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

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

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

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

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

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

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

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

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

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

LOCATION: Osborne Middle School Ke2Therm Defrost Control Established 5-23-11 3:10 pm osbourne

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Advantages of KE2 Evaporator Efficiency technology Minimal heat gain through convection and radiation Insignificant fog formation during defrost No icing around evaporator Reduced moisture loss and product shrinkage Low or no heating of stored products Quickest possible cooling at end of defrost Energy cost savings approx. 40 to 50% of the defrost energy. This represents nearly 10 to 15% of plants total energy use Copyright 2010 KE2 Therm Solutions, Inc. Washington, Missouri

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

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

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

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

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

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

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

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

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

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

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

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

Osborne Middle School Test

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

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

9 Defrosts in 5 Days. Total Time in Defrost 1.7 Hours Week Three LOCATION: Osborne Middle School Ke2Therm Defrost Control Established Room Temp +10F 9 Defrosts in 5 Days. Total Time in Defrost 1.7 Hours Coil Temp +50 F 5-18-11 8:28 am

3 Defrosts in 5 Days. Total Time in Defrost 1.0 Hours Week Four LOCATION: Osborne Middle School Ke2Therm Defrost Control Established Room Temp +10F Coil Temp +50 F 3 Defrosts in 5 Days. Total Time in Defrost 1.0 Hours 5-23-11 3:10 pm osbourne

Osborne Middle School

Osborne

Osborne

Osborne

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

Berkmar Middle School Test

22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours Week One LOCATION: Berkmar Middle School Room Temp +25F No Defrost Control Established (Baseline Data Only) 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours Coil Temp +100 F Bermar 5-19-11 10:56 am

22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours Week Two Room Temp +25F LOCATION: Berkmar Middle School No Defrost Control Established (Baseline Data Only) 22 Defrosts in 5 Days, Total Time in Defrost 8.0 Hours Coil Temp +100 F 5-24-11

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

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

Berkmar Middle School

Berkmar

Berkmar

Berkmar

Berkmar 19.4% Reduction 11.4% Reduction 94.4% Reduction