Any existing approved installer familiar with their kit won’t find HVRF too challenging to learn, sell and install.

Hybrid VRF schematic

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25/01/2016 15:40

M A I N T E N A N C E

FEBRUARY 2016

PUMP DOWN PROCEDURES ON TOSHIBA VRF AIR CONDITIONING SYSTEMS By Neil Wooldridge, Technical Manager, Toshiba Air Conditioning

he term pump-down is used to refer to a number of different procedures involving the transfer of refrigerant within an air conditioning system. It is commonly used to describe a process that involves drawing as much of a system’s refrigerant as possible into an outdoor unit, to enable work to be carried out on the refrigerant circuit external to the outdoor unit (indoor units, FS-Boxes and pipework).

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The idea is to use the compressor on the outdoor unit to evacuate refrigerant from the system into the outdoor unit. The percentage of a system’s charge that can be pumped into the outdoor unit will depend on the ambient temperature, pipe separation between indoor and outdoor units and the outdoor unit’s internal volume.

Any refrigerant left in the pipework must then be recovered using a refrigerant recovery machine. The term pump down can also be used to refer to the transfer of refrigerant from a failed outdoor unit to a working outdoor unit, using the good unit’s compressor. Continued on page 24

27/01/2016 10:43:25

Build the complete solution. Heating, hot water and now air-conditioning from Bosch.

NEW

In order to maintain our commitment to meeting your needs, Bosch has added air-conditioning to its commercial and industrial heating and hot water solutions. Our ALL-NEW Bosch Climate 5000 VRF range includes: SDCI Series - All Inverter Heat Pump MDCI Series - Mini VRF Heat Pump RDCI Series - All DC Inverter Heat Recovery For more information, please visit bosch-industrial.co.uk/VRF

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Bosch Commercial and Industrial UK

25/01/2016 15:00:18

M A I N T E N A N C E

24 FEBRUARY 2016

Refrigerant Leak Detection with Local Isolation

FS-Box

Indoor Unit

Leak Detection Panel

Leak Detection Input L30 Alarm - Local Shutdown Only

Continued from page 22

In the case of a system with a single outdoor unit, where the outdoor refrigerant circuit requires a repair, this is normally achieved by isolating the service valves at the outdoor unit and either recovering the refrigerant from the outdoor unit to a service cylinder using a reclaim machine, or by using the reclaim machine to pump refrigerant from the outdoor unit to the system pipework. The second option simply uses the pipework for containment rather than a cylinder. From this, it can be seen that refrigerant pump down and recovery processes are numerous and varied, and involve different techniques.

RD3

Modern VRF Systems

On early VRF systems, transferring refrigerant between outdoor units was relatively straightforward, due to the comparative simplicity of the design. With today’s modern systems, however, the procedure is more complex. In our experience, this approach is rarely used as it has little benefit to the engineer, as he will still need to remove the A copy of Toshiba’s Service Manual for Modular Air final residual Conditioning (A12-006) can be downloaded from: refrigerant www.toshiba-aircon.co.uk with a reclaim machine. For more details on Toshiba’s RD6 refrigerant leak In practice, detection and management system, see: engineers can http://w2u.eu/ToshibaRD6 simply isolate the affected outdoor unit at the service valves and either recover to

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a service bottle or to the pipework. Once the work has been carried out, and the outdoor unit pressure/leak tested and evacuated, refrigerant is then released back into the unit. An even more efficient option is available to engineers on systems equipped with Toshiba’s awardwinning RD6 leak detection and management system. This is primarily designed to monitor an air conditioning system for refrigerant leaks and, in the unlikely event of refrigerant loss, automatically pump down the system to prevent further leakage - until the source of the leak can be identified and repaired. However, RD6 also enables engineers to activate a full pump down at the flick of a switch, overcoming the need for the usual sequence of manual steps, thereby speeding up the whole process.

25/01/2016 16:36

WITH CERTIFIED PERFORMANCE IN YOUR COOLING TOWER YOU WILL ALWAYS HAVE THE BEST HAND.

MAKE AN INTELLIGENT DECISION TO REACH OPTIMAL SYSTEM PERFORMANCE WITH LOWEST CO2 FOOTPRINT. The COOLING TOWER certification programme “Eurovent Certified Performance” is new within the European HVAC&R industry. This programme responds to the Ecodesign regulations by adopting an energy efficient design to your building systems using Eurovent Rating Standard 9C-001. The COOLING TOWER certification is actively supported by the participating manufacturers:

By Eurovent Certitia Certiﬁcation, a leading Third-Party certiﬁcation body in Indoor climate - Ventilation & Air quality - Process cooling & Food cold chain. Getty Images ©JuSun

Check performances on line www.eurovent-certiﬁcation.com

High Efficiency Solutions.

PlantWatch PRO

The Latest in Refrigeration Supervisory Systems

The new generation PlantWatch PRO from CAREL offers the very latest in supervision of refrigeration systems providing data logging,intelligent energy saving algorithms,KPI comparison,data analysis plus local and remote alarms.The PlantWatch PRO3 is available in 3 sizes and in wall or panel mounted options,ensuring that it is the ideal solution for supermarkets or convenience stores. CAREL U.K. Ltd Unit 2 Roebuck Place, 110 Roebuck Road, Chessington, KT9 1EU tel +44 208 391 3540 - fax +44 208 391 0457 info.uk@carel.com - www.careluk.com

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Energy saving, monitoring & control, all great reasons to install CAREL

careluk.com

25/01/2016 15:09:18

R E F R I G E R A N T S

26 FEBRUARY 2016

F-GAS:

TEN STEPS TO BEST PRACTICE A-Gas Managing Director John Ormerod with his 10 top tips on how to manage the F-Gas Regulations.

Face up to the R404A challenge

The refrigerant quota phasedown under F-Gas is going to put considerable pressure on the supply chain. R404A is the most widely used refrigerant in commercial refrigeration and has the highest GWP. Observers in the industry, including independent commentators, say that supplies of R404A are going to be a problem. Everyone agrees that by 2018 there won’t be suﬃcient R404A around to service current needs. There will be shortages and the industry needs to start moving away from R404A very quickly.

Go for low GWP options

In the context of R404A there is a raft of options depending on how far down the GWP curve customers want to go. R407F (Genetron® Performax LT™) and R407A are two medium GWP alternatives which are currently available, cost effective, and in many cases, energy efficient. There are also newer generation refrigerants with a lower GWP like Solstice® N40 (R-448A) and Opteon® XP40 (R-449A) that offer additional benefits in terms of lower discharge temperatures. These low GWP options are already with us and offer customers the chance to make the switch from R404A now.

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Up your leak detection regime

John Ormerod

Most refrigerant supplied to the industry is for servicing systems and the reason they have to be topped up regularly is because they leak. Driving down leakage rates is a key part of managing refrigerant use under the F-Gas Regulations. It is well worth putting a lot of eﬀort into doing so if you want to achieve F-Gas best practice. Gone are the days of using soapy water and waiting for bubbles to form. Advanced leak detection methods are now a popular choice, with many engineers using trace gas methods such as hydrogen or helium mixtures.

Understand CO2 equivalents

The F-Gas Regulations are based upon working to Carbon Dioxide equivalents and if you don’t understand how this works achieving best practice won’t be possible. The calculation involves measuring the refrigerant in kilograms and then multiplying this by the GWP. Gas-Trak Online™ (GTO™) from A-Gas, a handy app which will calculate CO2 equivalents, is among the online tools which allows you to do these sums simply and eﬃciently.

Use the right tools for the job

The trend as we move away from high GWP refrigerants suggests that the further down the line we go with this, the more we will switch to flammable and mildly flammable refrigerants like R32. Currently, this takes the industry out of its comfort zone. Flammable refrigerants need to be handled with care and the correct flameproof equipment has to be used to allow you to manage the risks associated with these gases.

