The best sustainable solutions for the HVACR industry
03
14
EVENT PREVIEW
ENERGY STORAGE IS KING
Don’t miss these events, like CxEnergy.
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CALMAC’s IceBank energy storage system helped the Kings County Courthouse in California save energy and money while providing operational flexibility.
NEWS
16
All the latest from the HVACR industry
THINKING OUTSIDE THE BOX
06 EDITORS’ PICKS Curated by green HVACR staff
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Industrial cooling made to last—HDPE cooling towers from Delta Cooling eliminate the need for costly repairs at this Mississippi manufacturing plant.
SWITCHED RELUCTANCE MOTOR The Software Motor Company takes the motor to a whole new level with their high-efficiency switched reluctance motor technology—aka the “LED of Motors.”
17 THE EVOLUTION OF THE “IOT” IN HVACR Ron Zimmer, president of CABA, takes a closer look at how IoT-enabled systems are becoming more affordable in the industry.
12 LEADING THE CHARGE Reclaim, recover, recycle. Choice Refrigerants is making sustainable refrigeration more viable than ever through their own line of HVAC equipment and promoting education.
18 EXCHANGE Shanghai Tower in China is proof that even the biggest building can be more efficient.
APRIL+MAY 2018 GREENHVACRMAG.COM
INSIDE!
Solutions to make your BUILDING RUN BETTER and COST YOU LESS in the long run.
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greenhvacrmag.com VOL. 01-NO. 03 APRIL+MAY 2018
Event Previews EDITOR-IN-CHIEF
Christopher Howe ASSOCIATE PUBLISHER
Laura Heidenreich laura@gbdmagazine.com
APRIL 23–26 LAS VEGAS, NV
MANAGING EDITOR
Laura Rote lrote@gdmagazine.com ART DIRECTOR
C X E N E R GY
Kristina Walton Zapata ASSOCIATE EDITOR
Julia Stone ACCOUNT EXECUTIVE
Julie Veternick SENIOR ACCOUNT MANAGER
Brianna Wynsma
This conference on building commissioning and energy management hosts a variety of manufacturers and attracts countless HVAC professionals and others working in the built environment. The event offers a chance to participate in many technical workshops or simply network across the industry. Don’t miss the expanded exhibit hall this year, too. The conference also holds seminar and exam sessions for those interested in gaining accreditation in fields like energy management or commissioning. cxenergy.com
ACCOUNT MANAGERS
Briagenn Adams Ciara Gomez EDITORIAL INTERN
Brooke Nagler DESIGN INTERN
APRIL 23–26 PHILADELPHIA, PA
Sam Weber CONTRIBUTORS
Ed Sullivan, Ron Zimmer
H P C N AT I O N A L H O M E PERFORMANCE CONFERENCE & TRADE SHOW
green HVACR magazine 1765 N. Elston Ave. Suite 202B Chicago, IL 60642 Printed in the USA. © 2018 by Green Advocacy Partners, LLC. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations.
green HVACR is a certified B Corp. B Corp is to business what Fair Trade certification is to coffee or USDA Organic certification is to milk. B Corps are certified by the nonprofit BLab to meet rigorous standards of social and environmental performance, accountability, and transparency.
From panels about HVAC strategy to sessions about energy efficiency, policy research, and advocacy, the 2018 HPC National Home Performance Conference & Trade Show covers home performance and air quality from the state level all the way down to individual homes. The event provides opportunities to connect across the industry as well as discover new, innovative products and participate in workshops that offer detailed informational sessions on topics like HVAC design and installation techniques. homeperformance.org/conferences/HPC18
The magazine is also available in digital formats at greenhvacrmag.com/currentissue. Please recycle this magazine.
MAY 9–10 BOSTON, MA The best sustainable solutions for the HVACR industry
03
14
EVENT PREVIEW
ENERGY STORAGE IS KING
Don’t miss these events, like CxEnergy.
CALMAC’s IceBank energy storage system helped the Kings County Courthouse in California save energy and money while providing operational flexibility.
06 EDITORS’ PICKS Curated by green HVACR staff
08 NEWS
16
All the latest from the HVACR industry
THINKING OUTSIDE THE BOX
10
Industrial cooling made to last—HDPE cooling towers from Delta Cooling eliminate the need for costly repairs at this Mississippi manufacturing plant.
SWITCHED RELUCTANCE MOTOR The Software Motor Company takes the motor to a whole new level with their high-efficiency switched reluctance motor technology—aka the “LED of Motors.”
17 THE EVOLUTION OF THE “IOT” IN HVACR Ron Zimmer, president of CABA, takes a closer look at how IoT-enabled systems are becoming more affordable in the industry.
12 LEADING THE CHARGE Reclaim, recover, recycle. Choice Refrigerants is making sustainable refrigeration more viable than ever through their own line of HVAC equipment and promoting education.
18 EXCHANGE Shanghai Tower in China is proof that even the biggest building can be more efficient.
APRIL 2018 GREENHVACRMAG.COM
INSIDE!
H E A LT H C A R E S Y M P O S I U M
The 2018 Healthcare Symposium provides a chance to learn more about how HVAC systems work within health care spaces, and so much more. Many of the scheduled sessions focus on air quality and control, looking at optimal humidity levels for preserving patient health, airborne infectious disease control, and indoor hydration in infectious disease transmission. This year’s speakers range from Howard McKew, president of Building Smart Software, and author of Managing People in the HVAC/R Industry, to Steven Friedman, director of facilities engineering for Memorial Sloan Kettering Cancer Center. healthcaresymposium.org
Solutions to make your BUILDING RUN BETTER and COST YOU LESS in the long run.
ON THE COVER THIS MONTH Software Motor Company is changing the industry with its energy-efficient switched reluctance motor.
