CHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT

TABLE O F CONTENTS

3.1 I NTRODUCTION

........................................................................................................... 3­1

3.1.1 D efinitions............................................................................................................ 3­1

3.2 M ARKET ASSESSMENT

.............................................................................................. 3­4

3.2.1 Tr ade Association

................................................................................................ 3­4

3.2.2 M anufacturers and Market Share......................................................................... 3­4

3.2.2.1 S mall Businesses...................................................................................... 3­7

3.2.3 R egulatory Programs

........................................................................................... 3­8

3.2.3.1 C alifornia

................................................................................................. 3­8

3.2.3.2 C anada...................................................................................................... 3­9

3.2.3.3 C anadian Standards Association............................................................ 3­10

3.2.3.4 A ustralia

................................................................................................. 3­11

3.2.4 N on­Regulatory Initiatives................................................................................. 3­11

3.2.4.1 E NERGY STAR

.................................................................................... 3­12

3.2.4.2 C onsortium for Energy Efficiency......................................................... 3­12

3.2.4.3 F ederal Energy Management Program

.................................................. 3­12

3.2.4.4 R ebate Programs

.................................................................................... 3­12

3.2.5 Eq uipment Classes

............................................................................................. 3­13

3.2.6 S hipments........................................................................................................... 3­19

3.2.6.1 Ap pliance Magazine Data...................................................................... 3­21

3.2.6.2 C urrent Industrial Reports...................................................................... 3­21

3.2.7 Eq uipment Lifetimes.......................................................................................... 3­24

3.2.8 M arket Performance Data

.................................................................................. 3­25

3.3 TEC HNOLOGY ASSESSMENT.................................................................................. 3­28

3.3.1 Te chnologies and Designs Relevant to All Equipment Classes

........................ 3­28

3.3.1.1 H igher Efficiency Lighting

.................................................................... 3­28

3.3.1.2 H igher Efficiency Lighting Ballasts

...................................................... 3­29

3.3.1.3 R emote Lighting Ballast Location

......................................................... 3­29

3.3.1.4 H igher Efficiency Expansion Valves..................................................... 3­29

3.3.1.5 H igher Efficiency Evaporator Fan Motors

............................................ 3­30

3.3.1.6 Ev aporator Fan Motor Controllers......................................................... 3­31

3.3.1.7 H igher Efficiency Evaporator Fan Blades

............................................. 3­31

3.3.1.8 I ncreased Evaporator Surface Area

....................................................... 3­32

3.3.1.9 L ow Pressure Differential Evaporators.................................................. 3­32

3.3.1.10 A nti­Sweat Heater Controllers............................................................. 3­33

3.3.1.11 I mproved or Thicker Insulation

........................................................... 3­33

3.3.1.12 D efrost Mechanism.............................................................................. 3­33

3.3.1.13 D efrost Cycle Control

.......................................................................... 3­34

3.3.1.14 Th ermoacoustic Refrigeration

............................................................. 3­35

3.3.1.15 M agnetic Refrigeration

........................................................................ 3­35

3.3.1.16 El ectro­hydrodynamic Enhanced Heat Transfer.................................. 3­35

3.3.1.17 C opper Rotor Motors

........................................................................... 3­36

3­i3.3.2 Designs R elevant Only to Equipment without Doors........................................ 3­36

3.3.2.1 A ir­Curtain Design................................................................................. 3­36

3.3.3 Technologies a nd Designs Relevant Only to Self­Contained Equipment

......... 3­36

3.3.3.1 H igher Efficiency Compressors

............................................................. 3­37

3.3.3.2 L iquid Suction Heat Exchangers

........................................................... 3­37

3.3.3.3 I ncreased Condenser Surface Area

........................................................ 3­38

3.3.3.4 H igher Efficiency Condenser Fan Motors

............................................. 3­38

3.3.3.5 C ondenser Fan Motor Controllers

......................................................... 3­38

3.3.3.6 H igher Efficiency Condenser Fan Blades.............................................. 3­38

REFERENCES

.......................................................................................................................... 3­40

LIST O F TABLES

Table 3 .2.1 Commercial Refrigeration Manufacturers Division Members

................................ 3­5

Table 3.2.2 Non­Air­Conditioning and Refrigeration Institute Member Commercial Refrigerator

Manufacturers

.............................................................................................................................. 3­5

Table 3.2.3 “Other” Domestic Refrigerated Display Case Manufacturers

................................. 3­7

Table 3.2.4 Commercial Ice­Cream Freezer Manufacturers

...................................................... 3­7

Table 3.2.5 Small Business Manufacturers of Commercial Refrigeration Equipment............... 3­7

Table 3.2.6 California Energy Commission Efficiency Regulations for Commercial Ice­Cream

Freezers

............................................................................................................................... ......... 3­9