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R E F R I G E R A N T S

27 acrjournal.uk

Improve cylinder tracking

All refrigerant suppliers are levying charges on cylinders, especially on those described as slow moving. This can end up costing end users a fortune if they have lost track of where they have left them. GTO from A-Gas has a cylinder-tracking tool designed to make this job easier. Free to download on smartphones and tablets, it comes complete with a number of valuable features to help users locate their cylinders.

Cut down on paperwork

The F-Gas Regulations put the onus on users to record the amount of refrigerant they put in and take out of a system. Historically this has been completed on paper but now there are tools available that allow the task to be handled online in a quicker and more eﬃcient way. GTO provides accurate online reports, 24/7. In turn this removes the burden of endless ﬁling and the risk of losing paper copies. We live in a digital world and online tools are there to make the job easier – we should use them.

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Think lifecycle management

Refrigerant recovery has been a legal requirement within the industry for some time. Any refrigerant that is recovered needs to be kept within the industry and not released into the atmosphere. We can then recycle it, make it available on the market again and in turn relieve any shortages.

Produce top quality joints

Most piping used in the industry is copper and high quality brazing is needed to ensure you have strong, well-penetrated joints. To achieve this you have to have adequate heat input when you are applying the filler material. There are a range of products on the market and they vary as to the amount of heat they offer. Oxygen and acetylene when used together provide a flame temperature of 3500°C. This is significantly hotter than propane and propylene. If you are on a site where it is slightly windy or slightly cold, or the pipe

sizes are larger, it can be diﬃcult to get the heat required. High temperatures are key to achieving top quality brazing, so only use the best products. This will ensure strong, leak-free joints that are less likely to break and cause equipment breakdown.

Keep up to date

The industry has faced considerable change over the past 25 years. This will continue to happen as the F-Gas Regulations have a greater impact on our working lives. So it’s never been more important to keep up with what’s happening through the media online and in print. Trade associations, manufacturers, wholesalers and suppliers also have a role to play here. So keep your eyes and ears open – or you may miss something which could have a major impact on what you do and how you do it. www.agas.com

26/01/2016 15:09

R E F R I G E R A N T

28 FEBRUARY 2016

TIME TO PLAN YOUR M

In Part Two of this article, Peter Dinnage Technical Director at Climalife, discusses the other alternative refrigerants that can ease your move away from the high GWP refrigerant R-404A

ast month we highlighted the increasing need to move away from R-404A this year and looked at R-407F as an alternative to R-404A. If you missed the article it can still be found on the ACR Journal website. This month we cover lower GWP alternatives.

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27/01/2016 10:46:50

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R E F R I G E R A N T

29 acrjournal.uk

R MOVE AWAY FROM IT IN Lower GWP alternatives to R404A

There are a number of alternatives approved by compressor manufacturers with a GWP significantly lower than R-404A and whilst each have slightly different properties, it is their GWP where there is most difference. Both R-448A and R-449A have GWPs (AR4) just below 1400. Both contain R-125, R-134a, R-32 and R-1234yf, but R-448A also contains R-1234ze and it’s the presence of the HFOs which take the GWP lower than that of R-407A (2107) and R-407F (1825). Both these lower GWP alternatives can be used in supermarkets, cold stores and direct expansion food processing applications that have previously used R404A. Energy saving benefits compared to R-404A exist but may vary according to application and operating conditions. These savings tend to be greater in medium temperatures applications. Pressure temperature tables are available in various forms and feature on many of the popular free slide rule apps that are now available for smartphones. R-449A (Opteon™ XP40) is already proving a suitable alternative to R-404A with use growing across Europe in a wide range of applications. In the UK it has already been used in new convenience store applications and has been trialled in a number of larger supermarkets for retrofit and roll out in 2016 in further stores. On the industrial side it has been used successfully for retrofit and

has proven to be an easy conversion to carry out from R-404A, with no need to change from the POE oil used with R-404A. Where electronic expansion valves are in use, they can be adapted to R-449A whilst a small adjustment of thermostatic valves and the superheat settings are usually required for optimum operating conditions. To meet the phasedown requirements of F-Gas in 2018, retroﬁtting of existing R-404A equipment to lower GWP refrigerants is going to be vital to ensure the reduced quota meets the demands of the market. The lower GWP refrigerants such as R-449A (Opteon™ XP40) and R-448A will have a major part to play. New Store on Opteon™ XP40 (R449A) Whilst selection of new equipment will depend on the equipment manufacturers, for retroﬁtting existing systems the choice is with the contractor or the end user. Nevertheless the selection software of the compressor manufacturers for R-404A alternatives can still be used as a guide along with case study information from those where

conversions have taken place. It is always worth remembering that if you are retroﬁtting to follow the conversion guidelines from the producer / supplier as this will help ensure the check list is followed and potential pitfalls are avoided.

A2L Refrigerants as R404A replacements

Many have been holding off replacing R404A in the hope that even lower GWP replacements will be available and possibly a better option. However, A2L rated refrigerants will not be a retrofit option due to their mild flammability and even for new equipment there will be charge size restrictions based on the size of the room which will limit their use to small equipment. Some of these A2L refrigerants with low GWP will be a good option for new systems with a small charge, however the selection and approval process will be led by the equipment manufacturers and that may take time and assumes EN378 will formally incorporate the recommendations now on the table.

The need to replace R404A

R-449A IS ALREADY PROVING A SUITABLE ALTERNATIVE TO R-404A WITH USE GROWING ACROSS EUROPE IN A WIDE RANGE OF APPLICATIONS.

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If you are still in any doubt of the need for action to replace R404A in 2016 we recommend you look at the EPEE Gapometer presentation which can be found here; http://www.epeeglobal. org/epeedocs/internet/docs/201510-26-GAPOMETER-Final_9102.pdf Do also speak to refrigerant specialists, such as Climalife, to review all the options available to you and ensure it is the right choice for your particular system.

27/01/2016 10:47:10

N A C R H P A

30 FEBRUARY 2016

WINNERS ANNOUNCED ACR PROJECT OF THE YEAR

DOMESTIC AIR SOURCE PRODUCT

DOMESTIC GROUND SOURCE PRODUCT

MAURER BAKERY CASCADE

G AT T O N B A R N FA R M

DIMPLEX SOLUTION IN KINCRAIG

Maurer’s decision criteria over the refrigeration system for their new bakery plant was the ability not only to meet incoming regulations but to implement a strategy that would bear down on energy consumption and enable the company to meet its stated environmental

Gatton Barn Farm Key Points: ₀ Un-used barn from the 1600s ₀ Rural location with no insulation or heating system ₀ Conversion into a two storey family home with unique care needs ₀ Additional lodge built for guests.

Alan Bell approached BRE Scotland in August 2014, looking for a recommendation for a company to install a ground source Heat Pump using a Burren (river) beside his house as a heat source.

