Roundtable Discussion: Advances in HVAC technology

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Table of Contents

Official BUSRide Maintenance Roundtable Discussion: Advances in HVAC technology

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About DCM Manufacturing

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About SanUVAire

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About Thermo King

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About Bitzer

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Advances in HVAC technology BUSRide Maintenance gathered experts from the HVAC industry to discuss HVAC’s effect on bus efficiency, the relative advantages of different system types and how zero-emission technology is affecting air conditioning.

The panelists for this discussion are: Chad Sleiman – chief executive officer – SanUVAire Gary Eubank – product manager – DCM Manufacturing Matt Lish – business development manager – Bitzer Steve D. Johnson – product marketing manager, bus HVAC – Thermo King

What impact does the weight of an HVAC system have on bus efficiency?

Gary Eubank: Increasing overall vehicle weight has a negative effect on fuel consumption, while reductions in weight have a positive effect. The significance of this will depend upon the operational cycle of the vehicle and the weight of HVAC equipment as a percentage of overall vehicle weight.

Chad Sleiman: The HVAC system is the second or third largest bus component, after the engine and transmission, and it takes up considerable real estate on the bus. The weight of such a system has a direct impact on the vehicle’s mechanical components’ performance. This can affect life cycle and fuel consumption, regardless of whether it is CNG, diesel, or electric; as well as CO2 emission and heat dissipation, which contributes to global warming.

Matt Lish: There are many variables involved in the concept of “bus efficiency,” including drag coefficients, drive-train design, driver behavior, and operating terrain, therefore it’s hard to make definitive statements regarding this issue. There is a large body of testing evidence from Society of Automotive Engineers (SAE), the National Renewable Energy Laboratory (NERL) and the Environmental Protection Agency (EPA)

showing the reduction of vehicle weight (also referred to as “lightweighting”) in conventional-drive automobiles has a positive impact on vehicle efficiency, and reduces total fuel consumption over the life of the vehicle. Reductions in overall vehicle weight and specifically in the HVAC system contribute to fuel efficiency. Simply changing compressors can achieve reductions of 70 pounds or more This is why Bitzer designs our bus air conditioning compressors out of cast aluminum in lieu of older, heavier, cast iron models.

Steve D. Johnson: Start with the fact that an empty bus gets better fuel mileage than a full bus and you know weight matters. While the impact may not be huge, it is also not insignificant. Every one-tenth of MPG improvement counts.

What are the advantages of a top-mounted system? A rear-mounted system?

Eubank: Traditionally, rear-mounted HVAC has been approximately three to four times more popular than topmounted systems. This has been due to compactness, which in turn is viewed to have a positive effect on system robustness and reliability. Recently top-mounted systems have been gaining in popularity, because of improvements in technology, busridemaintenance.com | BUSRIDE MAINTENANCE

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and a need to provide more space in rear-engine compartments for emissions control equipment. Most buses have a maximum weight limit per axle, and top-mounted systems also allow transferring some of the system weight from the rear axle to the front axle.

Sleiman: There are advantages and disadvantages to both.

With a rear-mounted system, you have ease of install, access and maintenance since the system is not too compact. It also helps balance weight distribution on the bus. However, this creates higher exposure to grime, dirt and dust, as it is closer to the roads.

Top-mounted systems tend to be more linear and compact internally, which doesn’t leave much room for ease of access, maintenance and replacement parts after the initial install.

It is directly exposed to rain, and heat and ultraviolet rays from the sun, so it needs to be well-constructed and sealed to withstand the elements and provide for a long life-cycle.

It also needs to be lightweight, because the roof of the bus is not typically designed to support heavy components. It is less exposed to dirt and grime, but we still must keep an eye on condensation and drip-pan leakage issues.

Lish: Regarding the heart of any air-conditioning system, the compressor, it doesn’t matter where the rest of the system is located. What matters is that the system is designed to properly protect the compressor to ensure its long-term operation. Each location has challenges and may benefit from different protection strategies in order to properly protect the compressor from damage-causing events like liquid slugging or oil migration. Issues like belt alignment, belt tensioning, and shaft seal operation are all related to traditional diesel enginedriven piston compressors.

All electric, rooftop mounted compressors and systems come with different sets of challenges such as how repairable is the compressor, and challenges related to the heat from the sun.

