CHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT

TABLE OF CONTENTS

3.1 INTRODUCTION

........................................................................................................... 3-1 3.1.1 Definitions

............................................................................................................ 3- 1 3.2 MARKET ASSESSMENT

.............................................................................................. 3-4 3.2.1 Trade Association

................................................................................................ 3-4 3.2.2 Manufacturers and Market Share

......................................................................... 3-4 3.2.2.1 Small Businesses

...................................................................................... 3-7 3.2.3 Regulatory Programs

........................................................................................... 3-8 3.2.3.1 California

................................................................................................. 3-8 3.2.3.2 Canada

...................................................................................................... 3-9 3.2.3.3 Canadian Standards Association

............................................................ 3-10 3.2.3.4 Australia

................................................................................................. 3-11 3.2.4 Non-Regulatory Initiatives

................................................................................. 3-11 3.2.4.1 ENERGY STAR

.................................................................................... 3-12 3.2.4.2 Consortium for Energy Efficiency

......................................................... 3-12 3.2.4.3 Federal Energy Management Program

.................................................. 3-12 3.2.4.4 Rebate Programs

.................................................................................... 3-12 3.2.5 Equipment Classes

............................................................................................. 3-13 3.2.6 Shipments

........................................................................................................... 3-19 3.2.6.1 Appliance Magazine Data

...................................................................... 3-21 3.2.6.2 Current Industrial Reports

...................................................................... 3-21 3.2.7 Equipment Lifetimes

.......................................................................................... 3-24 3.2.8 Market Performance Data

.................................................................................. 3-25 3.3 TECHNOLOGY ASSESSMENT

.................................................................................. 3-28 3.3.1 Technologies and Designs Relevant to All Equipment Classes

........................ 3-28 3.3.1.1 Higher Efficiency Lighting

.................................................................... 3-28 3.3.1.2 Higher Efficiency Lighting Ballasts

...................................................... 3-29 3.3.1.3 Remote Lighting Ballast Location

......................................................... 3-29 3.3.1.4 Higher Efficiency Expansion Valves

..................................................... 3-29 3.3.1.5 Higher Efficiency Evaporator Fan Motors

............................................ 3-30 3.3.1.6 Evaporator Fan Motor Controllers

......................................................... 3-31 3.3.1.7 Higher Efficiency Evaporator Fan Blades

............................................. 3-31 3.3.1.8 Increased Evaporator Surface Area

....................................................... 3-32 3.3.1.9 Low-Pressure Differential Evaporators

................................................. 3-32 3.3.1.10 Anti-Sweat Heater Controllers

............................................................. 3-33 3.3.1.11 Improved or Thicker Insulation

........................................................... 3-33 3.3.1.12 Defrost Mechanism

.............................................................................. 3-33 3.3.1.13 Defrost Cycle Control

.......................................................................... 3-34 3.3.1.14 Thermoacoustic Refrigeration

............................................................. 3-34 3.3.1.15 Magnetic Refrigeration

........................................................................ 3-35 3.3.1.16 Electro-Hydrodynamic Enhanced Heat Transfer

................................. 3-35 3.3.1.17 Copper Rotor Motors

........................................................................... 3-36

3-i3.3.2 Designs Relevant Only to Equipment without Doors

........................................ 3-36 3.3.2.1 Air-Curtain Design

................................................................................. 3-36 3.3.3 Technologies and Designs Relevant Only to Self-Contained Equipment

......... 3-36 3.3.3.1 Higher Efficiency Compressors

............................................................. 3-36 3.3.3.2 Liquid Suction Heat Exchangers

........................................................... 3-37 3.3.3.3 Increased Condenser Surface Area

........................................................ 3-37 3.3.3.4 Higher Efficiency Condenser Fan Motors

............................................. 3-38 3.3.3.5 Condenser Fan Motor Controllers

......................................................... 3-38 3.3.3.6 Higher Efficiency Condenser Fan Blades

.............................................. 3-38 REFERENCES

..................................................................................................................... ..... 3-40

LIST OF TABLES

Table 3.2.1 California Energy Commission Efficiency Regulati ons for Commercial Ice-Cream Freezers

.................................................................................................................. 3-9 Table 3.2.2 Canadian Effici ency Regulations for Commer cial Ice-Cream Freezers

.............. 3-10 Table 3.2.3 Canadian Standards Association Eq uipment Classes and Efficiency Ratings

.... 3-11 Table 3.2.4 Commercial Refrig eration Equipment Families

.................................................. 3-16 Table 3.2.5 Commercial Refrig eration Equipment Classes

.................................................... 3-18 Table 3.2.6 Air-Conditioning a nd Refrigeration Institute Shipments of Commercial Refrigerators and Freezers by Equipment Class

.................................................. 3-20 Table 3.2.7 Historical Shipments of Refrigerated Display Cases

........................................... 3-21 Table 3.2.8 Statistical Forecasts of Re frigerated Display-Case Shipments

............................ 3-21 Table 3.2.9 Shipments of Open Refrigerate d Display Cases (Remote Condensing and SelfContained)

............................................................................................................ 3-22 Table 3.2.10 Shipments of Closed Refrigerated Display Cases (Remote Condensing and SelfContained)

............................................................................................................ 3-23 Table 3.2.11 Shipments of Commercial Reach-In Cabinets (Remote Condensing and SelfContained)

............................................................................................................ 3-24 Table 3.2.12 Estimates for Commercial Refrigeration Equipment Lifetimes

.......................... 3-25

LIST OF FIGURES

Figure 3.2.1 Domestic Refrigerated Display Case Market Shares

............................................. 3-6 Figure 3.2.2 Market Performance Data fo r the VOP.RC.M Equipment Class

......................... 3-26 Figure 3.2.3 Market Performance Data fo r the SVO.RC.M Equipment Class

......................... 3-26 Figure 3.2.4 Market Performance Data fo r the HZO.RC.M Equipment Class

......................... 3-27 Figure 3.2.5 Market Performance Data fo r the VCT.RC.L Equipment Class

.......................... 3-27 Figure 3.2.6 Market Performance Data for the VOP.RC.M, SVO.RC.M, and HZO.RC.M Equipment Classes: Comparis on of Air-Curtain Angles

.................................... 3-28

3-iiCHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT

3.1 INTRODUCTION

This document details the market and technolog y assessment that the U.S. Department of Energy (DOE) has conducted in support of the ongoing energy conservation standards rulemakings for commercial refrigeration equi pment (CRE), including commercial ice-cream freezers; self-contained commercial refriger ators, commercial freezers, and commercial refrigerator-freezers without doors; and remo te condensing commercial refrigerators, commercial freezers, and commercial refrigerator -freezers. These rulemakings are mandated by the Energy Policy Act of 2005 (EPACT 2005), and ar e effective for equipment manufactured on or after January 1, 2012.

This chapter consists of a market and tec hnology assessment. The goal of the market assessment is to develop a qualitative and quant itative characterization of the CRE industry and market structure based on publicly available information and information submitted by manufacturers and other stakehol ders. Manufacturer characteristics and market shares, existing regulatory and non-regulatory efficiency improveme nt initiatives, equipment classes, and trends in markets and equipment characteristics are ad dressed. The goal of the technology assessment is to develop a preliminary list of technologies that could improve the efficiency of commercial refrigeration equipment.

Commercial refrigeration equipment is used primarily to store and display perishable food products for sale in food-sales buildings ( e.g., supermarkets and convenience stores), some multi-line retail stores, and in so me food service applications lik e restaurants, salad bars, and cafeterias. The vast majority of equipment c overed under this rulemaking, however, is used in food-sales buildings, which represent about 1.75 percent (1.26 billion square feet) of the commercial floor space in the United States and 4.87 percent (668 trillion British thermal units per year (Btu/yr)) of the to tal energy consumption attributed to the commercial sector. a Fully 5.84 percent (61 terawatt hours per year (TWh/yr)) of the electrical consumption in commercial buildings is attributed to food-sales buildings. 1 Their high energy-use intensity is largely due to the extensive use of commercial refrigeration equipment.

3.1.1 Definitions

Section 136(c) of EPACT 2005 amended sectio n 342 of the Energy Policy Conservation Act (EPCA or the Act) to include new subsec tion (c)(4)(A) (42 U.S.C. 6313(c)(4)(A)), which mandates that DOE issue energy conservation standards by rule no late r than January 1, 2009, for the following equipment manufactured on or after January 1, 2012: commercial ice-cream freezers; self-contained commercial refriger ators, commercial freezers, and commercial refrigerator-freezers without doors; and remo te condensing commercial refrigerators, commercial freezers, and commerc ial refrigerator-freezers.

a The values indicated are source energy values.

3-1Section 136(a)(3) of EPACT 2005 amended section 340 of EPCA, in part by adding subsection 340(9) (42 U.S.C 6311(9)) with defini tions for the following terms that describe commercial refrigeration equipment:

“(9)(A) The term ‘commercial refrigerat or, freezer, and refrigerator-freezer’ means

refrigeration equipment that— (i) is not a consumer produc t (as defined in section 321); (ii) is not designed and marketed exclus ively for medical, scientific, or research
purposes; (iii) operates at a chilled, frozen, combination chilled and frozen, or variable temperature; (iv) displays or stores merchandise a nd other perishable materials horizontally, semivertically, or vertically; (v) has transparent or solid doors, s liding or hinged doors, a combination of hinged, sliding, transparent, or solid doors, or no doors; (vi) is designed for pull-down temper ature applications or holding temperature applications; and (vii) is connected to a self-contained condensing unit or to a remote condensing unit.

(B) The term ‘holding temperature a pplication’ means a use of commercial refrigeration equipment other than a pu ll-down temperature application, except a blast chiller or freezer. * * * (D) The term ‘pull-down temperatur e application’ means a commercial refrigerator with doors that, when fully loaded with 12 ounce beverage cans at 90 degrees F, can cool those beverages to an average stable temperature of 38 degrees F in 12 hours or less. (E) The term ‘remote condensing unit’ means a factory-made assembly of refrigerating components designed to comp ress and liquefy a specific refrigerant that is remotely located from the refrig erated equipment and consists of one or more refrigerant compressors, refrigerant condensers, condenser fans and motors, and factory supplied accessories. (F) The term ‘self-contained condensing unit’ means a factory-made assembly of refrigerating components designed to comp ress and liquefy a specific refrigerant that is an integral part of the refrigera ted equipment and consists of one or more refrigerant compressors, refrigerant conde nsers, condenser fans and motors, and factory supplied accessories.”

EPACT 2005 did not explicitly define the term s “self-contained commercial refrigerator, freezer, or refrigerator-freezer” or “remote c ondensing commercial refrigerator, freezer, or refrigerator-freezer.” DOE interpreted these two terms to mean “commercial refrigerator, freezer, or refrigerator-freezer that is connect ed to a self-contained condensing unit” and “commercial refrigerator, freezer , or refrigerator-freezer that is connected to a remote condensing unit,” respectively.

Accordingly, the three categories of equipment covered under this rulemaking are:

3-21. Remote condensing commercial refrigerato rs, commercial freezers, and commercial refrigerator-freezers: Under EPCA, this equipment includ es commercial refrigerators, commercial freezers, and commercial refrigerator -freezers that have a remote condensing unit, except for any remote condensing equi pment that would meet DOE’s definition of “ice-cream freezer” as set forth at 10 CFR 431.62, 71 FR 71369. They are typically used to store and display products for direct sale to the consumer, and are referred to as “refrigerated display cases,” “display cabin ets,” or “merchandisers.” The remote condensing unit has at least one compressor a nd a condenser coil, and most are connected to a remote condensing unit that consists of multiple compressors (a compressor “rack”) that serves multiple display cases.