APRIL/MAY 2018
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editor’s letter
TRENDING Check out some of our most read stories at greenhvacrmag.com
Fabric Ducts Stand Out In the February issue of green HVACR, we got the chance to explore what makes fabric ductwork truly special. As one of our most read articles on the website this past month, it turns out many of our readers wanted to know more, too. Find our story with Ductsox Corporation online to see just how much fabric ducts make a difference. greenhvacrmag. com/2018/fabricductwork-ductsox In the April/May issue of green HVACR magazine, we see just how far the inner workings of our buildings can go to make an overall project more efficient. From some exciting new products on the market (page 6) to taking an alternative approach to energy with an innovative solution like CALMAC’s IceBank energy storage system (page 14), this month’s issue asks you to think about things differently. CALMAC helped the Kings County Courthouse building earn LEED Silver Certification and save 26% in energy costs, just by making ice at night and using it to create cooling during peak times. This issue also zeroes in on some of the best inventions out there, like Software Motor Company’s new switched reluctance motor (page 10). They’re calling it the “LED of motors,” and it aims to change the industry as a leaner, smarter motor that can significantly reduce a building’s energy. SMC Executive Chairman Ryan Morris says the system can reduce HVAC energy use by up to 50% when compared to induction motors. Sometimes, though, all you need is a little remodel. At least, that was true for one Mississippi manufacturer (page 16), whose outdated, metal-clad cooling towers framed in wood were beginning to disintegrate. The plant ultimately decided to replace the old towers with Delta Cooling’s TM Series solution, made of HDPE, with enclosed, non-corroding PVC pipe and non-clog spray nozzles. Choice Refrigerants (page 12) is also doing exciting things in the industry. The offshoot of Refrigerant Management Services of Georgia (RMS) is offering environmentally friendly alternatives as well as establishing their own line of HVAC equipment. They’re making reclamation easier, too, incentivizing HVAC technicians to utilize recovery cylinders and get paid for the gas they recover.
à
CHRIS HOWE Publisher & Editor-in-Chief
The Best Products Each month we strive to bring you our favorite sustainable solutions from the industry. We highlighted some truly innovative products— from Messana’s mSense (the only home control technology designed for radiant cooling and heating systems) to AirIQ from Biome, which lets you quickly analyze your air quality. greenhvacrmag. com/2018/top-hvacproducts-february
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PHOTO: CONNIE ZHOU
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MYSA SMART THERMOSTAT This thermostat learns your habits so you’ll never be shocked awake by a cold bathroom in the morning, nor go to sleep shivering. When location is enabled, the system keeps track of when you are away to ensure no heat energy is wasted on an empty house. It also has a vacation setting to adjust temperatures for longer periods away. The system can be controlled by an app, displaying the temperature of all the rooms in your house for you to adjust anywhere at anytime. The app shows your thermostat schedule as well as your energy usage. MYSA can also generate an in-depth energy report so you can review your energy usage and costs. MYSA is compatible with the leading home technologies. It works with Apple HomeKit as well as Amazon Echo or Google Home. getmysa.com
Editors’ Picks A C LO S E R LO O K AT T H E TO P S U S TA I N A B L E P R O D U C T S IN THE INDUSTRY
> > >
Share your suggestions for the best new products by emailing info@greenhvacrmag.com
LENNOX SL280NV ULTRA-LOW NOX GAS FURNACE VENTACITY VS3000 RT HRV SYSTEM This high efficiency heat recovery ventilator (HRV) is able to provide quality heat ventilation using much less energy than traditional heat ventilators. Its design consists of a number of innovative and power reducing systems. Equipped with electronically commutated motors (ECMs) and backward curving blades, the system uses minimal energy and has noise reducing features. Moreover, the ventilator transfers up to 93% sensible heat between intake and exhaust air streams, which is 43% more efficient than traditional systems. This added efficiency means the system is more sustainable while also saving money. The ventilator works for a large variety of spaces. The unit provides a maximum flow rate of 3,000cfm of fresh air for spaces up to 40,000 square feet. Its durable galvanized steel case means it can even be placed in spaces with harsh weather environments. The system maintenance is simple with easy to access filters. ventacity.com
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Lennox is introducing the first residential ultra-low NOx gas furnace you can buy. This furnace has exciting environmentally friendly features—it releases 65% less NOx emissions than standard furnaces and its variablespeed motor and two-stage gas valve help maintain a constant temperature using minimal fuel. Furthermore, it has an energy rating of 80% AFUE (annual fuel utilization efficiency), meaning it will significantly reduce your heating costs. In fact, reports show five-year savings totaled more than $2,500. The furnace has iComfort® S30 ultra smart thermostat compatibility, so you can change your heat and energy usage depending on your household needs. This system detects when you or a family member is away from home using GPS, to make sure the temperature is comfortable when you are home. Additionally, it uses allergen detection to control pollen levels in the space. This furnace is quickly gaining recognition, as it won the “best of IBS” award for Best Green Building Product at this year’s NAHB International Builders’ Show due to its outstanding performance and efficiency. lennox.com greenhvacrmag.com
HEAT INDEX What’s hot and what’s not in the HVACR world
Johnson Controls is partnering with AtmosAir Solutions to provide enhanced air purification with their YORK Air Handling Systems.
MODINE ATHERION Looking for a way to bring fresh air into your indoor space? The Atherion unit is an efficient cost-saving HVAC system for any geographical location. It can provide ideal ventilation in humid warmer areas as well as dry cooler places, setting comfortable indoor temperatures for any facility. Its construction is durable and long-lasting, with a stainless steel drain pan to prevent corrosion and a double wall cover with a pre-painted galvanized G90 steel cabinet that meets the ASTM spec for 2500 hour salt spray test. The design meets the latest ASHRAE 189.1 and 62.1 standards for IEER efficiency, green building, and indoor air quality. The Atherion system has a variety of high efficiency features. Its air flow management consists of ultra low air dampers and an energy-efficient airfoil plenum fan. Its gas heating system option levels up to 94%, allowing for substantial cost-savings. modinehvac.com
Trump’s 2019 budget would eliminate the Advanced Research Projects Agency-Energy (ARPA-E).