Johnson: Rear-mounted systems generally weigh less, cost less and are easier to maintain, but can create an issue with axle weight. Space for the system is limited and so are the configuration options. Top-mounted systems provide more flexibility for installation locations, and more options on size, capacity and air distribution. They can be strategically placed to optimize axle weight. Having to cut holes in the roof and providing a good seal to prevent water ingress adds complexity and risks at installation. Being on the roof also adds safety risks during service functions.

This caused manufacturers to go back to the design boards and come up with a new design, better components and compliance. This triggered a change in size, dimensions and weight of HVAC units as well as some of their components to function with newer more eco-friendly refrigerants.

Lish: Zero-emissions and anti-idling legislation particularly are driving innovation in transport A/C. The adoption of electric buses particularly has driven Bitzer to develop a range of fully electric, variable speed compressors. We have seen enormous interest in electric a/c systems globally, with real traction here in the USA within the last year and a half. The ELV series is highly efficient and multiple system companies are adopting them as key components in their new electric system designs.

Johnson: While it is still early in the game, the push for more efficient systems has started. That means delivering the required capacity using the least amount of power possible from the battery. To achieve this, more system integration between the HVAC and the bus power management system must be developed. With the absence of the engine, noise reduction technology will be applied to the HVAC system.

How do you see HVAC technology evolving 5 years from now? 10 years from now?

Eubank: Life-cycle cost will gain importance in the coming years. Heat pump technology will also grow dramatically with the importance of electric vehicles.

Sleiman: In the next five years, we see the mandates and legislations for more efficient HVAC systems, zero emissions and eco-friendly refrigerants continuing to shape and drive the evolution of HVAC technology.

In the next 10 years, we believe that, like everything else that needs to be connected and accessible over a network, HVAC technology will follow suit and be smart, connected and accessible. However, we also see that such developments will play a role in making HVAC units bigger and heavier.

Lish: As market and legislative pressures continue to drive reductions in greenhouse gas emissions, new refrigerants will be adopted, and compressor innovations to work most efficiently with those new refrigerants will undoubtedly be developed. Additionally, innovative electric A/Cs, which are being widely adopted today in Asia, will become more prevalent in North America. A range of variable speed electric compressors, such as the ELV series, will allow component selections to possess variable speed capability allowing for very precise cooling and relying on only the power needed.

Johnson: In the near term, systems won’t change that much because of the low number of zero-emission buses and the slow adoption rate. There is a lot of in-service testing to be done to establish base lines. Suppliers will be developing the next generation HVAC platforms. In 10 years expect systems to be smaller and quieter, more modular, and lighter in weight.

Also, expect them to be using new environmentally-friendly gases, and have more efficient strategies for heating.

The push for more efficient systems has started.

What effect have zero-emission buses had on HVAC technology?

Eubank: Increased emissions controls have been a major driving force in migration from rear mounted HVAC systems to roof mounted systems. They have also been a driving force in reducing energy consumption of all the HVAC components, from the compressors to the fan motors.

Sleiman: It puts more pressure on the HVAC manufacturer to produce HVAC units that can meet such requirements.

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As HVAC technology advances, what affect does it have on preventative maintenance?

Sleiman: We have seen advancements that were a step forward in the right direction, but we have also seen backward steps. It’s a double-edged sword. On one hand, you equip the HVAC system with sensors and the ability to integrate to other monitoring systems to provide alerts and notifications, but that comes at a cost, which is more components that are too delicate and prone to frequent failure due to the harsh nature of the system functionality.

There are always great benefits to implementing technology advancements to allow for self-diagnostics, monitoring and alerts, but it means there are more specialized components that tend to be costly and require the maintenance staff to be trained to troubleshoot and replace them, or incur extra services cost. The question would be: what is the ROI like, overall, comparing systems with and without such advancements?

Advancements in the type of gas and refrigerants used is another serious issue.

Lish: With regard to compressors, those companies willing to invest in thoughtful design can integrate improvements more quickly thanks to advanced modeling and shortened development timelines.

As an example, recent integration of the Bitzer shaft seal oil reservoir and drain tube allows for the quick check of proper oil weeping from the shaft seal, allowing service staff to perform this routine compressor check more quickly and intelligently than in the past.

Another example would be the use of fully hermetic, or sealed, scroll compressors. There have been studies performed by transit authorities that have demonstrated fully hermetic compressors and systems with minimal access points experience fewer leaks and thus require less maintenance.