2. Self-contained commercial refrigerators, commercial freezers, and commercial refrigerator-freezers without doors : Under EPCA, this equipment includes all types of commercial refrigerators, commercial freezers, and commercial refrigerator-freezers that have a self-contained conde nsing unit and have no doors, except for self-contained commercial equipment that meets DOE’s definiti on of “ice-cream freezer” as set forth at 10 CFR 431.62, 71 FR 71369. As with remote c ondensing equipment, this equipment is typically used to store and display products for direct sale to the consumer, and is commonly referred to as “r efrigerated display cases, ” “display cabinets,” or “merchandisers.” Self-contained equipment is defined as having an integral condensing unit ( i.e., the condensing unit is not remote from th e refrigerated cabinet). (See 42 U.S.C. 6311(9)(F), added by EPACT 2005, section 136(a )(3).) The 2006 American Society of Heating, Refrigerating, and Air-C onditioning Engineers (ASHRAE) Refrigeration Handbook (Chapter 47, p. 47.1) defines “reach-in” refrigerators or freezers as being upright and box shaped, and havi ng hinged or sliding doors. Given this definition, selfcontained reach-in commercial refrigerat ors, commercial freezers, and commercial refrigerator-freezers ( i.e., self-contained equipment with doors) are not covered in this rulemaking, which only covers self-c ontained equipment without doors.

3. Commercial ice-cream freezers: The EPCA provision that required this rulemaking identifies “ice-cream freezers” separately from “self-contained commercial refrigerators, freezers, and refrigerator-freezers without doors” and “remote condensing commercial refrigerators, freezers, and refrigerator-fr eezers.” (42 U.S.C. 6313(c)(4)(A), added by EPACT 2005, section 136(c)) The Act neither specifies nor indicates that “ice-cream freezers” are limited to equipment with a particular door configuration ( e.g., with or without doors) or type of condensing unit ( i.e., remote or self-contained). Thus, pursuant to EPCA’s definition of “commercial refrig erator, freezer, and refrigerator-freezer” (42 U.S.C. 6311(9)(A), added by EPACT 2005, section 136(a)(3)), DOE believes commercial ice-cream freezers include equipment with all door types ( i.e., solid doors, transparent doors, or no door s) and configurations ( e.g., vertical or horizontal), as well as equipment with either integral or remote condensing units ( i.e., self-contained or remote condensing).

On December 8, 2006, DOE published a final rule, in which it adopted test procedures for commercial refrigeration equipment. In this fi nal rule, DOE adopted the following definition for “ice-cream freezer:” “a commercial freezer that is designed to operate at or below -5°F [degrees Fahrenheit] (-21°C [degrees Celsius]) and that th e manufacturer designs, markets, or intends for

3-3the storing, displaying, or disp ensing of ice cream.” 10 CFR 431.62, 71 FR 71369. In addition, this final rule prescribed th e rating temperature at -15°F fo r ice-cream freezers. 10 CFR 431.64, 71 FR 71370.

3.2 MARKET ASSESSMENT

The following market assessment identifies th e manufacturer trade association, domestic manufacturers of commercial refri geration equipment, manufacturer market share, regulatory programs, and non-regulatory initiatives; defines e quipment classes; provides historical shipment data, shipment projections, and equipment lif etime estimates; and summarizes market performance data.

3.2.1 Trade Association

The Air-Conditioning and Refrigeration Institute (ARI) is the trade association of commercial refrigeration equipment manufactur ers. On January 12, 2005, ARI developed an agreement with manufacturers to establish th e commercial refrigerator manufacturers division (CRMD) within ARI, and develop and implem ent a certification program for commercial refrigerators, commercial freezers, a nd commercial refrigerator-freezers.

The CRMD was originally a separate trad e organization founded in 1933. It serves supermarkets, food stores, convenience stores, restaurants, hotels, motels, food processing establishments, and hospitals. The t echnical activities of CRMD include

• harmonization of international equipment standards;

• development of industry performance standards for commercial refrigeration equipment;

• updating of industry guidelines for retail store fixture installation, design, energy conservation, electronic case controls, and specifications for equipment installation;

• communicating with refrigerant supplie rs and government agencies about environmentally acceptable chlorofl uorocarbon (CFC) alternatives; and

• providing input to government agencies concerning regulatio ns affecting the industry.

3.2.2 Manufacturers and Market Share

Current ARI CRMD members are listed belo w; parent companies are shown in parentheses if applicable.

3-4• Barker Company • Hussmann (Ingersoll Rand) • Spartan Showcase

• Beverage-Air • Killion Industries • Structural Concepts Corp.

• Columbus Showcase Co. • Kysor/Warren (Enodis) • Tyler Refrigeration (Carrier, United Technologies Corp.)

• Continental • Master-Bilt Products • Zero Zone Refrigerator (Standex)

• Federal Industries (Standex) • McCall Refrigeration

• Hill Phoenix (Dover Corp.) • Southern Store Fixtures

Source: CRMD manufacturers listed as of November 2006, http://www.ari.org/sections/s ection_groups/CommercialRefrigerator/manufacturers.htm

.
Non-ARI member CRE manufact urers are listed below; pare nt companies are shown in parentheses if applicable.

• Amteko* • Howard/McCray • Silver King*

• Arctic Air • Kelvinator • True Manufacturing*

• Arctic Star* • McCray* • Turbo Air

• Arneg USA* • Refcon* • Vogel*

• Custom Deli* • Regan-Pinnacle

• Custom Fabricators* • Royal Store Fixtures (Parisi)* *Based on ARI comment submitted to the Framework Document (ARI, No. 7 Exhibit A at p. 1) b with the addition of Silver King. 2

Five major manufacturers hold the majority of the domestic market share of selfcontained and remote condensing commercial refrigeration equipment without doors; parent companies are listed in parentheses if applicable: 3

• Hill Phoenix (Dover Corporation)

• Hussmann Corporation (Ingersoll Rand)

• Kysor/Warren (Enodis)

• Tyler Refrigeration (Carrier, Un ited Technologies Corporation)

• Zero Zone

Only self-contained refrigeration equi pment without doors and remote condensing equipment are applicable under this rulemaking. True Manufacturing al so manufactures selfb A notation in the form “ARI, No. 7 Exhibit A at p. 1” identifies a written comment DO E has received and included in the docket of this rulemaking. This particular notation refers to a comment (1) by the Air-Conditioning and Refrigeration Institute (ARI), (2) in document number 7 Exhibit A in the docket of this rulemaking (maintained in the Resource Room of the Building Technologies Program), and (3) appearing on page 1 of document number 7 Exhibit A.

3-5contained commercial equipment and has a la rge share of shipment s of self-contained commercial equipment without doors and commercial ice-cream freezers.

According to Appliance Magazine , four companies represent approximately 85 percent of the U.S. refrigerated display case market, with approximately 185,000 units shipped in 2004. 4 However, Appliance Magazine provides no precise definition of a refrigerated display case and it is therefore unclear what specific types of equipment the data covers—equipment that is selfcontained versus remote condensing, and equi pment with doors versus without doors.

As of 2004, Hussmann Corporation, a divi sion of Ingersoll Rand, was the largest domestic manufacturer of refrigerated display cases, holding approximate ly 48 percent of the U.S. market. Other manufacturers make up th e remaining 52 percent of U.S. market share (Figure 3.2.1).

Other

Kysor/Warren 6%

Hill Phoenix 15%

Tyler Refrigeration 15%

Hussmann 48%

16%

Source: Appliance Magazine , “28 th Annual Portrait of the U.S. Appliance Industry,” September 2005.
Figure 3.2.1 Domestic Refrigerate d Display Case Market Shares

Manufacturers in the “Other” category are listed below; parent companies are listed in parenthesis if applicable.

3-6• Arneg USA

• Barker Company

• Columbus Showcase Co.

• Federal Industries (Standex)

• Howard/McCray • Killion Industries • True Manufacturing

• Master-Bilt Products • Turbo Air (Standex)

• Royal Store Fixture (Parisi) • Zero Zone

• Southern Store Fixtures

• Structural Concepts Corp.
Source: Appliance Magazine , “28 th Annual Portrait of the U.S. Appliance Industry,” September 2005.

Manufacturers of commercial ic e-cream freezers are listed be low; parent companies are listed in parenthese s if applicable.

• Arctic Air

• Beverage-Air*

• Columbus Showcase Co.*

• Continental Refrigerator*

• Delfield (Enodis)

• Hill Phoenix (Dover Corp.)* • Hussmann (Ingersoll • Structural Concepts Rand)* Corp.*

• Kelvinator • True Manufacturing

• Kysor/Warren (Enodis)* • Tyler Refrigeration (Carrier, United Technologies Corp.)*

• Master-Bilt Products • Zero Zone* (Standex)*

• McCall Refrigeration*

• Silver King

* Based on ARI comments submitted to the Framework Document (ARI, No. 7 Exhibit A at p. 1).

3.2.2.1 Small Businesses

DOE is considering the possibility that energy conservation standards for commercial refrigeration equipment would adversely aff ect small businesses. The Small Business Administration (SBA) defines small business manufacturing enterprises for commercial refrigeration equipment as those having 750 employees or fewer. 5 SBA lists small business size standards for industries as they are described in the North American Industry Classification System (NAICS). The size standard for an industr y is the largest that a for-profit concern can be in that industry and still qualif y as a small business for Federal Government programs. These size standards are generally expressed in terms of the average annual re ceipts or the average employment of a firm. For commercial refrigera tion equipment, the size standard is matched to NAICS code 333415, Air-Conditioning and Warm Air Heating Equipment and Commercial and Industrial Refrigeration Equipment Manufacturing, and is 750 employees.

DOE studied the potential impacts on th ese small businesses in detail during the manufacturer impact analysis, which was c onducted as a part of the notice of proposed rulemaking analysis. DOE identified nine sma ll business commercial refrigeration equipment manufacturers which are listed below; parent comp anies are listed in parentheses if applicable.

3-7• Barker Company • Southern Store Fixtures

• Columbus Showcase Co. • Structural Concepts Corp.

• Killion Industries • Turbo Air

• Royal Store Fixture (Parisi) • Zero Zone

• Regal-Pinnacle

3.2.3 Regulatory Programs

Both Canada and California have efficiency standards for commercial ice-cream freezers but not for remote condensing commercial equi pment and self-contained commercial equipment without doors. In the case of remote condensing equipment, the Canadian Standards Association (CSA) established efficiency standards as part of its overall test standards. Australia has several efficiency standards for all the e quipment covered in this rulemaking.

The following States have established appl iance efficiency re gulations: Arizona, California, Connecticut, Maryland, Massachuset ts, Minnesota, New Jersey, New York, Oregon, Rhode Island, Vermont, and Washington. Of these, California is the only State that explicitly regulates commercial ice cream freezers and remo te condensing equipment with transparent doors.

Minnesota and Vermont do not regulate commer cial refrigeration equipment at all. Arizona, Oregon, Rhode Island, and Washingt on regulate certain types of commercial refrigeration equipment. However, these St ates specifically exclude commercial ice-cream freezers, remote condensing commercial equipmen t, and self-contained commercial equipment without doors.

Connecticut, Maryland, Massachusetts, New Jersey, and New York regulate certain commercial refrigeration equipment, but do not mention commercial ice-cream freezers. Connecticut and Maryland do not mention remo te condensing commercial equipment or selfcontained commercial equipment without doors. New York and Maryland legislation does not include remote condensing commercial equipm ent and self-contained commercial equipment without doors. New Jersey does not mention remote condensing commercial equipment, but does include self-contained commercial equipmen t without doors. However, New Jersey does not have any standards in place for self-c ontained commercial equipment without doors.

3.2.3.1 California

California Energy Commission (CEC) Applianc e Efficiency Regulations (effective July 1, 2006) establish efficiency standards for commer cial ice-cream freezers, but not for the other types of equipment covered in this rule making. The maximum allowed daily energy consumption (kilowatt hours (kWh) per day) fo r commercial ice-cream freezers varies based on the door type ( i.e., solid or transparent) and volume (V). Table 3.2.1 shows the two different standard levels with two di fferent effective dates of Ja nuary 1, 2006 and January 1, 2007.

3-8Table 3.2.1 California Energy Commission E fficiency Regulations for Commercial IceCream Freezers

Equipment Type Type of Door Maximum Daily Energy Consumption [kWh] Effective January 1, 2006 Maximum Daily Energy Consumption [kWh] Effective January 1, 2007 Reach-in cabinets, pass-through

cabinets, and roll-in or rollthrough cabinets that are icecream freezers Solid 0.398 x V + 2.28 0.39 x V + 0.82

Transparent 0.940 x V + 5.10 0.88 x V + 0.33

V = Volume in cubic feet (ft 3 ) Source: Appliance Efficiency Re gulations, July 2006, CEC-400-2006-002-REV1, section 1605.3, Table A-7.
The CEC regulations also have a design requ irement for lighting in remote condensing commercial equipment with transparent doors, remote condensing commercial equipment without doors, and self-contained commercia l equipment without doors. This design requirement mandates that the internal illumina tion must be provided by T8 fluorescent lamps with electronic ballasts or a lighting system that has no fewer lumens per watt than a system using only T8 fluorescent lamps with electronic ballasts. 6 This requirement is valid for all equipment manufactured and/or sold in California.