HIGHLY COMMENDED HIGHLY COMMENDED HIGHLY COMMENDED I-I-Ice Ltd AkzoBobel Building 145

Finalists

AB Group & EBM Papst M&S Energy Roll Out AB Group & EBM Papst M&S NET AB Group & EBM Papst Sainsbury’s Co Refrigeration Assets AB Group & EBM Papst M&S Energy Roll Out Munter’s Equinox Data Center

Geo Warmth Mitsubishi Electric Renewables Solution

Finalists

Abel Environmental Services Ltd Mitsubishi Electric Ecodan Oﬀ Grid Be Green Rebuild of Existing House RA Brown Heating NIBE Heat Pump in Norfolk Stiebel Eltron National Trust Installation Stiebel Eltron Castle Howard Installation Stratford Energy Solutions Ltd WPL 25AS

Viessmann Ltd & Green ACRT New Build in Tiddington

Finalists

Be Green New Build of Large House Finn Geotherm New Five Bedroom House Geowarmth Grand Designs NIBE Installation Kensa Heat Pumps Ltd Trent & Dove Housing Association RA Brown Heating Services Ltd NIBE Insallation in Old Farmhouse Stratford Energy Solutions Ltd Oil Boiler Replacement Viesmann Ltd Huf Haus at Brooklands

Essential Information for the Air Conditioning and Refrigeration Industry

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27/01/2016 11:03:16

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N A C R H P A

31 acrjournal.uk

ACR PRODUCT OF THE YEAR

NON-DOMESTIC GROUND SOURCE PROJECT

SMMS-E VRF SYSTEM

AV D A W S O N S T E E L S T O R E

Developments in three core technologies - the compressor, heat exchanger and advanced intelligent control - combine to ensure all outdoor units in the new SMMS-E VRF range have an ESEER (European Seasonally Adjusted Energy Eﬃciency Rating) higher than 7, an industry ﬁrst

AV Dawson is a truly multimodal provider oﬀering logistic services including road transport; rail freight; quayside loading and unloading as well as warehousing and storage, all from their Teesside Hub. They have created a purpose built storage facility allowing the store to hold over £15 million worth of stock at any one time.

NON-DOMESTIC AIR SOURCE PROJECT F O S T E R & PA R T N E R S S O U T H LO N D O N C A M P U S Architects Foster & Partners wanted to improve energy eﬃciency at their central London campus by moving away from traditional gas supply.

HIGHLY COMMENDED HIGHLY COMMENDED

Mitsubishi Electric City Multi YLM Range of VRF

Finalists

Business Edge Climate Zone ATU Klimatherm-GreePV Centrifugal Chiller Space Air (on behalf of Daikin Europe NV) VRV IC i-series Silentair Combi AC System Combi AC System

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HIGHLY COMMENDED

Kimpton Energy Solutions Grade 1 listed Country House

Finalists

Finn Geotherm 300 Year Old Barn Kensa Heat Pumps Thameside Homes TGE Group 50,000 Bird Capacity

SME (Specialist Mechanical Services) Ltd Montrose Port Authority

Finalists

Dimplex National Grid Substation Finn Geotherm Logan Botanic Gardens I-I-Ice Ltd Mitsubishi Electric Edinburgh Zoo Dimplex Dumfries House Estate

27/01/2016 11:05:07

N A C R H P A

32 FEBRUARY 2016

WINNERS ANNOUNCED

ACR ANCILLARY REFRIGERATION HEAT PUMP PRODUCT OF THE YEAR PRODUCT OF THE YEAR PRODUCT OF THE YEAR H E AT R E C O V E R Y U N I T

The Geyser heat recovery unit uses energy from AC and refrigeration systems that is usually discharged to atmosphere to provide free hot water and at the same time reduces energy consumption by the AC/ refrigeration equipment.

A D A N D E ® M AT C H B OX R E F R I G E R AT E D D R A W E R S WITH HYDROCARBON REFRIGERANT (R600A)

The Adande Matchbox system with hydrocarbon refrigerant operates on R600a, which is a non-toxic chemical compound, demonstrating negligible ozone depletion characteristics and a very low global warming potential. Models operating on hydrocarbon refrigerant are available at no additional capital cost.

F I F T H G E N E R AT I O N ECODAN RANGE

With the launch of the ﬁfth generation of the Ecodan range of air source heat pumps, Mitsubishi Electric is pushing the technological boundaries for domestic heat pumps once again.

HIGHLY COMMENDED

Space Air (on behalf of DAIKIN EUROPE) VRV IV i-Series Vaillant Ltd First Wall Mounted GSHP on market

Finalists

HIGHLY COMMENDED

Javac R32, R1234ze/yf service tools

Finalists

Chillair Ice Cold Space Air Range of 500 bespoke components

HIGHLY COMMENDED Gram UK The Superior Plus 72

Finalists

Blue Diamond The Actik Blue Dairy Tray A1 Engineering Solutions Emerald Hydrocarbon Glycol Plant

Climaventeta SPA EWHT Water to Water Heat Pump DPAC UK Ltd MULTI TUBE Technology Earth Save Products ESP Varimaax Units Hitachi Yutaki - S Combi Heat Pump LG ThermaVMonoblocTypeAir-WaterSeries Orangehouse Renewables ECOFOREST Heat Pumps Stiebel Eltron WPC 04-13 GSHP Stiebel Eltron Brine Water Heat Pump Warmﬂow Engineering Ground Source Heat Pump

Essential Information for the Air Conditioning and Refrigeration Industry

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26/01/2016 12:48

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N A C R H P A

33 acrjournal.uk

IN SITU MONITORING

ACR CONTRACTOR OF THE YEAR

HEAT PUMP INSTALLER OF THE YEAR

A1 Engineering Solutions is proudly celebrating 30 years of trading. This family run business has weathered two recessions and has grown signiﬁcantly over the past 30 years into the successful, progressive business we see today, with the same key goal of delivering a quality product and excellent customer service.

Dave Thompson, the Managing Director of Ground Heat ﬁrst began installing heat pumps over twelve years ago. As Installations Manager for a plumbing and heating company he was called out to look at a heat pump on behalf of Ice Energy and has never looked back.

WHOLESALER/ DISTRIBUTOR OF THE YEAR

REMOTE ENERGY MONITORING Mitsubishi Electric took in-situ monitoring to a whole new level with the introduction of remote energy monitoring as standard on all Ecodan air source heat pumps from 19th January 2015.

HIGHLY COMMENDED

Daikin UK (on behalf of Daikin Europe) High Eﬃciencies of Hybrid System

Finalists

Business Edge ClimaCheck PA PRO

NACRHPA_Winners.indd 33

HIGHLY COMMENDED

Ryan Jayberg Mitsubishi Electric Renewables Solution

Finalists

AB Group

HIGHLY COMMENDED Matrix Energy Systems

Finalists

Bryan Jones, Total NRG TGE Group Be Green Finn Geotherm Glevum Heating

RW was the former American owned United Refrigeration Wholesale UK business established in the early 90s.

HIGHLY COMMENDED Hawco

Finalists

Climate Center CDL Space Air

27/01/2016 11:04:15

C O M P A N Y

P R O F I L E

FEBRUARY 2016

is the new name in refrigerants

lthough the name is new, the company itself has over 80 years of history in the refrigeration market, stretching back to the days of Freon™. Chemours was formed in July 2015 when DuPont spun oﬀ its performance chemicals business. Under its new name, Chemours has continued to lead in the development and commercialisation of new refrigerants to meet the latest challenges.