Johnson: Overall, there are fewer mechanical parts to fail and maintain. The incidence of refrigerant leaks will drop dramatically. Maintenance costs can conservatively drop as much as 50 percent. Most of this can be attributed to the cost associated with checking, fixing and replacing the mechanical components.

• Implementation of sensors and smart components for better diagnostics, analytics and self- management.

Johnson: Durability is a given and systems will need to observe today’s standards as they change. Eco-friendliness will be driven by the new gases. Legislation will drive systems to lower leak rates which means designs with fewer fittings and no hoses. There may be laws dictating what the recyclable content must be or, leading suppliers could set those standards independently.

Tell us about the legislation that affects refrigerants in transportation applications.

Eubank: R134a is scheduled to be phased out by 2025.

HFC1234YF is the probable successor. This will require new refrigerant recovery and recycling equipment, and possible redesign of heat exchangers and sealing methods.

Lish: The U.S. EPA greenhouse gas regulation set standards based on a presumed across-theboard conversion to HFO1234yf between 2017 and 2022 for domestic automobiles. There have been no definitive timelines set for bus adoption. The good news, however, is when adoption does occur, provided nothing changes, those shops servicing HVAC systems which have passed the required one time certification with their EPA Regional Office proving they have already acquired and are properly using approved refrigerant handling equipment for CFC-12 or HFC-134a equipment will not be required to re-submit certification to EPA when they purchase new equipment for a different refrigerant, such as HFO-1234yf.

Johnson: Bus and Rail are no longer just lumped into the transportation category and left to try and interpret the rules. The EPA has recognized that the lower GWP refrigerants do not meet the flammability standards required to transport people safely. Currently the two refrigerants used for buses and trains, R407C and R134a remain acceptable for those applications. A list of refrigerants currently acceptable under EPA’s Significant New Alternatives Policy (SNAP) Program for air conditioning in passenger trains and buses is available at https://www. epa.gov/snap/acceptable-substitutes-mvac-passenger-airconditioning-buses-and-trains.

Sleiman: We already know that as of January 1, 2010, virgin HCFC-22, HCFC-142b and blends containing HCFC22 or HCFC-142b may only be used to service existing appliances. Consequently, virgin HCFC-22, HCFC-142b and blends containing HCFC-22 or HCFC-142b may not be used to manufacture new pre-charged appliances or appliance components or to charge new appliances assembled onsite.

The legislation focuses on the reduction of the F-GAS by 79% by 2030 and its impact on the Global Warming Potential (GWP) limit of 2500 of it by 2020. If you have R404A, all systems with more than 10KG will fall under the new F-Gas legislation.

Technological advancements can be a double-edged sword.

Are there advances in HVAC systems and component manufacturing that ensure durability, as well as ecofriendliness? If so, what are they?

Eubank: There is continual advancement in both average service life and consistent performance in all electrical components. Hazardous metals and materials have been removed both from the final HVAC components and from the processes used to manufacture them.

Sleiman: Some of the advancements that we are aware of or have knowledge of are: • Better compressors for better performance and durability • Type of coolants used per legislations and various evaluations • Layout of certain components within HVAC unit to provide for better performance, reliability and durability

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DCM Manufacturing, a wholly owned subsidiary of Dreison International, Inc. is a world leader in air movement components for the Mobile HVAC Industry serving the Bus, Truck and Off Highway markets. DCM and our FAZ division both manufacture a proprietary line of Axial Fans and Radial blowers, Permanent Magnet & Brushless DC Motors along with a full line of Plastic accessories.

History of DCM DCM became a Dreison International company in 1995. The company has grown through international partnerships, product development and the acquisitions of several companies in line with our growth strategy.

In 1999, DCM established off shore partnerships in China to manufacture DC motors, components and various other finished goods, all items related to Mobile HVAC markets.

During the same time, DCM also partnered with FAZ Elektrik of Izmir, Turkey to create a high end axial fan and radial blower line of products to supply both the North American and European markets.

In 2008, DCM acquired rival, Revcor Molded Products of Haltom City, Texas further expanding the offering of air movement products. This added North American injection molding process capabilities along with proprietary louvers and accessory lines. The Revcor business was relocated to our Empalme Mexico facility in 2009.