US Chiller Services now offers Smardt Chiller products to help bring high-efficiency low-maintenance chillers to building owners.
Federal legislation was passed to extend federal tax credits for residential and commercial installations of geothermal heat pumps.
President Trump’s proposed 2019 budget increases fossil fuel energy R&D funding by $81 million while cutting renewable energy research by $1.3 billion.
The global energy-efficient HVAC systems market is expected to grow at a CAGR of more than 11% between 2018 and 2022, according to Business Wire.
BREEZI’S AIRPULSE This Breezi product connects your HVAC system to your smart devices so you can keep your space comfortable and track your HVAC activity and condition. Breezi sees the HVAC system like any other living organism, understanding that its maintenance is essential for continued efficiency. The system can communicate through Amazon Alexa or Breezi’s chatbot, and it provides notifications on your smart devices when its filters need replacement. This makes HVAC maintenance easy and worry-free. It also saves time and upkeep, as clogged filters waste up to 15% more energy and can cause system breakdowns. Breezi also makes sure the air quality of the space is healthy and will recommend seasonal filters to deal with pollen and pollution. Breezi works through sensors installed in the HVAC filter. These detect HVAC health and account for environmental factors like humidity levels (to avoid mold) and volatile organic compounds. The sensors are also listening for any noise that may indicate mechanical trouble. breezi.io green HVACR
The North American Sustainable Refrigeration Council created nasrcnetwork.org to provide information about contractors that install equipment that uses natural refrigerants.
Danfoss A/S and OE3i ApS are beginning a strategic partnership to advance digitalization in the district energy segment.
APRIL/MAY 2018
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Roster Industry shakeups, new faces, promotions, and more
Enercare
News The Latest Headlines From the Industry
GEOTHERMAL HEATING AND COOLING MADE AFFORDABLE
Ontario-based Enercare, which provides home services and smart energy solutions, recently appointed John W. Chandler to its board of directors. Chandler is experienced in digital transformation and effective marketing strategies. “[Chandler’s] extensive leadership experience in navigating rapidly changing consumer and digital landscapes, marketing, and innovation will be a significant asset as we continue to build and maintain long-term shareholder value,” says Chair Jim Pantelidi.
A new sustainable heating and cooling method made by Dandelion uses the earth’s natural heat to provide a temperature control system that not only cuts greenhouse emissions but also allows for saving on monthly energy bills. The system consists of a pipe loop installed underground. Water and antifreeze run through the pipe; in the winter, the liquids warm to the 50˚F geothermal temperature, providing sustainable hot water and warm air for inside the home, and during the summer, the process is reversed. In the past, the high costs of geothermal heating
systems meant they were unavailable to most, but Dandelion is looking to make them more affordable, with plans for community-wide geothermal heating systems. Additionally, state and federal legislation is lessening the costs of these systems—Congress approved legislation to give a 30% federal tax credit for geothermal system installations, and New York promises to return a portion of the cost in rebate. With lower costs, there is less barrier to those looking for eco-friendly and efficient renewable energy systems. dandelionenergy.com
Grundfos Group
Grundfos Group, the Denmark-based supplier for pumps and pump merchandise, has named Catherine Yang as its new regional head of its China sales region. Previously the managing director of Carrier Commercial Refrigeration Asia at United Technologies Corp, she has led many development business ventures. “I am very pleased that Catherine Yang will be leading our very important China sales region, where we have seen very good sales growth for the past many years, and our market position is solid,” says Poul Due Jensen, executive vice president of Grundfos.
Honeywell recently announced former company executive Roger Fradin as the chairman of the Board for the Homes and Global Distribution business. “Over many decades in the industry, Roger has forged an unparalleled track record of performance through his ability to connect with customers, anticipate their needs, and drive the rapid introduction of highly desirable products,” says Darius Adamczyk, president and CEO of Honeywell. “Roger’s experience, passion, technical knowledge, unwavering focus on serving customers, and ability to attract and motivate a highly talented workforce will ensure the Homes spinoff thrives as an independent company.” Send your staff updates for consideration
“Geothermal is the most efficient way to heat and cool a home. Dandelion has developed hardware and software tools to make getting geothermal easier and more affordable than ever.” —Katie Ullmann, vice president of marketing, Dandelion
to jstone@greenhvacrmag.com.
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PHOTO, CENTER: COURTESY OF DANDELION
Honeywell
GO ERMAL H T O GE
NEW HVAC TRAINING CENTER Source 1, exclusive supplier of service parts and residential accessories for Johnson Controls’ residential and light commercial
HVAC products, recently opened the first in a series of training centers focused on residential service and installation as well as select commercial products. The center is a 1,200-square-foot space within the Source 1 base in Missouri, and its opening was attended by customers and industry professionals alike as well as YORK dealers and customers. The center will host a variety of training classes, helping technicians become YORK-certified technicians and providing an opportunity for the YORK sales team to better understand their products. The new facility will also be a space where trade school students can get hands-on experience.