The Opteon™ range of refrigerants is based on the groundbreaking HFO (hydrofluoro-olefin) technology that is set to revolutionise the refrigerants market. These new HFO building blocks have a global warming potential (GWP) lower than that of CO2. These materials also retain many of the favourable properties of HFCs (hydro fluoro carbons) that made them excellent refrigerants, but without the drawback of the high GWPs of products such as R-404A. In the automotive industry, Opteon™ YF is now in widespread use and by 2017 almost every new car sold in the EU will have R-1234yf in its air conditioning system, passing a significant environmental milestone with the phase out of R-134a. In stationary refrigeration, changes are being driven by the new F-Gas regulations and in particular the reduction in quota year on year. 2015 was the first full year of the new regulation and to match this saw the full-scale commercial introduction of the Opteon™ XP range of nonflammable HFO blends. This has sparked increasing interest from users of R-404A

Chemours_CP.indd 34

in commercial and industrial refrigeration who are now developing strategies to manage the bank of refrigerant they have in their existing estates. Many of these strategies involve the use of Opteon™ XP40 (R-449A) – a direct replacement for R-404A that can be used to easily retrofit existing systems. As well as having a GWP of around one third that of R-404A, it is also more efficient, which has led to some early adopters already embarking on significant retrofit programmes. In transport refrigeration, several major OEMs are already moving away from R-404A towards a direct replacement in the form of Opteon™ XP44 (R-452A), which has similar properties at about half the GWP. In chiller applications, the first units of Opteon™ XP10 (R-513A), which can directly replace R-134a but with less than half the GWP, are already on the market. Later in 2016 will see the commercial introduction of a new range of mildly

flammable HFO blends with ultra-low GWP in the Opteon™ XL family. This will follow the eagerly anticipated publication of the EN378 standard, which will determine the charge sizes that can be used in various applications. It is already clear that significantly larger charges will be allowed than is possible for hydrocarbon installations leading to much more extensive use of products with ultra-low GWP. Chemours is a global leader in titanium technologies, fluoroproducts and chemical solutions, providing solutions in a wide range of industries with market-defining products, application expertise and chemistry-based innovations. Chemours ingredients are found in plastics and coatings, refrigeration and air conditioning, mining and oil refining operations and general industrial manufacturing. www.chemours.com

25/01/2016 16:05

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A D V E R T O R I A L

35 acrjournal.uk

ARE YOU READY FOR

The refrigerant is here, the air conditioning systems are available, and the tools are ready. But, are you prepared for R32?

AIR CONDITIONERS The next generation of refrigerants are here and your customers are probably asking you for help on making them more energy eﬃcient while addressing their environmental concerns with their air conditioning systems. Interest in R32-based air conditioning systems is growing. But, what are the implications of R32 refrigerant? What sort of equipment is available which uses R32? Have you got the right recovery equipment to safely handle R32?

Vern Klein - A-Gas

Jason Roberts - Fujitsu

You are probably asking yourself these questions about the refrigerant and more. Don’t worry. The ACR Journal has teamed up with leading industry experts in R32 to help answer your questions and get you ready in a webinar - An Introduction to R32 Martyn Ives - Fujitsu

Scott Davies - Javac

Experts from A-Gas, Fujitsu and Javac will help answer your R32 questions in a free webinar on 17th March 2016 at 2.30pm GMT.

GET READY FOR R32 Sign up for the free webinar here: www.r32webinar.co.uk R32 Webinar advertorial.indd 35

27/01/2016 11:15:40

C O O L I N G

36 FEBRUARY 2015

THE FUTURE OF COLD By Professor Toby Peters, CEO, Dearman Engine

Toby Peters

Booming demand for cooling, particularly in the developing world, poses serious challenges around energy and the environment. But it also presents a massive opportunity. Innovative clean cold technologies are now being developed that promise both to make cooling far more sustainable and create a new global market.

ooling has been much ignored in the energy debate so far, but is a pillar of modern civilization. We need cold chains of refrigerated storage and vehicles to preserve food from farm to fork and protect vaccines. We need to cool the data centres that enable the online economy. We need air conditioning to make buildings comfortable places to live and work wherever they are. But there is an economic and environmental price to pay for cooling – or the lack of it.

Developing countries, where cooling infrastructure is rudimentary or nonexistent, suﬀer high levels of postharvest food loss, causing knock-on wastage of water and land and continued hunger, ill-health and poverty. The lack of adequate cold storage and refrigerated transport causes two million vaccinepreventable deaths each year, and the loss of 200 million tonnes of food. As the global population heads towards 10 billion by 2050, there is no question that such countries will need far more cooling.

Rising Aspirations

In the rapidly industrialising countries such as China and India, cooling demand is

already soaring, driven by rising incomes and a rapidly expanding middle class that aspires to western living standards. As one example, China bought 50 million air conditioning units in 2010 alone, equivalent to half the entire US domestic air conditioner ﬂeet. The IPCC projects that global air conditioning energy demand will grow 33-fold to more than 10,000 TWh in 2100 – or roughly half the total electricity generated worldwide in 2010. And it’s not just air-conditioning. We estimate that if nothing is done, within ﬁfteen years the electricity needed to power all cooling services worldwide will require an additional 139GW generating capacity – or more than Canada. This would cause an additional 1.5 billion tonnes of CO2 emissions per year – three times Britain. And that’s just from the power stations themselves. Cooling is also responsible for leaks of F-gas refrigerants, which are themselves highly potent greenhouse gases. Our analysis shows that while F-gas leakage accounts for just 17% of lifecycle CO2e emissions of transport refrigeration units (TRUs) in the EU, diesel consumption accounts for most of the rest, and for high levels of NOx and particulate emissions. A diesel TRU can

emit up to 6 times as much NOx and 29 times as much PM as a modern (Euro VI) truck propulsion engine. These are two of the key pollutants that contribute to 3.7 million premature deaths through outdoor air pollution worldwide each year. The current global TRU ﬂeet of four million could grow to almost 18 million by 2025 to cater for pent up demand in developing countries. Soaring cooling demand in developing countries only adds to high existing demand in the developed. In Britain, for example, around 16% of our power goes on cooling, and across the EU it is estimated that cooling for buildings could rise by over 70% by 2025.

Optimum Heat Transfer

High thermal efﬁciency and low viscosity to maximise Coefﬁcients Of Performance

Visit us at the ACR Show Stand G35, Hall9 all9 NEC NE

tel: 01792 586800 info@hydratech.co.uk Dearman.indd 36

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C O O L I N G

37 acrjournal.uk

zero-emission transport refrigeration system in on-vehicle testing

Doing Cold Smarter

For the sake of our health, the environment and to preserve natural resources, this has to change. We need to start doing cold smarter, and that means addressing how we generate, store and deliver cooling, across all sectors. One newly proposed form of cleaner cold is liquid air. Air can be turned into a liquid by cooling it to around -196C using standard industrial equipment powered by wrong-time energy, and the liquid can then be stored (in an unpressurised insulated vessel) – and transported by road tanker. When heat is reintroduced to liquid air it expands 700 times and turns back into a gas to drive a piston engine or turbine – producing power and loads of zero-emission cold. Clean cold technologies are already being developed to run on liquid air or nitrogen, led by Dearman, whose zero

emission transport refrigeration goes into fleet trials this year. Follow on applications include a diesel-liquid air ‘heat hybrid’ engine for buses and trucks that improves fuel economy by 25%, and a zero emission backup electricity generator. Liquid air is not yet produced commercially but liquid nitrogen, which operates in the same way, is widely available and usually produced from lower carbon off-peak electricity. In future, liquid air could be produced from ‘wrong time’ zero carbon renewable or nuclear power, and re-cycling waste cold from LNG re-gasification would reduce the electricity required to produce liquid air cost by more than 50%. We need to move beyond piecemeal solutions towards a fully joined up ‘Cold Economy’. It’s time we brought cooling in from the cold.

Dearman zero-emission liquid air engine

Specialist Fluid Solutions Dearman.indd 37

25/01/2016 16:12

Air Conditioning And Energy Solutions

Splits | VRF | Heat Pumps | Ventilation | Controls

Innovation for a Better Business Bespoke design and distribution of air conditioning products Units 1&2, The Heron Business Park, Eastman Way, Hemel Hempstead, Herts HP2 7FW Telephone: 01422 254 401 (North West) 01942 252888 | Website: www.pacair.co.uk Follow PACAIR

@PAC_AIR

Follow LG

@LGUK_B2B

First Choice aim to provide an unsurpassed level of service in the supply of spare parts to the UK Refrigeration and AC market. We supply both universal parts and OEM spares for refrigeration equipment from the leading manufacturers and also stock specialist tools and consumables used by refrigeration engineers, all available for next day delivery if ordered before 5.00pm.