The test methods used for determining co mpliance with the CEC regulations are the American National Standards Institute/Asso ciation of Home Appliance Manufacturers (ANSI/AHAM) HRF-1-1979, Household Refrigerators, Combination Refrigerator-Freezers, and Household Freezers , for volume measurements; ANSI/AS HRAE Standard 117-1992, Method of Testing Closed Refrigerators

, for energy consumption measurements of self-contained commercial refrigerators, commercial freezers and commercial refrigerator-freezers with doors; and ANSI/ASHRAE Standard 72-1998, Met hod of Testing Open Refrigerators , for energy consumption measurements of se lf-contained commercial refrigerat ors, commercial freezers, and commercial refrigerator-freezers without doors. The energy consumption tests are conducted with the following integrated av erage product temperatures (IAT): c

• Refrigerator compartment: 38 ° F ± 2 ° F (3.3 ° C ± 1.1oC)

• Freezer compartment: 0 ° F ± 2 ° F (-17.8 ° C ± 1.1oC)

• Wine chiller: 45 ° F ± 2 ° F (7.2 ° C ± 1.1oC)

• Ice-cream cabinet: -5 ° F ± 2 ° F (-20.6 ° C ± 1.1oC)

3.2.3.2 Canada

The Natural Resources Canada (NRCan) Office of Energy Efficiency has energyefficiency standards for self-contained commer cial “reach-in” refrigerators, freezers, and refrigerator-freezers with solid/opaque doors or tran sparent doors. Canada’s standards are based on California’s regulations. 7 Because NRCan considers commerc ial ice-cream freezers a type of self-contained commercial reach-in freezer, thes e regulations apply to commercial ice-cream freezers.

c Because the CEC standards for refrigerators and freezers are only for equipment with doors and a self-contained condensing unit, on ly the IAT for commercial ice-cream fre ezers is germane to this rulemaking.

3-9Canada’s approach differs from California ’s. Rather than specifying the type of equipment covered, the Canadian standards defi ne commercial refrigerators, commercial freezers, and commercial refrigerator-freezers by identifying only those units that are not covered by standards. Manufact urers of commercial refriger ators and commercial freezers without doors are requir ed to report the rated energy us e of the equipment, although the equipment does not have to meet any standard at this time. The test method for determining compliance is ANSI/ASHRAE Standard 117-1992, Method of Testing Cl osed Refrigerators

, with the following speci fications for the IAT:

• Refrigerator compartment: 38 ° F ± 2 ° F (3.3oC ± 1.1oC)

• Freezer compartment: 0 ° F ± 2 ° F (-17.8oC ± 1.1oC)

• Wine chiller: 45 ° F ± 2 ° F (7.2oC ± 1.1oC)

• Ice-cream cabinet: -5 ° F ± 2 ° F (-20.6oC ± 1.1oC)

The two tiers of performance standards for self-contained co mmercial freezers (under which ice-cream freezers are classified) t ook effect April 1, 2007 and January 1, 2008, respectively. As Table 3.2.2 shows, maximum da ily energy consumption depends on door type and volume.

Table 3.2.2 Canadian Efficiency Regu lations for Commercial Ice-Cream Freezers

Equipment Type Type of Door Volume (V) (liters) Maximum Daily Energy Consumption (E) Effective April 1, 2007 (kWh) Maximum Daily Energy Consumption (E) Effective January 1, 2008 (kWh)

Self-contained Opaque < 340 E = 7.62 E = 7.07

commercial

freezers Opaque ≥ 340 E = 0.0141 x V + 2.83 E = 0.0141 x V + 2.28 Transparent

- E = 0.0332 x V + 5.10

- Source: Amendment 9 to the Energy Efficiency Regulations published in Canada Gazette Part II, November 15, 2006.

3.2.3.3 Canadian Standards Association

CSA is an independent standards-setting ag ency that establishes test procedures and efficiency standards that the Canadian governme nt typically adopts. The Canadian standard CAN/CSA C657-04, Energy Performance Standard for Refrigerated Display Cabinets (Merchandisers), applies to remote condensing commerc ial equipment with and without doors, and self-contained commercial equipment with and without doors, except as covered by CSA C827-98 (R2003). Commercial refrigerators and commercial freezers with doors (including commercial ice-cream freezers) are covered in a separate test proce dure and standard, CSA C827-98 (R2003), Energy Performance Standard fo r Food Service Refrigerators and Freezers. This standard is a revision of the original CSA standard published in 1995. Among the changes are redefined equipment categories and new mi nimum energy performance standards (MEPS). d

The CSA C657-04 standard divides commercia l refrigeration equipment into seven classes and several sub-classes. Table 3.2.3 su mmarizes classes and MEPS levels from CSA

d Changes to the standard make it extremely difficult to co mpare levels between the 1995 and updated standards.

3-10C657-04. For equipment with a remote condensi ng unit, the MEPS use a pre-determined remote condensing unit efficiency to calculate daily energy use.

Table 3.2.3 Canadian Standards Associatio n Equipment Classes and Efficiency Ratings 8

Class IAT* (°F) Temperature Open/Closed Deck Number of Air Curtains Angle of Air Curtain

from Vertical MEPS 2004 (kWh/ft per day)
1 41.0 Medium Open Single/Multi 1 0-30° 4.0

2 41.0 Medium Open Single/Multi 1 30-60° 2.9

3 41.0 Medium Open Single/Multi 1 60-90° 1.6

4 0.0 Low Open Multi 2 or 3 0-30° 9.4

5 0.0 Low Open Single 1 60-90° 4.6

6a 41.0 Low/Medium Closed Multi Single Vent with Glass 2.3

6b 0.0 Same as 6a 6.1

7a 41.0 Medium Closed Single/Multi Glass N/A 2.6

7b 41.0 Same as 7a, except with only a gravity coil (no fan coil) 1.0

* IAT = the average temperature of all test packages recorded during testing. Source: CSA C657-04, Energy Perfor mance Standard for Refrigerated Display Cabinets (Merchandisers).

3.2.3.4 Australia

Australia has required efficiency standards for commercial refrigeration equipment since October 1, 2004. 9 The standards apply to both remote condensing and self-contained commercial equipment primarily used to store chilled and frozen food. The minimum energy performance standards are esta blished in Australian Standa rd (AS) 1731.14-2003 as total energy consumption per total display ar ea (TEC/TDA) in kWh/day/meter 2 (m 2 ) for various equipment types. The Australian standards categorize equipment by the following criteria:

• Remote or self-contained condensing unit

• Lit shelves or unlit shelves

• Number of shelves

• Solid door or glass door

• Fan coil or gravity coil

• High, medium, or low temperature

The standards also specify minimum ener gy performance by M-package temperatures (temperature of a load package) for self-cont ained cabinets. AS 1731- 2003 specifies the test procedures used to measure energy consumption.

3.2.4 Non-Regulatory Initiatives

DOE reviewed several voluntary programs promoting energy-efficient commercial refrigeration equipment in the United States, including the ENERGY STAR program for soliddoor commercial refrigerators and commercial freezers, the Consortium for Energy Efficiency (CEE)’s initiative for commercial refrigeration equipment, and the Federal Energy Management

3-11Program (FEMP)’s procurement program for en ergy-efficient commercial refrigerators and commercial freezers. DOE also reviewed variou s rebate programs offered by local utilities.

3.2.4.1 ENERGY STAR

The ENERGY STAR labeling program has specificati ons for self-contained solid-door commercial refrigerators and commercial fr eezers, including commercial ice-cream freezers. 10 This program does not apply to remote condensing commercial equipm ent or self-contained commercial equipment without doors. ENERGY STAR criteria for commercial ice-cream freezers specify the maximum energy consumption as follows:

• Maximum Energy Consumption ≤ 0.39V + 0.82 kWh/day, where V is the internal volume in ft 3

ENERGY STAR uses the ANSI/ASHRAE Standard 117-1992, Method of Testing Closed Refrigerators . Energy consumption tests are conducted with an IAT of -5 ° F ± 2 ° F for commercial ice-cream freezers. The ENERGY STAR criteria do not mention a test method for measuring internal volume.

3.2.4.2 Consortium for Energy Efficiency

The CEE has a Commercial Kitchen Initiati ve for solid door and glass-door reach-in commercial refrigerators and commercial freezers. 11 This program is based on ENERGY STAR levels and only applies to self-contained commer cial equipment with doors , and is therefore not relevant to this rulemaking. The program specifi es standard levels in terms of maximum daily energy use in kWh/day for various door types.

3.2.4.3 Federal Energy Management Program

FEMP has established purchasing specifica tions for energy-efficient equipment, including commercial ice-cream freezers. 12 Federal purchasers are now required by EPACT 2005 to purchase equipment that is ENERGY STAR qualified or FEMP designated. This equipment is in the upper 25 percent of energy effici ency in its class. The coverage of the FEMP program is identical to the ENERGY STAR program, and is theref ore not relevant to this rulemaking.

3.2.4.4 Rebate Programs

Several rebate programs for commercial refrigeration equipment are offered by local utilities, including Efficiency Vermont, the En ergy Smart Grocer Program, the Nevada Sure Bet Program, Otter Tail Power Company, Roseville Electric, Pacific Gas and Electric (PG&E), Southern California Edison (SCE), and San Diego Gas and Electric (SDG&E).

Efficiency Vermont, an organization offering te chnical assistance and financial incentives to encourage energy efficiency in Vermont, offers rebates for the installation of strip-curtain covers for commercial refrigera tion equipment without doors. Th e cash incentive is $6 per foot of display case covered by the curtain. 13

3-12The Energy Smart Grocer Program is funded by California utility ratepayers under the auspices of the California Public Utilities Commi ssion. Eligible participants include grocery and convenience stores, food processo rs, and refrigerated warehouses operating in PG&E, SCE, or SDG&E electric service territori es. The program offers reba tes for using night covers on commercial refrigeration equipment without doors , upgrades to more efficient case lighting, and replacing older equipment without doors with new high-efficiency equipment or new or refurbished reach-ins. 14

Sierra Pacific Power and Nevada Power offe r incentives promoting the installation of energy-efficient commercial re frigeration equipment through the Nevada Sure Bet Program. These rebates are available to the utilities’ commercial, industrial, and institutional customers. In addition to other refrigeration reba tes, the program offers $4 per line ar foot for the installation of night covers on commercial refrig eration equipment without doors. 15

Otter Tail Power Company offers rebates to Minnesota commercial customers under the Conservation Improvement Program. Under this program, customers are eligible to receive between $10 and $20 per linear foot of, or upgrade to, high-effici ency commercial refrigeration equipment. 16

Roseville Electric has a Custom Rebate prog ram that includes commercial refrigeration equipment. The customer is paid for energy-e fficiency projects that reduce peak kW; however, no rebates are paid on kWh savings. In this type of rebate, customers or their engineers present the project scope, including what equipment is currently installe d, what is proposed, and how the proposed equipment goes beyond what would be cons idered standard for today’s replacement. Engineering calculations are provided to show kW and kWh savings. Roseville Electric evaluates the customer’s proposal and advises if the project is e ligible for rebates and at what level. Typically, rebates are paid at $400/kW, but may be le ss if significant third-party engineering work is required to verify the peak load reductions. 17

PG&E, SCE, and SDG&E offer rebates to busin ess customers for retrofit refrigeration projects through the Express Efficiency Refrig eration Program. The program provides $9 per linear foot for night covers installed on existi ng commercial refrigera tion equipment without doors to all business customers. The program also gives incentives for th e installation of glass doors on existing equipment without doors. This re bate is applicable to both self-contained commercial equipment and remote condensing co mmercial equipment. The rebate provides $200 per door installed on an otherwise open low-temp erature display case and $150 per door installed on a medium-temperature display case. 18, 19, 20

3.2.5 Equipment Classes

Commercial refrigeration equipment can be divided into various equipment classes categorized by physical characteri stics that affect equipment efficiency. Most of these characteristics affect the merchandise that the equipment can be used to display, and how the customer can access that merchandise. Key physical characteristics are the operating temperature, the presence or absence of doors ( i.e., closed cases or open cases), the type of doors used ( i.e., transparent or solid), the angl e of the door or air curtain ( i.e., horizontal, semivertical, or vertical), and the type of condensing unit ( i.e., remote or self-contained). The following list

3-13shows the key physical characteristics of co mmercial refrigeration equipment that DOE identified in its Framework Document:

1. Operating Temperature

• Medium temperature ( 38°F, refrigerators)

• Low temperature (0°F, freezers)

• Ice-cream temperature (-15°F, ice-cream freezers) 2. Door Type

• Equipment with transparent doors

• Equipment with solid doors

• Equipment without doors 3. Orientation (air-curta in or door angle)

• Horizontal

• Semivertical

• Vertical 4. Type of Condensing Unit

• Remote condensing

• Self-contained

ARI proposed another organiza tion of equipment classes fo r commercial refrigeration equipment during the Framework comment period. ARI organized classes by equipment family (broad groups of covered equipment that have similar geometric characteristics), condensing unit type, and operating temperature. The equipment families ARI identified are:

• vertical without doors (air-c urtain angle of 0 to 10 ° from the vertical);

• semivertical without doors (air-curtain a ngle of 10 to 80° from the vertical);

• horizontal without doors (air -curtain angle of 80 to 90° from the vertical);

• vertical with doors;

• horizontal with doors; and

• service over-counter.