scriptive Rebate Program, which offers cash rewards for installing energy-efficient HVAC products like chillers and furnaces. The second offers customers making custom upgrades the incentive of $0.16 per kilowatt hour and $600 for each kilowatt energy reduction. Customers in the second option can also take advantage of Early Life and Extended Life programs, which encourage them to replace HVAC equipment before it breaks by paying some of the price difference. HVAC upgrades are expensive, so customers make these changes less frequently and have a harder time meeting the cost. But with these new incentives, Con Edison hopes to make the changes more accessible and affordable, encouraging customers to seek upgrades. coned.com
johnsoncontrols.com
as well as information from experts—accounting for materials, climate, orientation, air tightness, and indoor conditions. It also has data from real-world moisture durability testing in the laboratory. The database is currently undergoing beta testing but will soon be available and accessible to customers with a user-friendly design. “It has become challenging to make informed decisions because of modern building code requirements and new products and materials hitting the market,” says ORNL’s Philip Boudreaux. ornl.gov
NEW CENTER FOR INNOVATIVE GREEN TECHNOLOGY Magnolia Quality Development Corporation Limited recently opened the Research
& Innovation Sustainability Centre (RISC)
in its Bangkok headquarters, focused on cutting-edge methods for sustainability in workplace and residential spaces. RISC is developing new approaches to temperature control systems using IAQ sensors. This technology measures air quality features like humidity, potentially harmful airborne particles, and volatile organic compounds as well as temperature. The sensors display light signals—red for danger, yellow for caution, and green when the air is clear. The group is also working on light design that aids the sleep cycle and productivity of inhabitants through circadian lighting, glare, and color quality. RISC is working across residential and commercial examples to improve buildings. The research center offers its eco-materials library to all builders. mqdc.com
PHOTO: RACHEL BROOKS/OAK RIDGE NATIONAL LABORATORY, U.S. DEPT. OF ENERGY
REAP REWARDS FOR UPGRADED HVAC EQUIPMENT Con Edison is offering big rewards and incentives for customers who upgrade their HVAC equipment. They are doing this through two programs. The first is the Pre-
NEW DATABASE FOR CHOOSING BUILDING PRODUCTS Oak Ridge National Laboratory is developing a new system to help professionals in building and construction determine the best materials for long-term building construction. Using ORNL’s Titan supercomputer, the system draws upon data from running 800,000 building envelope simulations
BEST LS M A T E R IA
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Spotlight A Closer Look at Top Innovations
SWITCHED RELUCTANCE MOTOR How the Software Motor Company is changing the game with the “LED of Motors” By Julia Stone
M M
o t o r s c on s u m e more than 45% of a building’s electricity but are often overlooked when it comes to reducing energy. The
Software Motor Company (SMC) based in Silicon Valley is
working to address that. “Electric motor technology hasn’t changed much in 75 years until now,” says Ryan Morris, executive chairman at SMC. Morris and his team are on a mission to put motors on the energy-saving map with their smart, ultra-efficient, high-rotor-pole switched reluctance motor. Switched reluctance motors (SRM) have been used for years in niche applica-
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tions—such as inside nuclear reactor cores or mines—where reliability is key. “SRMs are the most reliable electric motors because they eliminate most potential failure modes of motors such as magnets, overlapping coils that can short, and rotor currents,” Morris says. “While the motors are reliable, they have historically not been very efficient.” SMC designed a mechanically leaner, switched reluctance motor and developed intelligent software to control it, making the motor inherently more efficient and reliable. The company’s patented and award-winning system has been tested in labs and the field and found to boost efficiency—reducing HVAC energy use by up to 50% when compared to induction motors. “A motor is typically just a motor. But SMC has taken the motor to a whole new
level,” says Mike Petouhoff, former energy manager at Apple who is now vice president of business development at SMC. He says SMC’s switched reluctance motor benefits customers four ways: improved energy efficiency, intelligent controllability, increased reliability, and affordability.
Energy Efficiency “HVAC motors are either standard or premium efficiency. SMC motors are in the ultra-premium category and demonstrably better than what you get from standard or premium efficiency motors,” says Richard Almini, president and CEO of Legacy Mechanical & Energy Services, an energy-focused HVAC design-build firm in the San Francisco Bay Area. greenhvacrmag.com
SWITCHED
Almini’s company conducted eight pilot projects with The motor shares intelligence on speeds and torque customers in different industry sectors to demonstrate the loads and other actionable data that can be used for diSMC motor’s energy efficiency. It measured the energy agnostics. “The data is not just about how the motor savings by attaching watt nodes to the motor’s power is performing. It shows how the entire building syssource. The watt nodes are fed into the SMC controltem is operating and generates alerts and notifications ler that automatically uploads performance data to the highlighting whether, for example, a filter needs to be cloud. “We consistently documented energy changed or the air flow is being blocked,” savings in real-time starting as soon as the Petouhoff says. motors were operating,” Almini says. One SMC’s Smart Motor Drive can also reLegacy customer was so impressed with ceive and process input from devices like the smart motor’s capabilities that it concarbon dioxide sensors, pressure sensors, HOW TO tracted to install motors in eight additional and room thermostats, and process this data GET IT locations. for meaningful control sequences. The SMC “Other companies have intelligent concomponents can also be easily tied into an Visit softwaremotor.com trols, but they don’t have the motor SMC reexisting building management system, or call 669.224.4377 designed to be smart and more reliable. One allowing the motor’s intelligence to of the main selling points to our customer automatically process the data and base has been its affordability. It costs less to purchase than use it to precisely control the motor and imvariable frequency motors and its streamlined design and prove system performance. “SMC’s intelligent simplicity make it much less expensive to operate.” motors tell the whole story and we believe they It’s not just the physics that are more efficient. SMC could be the end of the story for motors with dated motors maintain efficiency at slower speeds where the designs that have little if any smarts,” Petouhoff says. best airflow economies are achieved. The total annualized energy savings in four field trials—when comparing Reliability SMC motors against induction motors running at The ultra-premium design that makes the motor more variable speeds—averaged 63%. At reduced speeds efficient also makes it more reliable. A standard motor will used for heating, cooling, and venting, the savings fail when it overheats, as the heat impacts winding insuwere as high as 91%. lation and bearing lubrication. SMC motors run cooler “Contractors are ultimately in the business of and reduce overheating failures. SMC motors use military saving energy for their customers. SMC’s motor is grade bearings and wide-radius independent coils that are a cost-effective way to take the biggest piece out of fully encapsulated. the energy pie, requiring a company to make a much Another growing reliability challenge for induction molower investment than what it would spend to replace tors controlled by VFDs is “fluting,” bearing damage caused other HVAC equipment,” Petouhoff says. by numerous small arcs from rotor currents. Because the Another savings benefit: replacing the motor is a SMC motor has no rotor currents, this isn’t an issue. simple, cost-effective retrofit. “It takes an average of Electronically commutated motors (ECMs) were first two hours to remove an existing motor and install a new introduced in the 1980s, gaining traction in HVAC, but can one,” Morris says. also fail when their glued-on magnets detach or overheat and de-magnetize. SMC motors do not use magnets. Intelligent Controllability And, unlike induction motors that can stop working Variable frequency drives (VFD) in induction motors when one of its phases drops out, the SMC motor contincan control motor speeds but can’t provide intelligent ues operating because its intelligence automatically takes feedback. SMC’s motor collects this data because it is control and powers the two remaining phases. self-sensing by design. No external sensors are needed “These are a few of the ways SMC avoids the fault because the motor is the sensor. modes that plague the induction motor,” Petouhoff says.