DANFOSS TL5G

EMBRACO NEK6144GK-A TRADE PRICE

£60.01 +VAT

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£37.36

£70.64

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One Stop Shop for Refrigeration Spares FIRST CHOICE REFRIGERATION SPARES LTD

Unit 1 Swaffield Park, Hyssop Close, Hawks Green, Cannock, Staffs WS11 7FU tel: 01543 460398 fax: 01543 504141 email: refrigeration@firstchoice-cs.co.uk web: www.firstchoice-cs.co.uk

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25/01/2016 15:14:45

C H I L L E R S

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CARRIER RENTAL SYSTEMS SAVES ENERGY

AND BOOSTS CHILLER CONTROL Carrier Rental Systems (UK) Ltd, the UK’s leading temperature control hire specialist, has introduced full Building Energy Management System (BEMS) capability for its ﬂeet of chillers, enabling chillers on temporary cooling duty to be fully integrated into a building’s existing control system.

he addition of BEMS capability to temporary chillers enables the customer’s existing BEMS to automatically control the machine and send signals for run, fault, remote on/off. It also allows end-users to optimise chiller performance for occupant comfort and energy consumption.

It will particularly benefit temporary cooling projects in complex and critical applications such as hospitals, data centres, manufacturing industry and large commercial offices. “Traditionally, rental chillers operate as stand-alone units, independent of existing heating, ventilation and air conditioning systems,” says Marc White, director, Carrier Rental Systems. “With the addition of the new BEMS capability, temporary unitsm can be fully integrated into a building’s existing systems and work seamlessly to optimise building control and energy efficiency.” A temporary cooling system operating independently, without BEMS capability,

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may work in opposition to existing heating, ventilation and air conditioning systems (HVAC) systems, which can incur a large energy penalty and result in high running costs. The company’s solution is to offer a new range of hire chillers with full BEMS connectivity built in, enabling them to be linked into the existing building system and come under its overarching supervision. “Today’s buildings have intelligent, algorithm-based controls designed to integrate the operation of the existing HVAC system. The arrival of a stand-alone temporary chiller can have a negative impact on the carefully calibrated balance of the system, particularly as the temporary chiller is often a replacement for an existing chiller that is either being repaired or replaced – and therefore offline,” said Marc White. The new approach addresses and overcomes this problem, offering endusers and building managers a significant additional benefit to maintain overall

building performance, optimise occupant comfort, and minimise running costs and environmental impact during chiller rental periods. A Carrier chiller with onboard BEMS capability was deployed recently as part of a temporary cooling project at a hospital in Northern Ireland. It enabled the chiller to be fully integrated within the hospital’s central building control and monitoring system, ensuring conditions were maintained within required limits for patients and staﬀ in medical wards and operating theatres. The company’s new chiller ﬂeet with full BEMS capability is available nationwide for hire, for a variety of commercial applications.

25/01/2016 15:14

E N E R G Y

E F F I C I E N C Y

FEBRUARY 2016

BEYOND COMPLIANCE Consultants BJA are reminding businesses that they have to be Energy Savings Opportunity Scheme (ESOS) compliant by 29th January 2016. ESOS means that companies have to audit their energy usage.

fter the deadline, companies that have failed to notify the EA will see enforcement action begin. To encourage businesses, the EA recently sent out informal warnings to organisations that have not advised them they were ESOS compliant.

That meant around one third of all businesses eligible for the mandatory scheme received the warning. About 4,000 businesses submitted their final ESOS report by the original deadline of 5 December deadline. A further 2,500 had notified the Environment Agency of their intent to comply. Although the legal deadline for compliance remains 5th December 2015, companies will not face enforcement action if they notify the EA of compliance before 29 January 2016. The Agency is also offering a three month derogation, after enforcement notices are sent out, before any civil action will occur.

For cold storage, it can be towards to Around 3,000 UK businesses have To identify the true opportunities not told the Environment Agency (EA) 85%. for energy savings, companies should use that they intend to follow the ESOS specialist independent experts, in both legislation. If an organisation meets refrigeration and energy efficiency, to carry out the energy audits. the qualification criteria but fails to follow the legislation, it could face a TM44 Air Conditioning Inspections and ESOS fine of up to £90,000. Since 4th January 2011, all organisations their refrigeration plant is often one of their largest consumers. This can account for anywhere between 25% and 60% for food production facilities.

in England and Wales with air-conditioning systems over 12kW, have to carry out an independent energy inspection of their units. (See Article 9 of the Energy

ESOS Audit

ESOS energy audits of buildings have a specific route that is allowable. The appointed lead assessor (Registered on the Approved Professional Body ESOS Register) has the responsibility to assess any existing energy audits. This covers the organisation’s portfolio of buildings that contribute to the “Significant” energy use. These audits have to relate to the reference period and they have to be ESOS Compliant Energy Audits. For many users of refrigeration equipment, the energy consumed by

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E N E R G Y

E F F I C I E N C Y

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WHAT IS ESOS? The ESOS Regulations 2014 bring into force Article 8 of the EU Energy Efficiency Directive and mandate that all large businesses in the UK undertake comprehensive assessments of energy use and energy efficiency opportunities at least once every four years. The deadline for the first compliance period is 29th January 2016, by which time qualifying businesses will have to achieve compliance with the regulations and notify the Environment Agency. The criteria for inclusion to ESOS is not straightforward, but it applies to any ‘large undertaking’ that carries out a trade or a business, and any corporate group where at least one member of the UK group meets the ESOS criteria.

Chris Williams

Performance of Buildings (Certificates and Inspections) Regulations 2007). TM44 Air Conditioning Inspections and certification are still a mandatory. But, they will not on their own meet the ESOS rule as they only cover comfort cooling air conditioning and exclude other areas of the organisation’s energy usage, such as process cooling. Therefore, TM44 does not in itself make an organisation ESOS compliant. Yet, the report produced by a TM44 audit could and should influence the Energy Saving Opportunities database. Energy savings already identified in the TM44 report would be incorporated if the Lead assessor approves their inclusion in to the ESOS report. So TM44 Air Conditioning inspections remain important to meet legal obligations and also help with ESOS. BJA is working with leading retail, commercial and industrial organisations to meet their legal obligations and identify inefficient units to reduce energy consumption.

Beyond compliance

Only complying with the Regulations misses the point of ESOS. Use ESOS to identify opportunities to reduce energy use and to cut consumption, emissions and cost. Whilst there is no statutory need to take action on these opportunities, not to do so is to reduce ESOS to a costly compliance exercise rather than a means to achieve real savings.

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A large undertaking is one that employs at least 250 people or has an annual turnover over £40 million and a balance sheet more than £34 million. Most public sector bodies are excluded, but some, such as many Universities may qualify.

Opportunity?

There will be some that approach ESOS as a ‘box ticking exercise’. For them this will not be an opportunity gained, but an opportunity lost. There are real proven business benefits for organisations in reducing the amount they spend on energy. Refrigeration and air conditioning plant users often waste around 20% of their annual energy costs by using inefficient equipment. An ESOS audit will identify this equipment. BJA’s expert knowledge and tailored services make the implementation of energy reduction projects easy and cost effective.