One equipment family ARI proposed, “servi ce over-counter,” was not included in the DOE organization of equipment classes. This equipment is unique because it is designed to display products, but access to th e products is from the back of the cabinet. Such equipment is designed to display products that typically only sales personnel ha ve access to. This equipment family is necessary, as this type of equipment pr ovides a different utility to the end-user than any of the other proposed classes.

ARI’s organization also differentiates equipm ent by operating temperature. Because not all models can be tested at one of the three temperatures DOE proposed (medium, low, and icecream), ARI proposed a third temperature categ ory: an “application” temperature.

DOE examined the shipment data ARI provi ded (section 3.2.6) to determine how much equipment operates at an application temperatur e and how much operates at one of the three temperatures DOE proposed. Excluding equipm ent for which EPACT 2005 amended EPCA to set standards (self-contained commercial re frigerators and commercial freezers with doors),

3-14170,949 units of remote condensing and self-con tained equipment were shipped in 2005. (Shipments of commercial refrigerator-freezers were not reported, but are considered very small.) Of the total shipments, only 1.7 percen t were self-contained and remote condensing equipment that operate at 45 ° F, 20 ° F, 10 ° F, or -30 ° F (application temperatures), and 98.3 percent were self-contained and remote condensing equipment that operate at 38 ° F, 0 ° F, or ­ 15 ° F. By far, the application temperature with the largest number of units shipped is the 45 ° F category (typically wine chillers), and these we re predominately remote condensing equipment. In all, 1,834 units of remote condensing wine ch illers were shipped in 2005, compared to 85,001 units of remote condensing refrigerators that operate at 38 ° F.

DOE’s test procedure for commercial refriger ation equipment (Chapt er 2) requires that all equipment, including equipment designed to opera te at application temper atures, be tested at one of the three rati ng temperatures: 38 ° F for refrigerators, 0 ° F for freezers, and -15 ° F for icecream freezers. Given the relatively low shipme nt volumes of equipment that operates at application temperatures, that some of this equipm ent already can operate and be tested at one of the standard rating temperatures, and that ma nufacturers might be able to redesign other equipment in relatively minor ways to have th ese capabilities, DOE believes this requirement will not place an unreasonable burden on manufactu rers. If necessary, manufacturers could seek waivers from the DOE test procedure, pursuan t to 10 CFR 431.401. For these reasons, DOE will not develop separate standards for equipment that operates at appl ication temperatures.

DOE is organizing its equipment classes in a manner similar to ARI’s, and used the six ARI equipment families as a starting point to devel op a list of equipment classes. The “vertical with doors” equipment class and the “horizontal w ith doors” equipment class were split into two each based on having either transparent or solid doors. Table 3.2.4 shows the eight commercial refrigeration equipment families DOE proposed.

3-15Table 3.2.4 Commercial Refrigeration Equipment Families
Equipment Family Designation Description

Vertical Open VOP Equipment without doors and an air-curtain angle ≥ 0° and < 10°

Semivertical Open SVO Equipment without doors and an air-curtain angle ≥ 10° and < 80°
Horizontal Open HZO Equipment without doors and an air-curtain angle ≥ 80°

Vertical Closed Transparent VCT Equipment with hinged or sliding transparent doors and a door angle < 45°

Vertical Closed Solid VCS Equipment with hinged or sliding transparent doors and a door angle ≥ 45°

Horizontal Closed Transparent HCT Equipment with hinged or sliding solid (opaque) doors and a door angle < 45°

Horizontal Closed Solid HCS Equipment with hinged or sliding solid (opaque) doors and a door angle ≥ 45°

Service Over Counter SOC Equipment with sliding or hinged doors intended for use by sales personnel and fixed or hinged glass for displaying merchandise

Within each of these eight equipment familie s is equipment that can have one of two condensing unit types and one of three operating temperatures. The condensing unit type has a significant impact on utility and energy use, and can be either remote condensing (RC) or selfcontained (SC). Remote condensing equipment is typically more effici ent than self-contained because of the use of large, multiplex compresso r rack systems that feed multiple pieces of equipment. Remote condensing equipment canno t be easily relocated, due to the refrigerant piping required, whereas self-contained equipment is more mobile, requiri ng only an electrical outlet for operation.

The operating temperature of the equipment al so has a significant impact on utility and energy use, and can be medium (M), low (L) or ice-cream (I), representing a rating temperature (or IAT) of 38 ° F, 0 ° F, or -15 ° F, respectively (± 2 ° F). Because different types of merchandise require different temperatures ( e.g., chilled and frozen), operating temperature was a necessary distinction. The larger temperature differences and thermodynamic behavior of refrigerants means that equipment with lower operating temper atures runs less efficiently than equipment with higher operating temperatures.

For open cases, “vertical” represents an air-curtain angle of < 10 ° from the vertical, “semivertical” represents an air-curtain angle of ≥ 10 ° and < 80 ° from the vertical, and “horizontal” represents an air-curtain angle of ≥ 80 ° from the vertical. DOE developed a definition for air-curtain angle: (1) For equipment without doo rs and without a discharge air grille or discharge air honeycomb, the angle be tween a vertical line extended down from the highest point on the manufacturer’s recommende d load limit line and the load limit line itself, when the equipment is viewed in cross- section; and (2) For all other equipment without doors, the angle formed between a vertical line and the st raight line drawn by c onnecting the point at the inside edge of the discharge air opening with the point at the inside edge of the return air opening, when the equipment is viewed in cross-section

3-16Using all combinations of equipment fam ilies, operating mode and temperature, 48 equipment classes are possible, as illustrated in Table 3.2.5. Ho wever, self-contained equipment with doors that operate at a medium temperature, low temperature, or both , already had standards established in EPACT 2005. Theref ore, these ten equipment classe s were not included in this rulemaking and are indicated by asterisks in Table 3.2.5.

DOE also developed a lettering system to simp lify discussion of equipment classes. The lettering designation for a partic ular equipment class consists of the abbreviations for the equipment family, operating mode, and temperatur e, separated by periods. Table 3.2.5 shows a complete list of equipment classes with lette ring designations organize d by family, operating mode, and temperature.

3-17Table 3.2.5 Commercial Refrigeration Equipment Classes

Equipment Family Equipment Family Designation Equipment Family Image Operating Mode Designation Temperature Designation Equipment Class Designation

Vertical Open VOP RC M (38°F) VOP.RC.M L (0°F) VOP.RC.L I (-15°F) VOP.RC.I

SC M (38°F) VOP.SC.M L (0°F) VOP.SC.L I (-15°F) VOP.SC.I

Semivertical Open SVO RC M (38°F) SVO.RC.M L (0°F) SVO.RC.L I (-15°F) SVO.RC.I

SC M (38°F) SVO.SC.M L (0°F) SVO.SC.L I (-15°F) SVO.SC.I

Horizontal Open HZO RC M (38°F) HZO.RC.M L (0°F) HZO.RC.L I (-15°F) HZO.RC.I

SC M (38°F) HZO.SC.M L (0°F) HZO.SC.L I (-15°F) HZO.SC.I

Vertical Closed

Transparent VCT RC M (38°F) VCT.RC.M L (0°F) VCT.RC.L I (-15°F) VCT.RC.I

SC M (38°F) VCT.SC.M* L (0°F) VCT.SC.L* I (-15°F) VCT.SC.I

Vertical Closed Solid VCS RC M (38°F) VCS.RC.M L (0°F) VCS.RC.L I (-15°F) VCS.RC.I

SC M (38°F) VCS.SC.M* L (0°F) VCS.SC.L* I (-15°F) VCS.SC.I

Horizontal Closed Transparent HCT RC M (38°F) HCT.RC.M L (0°F) HCT.RC.L I (-15°F) HCT.RC.I

SC M (38°F) HCT.SC.M* L (0°F) HCT.SC.L* I (-15°F) HCT.SC.I

Horizontal Closed Solid HCS RC M (38°F) HCS.RC.M L (0°F) HCS.RC.L I (-15°F) HCS.RC.I

SC M (38°F) HCS.SC.M* L (0°F) HCS.SC.L* I (-15°F) HCS.SC.I

Service Over Counter SOC RC M (38°F) SOC.RC.M L (0°F) SOC.RC.L I (-15°F) SOC.RC.I

SC M (38°F) SOC.SC.M* L (0°F) SOC.SC.L* I (-15°F) SOC.SC.I

* These equipment classes have standards established by EP ACT 2005 and are therefore not covered under this rulemaking.

3-183.2.6 Shipments

As part of its comments on the Framework Do cument (ARI, No. 7 Exhibit B at p. 1), ARI submitted annual shipment data by equipment class for its member companies. DOE understands that these data do not include the entire industry, si nce ARI does not represent all major manufacturers. e However, because these data cover the vast majority of the remote condensing equipment sold, and because no other de tailed data were availa ble, the ARI shipment data became the basis of DOE’s analysis.

Table 3.2.6 shows 2005 annual shipments for each category of commercial refrigeration equipment by equipment class. The ARI data incl uded shipments for equipment that operates at an “application” temperature ( e.g., wine chillers that operate at 45°F and freezers that operate at ­ 30 ° F). However, DOE only considered shipment s of equipment at the three temperatures considered in this rulemaking (38°F, 0°F, a nd -15°F; see section 3.2.5). The shipments of equipment that operate at one of these three temperatures constitute approximately 98 percent of the shipments ARI reported.

e Most notably, True Manufacturing, which DOE understands has a large market share of self-contained equipment with doors and ice-cream freezers.