Table 3.2.7 Canadian Efficiency Regulations for Commercial Ice­Cream Freezers................ 3­10

Table 3.2.8 Canadian Standards Association Equipment Classes and Efficiency Ratings

...... 3­11

Table 3.2.9 Commercial Refrigeration Equipment Families

.................................................... 3­16

Table 3.2.10 Commercial Refrigeration Equipment Classes.................................................... 3­18

Table 3.2.11 Air­Conditioning and Refrigeration Institute Shipments of Commercial

Refrigerators and Freezers by Equipment Class

........................................................................ 3­20

Table 3.2.12 Historical Shipments of Refrigerated Display Cases........................................... 3­21

Table 3.2.13 Statistical Forecasts of Refrigerated Display­Cases Shipments

.......................... 3­21

Table 3.2.14 Shipments of Open Refrigerated Display Cases (Remote Condensing and SelfContained).................................................................................................................................. 3­22

Table 3.2.15 Shipments of Closed Refrigerated Display Cases (Remote Condensing and SelfContained).................................................................................................................................. 3­23

Table 3.2.16 Shipments of Commercial Reach­In Cabinets (Remote Condensing and SelfContained).................................................................................................................................. 3­24

Table 3.2.17 Estimates for Commercial Refrigeration Equipment Lifetimes

........................... 3­25

LIST O F FIGURES

Figure 3 .2.1 Domestic Refrigerated Display Case Market Shares

.............................................. 3­6

Figure 3.2.2 Market Performance Data for the VOP.RC.M Equipment Class......................... 3­26

Figure 3.2.3 Market Performance Data for the SVO.RC.M Equipment Class......................... 3­26

Figure 3.2.4 Market Performance Data for the HZO.RC.M Equipment Class......................... 3­27

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

.......................... 3­27

Figure 3.2.6 Market Performance Data for the VOP.RC.M, SVO.RC.M, and HZO.RC.M

Equipment Classes: Comparison of Air­Curtain Angles

.......................................................... 3­28

3­iii3­ivCHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT

3.1 INTRODUCTION

This d ocument details the market and technology assessment that the U.S. Department of

Energy (DOE) has carried out in support of the ongoing energy conservation standards

rulemakings for commercial refrigeration equipment (CRE), including commercial ice­cream

freezers; self­contained commercial refrigerators, commercial freezers, and commercial

refrigerator­freezers without doors; and remote condensing commercial refrigerators,

commercial freezers, and commercial refrigerator­freezers. These rulemakings are mandated by

the Energy Policy Act of 2005 (EPACT 2005), and are effective for equipment manufactured on

or after January 1, 2012.

This c hapter consists of two sections: the market assessment and the technology

assessment. The goal of the market assessment is to develop a qualitative and quantitative

characterization of the CRE industry and market structure based on publicly available

information and data and information submitted by manufacturers and other stakeholders. Issues

that are addressed include manufacturer characteristics and market shares, existing regulatory

and non­regulatory efficiency improvement initiatives, equipment classes, and trends in markets

and equipment characteristics. The goal of the technology assessment is to develop a

preliminary list of technologies that could be used to improve the efficiency of commercial

refrigeration equipment.

Commercial r efrigeration equipment is used primarily to store and display perishable

food products for sale in food­sales buildings (e.g., supermarkets and convenience stores), some

multi­line retail stores, and in some food service applications like restaurants, salad bars, and

cafeterias. The vast majority of equipment covered under this rulemaking, however, appears to

be used in food­sales buildings. Food­sales buildings 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 total 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 food­sales buildings. 1 The high energy­use

intensity of food­sales buildings is largely a product of the extensive use of commercial

refrigeration equipment.

3.1.1 Definitions

Section 1 36(c) of EPACT 2005 amended section 342 of the Energy Policy Conservation

Act (EPCA or the Act) to include new subsection (c)(4)(A) (42 U.S.C. 6313(c)(4)(A)), which

mandates that DOE issue by rule, no later than January 1, 2009, energy conservation standards

for the following equipment, manufactured on or after January 1, 2012: commercial ice­cream

freezers; self­contained commercial refrigerators, commercial freezers, and commercial

refrigerator­freezers without doors; and remote condensing commercial refrigerators,

commercial freezers, and commercial refrigerator­freezers.

a The values indicated are source energy values.

3­1Section 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 definitions for the following terms that describe

commercial refrigeration equipment:

“(9)(A) Th e term ‘commercial refrigerator, freezer, and refrigerator­freezer’ means

refrigeration equipment that—

(i) is n ot a consumer product (as defined in section 321);

(ii) is n ot designed and marketed exclusively for medical, scientific, or research

purposes;

(iii) operates a t a chilled, frozen, combination chilled and frozen, or variable

temperature;

(iv) displays o r stores merchandise and other perishable materials horizontally,

semivertically, or vertically;

(v) has t ransparent or solid doors, sliding or hinged doors, a combination of

hinged, sliding, transparent, or solid doors, or no doors;

(vi) is d esigned for pull­down temperature applications or holding temperature

applications; and

(vii) is c onnected to a self­contained condensing unit or to a remote condensing

unit.