Looking beyond the low-hanging fruit It’s no surprise that low-cost/no-cost energy efficiency measures tend to get the most uptake. But, it is a misconception that only the low-hanging fruit is worth harvesting. On the contrary, it’s estimated that so-called ‘investment’ measures (those involving slightly longer payback periods) can unlock typical energy savings of 15%. That is 15% on top of that saved by low-hanging fruit upgrades. The landscape of energy-saving technologies is evolving so rapidly that many solutions that were once thought of as longer-term investments are now becoming low-hanging fruit. Prices are coming down, payback periods are improving – all of which makes it worthwhile to look beyond the obvious and to make sensible, well informed decisions when it comes to investment projects.

Making well-informed investments

The time and money currently invested to achieve ESOS compliance is unvoidable unless one wishes to risk facing a fine. Implementing and maximising the energy savings opportunities identified, and to take full advantage of the ESOS opportunity is the most effective way to ‘offset’ the cost of the ESOS audit. This will involve making upgrades, installing new equipment, improving procurement, etc,. BJA has specialist project managers in the cooling and energy efficiency sector, and can manage this process for the end-user. BJA advises companies not to look at ESOS as a pointless box-ticking exercise. Instead, BJA encourage them use it as a chance to improve their energy strategy, to reduce energy waste, and to uncover the next layer of energy savings. BJA Refrigeration Consulting Engineers are specialist independent refrigeration consultants who work with many of the UK’s leading food processing, storage, retail and distribution companies to ensure that their clients enjoy the most energy efficient, reliable, and innovative solutions. They provide specialist ESOS energy audits, and also undertake TM44 Air Conditioning inspections. With a long background in project management, they are well placed to advise of energy saving investments for cooling equipment and to manage the implementation process from start to finish.

29/01/2016 08:39:02

C H A N G I N G

F A C E S

FEBRUARY 2016

Andy Reed

₀ LG Appoints Andy Reed as UK Director LG Electronics has announced that Andy Reed is the South Korean air conditioning and heat manufacturer’s new UK director. Andy Reed takes over the position opened by the departure of Jody Lees recently. Andy was previously a Business Director with air conditioning and refrigeration wholesaler, Dean & Wood. He has a long career in the industry having worked in senior sales roles with Dean & Wood and Danfoss. Andy stated: “These are very exciting times for LG and I’m delighted having worked with LG as a customer for several years to be given the opportunity of leading this excellent team in the months and years ahead.

Andy Munson

Nick Baldwin

₀ Mansfield Pollard kick starts 2016 with new appointment Air management experts Mansfield Pollard – suppliers of energy efficient ventilation and sound management equipment to a global consumer base - has announced that Nick Baldwin has joined the organisation as its new Estimating and Proposals Manager. In this key role, Nick will lead the team which creates proposals for its customers and is responsible for the evolution of proposal and tender formats. Nick’s appointment reflects the business’ growth plan and its strategy of focusing on the delivery of industry leading levels of customer service.

Dr. Klaus Weiß

₀ Ziehl-Abegg Appoints New Chief Operations Officer German fan manufacturer, Ziehl Abegg, has appointed Dr. Klaus Weiß, 52, as its new Chief Operating Officer as part of the company’s plans to expand. Dr. Weiß will sit on Ziehl Abegg’s executive board and will be instrumental in the planned organisational restructure needed to adapt to the new market conditions. The business is focusing on its business’ development, production, sales and financial operations. Dr. Weiß has a background in engineering specialising in fluid kinetic machinery and manufacturing. He has a PhD from the Technical University Darmstadt.

Aaron Swain Tim Rook

Jack verber

₀ Andy Munson joins Humidity Solutions

₀ LJJ appoints Central Ops Manager

₀ BESA Builds Its Technical Team

Humidity Solutions is delighted to announce the continued strengthening of its sales team with the addition of Andy Munson. Andy has many years of experience in the HVAC sector, particularly in the delivery of air handling and dehumidification solutions for the industrial and process industries. He will be heading Humidity Solutions’ further expansion into the dehumidifier market, leveraging his experience of the products and their application.

LJJ has appointed Aaron Swain to the new post of mechanical operations manager at the company’s central office in Solihull. The appointment is part of the company’s ambitious plans for growth in the central region and sees Aaron taking on responsibility for overseeing the company’s contracts managers, reporting directly to operations director, John Daly. Aaron joins LJJ from a major mechanical and electrical contractor where he progressed from project manager to operations manager during a 13 year tenure. Having originally started as a junior engineer with a major building services specialist straight from college, his career has always been in mechanical engineering.

BESA (the updated acronym for the Building Engineering Services Association), has two new members of its technical team, Tim Rook and Jack Verber, to help its members keep up to speed with technical innovations. Tim Rook is BESA’s technical director, a new post, and Jack Verber is its new technical assistant.

Changing Faces.indd 42

25/01/2016 15:15

Improve sales with the new face of frozen food display

Want to improve shoppers‘ experience and sales? Iconic’s unique semi-vertical freezer improves space efficiency and increases product display area to maximise sales and revolutionise the supermarket freezer section. Iconic from Viessmann is the first semi-vertical freezer, designed to transform the freezer section into a flexible, accessible space for retailers with an appealing marketplace feel for shoppers. With a focus on aesthetics and ergonomics, 50% more display volume has been created in same footprint as a traditional freezer island. A pilot scheme of Viessmann Iconic in a supermarket increased frozen food sales revenue 10% and profit by 18%.

For more information, see www.viessmann-refrigeration.com/en tel. 0800 634 6555, email: sales@viessmann-coldtech.co.uk

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25/01/2016 15:12:07

E L E C T R I C A L

S A F E T Y

FEBRUARY 2016

TO ISOLATE OR NOT TO ISOLATE - W by Stephen Benton, Cool Concerns Often we hear “I have always done it like this”. If we are honest with ourselves we have all said it at some time, the more fundamental question we should ask is “have we always been doing it right?”.

here is a right way and a quick way; sometimes they are the same thing, but more often we think the right way will delay us from getting to the next three jobs. Consider then that the failure to do something correctly, that might only involve 5 minutes more work, could result in weeks off work with an injury or a lifetime dead (that’s a more permanent delay, is it not?). That perceived need to save time is often why accidents happen, coupled with the certainty that all men have “that it will not happen to me”! Engineers often don’t safely isolate electrical equipment before working. I worked for decades without correctly locking off electrical equipment before undertaking maintenance or repair work. The Health & Safety culture in the refrigeration industry has certainly improved beyond all recognition from those days, but largely from a paper trail perspective. Engineers still follow less than best practice on a daily basis. So, what are the reasons / barriers to safe electrical isolation, with the inevitable first on my list:

1. 2. 3. 4. 5. 6.

So with the majority of us fitting now uneasily into categories 1 and 5 of the above read on. Incorrect isolation can result in electric shock and / or injuries due to equipment starting up unexpectedly. Both outcomes are potentially fatal at worst and can inflict horrendous or life changing injuries at best. Remember, when you joke with colleagues that you

got yet another electric shock “only a little tickle”, this is only emphasising to everyone that there are some basics missing in your competence. Engineers are not always aware of correct isolation procedures and may not have the appropriate training or equipment. We have developed simple training to meet the needs of one contractor whose engineers had suffered a few accidents which

I have always done it like this; I don’t have an safe electrical isolation procedure; I don’t have electrical isolation ‘lock off’ equipment; I thought I was doing the customer a favour; I have items 2 and 3 but still make the decision based on 1, 4 and 6; It’s never happened to me!

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S A F E T Y

45 acrjournal.uk

E - WORKING DEAD TO STAY ALIVE Equipment Required: ₀ ₀ ₀ ₀ ₀ ₀

Isolation padlock & key Multiple worker isolation padlock tag Isolation devices to suit different isolators / MCB’s etc Warning notices Voltage tester Voltage proving unit.