3-19Table 3.2.6 Air-Conditioning and Refrigeration Institute Shipments of Commercial Refrigerators and Freezers by Equipment Class

Equipment

Family Equipment Family Designation Operating Mode Designation Temperature Designation Equipment Class Designation ARI Shipments**

Vertical Open VOP RC M (38°F) VOP.RC.M 38,743 L (0°F) VOP.RC.L 0 I (-15°F) VOP.RC.I 0

SC M (38°F) VOP.SC.M 6,512 L (0°F) VOP.SC.L 0 I (-15°F) VOP.SC.I 0

Semivertical Open SVO RC M (38°F) SVO.RC.M 29,552 L (0°F) SVO.RC.L 0 I (-15°F) SVO.RC.I 0

SC M (38°F) SVO.SC.M 9,750 L (0°F) SVO.SC.L 0 I (-15°F) SVO.SC.I 0

Horizontal Open HZO RC M (38°F) HZO.RC.M 4,541 L (0°F) HZO.RC.L 14,278 I (-15°F) HZO.RC.I 0

SC M (38°F) HZO.SC.M 838 L (0°F) HZO.SC.L 1,738 I (-15°F) HZO.SC.I 0

Vertical Closed

Transparent VCT RC M (38°F) VCT.RC.M 2,767 L (0°F) VCT.RC.L 38,483 I (-15°F) VCT.RC.I 0

SC M (38°F) VCT.SC.M* 43,374* L (0°F) VCT.SC.L* 2,472* I (-15°F) VCT.SC.I 1,898

Vertical Closed Solid VCS RC M (38°F) VCS.RC.M 49 L (0°F) VCS.RC.L 2 I (-15°F) VCS.RC.I 43

SC M (38°F) VCS.SC.M* 4* L (0°F) VCS.SC.L* 4,202* I (-15°F) VCS.SC.I 470

Horizontal Closed Transparent HCT RC M (38°F) HCT.RC.M 0 L (0°F) HCT.RC.L 15 I (-15°F) HCT.RC.I 0

SC M (38°F) HCT.SC.M* 724* L (0°F) HCT.SC.L* 0* I (-15°F) HCT.SC.I 9,056

Horizontal Closed Solid HCS RC M (38°F) HCS.RC.M 37 L (0°F) HCS.RC.L 0 I (-15°F) HCS.RC.I 0

SC M (38°F) HCS.SC.M* 39,761* L (0°F) HCS.SC.L* 4,109* I (-15°F) HCS.SC.I 0

Service Over

Counter SOC RC M (38°F) SOC.RC.M 9,312 L (0°F) SOC.RC.L 9 I (-15°F) SOC.RC.I 0

SC M (38°F) SOC.SC.M* 1,108* L (0°F) SOC.SC.L* 0* I (-15°F) SOC.SC.I 0

* These equipment classes have standards established by EP ACT 2005 and are therefore not covered under this rulemaking. ** Source: ARI, No. 7 Exhibit B at p. 1.

3-203.2.6.1 Appliance Magazine Data

Appliance Magazine publishes historical and forecasted shipments of refrigerated display cases, shown in Table 3.2.7 and Table 3.2.8. f For this rulemaking, only the self-contained equipment without doors and all remote condensing equipment are applicable.

Table 3.2.7 Historical Shipments of Refrigerated Display Cases

Year Unit Shipments

1996 316,500

1997 324,000

1998 302,625

1999 340,453

2000 347,262

2001 175,000

2002 183,300

2003 191,549

2004 185,000

2005 170,000

Source: Appliance Magazine , “53 rd Annual Statistical Review,” May 2006.

Table 3.2.8 Statistical Forecasts of Refrigerated Display-Case Shipments

Year Unit Shipments

2007 181,000

2008 185,000

Source: Appliance Magazine , “54 th Appliance Industry Forecasts,” January 2006.
It is unclear what is respons ible for the sharp decline in unit shipments between 2000 and 2001 reported by A ppliance Magazine . A similar decline is reporte d in other market literature, followed by an increase in shipments predicted by 2008. 21 DOE believes that some fraction of the observed decline in shipments is the result of a general slowdown in the U.S. economy in the second and third quarters of 2001. Financial re ports by CRE manufacturers discuss depressed investment and uncertainty in the retail food indus try between 2000 and 2005 as contributing factors to low sales of commerci al refrigeration equipment. Th ere may be other explanations, including possible change s in what equipment Appliance Magazine included in “refrigerated display cases.”

3.2.6.2 Current Industrial Reports

The U.S. Census Bureau’s Economic Census of Manufacturing Indus try Series and its Current Industrial Reports (CIRs) publish statis tics on the quantity and value of shipments for those companies with shipments over $100,000 in value. 22,23 There are eight categories for

f As mentioned earlier, Appliance Magazine describes the da ta as representing refrigerat ed display cases but does not provide a precise definition of the equipment. It is un clear what types of equipment this term covers–whether it is equipment that is self-contained or remote conde nsing, or equipment with doors or without doors.

3-21display cabinets and display cases , including reach-ins. These are sub-divided into reach-in, closed display, and open display. As the tables be low show, the data reported in the CIRs are not complete ( i.e., shipments data are not provided for most sub-categories). g The data also indicate some very large changes in the va lue of shipments in 1992, 1997, and 2002.

Table 3.2.9 shows shipment data for open refri gerated display cases, which include both self-contained units without doors and remote conde nsing units without doors. It is not possible to determine from Table 3.2.9 which shipments ar e for self-contained units and which are for remote condensing units since the census data re ports these together. Only the self-contained open refrigerated display cases and remote c ondensing open refrigerat ed display cases are applicable to this rulemaking.

Table 3.2.9 Shipments of Open Refrigerate d Display Cases (Remote Condensing and SelfContained)

Type Open or Closed Temperature Survey Year Number of Companies with Sales Over

$100,000 Shipment Quantity (1,000s) Shipment Value ($1,000)

Display Case

One Level Open Normal 2002 6

- 89,622
1997 13

- 140,259 1992 12

- 142,268
Display Case Multi Level Open Normal 2002 9

- 341,472
1997 11 58.6 258,310 1992 9

- 151,760

Display Case Open Frozen Food 2002 6

- 11,538
1997 7 20.4 90,213 1992 8

-­ 61,776 Source: U.S. Census, Current Industrial Reports, http://www.cens us.gov/cir/www/index.html ; U.S. Census, Economic Census, Manuf acturing Industry Series 1997, EC97M-3334D, http:// www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing Industry Series 2002, EC02-31I-333415 (R V), http://www.census.gov/econ/census02.
Table 3.2.10 shows shipment data for closed refrigerated display cases, which include both self-contained units with doors and remote conde nsing units with doors. It is not possible to determine from Table 3.2.10 which shipments are fo r remote condensing units. Only the remote condensing closed refriger ated display cases are c overed in this rulemaking.

g Shipments are not typically published for equipment with low shipments or shipments from only a small number of manufacturers in order to protect business sensitive information.

3-22Table 3.2.10 Shipments of Closed Refrigera ted Display Cases (Remote Condensing and Self-Contained)

Type Open or Closed Temperature Survey Year Number of Companies with Sales Over

$100,000 Shipment Quantity (1,000s) Shipment Value ($1,000)

Display Case Closed Normal 2002 11

- 50,601
1997 15

- 91,892 1992 14

- 43,576

Cabinet Closed Frozen Food 2002 8

- 20,618
1997 9

- 112,873 1992 6 38,171
Other Display

Cases Not stated Low Temp. 2002 7

- 58,549
1997 6

- 43,150 1992 9 9.6 39,629 Source: U.S. Census, Current Industrial Reports, http://www.cens us.gov/cir/www/index.html ; U.S. Census, Economic Census, Manuf acturing Industry Series 1997, EC97M-3334D, http:// www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing Industry Series 2002, EC02-31I-333415 (R V), http://www.census.gov/econ/census02.

For the data in Table 3.2.9 and Table 3.2.10, the following two commercial refrigeration equipment sub-categories are not included:

• Commercial reach-in refrigerators and reach-in vertical display cabinets for normal temperature applications (not intended fo r frozen foods, etc.), including selfcontained and remote units.

• Commercial reach-in refrigerators and reach-i n type vertical display cabinets for lowtemperature applications, includi ng self-contained and remote units.

Table 3.2.11 shows shipment data for commerci al reach-in (vertical ) cabinets (including self-contained units and remote condensing units). These cabinet s can have either solid or glazed doors. It is not possible to determine from Table 3.2.11 which shipments are for remote condensing units and which shipments are for self -contained units. Only the remote condensing reach-in cabinets are covered in this rulemaking.

3-23Table 3.2.11 Shipments of Commercial Reach-In Cabinets (Remote Condensing and SelfContained)

Type Open or Closed Temperature Survey Year Number of Companies with Sales Over

$100,000 Shipment Quantity (1,000s) Shipment Value ($1,000)
Display Cabinets -

Not for Frozen Foods Not Specified Normal 2002 21 381.7 465,553

1997 29

- 439,081

1992 31 165.8 224,018

Display Cabinet Not Specified Low Temperature 2002 16

- 259,105
1997 24

- 307,605 1992 24 59.5 219,544 Source: U.S. Census, Current Industrial Reports, http://www.cens us.gov/cir/www/index.html ; U.S. Census, Economic Census, Manuf acturing Industry Series 1997, EC97M-3334D, http:// www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing Industry Series 2002, EC02-31I-333415 (R V), http://www.census.gov/econ/census02.
In summary, although the U.S. Census Bureau Data contain some limited shipments data that would be useful for conducting technical anal yses, not enough detail is available to provide specific assessments for shipments within each of the three primary categories covered in this rulemaking.

3.2.7 Equipment Lifetimes

DOE reviewed available literature and consulted with experts on commercial refrigeration equipment to estab lish typical equipment lifetimes. The literature and individuals consulted estimated a wide range of typical equipment lifetimes, shown in Table 3.2.12.

Individuals with previous e xperience in the manufacture or distribution of commercial refrigeration equipment suggested a typical case life of 5 to 15 years. Experts in the field suggested that while the equipment is typically robust in design, much of the equipment is replaced for cosmetic reasons during store re modeling (typically ever y 10 years or so). Consultation with one distribu tor suggested that U.S. tax de preciation schedules, which allow depreciation over a 5-year period for retail fi xtures, including commerc ial refrigerators and commercial freezers, 24 are one driver for regular replacem ent of commercial refrigeration equipment in the United States.

Some literature suggested lifetimes of up to 20 years or more for commercial refrigeration equipment. Many of the studies cite d here related to examination of environmental impacts of refrigerant emissions and therefore may not always clearly distinguish between the lifetime of the case and the li fetime of the compressor racks. 25 However, consultation with experts in the field suggested th at smaller, independently owned grocery stores were more likely to keep equipment longer th an larger chain stores.

Several industry experts sugge sted there is a significant used/refurbished equipment market. However, DOE did not determine the size of the used market relative to the new market. Those consulted generally agreed that the sa lvage value of used equipment was very low compared to the initial purchase price. This is due to both cosmetic concerns and the custom

3-24nature of much of the equipment. The difficulty in collecting used equipment of the same “look” for planned display case line-ups was cited as another reason for the low price of used equipment. A survey in the Pacific Northwest re ported that for small, in dependent grocery stores (<20,000 square feet) and independe ntly owned convenience stores, the fraction of owners who would consider purchase of refurbished equipment was 25 and 16 percent, respectively. For larger regional chains, this fr action was approximately 11 percent. None of the large grocery chains surveyed had plans to purchase refurbished equipment.

Table 3.2.12 Estimates for Commercial Refrigeration Equipment Lifetimes Life Reference 15 years “New York Energy Smart Pr ogram Cost-Effectiveness Assessment” December 2004, NYSERDA 26 5-7 years (large chains) Verisae 27

15 years (Smaller chains and independent grocers. May go up to 20 years) Verisae 28

7-15 years Mark Ellis & Associates, 29 New Zealand Minimum Energy Performance Standards for Commercial Refrigeration Cabinets 15 years Foster-Miller (2001) 30 15-20 years EPA (2001) 31 15 years Arthur D. Little (ADL) (2002) 32 9-10 years (9 years with doors, 10 years without doors) CEC 2004 33

5-15 years (typically 10 years) Hansen 2006 34 10 years PG&E 2004 3 7-10 years (remote condensing) 8-12 years (self-contained) Intergovernmental Panel on Climate Change 2001 35

7 years Fisher 1991 36

3.2.8 Market Performance Data

DOE conducted a survey of existing remote condensing refrigerated equipment from major manufacturers and compiled a performance da tabase. The primary source of information for the database was equipment data sheets th at were publicly availa ble on manufacturers’ websites. From these data sheets, equipment information such as total refrigeration load, evaporator temperature, light ing power draw, defrost power draw, and motor power draw allowed determination of calculated daily ener gy consumption (CDEC) according to the test procedure in ARI Standard 1200-2006, Performan ce Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets

. Figure 3.2.2 through Figure 3.2.5 s how CDEC values as a function of TDA for select remote condensi ng equipment classes. Figure 3.2.6 shows the relationship between air-curtai n angle (measured from the vertical) and CDEC/TDA for the VOP.RC.M, SVO.RC.M, and HZ O.RC.M equipment classes.