In 2010, DCM acquired FASCO/Von Weise a DC Motor Manufacturer in Cambridge, Ontario Canada. This production facility was also relocated to the Empalme, Sonora Mexico plant.

This facility is ISO-9001:2008 certified.

In 2016, DCM acquired our long term partner of 18 years, FAZ Elektrik to further our goal as a global leader in the Mobile HVAC components industry. This facility is TS:14001:2004 / ISO-9001:2008.

DCM now has engineering, manufacturing and tooling facilities in the US, Mexico and Turkey giving us the capability to supply both North American and Europe with reduced lead times, technical support and distribution.

Engineering All parts are designed to both North American and European standards. We assist customers with Motor design, 3D modeling, mold design and rapid prototyping. Component performance and durability testing are just some of the engineering capabilities DCM/FAZ provides its OEM customers. With DCM you truly have one stop shopping from part design to production.

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DCM Manufacturing www.dcm-mfg.com 216-265-8006 x245

FAZ Elektrik www.faz.com.tr +90 232 478 1898

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ABOUT

SanUVAire, LLC, is setting new and improved clean air and safety systems standards in its first full year of business, the woman owned, certified WBE that has designed, manufactured, and supplied technology solutions for the public transportation industry for over 25 years. SanUVAire prides itself on crafting customized indoor air quality units for individual applications and is expanding its portfolio to include all types of products addressing transit specific health and safety needs.

The company’s CEO, Chad Sleiman, brings a wealth of knowledge and experience in technology and solution-based approaches. “Education is key”, says Sleiman, in advancing public health and safety for transit ridership by improving vehicle interior air quality, lowering maintenance costs, reducing the risk of illness as well as accident prevention & avoidance!

Indoor Air Purification for Bus & Rail: Elimination of Airborne Diseases and Odors BREATHE-SAFE UVGI TECHNOLOGY: The company’s premier and newly enhanced product, “Breathe-Safe Systems”, was designed and manufactured under a licensing agreement with a major patent holder. Over 2000 Breathe-Safe Systems have been successfully deployed on various transit vehicles and railcars to date. It is the only tested, tried and proven UV germicidal irradiation product specifically designed for transit vehicles.

The system was originally deployed and tested through a project sponsored and partially funded by the Transportation Research Board of the National Academy of Sciences. The Transit IDEA Program awarded the project, and its research and final report led to validation and quantification of the effects of safely designed and installed UV ventilation treatment systems in all modes of public transportation. The project included the collection and analysis of molds, viruses, bacteria, and other pathogens found in transport vehicles. Additional research and testing was conducted to determine the specific effects of the “Breathe-Safe System” on airborne transmitted contaminants.

The data and analysis used to determine the contaminant kill rate of 99% in most cases and required exposure times was based on research of the USEPA, CDC, ASHRAE, the Department of Homeland Security, and more.

SanUVAire is upgrading the existing technology with transit specific feedback. The product line will include a multi-faceted ‘safety’ approach to its air purification as well as smart improvements designed to assist in maintenance and management of the systems. “We are always investing in R&D to accommodate industry needs and feedback” says Sleiman, whose technological expertise also steer the expansion process.

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BUSRIDE MAINTENANCE | ADVANCES IN HVAC TECHNOLOGY

Accident Prevention and Bus Safety STOP PROJECT: A flashing and programmable “S-T-O-P Alert LED” sign alerts drivers approaching too close behind a bus; it was designed in cooperation with several transit properties to provide a new and effective way to reduce rear end accidents. In turn, it helps increase safety and awareness while reducing accidents, injuries, insurance claims and financial burdens! We tell drivers following the bus when it is stopping. When the bus driver applies the brakes the “STOP” is illuminated and continuously flashes one letter at a time. The super bright twin rows of LED’s are designed to be readable in the brightest of sunlight and all of the electronics are encapsulated in a high temperature epoxy to withstand extreme weather and daily trips through the bus wash.

CURB AVOIDANCE PROJECT: SanUVAire’s “Curb-Alarm” system is designed to reduce tire and wheel damage by alerting drivers when they are approaching too close to a curb; another collaborative effort with several transit properties investing in the design requirements. Looking closely at the financial costs incurred due to the damage to tires and wheels, the labor involved and loss of productivity, it became very apparent there was a considerable financial benefit to the transit properties to implement a system that can help them avoid such situations.