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R E L U C TA N C E M OTO R AT A G L A N C E
[ HVAC
energy reduced by up to 50%
[ Superior
motor efficiency
[ Smart
Motor Drive automatically operates motor at optimum speed
[ Longer lifespan than induction motors [ Notifications via the cloud [ Cost-effective retrofit [ User-friendly IoT controls [ Made of high-quality raw materials
[ Industry
leading five-year motor warranty
“Equally important, because the SMC motor provides ongoing feedback, it provides preemptive notification well in advance so our customers can take corrective action and mitigate any performance issues.” Looking Ahead By bringing the Internet of Things to the electric motor industry and designing the “LED of motors,” SMC is well positioned to provide value-added services that solve everyday commercial energy challenges. SMC is also currently the only electric motor provider that offers a five-year warranty. In the coming months, SMC plans to release the certified findings of its lab and field tests. The company currently markets motors from half to 5HP and plans to introduce models up to 20HP and 100HP this year. “Motors are the proverbial low-hanging fruit when it comes to making dramatic improvements in building energy efficiency,” Morris says. “The widespread adoption of these motors will be a big step toward a better, more sustainable future.”
PHOTOS: COURTESY OF SMC
SMC’s motor is made of high-quality raw materials and is self-sensing by design.
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Behind the Scenes with the Industry’s Leading Innovators
R R
Choice Refrigerants’ environmentally friendly options include a mid-temp R-22 replacement.
ecover, reclaim, recycle. That’s been Choice Refrigerants’ motto since the beginning. Choice is an offshoot of Refrigerant Management Services of Georgia (RMS), one of the original 13 EPA approved refrigerant reclamation centers, founded in 1993. RMS developed their first product— Choice R-420A (HCFC), the first environmentally friendly R-12 (CFC) replacement, greatly reducing the impact on our ozone. In the early 2000s, RMS expanded the Choice Refrigerants line by adding a mid-temp R-22 replacement (Choice R-421A - HFC) and a low-temp R-22 replacement (Choice R-421B - HFC). Choice is truly leading the charge when it comes to sustainable refrigerants, advancing the industry through education and by establishing their own line of HVAC equipment. “We’re disruptors. That’s what we’ve always been,” says PK Graff, product development manager at Choice Refrigerants. “We are always taking strides to reduce the amount of ozone depleting gases released into the environment.”
LEADING THE CHARGE Choice Refrigerants is making sustainable refrigeration more viable than ever. By Julia Stone
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The Importance of Reclamation Choice is focused on further developing reclamation to make the process more efficient and easier for technicians to use coming in from the field. “Reclamation has been a mainstay of our company, and we still do it to this day. We have recovery jobs going all the time with HVAC companies,” Graff says. He and his team maintain a large fleet of recovery cylinders and go out into the field to bring gases back to recertify, repackage, and resell. Choice wants to make it easy for HVAC technicians to utilize recovery cylinders and get paid for the gas they recover. “We offer full-service HVAC solutions by selling gases and then providing an easy way for technicians to return the refrigerants to us as opposed to venting it out, which is illegal,” Graff says. This not only helps the environment—it also benefits business. The success of Choice’s reclamation program hinges on good practices. “We want to incentivize the technicians to avoid mixing refrigerants,” Graff says. Once technicians understand that if they turn in dirty greenhvacrmag.com
but high-purity gas they make a profit, it can be part of their business model. Graff says the industry realized penalizing technicians for mixed-gas doesn’t work; incentive is the way to go. Educating the Industry As the alternative refrigerant market expands, the biggest battle is education, Graff says. Choice is currently building an educational center to teach others about best practices in reclamation and recovery, and how to use alternative refrigerants. “We are lovingly referring to the space as Choice University for the time being,” Graff says. “We want to provide a friendly and home-like environment where people can come in, have breakfast and coffee, and then go out to the warehouse to do some hands-on learning.” Graff and his team are planning to sponsor and organize educational programs for HVAC technicians and wholesalers in order to help them comply with the new 608 refrigerant management provisions. Choice also wants to host HVAC companies in the space so they can bring in their team to teach courses on unitary maintenance, refrigerant recovery, and more. As far as teachers and instructors, Choice will feature their own courses and work with industry specialists to build high value curriculum.
In the last year, Choice’s team has had serious conversations with unitary manufacturers. “The first company to jump on board with our idea was Johnson Controls, one of the most renowned unitary manufacturers in the industry,” Graff says. Running on R-421A, this new line of equipment could help the multi-family development industry by replacing R-22 systems without costly modifications to line sets. “You get to keep all of the R-22 components that still work and replace only the broken parts with Choice Systems equipment, significantly reducing waste,” Graff says. “The fight in our market is to get technicians and suppliers to understand that R-421A is the best choice in new and replacement systems. It all boils down to real-world efficiency.”