3-25Figure 3.2.2 Market Performance Data for the VOP.RC.M Equipment Class

Figure 3.2.3 Market Performance Data for the SVO.RC.M Equipment Class

3-26Figure 3.2.4 Market Performance Data for the HZO.RC.M Equipment Class

Figure 3.2.5 Market Performance Data for the VCT.RC.L Equipment Class

3-27Figure 3.2.6 Market Performance Data for the VOP.RC.M, SVO.RC.M, and HZO.RC.M Equipment Classes: Comp arison of Air-Curtain Angles

3.3 TECHNOLOGY ASSESSMENT

The purpose of the technology assessment is to develop a preliminar y list of technologies that could potentially be used to improve the e fficiency of commercial re frigeration equipment. The following assessment provides descriptions of technologies and designs that apply to all equipment classes; designs that apply to equipment without d oors only; and technologies and designs that apply to se lf-contained equipment only.

3.3.1 Technologies and Designs Relevant to All Equipment Classes

The following technologies and designs are rele vant to all equipment classes: higher efficiency lighting, higher efficiency ballasts, remote ballast locati on, higher efficiency expansion valves, higher efficien cy evaporator fan motors, eva porator fan motor controllers, higher efficiency evaporator fan blades, incr eased evaporator surface area, low-pressure differential evaporators, anti-sw eat heater controllers, insula tion increases or improvements, defrost mechanism, and defrost cycle control.

3.3.1.1 Higher Efficiency Lighting

Commercial refrigeration equipment often incl udes lighting to illuminate the contents. Some commercial refrigeration equipment also includes an illuminated sign on the unit’s exterior. Higher efficiency lighting leads to en ergy savings in two ways: less energy is used directly for lighting, and less heat energy is dissi pated into the refrigerated case by the lamp.

3-28Efficiency in lighting is commonly measured as efficacy (lumens/watt), or the quantity of light output (lumens) per electrical energy input (watts, W).

Recently, the commercial refrigeration indus try has been moving toward using T8 fluorescent lighting in all cases. T8 lighting is substantially more effica cious than T12 lighting and is predominantly used with electronic balla sts, which are more efficient than magnetic ballasts commonly used in T12 lighting. The indust ry is also increasing ly interested in T5 lighting, although T5 lighting systems are not sign ificantly more efficacious than T8 systems.

An even more recent trend is the use of light emitting diode (LED) technology. Although LEDs are less efficacious than fluorescent technol ogy, they are more dire ctional than linear fluorescent bulbs, allowing for comparable product illumination with less total wattage. There have been recent advancements in LED efficacy and large food retaile rs have adopted LED technology. 37 Research by the Lighting Resource Cent er indicates that co nsumers found lighting in display cases using LEDs desirable. DOE predicts that LEDs will steadily increase in efficacy and decrease in cost as technology improves. 38

3.3.1.2 Higher Efficiency Lighting Ballasts

Higher efficiency lighting ba llasts reduce energy consumpti on by requiring less electrical power to operate, and by reducing waste heat generation, which contribu tes to case heat load.

Most illuminated display cases in supermarkets use fluores cent lighting with magnetic ballasts, which use inductance to modulate power flow to fluorescent lamps. Magnetic ballasts have significant electrical resistance losses. El ectronic ballasts use solid state electronics to modulate power provided to fluorescent lamps. Electronic ballasts, which convert power at high frequency, have lower electrical resistance losses compared to magnetic ballasts, which operate at line frequency. Fluorescent lamps also opera te more efficiently at the higher frequency provided by electronic ballasts.

In addition to the direct reductions in electr ical power consumption, heat generated by the lighting and the lighting ballast co ntribute to the case heat load. Increasing ballast efficiency also reduces the compressor load.

3.3.1.3 Remote Lighting Ballast Location

Because lamp ballasts may be located apart fr om the fluorescent lamps they power, they may be within the display case cabinet but outside of the refrigerated spac e, reducing heat load and case energy consumption.

3.3.1.4 Higher Efficiency Expansion Valves

Expansion valves are refrigerant metering devi ces that control the amount of refrigerant flowing to the evaporator coil. In doing so, they simultaneously decrease the temperature and pressure of the refrigerant, creating a cold li quid-vapor mixture. The low temperature of the refrigerant leaving the expansi on valve creates the dr iving force to move heat out of the refrigerated space and into the evaporator.

3-29The most basic type of expansion device is a capillary tube, which may be found in small self-contained commercial refrigeration equipment. The capillary tube is a long, thin piece of pipe that creates a pressure drop in the refriger ant through frictional losses. Capillary tubes must be sized to the particular application and cannot adjust for variations in load or ambient operating conditions. They are often oversized for worst- case conditions, and therefore may operate at reduced efficiency during normal operation.

The thermostatic expansion valve (TXV) is common in remote condensing commercial refrigeration equipment. This device uses an orifice to reduce the pr essure of the entering refrigerant and a sensing bulb to monitor and main tain the temperature of the superheated vapor leaving the evaporator. Because the TXV allows for some degree of adjustment of refrigerant expansion, it may be somewhat more efficien t than the capillary tube device under varying conditions. However, a TXV will likely not pr ovide significant energy savings over a properly sized capillary tube unde r steady-state conditions.

The electronic expansion valve (EEV) is si milar to the TXV, but uses an electronic control system to optimize refrigeration-syst em performance under all operating conditions. Because it does this with greater flexibility th an a TXV allows, an EEV theoretically allows for increases in energy efficiency under varying cond itions. However, as with the TXV, an EEV will likely not provide significant energy savings over a properly sized capillary tube or a TXV under steady-state conditions.

3.3.1.5 Higher Efficiency Evaporator Fan Motors

Evaporator fan motors are fractional horsepow er in size, are responsible for moving air across the evaporator coil, and typically run at one speed. Th e manufacturer will match the motor size and blade to the evaporator coil to meet the expected load on the case under most conditions. Higher efficiency evaporator fan motors reduce energy consumption by requiring less electrical power to genera te motor shaft output power.

Electric motors operate based on the inter action between a field magnet and a magnetic rotor. In a brushed motor, the field magnets are permanent magnets and the rotor is an electromagnet; the situation is re versed in a brushless motor. The electromagnetic interactions between these two magnets cause the rotor to rotate.

Single-phase, the simplest type of electric motors, suffer from a serious shortcoming. Single-phase motors only produce a rotating magnetic field when the rotor is rotating, and simply powering the electromagnet is therefore not sufficient to start such a motor. One of the most significant differences between different types of single-phase motors is the way in which they handle this start-up problem.

Nearly all inexpensive fan motors are of e ither shaded-pole or permanent split capacitor (PSC), and the same is most likely true for st andard commercial refrigeration equipment fan motors (fan motors not marketed as “high efficien cy”). In both cases, th e electromagnet consists of windings of electrical wire th rough which current is driven. In a shaded-pole motor, a portion of these windings is “shaded” by a copper loop. The interactions between the magnetic field generated by the shaded portion and that ge nerated by the un-shaded portion induce rotation

3-30when the motor is powered. Because the imba lance between the shaded and unshaded portions of the magnet remains throughout operation, howeve r, shaded-pole motors are inefficient, with typical motor efficiencies less than 20 percent. 39 Shaded-pole motors ar e, however, electrically simple and inexpensive.

In a PSC motor, a smaller, start-up winding is present in addition to the main winding. The start-up winding is electricall y connected in parallel with the main winding and in series with a capacitor. At start up, the interactions between the magnetic field generated by the startup winding and that generated by the main windi ng induce rotation. Because of the capacitor, however, the current to the start- up winding is cut off as the motor reaches steady state. Because of this, PSC motors are more energy efficient than their shaded-pole counterparts, with motor efficiencies ranging from 50 to 70 percent. Like shaded-pole motors, PSC motors are produced in large quantities and are relatively inexpensive. 40 The energy efficiency of commercial refrigeration equipment fans that use shaded -pole motors can be substantially improved by replacing them with PSC motors.

A third type of electric motor, the electr onically commutated permanent magnet (ECM) motor (also known as the brushless permanent ma gnet motor), is more energy-efficient than either shaded-pole or PSC motors. ECM motors , which are sold in high volumes, are threephase electric motors with efficiencies even gr eater than PSC motors. However, ECM motors can weigh about twice as much and are more expensive than equivalent PSC motors.

3.3.1.6 Evaporator Fan Motor Controllers

Evaporator fan motor controllers allow fan mo tors to run at variable speed to match changing conditions in the case. During periods of frost build-up, fan mo tor power requirements increase; during the post-defrost period, power requirements decr ease. Matching the fan speed to all conditions ensures more st able discharge air temperatures (and thus more stable product temperatures) and improves coil performance. Evaporator fan motor controllers would also allow the case to run more efficiently at di fferent ambient humidity and temperature levels.

3.3.1.7 Higher Efficiency Evaporator Fan Blades

High-efficiency evaporator fa n blades, or tangential evaporator fans, move air more efficiently, yielding energy consum ption savings by reducing the re quired fan shaft power. The evaporator fans typically used in commercial re frigeration equipment have sheet metal blades. Usually, the fan blade manufactur er supplies the blades and th e equipment manufacturer mounts them. These fan blades are not optimized for co mmercial refrigeration equipment. Evaporator fans may have lower efficiencies due to the hi gher required pressure drops, for which sheet metal fans are not well suited. Requi red fan shaft power could be re duced if the fan blades were optimized for each application.

Tangential fans also provide an opportunity to decrease equipment energy consumption. 41 Tangential fans use a vortex builder to generate a uniform airflow over a large surface. This makes them better suited to eva porator and condenser fans, which need to distribute airflow over a large coil surface area. A single long tangentia l fan can meet the airflow requirements for an entire refrigerated cabinet, and require only one high-efficiency fan motor.

3-313.3.1.8 Increased Evaporator Surface Area

The evaporator is a refrigerant-to-air heat exchanger composed of metals with high thermal conductivity such as aluminum and coppe r. It is responsible for evaporating and superheating the entering refriger ant liquid-vapor mixture while ex tracting heat from the air in the refrigerated space. The internal heat-exc hanging surfaces in contact with refrigerant are commonly referred to as “refrige rant-side,” while the external heat-exchanging surfaces in contact with the air are re ferred to as “air-side.”

Depending on the requirements of the equipment, the evaporator will have a discharge air temperature (DAT) that can be up to 10 ° F colder than the desired temperature of the product. Because a temperature difference is necessary to dr ive heat from the air into the refrigerant, the saturated evaporator temperature (SET) must be considerably colder than the DAT. The magnitude of this driving force is directly related to the total re frigeration load and the thermal characteristics of the evaporat or, as shown in Equation 3.1:

Q
UA TSETDAT == Δ− Eq. 3.1

where Q is the total refrigeration load (Btu/h), U

is the heat transfer coeffi cient of the evaporator (Btu/ ° F/ft 2 ), A is the area of the evaporator (ft 2 ), and Δ T is the temperature difference between the discharge air temperat ure and evaporator temperature ( ° F).

Increasing the area of the coil will decrease the necessary Δ T and therefore decrease the SET. This results in an increased compressor ener gy efficiency ratio (EER) and lower compressor energy consumption.

Enhancements to the refrigerant-side surface area of the evaporat or typically include rifled or diamond-pattern tubing and increased number of tube passe s. Enhancements to the airside surface area include increa sed fin pitch (decreased fin spaci ng), fin patterns (wavy or zigzag), and increased numbers of tube passes.

Increasing the overall size of the coil in one or more dimensions without changing other aspects of the coil is another way to increase th e area. However, most applications limit the amount of coil size increase. Most approaches to increasing the evaporator surface area also result in an increase in required fan motor power and an increase in refrigerant pressure drop.

3.3.1.9 Low-Pressure Differential Evaporators

Decreasing the air-side pressure drop of an evaporator coil allows for the use of lower power evaporator fan motors. This requires reducing restrictions to the flow of air across the coil such as high fin pitch and high numbers of tube passes. Large spaces between fins and tubes also reduce frost “bridging,” wh ich can completely block airflow through portions of the coil.

3-323.3.1.10 Anti-Sweat Heater Controllers

Anti-sweat heating controllers match the on-tim e of anti-sweat heaters to the anti-sweat heating requirements imposed by the ambien t humidity, reducing energy consumption when ambient humidity is low. Anti-sweat heating is necessary to prevent moisture condensation on surfaces of display cases, the temperatures of which can be below the ambient dew point.