Safe Isolation 1. Identify the circuit or equipment to be worked on 2. Check condition of voltage tester and operation against a known voltage supply 3. Isolate supply and secure isolation – lock off (multi lock off if multiple workers) 4. Prove circuit dead – use voltage tester and re check against a known voltage supply 5. Retain keys and post ‘caution’ and ‘danger’ notices 6. Take precautions against adjacent live circuits / equipment – if any 7. Issue permit to work 8. Work dead.

Reinstating the Supply could have been avoided with safe electrical isolation practices. In reality most refrigeration engineers need an introduction to / a reminder of good practice. This is part of a larger culture change needed throughout our industry to ensure that we are all safe in an increasingly pressurised work environment. What we covered – back to basics: ₀ What to expect when you measure voltage, current, resistance; ₀ How to measure, using appropriate tools safely; ₀ Working dead (an odd title but directly related to staying alive); ₀ Safe electrical isolation; ₀ Diagnosing electrical faults – probes, fan motors; ₀ Replacing probes and motors so the replacement works reliably – cable joints.

Cool Concerns.indd 45

1. 2. 3. 4. 5. 6.

Ensure all work is complete Ensure all covers and lids are replaced Remove lock off and warning notices (multi unlock if multiple workers) Reinstate supply Turn on equipment locally if possible Sign off permit to work.

The training includes practical hands on exercises. Each candidate is assessed using RoSPA accredited e-learning and a practical assessment measuring single and three phase power supplies and safely isolating, confirming isolation, locking off and reinstating. For practical health and safety to triumph we need a culture change at all levels. The A4 folder of risk assessments we all carry in the vehicle is less important than using the right electrical test and lock off tools and competently isolating and

locking off an electrical supply before working on a piece of equipment. So ask yourself, do you have the below in your tool bag and do you know how to use and apply it following the procedure? If you do, great! If you don’t then correct that today, yours or a colleague’s life might depend on it! If it is not safe to work - be confident to say NO. For more information contact hello@coolconcerns.co.uk

27/01/2016 11:31

H E A T

P U M P S

FEBRUARY 2016

Stiebel Eltron UK heat pump technology is helping to keep energy bills to just £15 a year for a North West home-owner and self-build architect.

olin Usher an architect and director at Liverpool-based John McCall Architects, incorporated Stiebel Eltron’s heat pump technology in his new-build property – a four bedroom house in West Kirby that he designed himself. Colin demolished the original property on-site and developed a new home, at a total cost of £240,000. The new-build property has been designed as an eco-home, with minimal energy usage. The private house comprises an insulated masonry and concrete structure, under ﬂoor heating, triple glazing, LED lighting, heat recovery ventilation and an air source heat pump. Stiebel Eltron’s WPL15 air source heat pump is an integral part of the property’s energy eﬃcient operation. The WPL15 AS product was developed by Stiebel Eltron UK to meet the bespoke

Stiebel Eltron.indd 46

requirements of the UK market. The range is Stiebel Eltron’s most compact yet and oﬀers optimal eﬃciency using a single phase supply. All component parts of the machine have been optimised to suit UK demands and the pump has the best seasonal performance on the market in its class. The heat pump, supplemented by the use of solar panels, is now providing all heating and hot water energy requirements for Mr Usher’s home. As a result of the air source heat pump,

savings of £1800 per year are being made against traditional fuel sourcescontributing to Mr Usher’s exceedingly low energy bills. The house has now been occupied for two years and the energy cost for heating, lighting, hot water and cooking was less than £15 per year for this period. The £15 yearly energy costs are so low, in fact, that the property has received national media attention, featuring in the Daily Mail and on BBC broadcast and online channels. In addition, the project was recently hailed as the winner in the Domestic New Build category of the Buildings and Energy Efficiency Awards 2015. Commenting on the energy savings reaped by installation of the Stiebel Eltron heat pump, Mr Usher said, “We are delighted with our new home and to have won the Domestic New Build category of the Buildings and Energy Efficiency Awards 2015 because it proves eco homes don’t have to be over expensive or need to be conspicuously unconventional in appearance. The property is very comfortable to live in and its appearance is not incongruous with surrounding houses. This is helped by Stiebel Eltron’s air source heat pump – which is unobtrusive and makes barely any operation noise. Our home dispels the myth that an eco-driven home needs to be expensive and radically different in appearance.”

27/01/2016 11:26:59

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25/01/2016 15:32:40

P R O D U C T S

48 FEBRUARY 2016

Calorex measures up Going the extra mile to meet the needs of its customers, Calorex Heat Pumps has introduced a brand new quoting system to its website, to allow users to quickly and efficiently work the correct dehumidification equipment required for each application. The online Dehumidifier Sizing Tool software can be accessed from a desktop or smartphone and provides customers with the latest technology in online quoting. Users simply fill in the online form with all the requirements they need and the software will calculate the product that best suits the space for the business or home environment.

Contact: Calorex Heat Pumps 01621 856611 sales@calorex.com www.calorex.com

WHAT’S NEW Promax launches “R32 ready” recovery unit Advanced Engineering announce the launch of the all-new Promax RG 6-E refrigerant recovery device: a twincylinder unit that is future-proofed to work alongside the new class of A2L ﬂammable refrigerants such as R32 and R1234yf. The RG 6-E’s new spark-proof sealed switches and fuseless VDE/UL circuit breaker ensure it is ideal for the new mildly ﬂammable A2L class, while also being backwards compatible with existing CFC, HCFC and HFC refrigerants, including R410A.

www.advancedengineering.co.uk

New DXR range of BACNet controllers for terminal units from Siemens Building Technologies

Victaulic StrengThin™ 100 System is a game changer for stainless steel piping systems

The DXR range from Siemens Building Technologies offers robust control for a number of widely-used terminal units and uses the truly open BACnet protocol. The controls are easy to install, saving money at the outset, but also able to support good occupant energy use through its unique Green Leaf programme. The Siemens DXR offers excellent engineering options and robust performance. This new range of terminal unit controllers is focused on easier, quicker and more cost effective installation, as well as better end-user experience.

Safer, faster and easier to install, Victaulic® launches the StrengThin™ 100 mechanical piping system, further maximizing the efficiencies of choosing thin wall stainless steel pipe Victaulic, the world leader in mechanical pipe joining systems, is pleased to announce the ﬁrst and only grooved pipe joining system of its kind: the StrengThin 100 System, designed exclusively for jobs utilizing thin wall (2 and 3 mm) 304/316 stainless steel pipe.

For further information: www.siemens.co.uk

For further information: www.victaulic.com

Win a a fun day out at Brands Hatch at the ‘Dunlop MSA British Touring Car Championship’, thanks to Johnson Controls.

JS Air Curtains Publishes New Product Catalogue

Where is the oldest working York Chiller in the UK and Ireland? To have a chance of winning and answering the question, send a picture of the data plate along with a brief description of the York chiller’s location and its application. Johnson Controls will acknowledge and verify the information. Entries have to be in by 5pm on 17th February 2016. The winner will be announced on 18th February at Johnson Controls’ stand at the ACR Show. alpesh.trivedi@jci.com using the subject line “Oldest YORK chiller” with the details.

JS Air Curtains, the UK’s leading air curtain specialist, is pleased to announce the launch of its new product catalogue. Packed with detailed information on its wide range of exposed, recessed, industrial and revolving door units, the catalogue incorporates quick glance product options and performance data tables for each model. Tim Scott, Head of Sales at JS Air Curtains comments, “This catalogue has many new products, an easy to view selection guide, information on heat pump technology and more control options. These details and its comprehensive range for all air curtain applications, makes this catalogue the “go-to” resource for air curtain selection and expert advice”.