Reducing Waste Choice cuts back on waste when it comes to replacing HVAC systems. Technicians often tell property owners they need to replace the whole system even if only one component in their R-22 system is broken. This involves getting rid of old components that still work fine and replacing them with R-410A systems, which means high labor costs and ripping out line sets that might run through multiple interior spaces or even concrete structures. F o r t u n a t e l y, Choice Systems allows users to continue using good components; they only need to replace broken parts. Their Choice Systems new line of equipunits converted Choice is the first ment keeps existing refrigerant manuequipment working facturer to develop longer, not only rea line of privately ducing waste, but labeled HVAC cost, too. equipment, Choice Choice is also Millions of pounds Systems. “We have working on reducof R-421A sold al way s wanted ing waste in their to have a line of manufacturing HVAC equipment process by workthat we could call ing directly with our own,” Graff wholesalers and says. “ We made technicians. This years in business this bold move to helps reduce the further assert our amount of shipping gas (R-421A), as waste. “We create we believe it to be the ‘easy choice’ to rea fair marketplace by driving down distriplace R-22 systems and especially to combution costs, which results in savings on pete with R-410A systems in high ambient shipping costs—like diesel fuel, plastic, and temperature environments and multifamily cardboard—which leads to less waste.” Our applications. Our line of equipment is brand goal is improve our customer service while new and still evolving every day, but it has also coming up with innovative ways to get been received very well by our customers,” our products in the hands of our end-users Graff says. more efficiently.
Choice’s TRAX is easyto-use record-keeping software that tracks the refrigerants sold, used, and recovered.
The Scope
5M
PHOTOS: COURTESY OF CHOICE REFRIGERANTS
R-421A 25
green HVACR
Research & Development Choice is investing in R&D to better understand their customers and supply chain. They are using algorithms, machine-learning, and artificial intelligence to glean insights into their data—from when their shipments need to arrive to which parts of their production process are costing the most money, time, and energy. “By improving parts of the manufacturing process, we’ll improve the whole,” Graff says. Choice is helping to lead the way in managing the recovery and record-keeping requirement in the 608 provision—pushing to implement new services on platforms like a cloud-based version of their TRAX software. “In the future, we’ll use our manufacturing data to further improve processes and continue to provide products at the best market value we possibly can,” Graff says. TRAX is an easy-to-use record-keeping software that helps wholesalers, owners, and technicians re-
cord and track the refrigerants they sell, use, and recover—making 608 compliance easier. Defeating the Odds Big companies typically have massive teams, but Choice can get work done quickly, too. The head of operations is in the office next door to Graff, and he has a direct line of communications with the owner/CEO. “If you want to get a cog in the machine moving, I know exactly who to talk to, whereas that might take weeks in a big company.” Being a small manufacturing facility can be a disadvantage at some times, but that doesn’t stop Choice from leading the charge toward a greener, more sustainable future. “In an industry with bigname companies with billions of dollars of revenue, we’re this little disruptor down in Georgia that comes up with innovative solutions, and the industry has learned that Choice punches above its weight class and will continue to do so.” APRIL/MAY 2018
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Case Study In-Depth Project Profiles
ENERGY STORAGE IS KING How a California courthouse saved energy and money with CALMAC’s IceBank energy storage system By Laura Rote
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O
UTDATED PLUMBING, an inefficient HVAC system, old wiring—like many courthouses across America, the Kings County Courthouse in Hanford, California, was an antiquated hodgepodge of buildings. While renovation was imminent, the decision-makers chose to take the project a few steps further, seeking LEED Silver certification that included upgrades like thermal energy storage tanks. “Those buildings were reaching their life cycle end in terms of the mechanical system as well as parts of the building,” says Paul Valenta, vice president of sales and marketing for CALMAC, adding that building owners wanted a usable complex that was sustainable, too. “The biggest bang for your buck in terms of gaining LEED points is in energy costs.” CALMAC’s IceBank energy storage system gave the courthouse operational flexibility to store energy during off-peak hours that could then be used on hot summer days. Ultimately CALMAC was able to reduce the facility’s energy costs by 26%, or a savings of $102,000 annually. The courthouse was LEED Silver certified in 2017. “Ice-based thermal energy storage systems are a great solution for customers with energy reduction goals because they also provide proven reliability and lower opergreenhvacrmag.com
RENDERING AND PHOTO: COURTESY OF CALMAC
Project Details
Project
Problem
Superior Court of California, Kings County
Energy storage
Location
Hanford, California
ating costs,” Valenta says. “Applying thermal energy storage as part of the design at the Kings County Courthouse was crucial. In California, energy costs vary based on peak and non-peak times of the day. Shifting the load to times when energy is less expensive reduces energy use and saves the county and its taxpayers considerable costs.”
I bring it back into the grid so my grid can be a reliable utility?” Valenta says. Many states are working to set mandatory energy storage targets, according to the Energy Storage Association. “No matter what this administration does, coal is going away,” Valenta sways. “The reliability of the grid is a big issue, and that’s where we fit in.”