Freezer-door gaskets are a typical example of such a surface. Anti-sweat heaters on freezer-door gaskets are typically always on, but the installation of controls that sense ambient humidity levels can turn off the heater when anti-sweat heating is not required, reducing electricity consumption. Such control requir es measuring the local dew point or relative humidity, and measuring external surface temperat ures. A particular heater can be turned on when the temperature of a particular surface fa lls below the dew point, or the heaters can be cycled with on-times increasing with dew point. Reducing anti-sweat heater on-time will also yield additional energy savings in display-case heat load reduc tions, since anti-sweat heaters contribute to case heat load.

It is possible that electric anti-sweat h eaters could be replaced by a hot gas line running around the doorframe. Although manuf acturers have claimed that th is is a difficult technology to implement, it has seen widespread and successful use in re sidential freezers.

3.3.1.11 Improved or Thicker Insulation

Either increasing the insulation thickness or reducing insulation conductivity will reduce the energy consumption of commercial refrigerati on equipment. Typical insulation thickness for refrigerated display cases ranges from 11⁄2 to 2 inches. Blow-in polyurethane foam is used for most cases. The impact of an increase in insula tion thickness and insulation quality is limited for open cases since a large portion of the cooling load is due to infiltration.

Improved technology polyurethane foam in sulation has reduced conductivity, reducing case heat load. The improvement is due mainly to the formation of smaller air cells within the foam insulation structure and better cell-size consistency. Use of the be tter foam would reduce display case wall load, assu ming no wall thickness change.

The importance of display case volume sugge sts that technologies that would allow reduction in insulation thickness while maintainin g thermal resistivity (R-value) would be of interest. Vacuum panels could provide such perf ormance. Vacuum panels are airtight panels sealed with glass or plastic, which are evacuat ed to eliminate a conduction path. They are generally filled with supporting powder that preven ts collapse of the external seal. Much work needs to be done to demonstrate that vacuum pane ls will perform for many years without leaking and losing their insulating value. Additionall y, existing vacuum panels do not provide the necessary structural rigidity be tween sheet metal panels that is possible with foamed-in-place polyurethane insulation.

3.3.1.12 Defrost Mechanism

As the air in the refrigerated space is cool ed, water vapor condenses on the surface of the evaporator coil. In refrigerators and freezers, wher e the evaporator coil is below 32°F, this water

3-33freezes as it collects, forming a gr owing layer of frost. The fros t reduces cooling performance by increasing the thermal resistance to heat transf er from the coil to the air, and by obstructing airflow. Both the method in which defrost is performed and control of the defrost cycle can lead to increased energy savings.

There are several methods available for defros ting the evaporator coil: off-cycle defrost, electric defrost, and hot-gas defr ost. Off-cycle defrost involves shutting off refrigerant flow to the coil while leaving the evaporator fan running. This method is used where case air is above the freezing point of water and can be used to melt th e frost. Electric defrost is used when the air temperature is not high enough to defrost the co il, and when defrost must occur quickly to prevent any significant rise in product temperatur e. Electric defrost involves melting frost by briefly turning on an electric resist ance heater that is in contact with or near the evaporator coil.

Hot-gas defrost is only applicable to remote condensing systems and involves the use of the hot compressor discharge gas to warm the eva porator from the refrigerant side. Electricity usage is reduced in comparison to the electric defrost method because available heat, which would otherwise be rejected in th e condenser, is used. The hot ga s defrost system requires more complicated piping and control th an electric defrost. An addi tional drawback is the thermal stress inflicted upon the refrigeran t piping by the alternating flow of hot gas and cold refrigerant.

3.3.1.13 Defrost Cycle Control

Defrost-cycle control involves managing the in itiation and termination of defrost cycles, and thereby the frequency and duration of defros t cycles. In the past, defrost cycles were completely scheduled, and initiation and termin ation were timer-controlled. Cycles were initiated at regular intervals and terminated afte r a fixed amount of time. Cycle frequency and duration were then unrelated to actual frost cond itions. Under timer control, the frequency of defrost cycles is determined by the amount of time the manufacturer expects it to take for a large frost layer to develop in the worst-case scenar io, and the cycle durati on must be long enough to ensure complete defrost in the worst-case sc enario. Timer-based defrost can lead to unnecessarily frequent and long defrost cycles.

The current practice involves scheduled cy cle initiation, determined by a timer, and demand-based cycle termination, determined by temp erature sensors. Defr ost cycles are still initiated at regular intervals, but are termin ated when the coil temperature reaches a value indicating complete defrost. Partial demand-based defrost sa ves energy relative to fully scheduled defrost by limiting cycle durati on, but cycle frequency can still be high.

Fully demand-based defrost would eliminate unnecessary defrost cycles. Two methods currently exist for measuring demand-based defros t—measurement of cross-coil air-temperature drop and optical detection of frost buildup. Prob lems with these methods are associated with possible reduction of airflow due to dust collecti on, evaporator fan problems, varying product fill levels, and external flow disturbances.

3.3.1.14 Thermoacoustic Refrigeration

Thermoacoustic refrigeration uses high-amp litude sound waves in a pressurized gas to pump heat from one place to another. A device consisting of a series of small parallel channels,

3-34referred to as a “stack,” is fixed in place at a set location inside a resonator tube. In the case of a thermoacoustic refrigerator, external work is supplied by the standing sound wave in the
resonator.
The longitudinal standing sound wave causes the gas particles to oscillate back and forth parallel to the walls of the stack. The altern ating compression and raref action of the gas causes the local temperature of the gas to oscillate due to the adiabatic nature of sound waves. If the local temperature of the gas becomes higher than th at of the nearby stack wa ll, heat is transferred from the gas to the stack wall. If the local temp erature of the gas drops below that of the stack wall, heat is transferred from the wall to the gas.

Prototypes of thermoacoustic refrigerators have been de monstrated for commercial refrigeration applications. A prototype thermo acoustic refrigeration unit designed for an icecream freezer has been measured to be as effi cient as the vapor compression unit it replaces. DOE expects this technology to improve in e fficiency with further development of heat exchangers and other subsystems. It is also lik ely that efficiency in many applications could improve because thermoacoustic refrigerators ar e well suited to proportional control, meaning that the cooling capacity can be continuously cont rolled so that the ou tput can be adjusted accurately for varying load conditions. Althoug h this technology currently does not improve the efficiencies of conventional refrigeration technology, thermoacoustic refrigeration has the environmental benefit of being refrigerant-free.

3.3.1.15 Magnetic Refrigeration

Magnetic refrigeration uses the magnetocalori c effect in which magnetocaloric materials like gadolinium absorb heat from their surroundings when entering a magnetic field, then reject heat to their surroundings when exiting a magne tic field. When magnetocaloric materials are circulated through magnetic fields and combined with heat exchange rs to transfer heat, they can be used to remove heat from a refrigerat ed space and reject heat to the surroundings.

This refrigeration technology could be used in any possible applic ation where cooling, heating, or power generation is used today. Beca use of the early stage of development, however, many technical issues need to be addressed fo r this technology to be commercially viable.

3.3.1.16 Electro-Hydrodynamic Enhanced Heat Transfer

Electro-hydrodynamic (EHD) enhanced heat tran sfer is the result of applying a highvoltage electrostatic potential fiel d across a heat transfer fluid, such as a refrigerant or refrigerant mixture. The applied field destabilizes th e thermal boundary layer, thereby producing better mixing of the bulk fluid flow and increasing the net heat transfer coefficient. This procedure appears to be more effective when applied to phase-change processes ( e.g., boiling and condensation).

This phenomenon is typically used to elec tronically control th e capacity of a heat exchanger by raising the applied vo ltage to increase the heat transf er. This can lead to improved efficiencies by using smaller capacity equipment, most of the time without EHD, and then using the EHD effect during peak loads. EHD can re place, or work in conjunction with, enhanced surface heat exchangers. To use EHD, an electri cal voltage (from a few volts to thousands of

3-35volts) is applied to the heat transfer device. However, because the heat transfer fluids are typically dielectric (of low el ectrical conductivity), even high voltages pr oduce very little current. This low current helps keep the power (voltage x current) and the associated energy penalty low.

3.3.1.17 Copper Rotor Motors

Making the critical components of an induction motor's rotor ( e.g., conductor bars and end rings) out of copper instead of aluminum, which is the co mmon current practice, improves the motor’s energy efficiency. The greater condu ctivity of copper results in lower resistance heating losses in the rotor and thus lower losse s in the motor. Improvements in the design and fabrication of copper motors, such as optimizatio n of the steel laminations, could further increase the efficiency of copper motors over aluminum motors.

3.3.2 Designs Relevant Only to Equipment without Doors

The air-curtain design option is releva nt only to equipment without doors.

3.3.2.1 Air-Curtain Design

Refrigerated display cases without doors allow consumers easy access to products while maintaining temperatures that ensure food safet y. The absence of doors necessitates the use of a circulated air curtain to keep co ld air inside the case. The refr igeration load for these cases is dominated by infiltration, or the entrainment of warm and moist air in to the curtain. This infiltration adds both sensible and latent heat to the case, and deposits additional moisture on the evaporator coil, which must be removed through defrosting.

Improved air-curtain design is aimed at lessening the impact of infiltration by reducing the entrainment of warm ambient air. Making the air curtain flow as laminar as possible reduces entrainment. This involves configuring the plenum before the air curtain discharge grill to shape the velocity profile using a honeyc omb grill to align the airstream s and encourage laminar flow. Improvements to the velocity profile and discharg e air grill may enhance the performance of the air curtain and reduce th e infiltration load.

3.3.3 Technologies and Designs Relevant On ly to Self-Contained Equipment

The following technologies and designs are re levant only to self-contained equipment: higher efficiency compressors, liquid suction heat exchangers, increased condenser surface area, higher efficiency condenser fan motors, condenser fan motor controllers, and higher efficiency condenser fan blades.

3.3.3.1 Higher Efficiency Compressors

Several technologies exist to increase the efficiency of commer cial refrigeration equipment compressors. High-efficiency reci procating and scroll compressors, sometimes incorporating variable-speed motors, all ha ve higher efficiencies than the traditional reciprocating compressors commonly used in commercial refrigeration equipment.

3-36Scroll compressors compress gas between two sp irals, one fixed and one rotating. This method is fundamentally different from that of traditional compressors. High-efficiency reciprocating compressors are as efficient, or mo re efficient, than scroll compressors. However, when compared to scroll compressors, some drawbacks exist, includ ing noise, cost, and reliability.

Variable-speed compressors are implemen ted through an electronic control on the compressor motor, which allows the motor to ope rate at different speed s. Variable-speed compressors reduce energy c onsumption in three ways: h

1. When refrigerant flow is reduced duri ng part-load operation, the condenser and evaporator (designed for full flow conditi ons) are more effective and thus more efficient. Temperature drops decrease, resu lting in reduced pressure rise across the compressor, which also improves efficiency.

2. Close matching of load eliminates the cycling that occurs with single-stage compressors. Maintaining a constant pressure is more efficient because losses at higher pressure rise are greater th an gains at lower pressure rise.

3. During the off cycle, the pressure in the system equilibrates. At intermediate pressure, refrigerant vapor will condense in the cold evaporator rather than the condenser. Essentially, some of the heat reje ction load is rejected to the evaporator during this time, reducing overall system performance. Variable-speed operation would eliminate or significantly redu ce compressor off-time and the related inefficiencies.

3.3.3.2 Liquid Suction Heat Exchangers

The goal of a liquid suction heat exchanger is to further cool the flow of liquid refrigerant entering the expansion valve using the flow of ga seous refrigerant leaving the evaporator. The exchanger provides sub-cooling for the enteri ng liquid by super-heating the exiting suction vapor. Hotter suction vapor is less susceptibl e to heat gains in th e return piping to the compressor rack. The compressor work is incr eased, however, because the suction vapor has greater enthalpy. In addition, the possibility of compressor overheating problems brought on by the combination of increased compressor work an d hotter vapor limits the use of this method in some situations. The possibility for these problem s and the potential efficiency gains from liquid suction heat exchangers depend on several factors, including evaporator temperature, type of refrigerant used, and system pressures.