The company is also working hard to build a reputation as a socially conscious supplier of products and services focused on the transit dependent population. Collectively, SanUVAire has over 60 years of engineering, design, development and application of technology solutions for public transportation. The company’s work quantifies the scope and scale of the potential problems that can occur on all transit vehicles and paves the way for healthier and cleaner environments for all transit ridership.

To learn more visit www.SanUVAire.com.

For publications, references, case studies, and reports visit http://www.sanuvaire.com/blogpublications.html

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THERMO KING Thermo King is the world leader in transport temperature control systems for trucks, trailers, buses, rail cars and shipboard containers. Thermo King also manufactures auxiliary power units, which dramatically reduce engine idling. All Thermo King products are backed by a nationwide dealer network, which provides expert factorytrained service and a complete line of genuine and competitive parts.

THERMO KING HISTORY It all started on a hot summer day in 1938 and a customer’s need to keep a load of fresh chickens cold while transporting them to market. Joe Numero accepted the challenge, and with the engineering genius of Frederick M. Jones, the two launched Thermo King and began the age of modern transport refrigeration.

Ever since that day, Thermo King has been developing customer-focused innovations that deliver efficiency, reliability and safety across the planet. That commitment to innovation continues, helping to grow businesses and improve lives now and into the future.

PRODUCT PERFORMANCE Long-term value for your business When your transportation equipment meets the demands of service with reliability and efficiency, it contributes to your profitability. With 75 years in the industry, Thermo King equipment has repeatedly proven its dependability, and our products retain their value longer than any others in the industry.

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Built-in savings Better design means a lower cost of ownership.

Tough construction, proven reliability and efficiency help you save money on service and maintenance costs. Our sustainable designs pay off with reduced energy consumption, including built-in technology to modulate the engine and maintain temperature.

Quality testing in our labs improves product performance, which means fewer breakdowns.

With our longer maintenance cycles, you’ll save time and money.

Expert service and support When you need support, you’ll get assistance from providers who are trained and certified to specifically service our products. And with the largest service network in North America providing assistance 24 hours a day, you have the support you need anytime, anywhere.

Through Thermo Gard™ Service and Maintenance Solutions, you can choose the service program that best fits your business needs. Take advantage of repair authorization options, centralized billing, extended warranty options, and service at any of our over 200 factoryauthorized service centers nationwide.

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T-SERIES

A TRUE EXAMPLE OF SUSTAINABILITY

SINCE 1981. THE HVAC SYSTEM THAT CHANGED AN ENTIRE INDUSTRY IS BETTER THAN EVER!

1981

2017

Controls: ............................................................. Mechanical

Controls:......................................... IntelligAIRE Microprocessor

Communication Protocol: .............................................None

Communication Protocol: ....................................CANBus J1939

Weight:..................................................................... 500 lbs.

Weight: ............................................................................ 385 lbs.

Motors: .............................. Permanent Magnet/Wound Field

Motors:................................................................. Brushless ECD

Heat Controls: .............................................. On/Off Solenoid

Heat Controls: .....................................Motorized PWM Controls

Capacity Control:................................................. Mechanical

Capacity Control: ...................................... Electronic (saves fuel)

Refrigerants: ....................................................... R12 & R22

Refrigerants:.......................................................R134a & R407C

Compressors: ..................................................... X426/X430

Compressors:.............................X426, X430, S391/S616 Screw and Hermetic Scroll

Configurations: ...................................................HVAC & HV

Configurations:..........................................HVAC, HV, All-Electric and Alternator Powered All-Electric

ENERGY-EFFICIENT OPTIONS

THERMO KING INVESTMENT AND INNOVATION MEANS MORE EFFICIENT, RELIABLE PRODUCTS FOR TRANSIT.

BITZER is the world leader in Bus/Coach air conditioning compressors. BITZER’s product range covers all compressor technologies from reciprocating to scroll and screw compressors.

BITZER bus a/c compressors are designed specifically to excel within the harsh environment of today’s engine compartments.

BITZER’s bus a/c compressors offer superior capacity to cool coaches, school buses, transit buses, including larger articulated and double decker buses.

Please visit our website for more information regarding your bus and shuttle air conditioning needs. www.bitzerus.com

BITZER US, Inc. // (770) 718-2900 // www.bitzerus.com // marketing@bitzerus.com