How They Do It To save money on energy costs, the CALMAC system makes ice at night, when energy rates are lowest, and the building uses the ice to cool the building during the day. “Nighttime energy is used to create cooling that will be used during peak times. To start the cooling day, typically, the right-sized electric chiller will cool the load first. As the load increases above the chiller capacity or a peak time occurs, the stored cooling is discharged to augment the right-sized chiller.” CALMAC ice storage tanks are integrated with Trane commercial HVAC systems to take pressure off of the energy grid. The ice storage tanks store energy, similar to a battery, to be used when needed. This reduces the strain on public utilities, lessens operating costs for building owners, and allows for better use of renewable energy. CALMAC builds the Ice Bank thermal energy storage tank and ships it to you, ready to go. The tank is made of a single seamless piece of high-density polyethylene for containment and structure—nothing can rust or corrode. “It’s the same material used to distribute natural gas throughout the U.S.,” Valenta says. “That’s going to last 30 or 40 years. The ice tank will probably outlive that right-sized chiller. Instead of replacing a 100-ton chiller in a conventional cooling system, the thermal energy storage system requires a smaller replacement.” Typically a building requires 100 tons of cooling, but CALMAC has “right-sized” that need to 60 tons, with the other 40 to come from the thermal energy storage tanks. The IceBank tanks are modular, so you can add more tanks over time and relocate them easily. CALMAC also provides a limited five-year parts warranty on internal workings and a 10-year limited parts warranty on the tank vessel. But the tanks are resilient. If the chiller ever stops working or a power outage occurs, the standby generator will power the pump and keep the building cool. Add to that the question of reliability around renewals—you have to have the sun or wind to have energy, right? “If I’m removing that coal or that energy storage, how do
A Sustainable Story CALMAC has been part of Trane since late 2017, but the company itself has a long history of sustainability and leadership, having started in 1947. “I call us the Porsche of HVAC because research is a big part of what we did even then. And sustainability was a big part of that,” Valenta says. He recalls seeing old videos from when the company’s owner, Mark MacCracken,
green HVACR
Solution
CALMAC’s IceBank
Savings
26% energy costs reduction, or $102,000 annually
was just a boy helping his dad as part of the first photovoltaic conference in Phoenix. “His dad was always into solar and always inventing. In fact, when I was hired, I never saw him [founder Calvin MacCracken] in his office. He was back in his lab.” Efficiency has always been part of the CALMAC story. “For the past 30 years we’ve focused on energy storage, and within the last 25 years of that we’ve had a great relationship with Trane, with our goal of making comfort cooling less impactful on the environment,” Valenta says. CALMAC has also eliminated ABS and PVC materials, gluing agents, and all internal mechanical fittings in the construction of IceBank tanks. Tanks are 99% reusable or recyclable, and the manufacturing facility in New Jersey is LEED Gold–certified.
Architect
DLR Group Structural Engineer
Buehler & Buehler
CALMAC’s IceBank energy storage reduced the facility’s energy costs by 26% annually.
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Case Study In-Depth Project Profiles
THINKING OUTSIDE THE BOX HDPE cooling towers from Delta Cooling protect one manufacturer’s plant operations. By Ed Sullivan
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stressed would be required,” he says. “Those included lower maintenance costs, longer lifespan, and operational cost savings.” Avoiding the Pitfalls of Metal Cready knew the drawbacks of metal-clad cooling towers, like costly maintenance due in part to their susceptibility to corrosion. They often require repeated, expensive repairs like re-sheeting and welding and expensive water treatment chemicals, too. “Servicing some metal-clad cooling towers can be a nightmare,” Cready says. “Some models have thousands of nuts and bolts that can slow repairs to sometimes weeks.” Cready proposed using engineered plastic cooling towers made of high-density polyethylene (HDPE). These are impervious to weather, caustic conditions, and water treatment chemicals and won’t rust or corrode. Cready recommended and the facility engineers installed towers made by Delta Cooling, who pioneered the HDPE design in the 1970s and offers a 20-year factory warranty. Ensuring a Longer Lifespan The second requirement, a long lifespan, is an inherent benefit of HDPE. The mill selected Delta’s TM Series, an induced-draft, counter-flow design available in single unit
Project Details
capacities from 250 to roding PVC pipe and non2,500 cooling tons. The clog spray nozzles to further Before and After: TM Series offers a modreduce maintenance costs. A new tower from ular design that allows the The old metal-clad tower Delta Cooling replaced the old metal-clad towers to be assembled in had an exterior containment tower with something multiple configurations of pond, which is no longer rethat won’t rust or up to six units. “It makes it quired because the new towcorrode—and it’s easier for them to add on ers are self-contained. “That easy to assemble. to the existing towers to eliminates a troublesome meet future cooling needs,” Cready says. chore, keeping the pond free of dust and deThe new cooling towers are self-contained bris that often traveled from our equipment and factory assembled, so installation was into the containment water,” says Lloyd. easier and less intrusive. “Installation didn’t “Also, we no longer have the need to treat require a big crew, so we had only a few peothat water with expensive chemicals.” ple coming in and out of the facility, which Lloyd says the new cooling towers also helped reduce any disruptions to plant operconsume less power, and the blowers are ations,” Cready says. It took just a few hours. independent. The old metal-clad tower had one big fan on top, so they’d have to shut the Adding Convenience and Savings tower down and deal with a big 60hp motor The new design promises to add substantial with a large fan on top. With the smaller savings to the plant. For example, in addiindependent fans, if you have one go out tion to the HDPE structural material, the they are simple to replace, saving time and tower’s “plumbing” has enclosed, non-cormaterial costs.