3.3.3.3 Increased Condenser Surface Area

Like the evaporator, the condens er is a refrigerant-to-air heat exchanger composed of metals with high thermal conductivity such as al uminum and copper. It is responsible for condensing and sub-cooling the entering refrige rant vapor while rejecting heat from the refrigerant to the ambient air.

h Variable-speed compressors typically increase efficiency over a broad operating range but do not inherently increase maximum efficiency at the compressor rating point

3-37Depending on the requirements of the equipm ent, the condenser’s saturated condenser temperature (SCT) is about 14°F warmer than the ambient air. As with evaporator coils, increasing the area of the condenser coil will decrease the necessary Δ T across the coil and therefore decrease the SCT, resulting in increas ed compressor efficiency (and thus increased EER).

Enhancements to the refrigerant-side surf ace area of the condenser typically include rifled or diamond-pattern tubing an d increasing the number of tube passes. Enhancements to the air-side surface area include increased fin pitch (decreased fin spacing), fin patterns (wavy or zig-zag), and increased numb ers of tube passes.

Increasing the overall size of the coil in one or more dimensions without changing other aspects of the coil is another way to increase th e area. However, most applications limit the amount of coil size increase in order to main tain overall equipment dimensions. Most approaches to increasing the condenser surface area also result in an increase in required fan motor power and an increase in refrigerant pressure drop.

3.3.3.4 Higher Efficiency Condenser Fan Motors

Condenser fan motors are responsible for moving air across the condenser coil and typically run at one speed. The manufacturer will match the motor size and blade to the evaporator coil to meet the expected load on the case under most conditi ons. Higher efficiency condenser fan motors reduce energy consumption by requiring less electrical power to generate motor shaft output power. Condenser fan motors are generally of the same size and type as evaporator fan motors. See section 3.3.1.5 for a discussion of higher efficiency fan motor technology.

3.3.3.5 Condenser Fan Motor Controllers

Condenser fan motor controllers allow fan mo tors to run at variable speed to match changing conditions in the case. Matching th e fan speed to all conditions improves coil performance. This allows the refrigeration system to run more efficiently at different ambient humidity and temperature levels. However, under steady-state conditions, there is no energy savings benefit with condenser fan motor controllers.

3.3.3.6 Higher Efficiency Condenser Fan Blades

High-efficiency condenser fan blades, or tangential condenser fans, move air more efficiently, yielding energy consum ption savings by reducing the re quired fan shaft power. The condenser fans typically used in commercial refr igeration equipment have sheet metal blades. Usually, a fan blade manufacturer supplies the blades and the equipment manufacturer mounts them to the motor. These fan blades are not op timized for commercial refrigeration equipment. Required fan shaft power could be reduced if the fan blades were optimized for each application.

Tangential fans also provide an opportunity to decrease CRE energy consumption. These fans use a vortex builder to generate a uniform airflow over a large surface. This makes them ideal for evaporator and condenser fans that need to distribute airflow over a large surface area.

3-38A single long tangential fan can meet the airf low requirements for an entire condenser, and require only one high-efficiency fan motor.

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. The June 25, 2007, material from this website is available in Docket EE-2006-STD-0126. For more information, contact Bre nda Edwards-Jones at (202) 586-2945.

3-4011 Consortium for Energy Efficiency. Commercial Kitchens Initiative High-Efficiency Specifications . 2006. (Last accessed June 25, 2007.) http://www.cee1.org/com/com

kit/com-kit-fridge-specs.pdf. The June 25, 2007, material from this website is available in Docket EE-2006-STD-0126. For more inform ation, contact Brenda Edwards-Jones at (202) 586-2945.

12 Federal Energy Management Program. Procurement Specifications . 2007. (Last accessed June 25, 2007.) http://www.eere.ener gy.gov/femp/procurement /. The June 25, 2007, material from this website is ava ilable in Docket EE-2006-STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

13 Efficiency Vermont. Small Commercial Refrigeration Rebate Application . 2007. (Last accessed June 25, 2007.) http://www. efficiencyvermont.com./stella/filelib / Refrig%20Form%202007%20FINAL%2012-11- 06.pdf. The June 25, 2007, material from this website is available in Do cket EE-2006-STD-0126. For more information, contact Brenda Edwards- Jones at (202) 586-2945.

14 Energy Smart Grocer. Refrigeration–ESG Rebate Worksheet . 2007. (Last accessed June 25, 2007.) http://www.energysmartgrocer.org/pdfs/PGE/Rebate_Worksheet.pdf. The June 25, 2007, material from this website is available in Docket EE-2006-STD-0126. For more information, contact Bre nda Edwards-Jones at (202) 586-2945.

15 Nevada Sure Bet Program. 2007. (Last accessed June 25, 2007.) http://www.nevadasurebet.com/ProjectCenter

. The June 25, 2007, material from this website is available in Docket EE-2006- STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

16 Otter Trail Power Company. Rebates . 2007. (Last accessed June 25, 2007.) http://www.otpco.com/SaveEnergyMoney/Reba tes.asp . The June 25, 2007, material from this website is available in Do cket EE-2006-STD-0126. For more information, contact Brenda Edwards- Jones at (202) 586-2945.

17 Blair, K. Personal Communication. Rose ville Electric. E-mail between Navigant Consulting and Kris Blair of Ro seville Electric. June 27, 2007.

18 Pacific Gas and Electric. Energy Efficiency Rebates for Homes, Businesses, and Multifamily Dwellings . 2007. (Last accessed June 27, 2007.) http://www.pge.com/includes/docs/pdfs/ application/07Refrigeration.pdf and http://www.pge.com/includes/docs/pdfs/app lication/07Lighting.pdf . The June 27, 2007, material from this website is availa ble in Docket EE-2006-STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

3-4119 Southern California Edison. 2007 Business Incentives & Services . (Last accessed June 25, 2007.) http://www.sce.com/NR/rdonlyres/9F43D4BB-9696-4B7C-AA2A

75C0D1A0E690/0/2007EdisonAppFormsFina l052407.pdf. The June 25, 2007, material from this website is available in Do cket EE-2006-STD-0126. For more information, contact Brenda Edwards- Jones at (202) 586-2945.

20 San Diego Gas and Electric. 2 007 Rebates and Services fo r Food Service Facilities

. 2007. (Last accessed June 27, 2007.) http:/ /www.sdge.com/foodservice/index.shtml

. The June 27, 2007, material from this website is available in Docket EE-2006-STD-0126. For more information, contact Bre nda Edwards-Jones at (202) 586-2945.

21 Freedonia. Commercial Refrigeration Equipment to 2008 . Study 1849. October 2004. Freedonia Group, Inc., Cleveland, Ohio.

22 U.S. Bureau of Census. 2002 Economic Census, Manufacturing, Industry Series, AirConditioning and Warm Air Heating E quipment and Commercial and Industrial Refrigeration Equipment Manufacturing: 2002 . December 2004. EC02-31I-333415 (RV).

23 U.S. Bureau of Census. 1997 Economic Census, Manufacturing, Industry Series, AirConditioning and Warm Air Heating E quipment and Commercial and Industrial Refrigeration Equipment Manufacturing: 1997 . September 1999. EC97M-3334D.

24 U.S. Internal Revenue Service. Field Directive on the Pl anning and Examination of Cost Segregation Issues in the Retail Industry . 2004. (Last accessed June 25, 2007.) http://www.irs.gov/businesses/article/0,,i d=151273,00.html . The June 25, 2007, material from this website is available in Do cket EE-2006-STD-0126. For more information, contact Brenda Edwards- Jones at (202) 586-2945.

25 Sand, J.R., S.K. Fisher, and V.D. Baxter. Energy and Global Warming Impacts of HFC Refrigerants and Emerging Technologies . 1997. (Last accessed June 25, 2007.) http://www.afeas.org/tewi/tewi-iii .pdf . The June 25, 2007, material from this website is available in Docket EE-2006-STD-0126. Fo r more information, contact Brenda Edwards-Jones at (202) 586-2945.

26 NYSERDA. Heshong Mahone Group, Inc. New York Energy Smart. Program CostEffectiveness Asse ssment December 2004 . (Last accessed June 26, 2007.) http://www.nyserda.org/Energy_Information/S BC/cost_effectiveness.pdf . The June 26, 2007, material from this website is ava ilable in Docket EE-2006-STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

27 Glasch, V. Personal Communication. Veri sae. Communication with Keith Glasch. 2006.

28 Hepperla, P. Personal Communication. Verisae. Communica tions with Paul Hepperla. 2006.

3-4229 Mark Ellis & Associates. New Zealand Minimum Energy Performance Standards for Commercial Refrigeration Cabinets, Prepared for the Energy Efficiency and Conservation Authority . 2003. (Last accessed June 26, 2007.) http://www.eeca.govt.nz/eeca-library/products/sta ndards/report/meps-for-commercial

refridgeration-cabinets-03.pdf. The June 26, 2007, material from this website is available in Docket EE-2006-STD-0126. For more inform ation, contact Brenda Edwards-Jones at (202) 586-2945.

30 Foster-Miller. Development and Demonstration of an Advanced Supermarket Refrigeration/HVAC System . 2001. Oak Ridge National La boratory: Oak Ridge, TN. Report No. ORL-970163.

31 U.S. Environmental Protection Agency Office of Air and Radiation. U.S. High GWP Gas Emissions 1990–2010: Inventories, Project ions, and opportunities for Reductions, June 2001 . (Last accessed June 26, 2007.) http://www.epa.gov/highgwp/ projections.html. The June 26, 2007, material fr om this website is available in Docket EE-2006-STD-0126. For more information, cont act Brenda Edwards-Jones at (202) 586­ 2945.

32 ADL. Final Report to the Alliance for Respons ible Atmospheric Policy, March 21, 2002 . (Last accessed June 26, 2007.) http:// www.arap.org/adlittle/toc.html . The June 26, 2007, material from this website is available in Docket EE-2006-STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

33 California Energy Commission. Update of Appliance Efficiency Regulations: California Energy Commission Staff Report, November 2004 . California Energy Commission: Sacramento, CA. Report No. 400-04-007F.

34 Hansen, M. Personal Communication. Key Mechanical, Kent, Washington. Communication with Mary Hansen. 2006.

35 Intergovernmental Panel on Clim ate Change, World Meteorological Organization/United Nations Environment Programme . Good Practice Guidance and Uncertainty Management in Na tional Greenhouse Gas Inventories . 2001. (Last accessed June 26, 2007.) http://www.ipcc- nggip.iges.or.jp/public/gp/english / 3_Industry.pdf. The June 26, 2007, material from this website is available in Docket EE-2006-STD-0126. For more information, cont act Brenda Edwards-Jones at (202) 586­ 2945.

36 Fischer, S. Energy and Global Warming Impacts of CFC Alternative Technologies

. 1991. AFEAS and DOE.

3-4337 Lightnow. Wal-Mart Uses GE LED Refrigerated Display Lighting to Save Green

. 2006. (Last accessed June 26, 2007.) http://www.lightsearch.com/lightnow/lightnow _news/1106/1106_walmart.htm. The June 26, 2007, material from this website is available in Docket EE-2006-STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

38 Ramesh Raghavan and Nadarajah Narendran. 2002 Solid State Lighting II: Proceeding of the Society of Photo-Optical Instrumentation Engineer - Refrigerated Display Case Lighting with LEDs . 2002. Lighting Research Center, Rensselaer Polytechnic Institute: Rensselaer, NY.

39 Leeson. Single-phase Electric Motors . 2006. (Last accessed on June 26, 2007.) http://www.iprocessmart.com/leeson/leeson_sin glephase_article.htm. The June 26, 2007, material from this website is availa ble in Docket EE-2006-STD-0126. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

40 U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy. Energy Conservation Program for Consumer Products: Technical Support Document for Energy Conservation Standards for Room Air Conditioners. September 1997. Washington, D.C., http://www.eere.ener gy.gov/buildings/appliance_standards / residential/pdfs/tsdracv1.pdf.

41 Walker, D.H. Investigation of Energy-Efficie nt Supermarket Display Cases . 2004. Oak Ridge National Laboratory: Oak Ridge, TN. Report No. ORNL/TM-2004/292.

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