To download or request a copy, visit: www.jsaircurtains.com/catalogue

To advertise your product in the ‘What’s New’ section please contact What's New Feb_2016.indd 48

theresag@warnersgroup.co.uk

25/01/2016 15:50

Gas Monitoring Solutions

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Call us now on 01474 338705/338725 www.ashburyassociates.co.uk Email: info@ashburyassociates.co.uk

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Hants, Berks, & Oxon c£38k + com + car This distributor of refrigeration and air conditioning equipment is looking for a Sales Engineer. You will be responsible for assisting account customers with the design/selection and pricing of equipment and associated components. Ref: T3303

Nationwide to £46k+car+benefits This well-established Industrial Refrigeration contractor is looking to appoint an experienced Project Manager. You will be responsible for overseeing the installation of industrial refrigeration systems in the food process sector countrywide. Ref: T3310

Australia Neg. salary Our client, a leading, nationally based industrial refrigeration company in Australia, wish to recruit Industrial Refrigeration Engineers/technicians with extensive relevant experience, including ammonia systems. Applicants must be interested in relocating (emigrating) to Australia. Ref: T3315

DESIGN ENGINEER

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Northern England to £46k + bens + car This well-established industrial refrigeration contractor is looking to appoint an additional design engineer. You will be responsible for the design, selection and pricing of industrial refrigeration systems for food process applications. Ammonia experience would be ideal. Ref: T3321

M25 Radius Neg Package + van This major contractor is looking to appoint 2 installation engineers to work on major air conditioning projects in the London area. Applicants must have experience of installing large VRV/VRF systems. F-Gas is essential. Also requirements for mates to work alongside the engineers. Ref: T3320

Various areas c£31,500+van+o/t This busy contractor is seeking fully qualified and certificated engineers with extensive experience in both air conditioning and commercial refrigeration. Candidates will be based in or close to one of the following postcodes S, PE and GL. Ref: T3319

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North/Midlands to £60k+car+benefits Our client is looking to appoint an experienced industrial refrigeration sales/design engineer with NH3 experience. You will be responsible for liaising with clients and designing systems for the food industry, with some project management involvement Ref: T3295

Dubai Generous tax free salary and allowances Specialist chiller service company requires engineers with experience on water cooled centrifugal chillers and air cooled liquid chillers. You will work independently and perform service and repairs on all makes and models of chillers and ancillary equipment. Ref: T3291

London c£35k+van+benefits This well-established air conditioning contractor has a requirement for an experienced air conditioning / chiller service and maintenance engineer. You will be responsible for the service and maintenance of all air conditioning equipment and chillers on 3 sites in west London and Middlesex. Ref: T3309

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South West c£35,000 +bens +car This leading distributor of refrigeration equipment is looking to appoint an Applications Engineer. You will be responsible for the design, selection and pricing of a wide range of commercial refrigeration projects. A strong technical background is essential. Ref: T3288

Greater London/M25 to £34k+van+o/t+t/t Busy refrigeration contractor requires an experienced service engineers with extensive and varied experience of a wide range of commercial refrigeration equipment chillers. Work will include retail contracts and warranty work for a leading refrigeration cabinet manufacturer. Ref: T3317

p49_acrfeb16.indd 1

For further details please contact TERRY WHITE or ROGER For further details contactPRICE either TERRY WHITE at or ROGER Ashbury Associates, The Old Rectory,PRICE Springhead Road, Ashbury Associates Ltd., Kent House, Crown Northfleet, DA11 8HNHome Gardens, 1DZ 338749 Kent DA1 t 01474 Dartford, 338705/338725 f 01474 t 01322 424636 f 01322 424637 e info@ashburyassociates.co.uk e info@ashburyassociates.co.uk

25/01/2016 15:24:19

C L A S S I F I E D S

50 FEBRUARY 2016

F-GAS DETECTOR CALIBRATION

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For natural and low GWP refrigerants. ATEX approved accessories are available upon request.

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25/01/2016 16:11:56

51 51

C L A S S I F I E D S

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25/01/2016 16:12:01

C H I L L Y

C H A T T E R

FEBRUARY 2016

CHILLY CHATTER SPONSORED BY

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IN THE COUNTRY WITH EJM CRYOTECH With the recent news that industrial and commercial cooling experts EJM had bought Derby-based Cryotech, ACR Journal editor, Will Hawkins, spent some time with the company’s top team, Matt Morton, Paul Cable and Ron Mearns to learn more about their business while shooting in the grounds of Ripley Castle. Before Christmas, Matt Morton, chairman of EJM Engineered Systems announced that, after talks over a number of years with Cryotech majority shareholder, Ron Mearns, they had agreed terms for Matt to buy Cryotech’s business. The fit was natural. Both companies have extensive and varied experience in the refrigeration industry, and each business needed to find a better way of growing their enterprises and serving their customers. Now part of the same business, EJM Cryotech is set to help its customers better with its refrigeration, air conditioning and ventilation solutions for industrial and commercial applications. Matt is investing heavily to enable the newly joined team of engineers to cover the UK and Ireland more effectively, not least by providing all the field engineers with the same, well equipped pick-up vehicles to safely move between jobs. With 16 engineers, the new business will be able to cover the UK more efficiently between its Derby and Shotton Colliery bases.

The Shooting Party

But, shooting? Matt Morton and Paul Cable are keen game shooters, and they regularly shoot in Yorkshire on the beautiful grounds of Ripley Castle, near Matt Morton shooting Harrogate. I met Matt mid-afternoon to get some practice in before the next day’s shoot. I have not been shooting for over 30 years so Matt spared some time to see if I could hit anything smaller than a barn door. We stood in the valley below Ripley Castle’s shooting yard. Matt loned me one of his shotguns, a Beretta. It was beautifully light and well-balanced. Accuracy was down to me. After all the rain in the month before, the ground was saturated. As dusk drew in, we waited for some ducks to come home to roost. We heard

Chilly Chatter.indd 52

many pheasants roosting nearby and saw two ducks high up but, unfortunately, none came near enough for me even to frighten, let alone try to have them for the pot. Nevertheless, it was good to be outside in the fresh air and away from my computer. Afterwards, we all met, including Ron Mearns and Paul Roberts (now retired from the industry), at The Boar’s Head in the village to discuss the state of the cooling industry over dinner and some local ale.

Better Together

Amongst the global challenges of the ACR industry we discussed, skills, or lack of, in the industry was a consistent theme of the night. Attracting new talent is a perennial challenge and it is one which prevents many refrigeration and air conditioning contractors from expanding their business to meet demand. It is one reason behind EJM and Cryotech Systems coming together. Rather than competing, joining forces made more sense. When there is a skills shortage, it makes sense to

25/01/2016 15:18

C H I L L Y

C H A T T E R

53 acrjournal.uk

find common ground and work together. With the forthcoming ‘RACHP EngTech Apprenticeship’ due to launch soon, the industry is attempting to address the skills shortfall. However, with the first apprentices not due to come out of that scheme until Autumn 2019, there is still a gap to fill.

Let the Shooting Begin

The weather beat down on us in the morning. Rain, rain and wind. The weather adds Paul Cable to the excitement, however. It adds a few extra miles per hour on the birds giving them a better chance of surviving (when coming towards me, anyway). But, that did not stop the nine ‘guns’ from bagging a good collection of birds before lunch. Matt, Paul and Paul are all good shots and I saw them making contact with partridges and pheasants quite easily. Shooting with Matt, Paul and Paul was great fun. This industry is, perhaps, the friendliest I have ever worked in. The team at EJM Cryotech typify the people in it: friendly, technical experts and a pleasure to work with. Spending 24 hours with them was

Matt Morton, Paul Cable, Ron Mearns

an absolute delight. Expect to see more about their projects in the coming months in the ACR Journal. They are very good at solving problems for their customers too.