Project
Specifier/Installer
Mississippi paper mill
Russell Cready, Tencarva Machinery Company
Project Manager
Cooling Tower Manufacturer
Delta Cooling Towers
Brian Lloyd
greenhvacrmag.com
PHOTO: COURTESY OF DELTA COOLING
H
HVAC systems play a crucial role in industrial cooling applications. Made of cooling towers, chillers, and air handlers, these are used to cool areas where high heat loads can shut down critical processes. This could stem from machinery that generates extensive heat, or where cooling and ventilation are required to protect temperature- and humidity-sensitive equipment. In the case of a large paper mill operated by one of the leading makers of tissue, pulp, paper, and packaging products, a primary cooling tower and other HVAC apparatus is vital to keeping the electrical equipment rooms cooled. These enclosures hold heat-sensitive instrumentation used to monitor and control essential plant operations. The Mississippi plant is one of the U.S.’s largest producers of container boards, used in the fabrication of durable cardboard boxes. The mill recently needed to replace the cooling tower used for the electrical rooms along with an additional tower that supplied comfort air to the building’s offices. Both cooling towers were the classic metal-clad design framed with wood and were beginning to disintegrate. “Our cooling towers were maintenance-intensive and getting to be unreliable,” says Brian Lloyd, an electrical and instrumentation planner for the mill. “We decided to immediately replace the two that were integrated with the HVAC equipment.” Cooling towers have undergone serious design changes over the years. To evaluate options, Lloyd consulted with experts like Russell Cready of Tencarva Machinery Company. “In addition to all of the standard functional necessities, there were a few other specific requests the mill’s engineers
Blueprint
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Advice, Columns, and Tips From the Experts
THE EVOLUTION OF IOT IN HVACR IoT-enabled systems are becoming increasingly affordable within the industry. By Ron Zimmer
T’S NO SECRET THE “INTERNET OF THINGS,” or IoT, can greatly improve building automation systems. As the industry emphasizes the need to understand the building IoT market, the Con-
tinental Automated Buildings Association (CABA) has taken a closer look at the
major aspects of IoT related to commercial buildings. Over the course of a year, CABA’s research showed that, while IoT is not a specific device or technology, it’s a conceptual framework driven by embedding connectivity and intelligence in a range of devices. Most industry defines IoT as a system of physical things embedded with sensors, software, and connectivity that can exchange data with other connected devices. An IoT device is one with some embedded connectivity that allows hardware to be linked to the Internet or tethered to an Internet-addressable device. Our market research projects that by 2025’s end, there will be roughly 70 billion IoT-connected devices. The first stage of IoT evolution saw the birth of manifold connected and intelligent devices, with innovations developed for smartphones finding their way into the nascent IoT market. Now IoT is shifting from pure hardware connectivity toward collecting data from devices, due to continuing advances in sensor and storage technology. Such advances in connectivity and computing power means IoT-enabled systems are more affordable and available within the industry. As an example, five years ago, property owners or managers of small standalone, 20,000-square-foot office buildings could not afford extensive digital direct control temperature systems with energy management features. Now, owners of smaller buildings can leverage enhanced control systems that are Internet-connected with minimal initial costs. Our research shows owners of large commercial building portfolios are also incorporating IoT in exciting ways. Building automation systems can now leverage control functions that maximize system performance using mobile Internet data services, along with equipment that allows millions of data points to green HVACR
The Continental Automated Buildings Association (CABA) has found that by the end of 2025, there will be approximately 70 billion IoT-connected devices.
NUMBER OF INTERNET CONNECTABLE DEVICES CONNECTED DEVICES—INSTALL BASE (MILLIONS)
II
OVERALL DEVELOPMENT OF IoT DEVICES
80,000 70,000 60,000 Military & Aerospace
50,000 40,000
Medical
30,000
Industrial
20,000
Consumer
10,000
Computer
0
Communications 2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
Automotive
SOURCE: IHS MARKIT
be stored and reviewed. In addition, powerful appliances, including wireless thermostat technology, can be interconnected, creating affordable options for building owners and managers to link to countless building controls through a specific property or throughout a wider property portfolio. Having such smart technology in building automation equipment means equipment issues can be diagnosed before service technicians are required to be dispatched. Predictive maintenance through IoT systems will prevent possible equipment failure and associated downtime, thereby saving time and money. Through new IoT technology, property owners and managers can control building operations and re-
spond to tenant requests from apps on their smart devices. One challenge our market research found, however, is regarding standards, open APIs, cybersecurity, and the cloud. These must be resolved to determine how to manage and access huge data sets and yield meaningful insights. We project real value from IoT will amass in the years ahead, as mountains of data accessed from HVACR devices are examined. Our research affirms the value of IoT is expressed through practical applications like intelligent buildings, where previously isolated systems become functionality integrated, sharing data, and thereby providing wider benefits.
is president and CEO of CABA (Continental Automated Buildings Association). He is a certified association executive with more than 30 years of association management experience. He regularly makes presentations on integrated buildings and home/building automation at international industry events. RON ZIMMER
APRIL/MAY 2018
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Exchange INSPIRING PROJECTS FROM AROUND THE WORLD
Project
Shanghai Tower Location
Shanghai, China LEED Platinum Certified
2015 Size
4,090,300 sq ft Height
2,073 feet Architect
Gensler
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APRIL/MAY 2018
PHOTO: BLACKSTATION
Shanghai Tower hosts whole neighborhoods within its 128 floors. China’s tallest building and the second tallest in the world, it has nine vertical zones, each 12 to 15 floors, that house offices, hotels, observation decks, and gardens. Using 80% less energy for its heating and cooling than equivalent towers, it’s the first Passivhaus-certified office tower. The tower’s shell has transparent double walls that insulate, allow for air ventilation, and let in sunlight. You’ll also find green spaces in and around the building, with extensive landscaping that comprises one-third of the space. The tower may be in one of the most polluted places, but this project maximizes its sustainability. Shanghai Tower’s many strategies will reduce its carbon footprint by 25,000 metric tons per year. Within the façade are 270 wind turbines, which power the exterior lighting. greenhvacrmag.com
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THE SMC SMART MOTOR SYSTEM IS FOR COMMERCIAL & INDUSTRIAL HVACR AND PUMPING APPLICATIONS AND GIVES CONTRACTORS A REVOLUTIONARY WAY TO BUILD VALUE-ADDED CUSTOMER RELATIONSHIPS AND IMPROVE FIELD PRODUCTIVITY.
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