(B) The t erm ‘holding temperature application’ means a use of commercial

refrigeration equipment other than a pull­down temperature application, except a

blast chiller or freezer.

* * *

(D) The t erm ‘pull­down temperature 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 t erm ‘remote condensing unit’ means a factory­made assembly of

refrigerating components designed to compress and liquefy a specific refrigerant

that is remotely located from the refrigerated equipment and consists of one or

more refrigerant compressors, refrigerant condensers, condenser fans and motors,

and factory supplied accessories.

(F) The t erm ‘self­contained condensing unit’ means a factory­made assembly of

refrigerating components designed to compress and liquefy a specific refrigerant

that is an integral part of the refrigerated equipment and consists of one or more

refrigerant compressors, refrigerant condensers, condenser fans and motors, and

factory supplied accessories.”

EPACT 2 005 does not explicitly define the terms “self­contained commercial

refrigerator, freezer, or refrigerator­freezer” and “remote condensing commercial refrigerator,

freezer, or refrigerator­freezer,” which delineate two of the categories of equipment covered by

this rulemaking. DOE construes these two terms to mean “commercial refrigerator, freezer, or

refrigerator­freezer that is connected to a self­contained condensing unit” and “commercial

refrigerator, freezer, or refrigerator­freezer that is connected to a remote condensing unit,”

respectively.

3­2Accordingly, the three categories of equipment covered under this rulemaking are:

1. Remote c ondensing commercial refrigerators, commercial freezers, and commercial

refrigerator­freezers: Under EPCA, this equipment includes commercial refrigerators,

commercial freezers, and commercial refrigerator­freezers that have a remote condensing

unit, except for any remote condensing equipment that would meet DOE’s definition of

“ice­cream 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 cabinets,” or “merchandisers.” The remote

condensing unit has at least one compressor and 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. Self­contained c ommercial refrigerators, commercial freezers, and commercial

refrigerator­freezers without doors : Under EPCA, this equipment includes all types of

commercial refrigerators, commercial freezers, and commercial refrigerator­freezers that

have a self­contained condensing unit and have no doors, except for self­contained

commercial equipment that meets DOE’s definition of “ice­cream freezer” as set forth at

10 CFR 431.62, 71 FR 71369. As with remote condensing equipment, they are typically

used to store and display products for direct sale to the consumer, and are commonly

referred to as “refrigerated display cases,” “display cabinets,” or “merchandisers.” Selfcontained equipment is defined as having an integral condensing unit (i.e., the

condensing unit is not remote from the 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 Air­Conditioning Engineers (ASHRAE) Refrigeration Handbook

(chapter 47, p. 47.1) defines “reach­in” refrigerators or freezers as being upright and box

shaped, and having hinged or sliding doors. Given this definition, self­contained reach­in

commercial refrigerators, commercial freezers, and commercial refrigerator­freezers (i.e.,

self­contained equipment with doors) are not covered in this rulemaking because the

rulemaking only covers self­contained equipment without doors.

3. Commercial i ce­cream freezers: The EPCA provision that requires this rulemaking

identifies “ice­cream freezers” separately from “self­contained commercial refrigerators,

freezers, and refrigerator­freezers without doors” and “remote condensing commercial

refrigerators, freezers, and refrigerator­freezers.” (42 U.S.C. 6313(c)(4)(A), added by

EPACT 2005, section 136(c)) The Act neither specifies nor indicates that “ice­cream

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 self­contained). Thus, pursuant

to EPCA’s definition of “commercial refrigerator, freezer, and refrigerator­freezer” (42

U.S.C. 6311(9)(A), a dded by EPACT 2005, section 136(a)(3)), DOE believes

commercial ice­cream freezers include equipment with all door types (i.e., solid doors,

transparent doors, or no doors) and configurations (e.g., vertical or horizontal), as well as

equipment with either integral or remote condensing units (i.e., self­contained or remote

condensing).

On D ecember 8, 2006, DOE published a final rule, in which it adopted test procedures for

commercial refrigeration equipment. In this final rule, DOE adopted the following definition for

3­3“ice­cream freezer:” “a commercial freezer that is designed to operate at or below ­5°F (­21°C)

and that the manufacturer designs, markets, or intends for the storing, displaying, or dispensing

of ice cream.” 10 CFR 431.62, 71 FR 71369. In addition, this final rule prescribed the rating

temperature at ­15°F for ice­cream freezers. 10 CFR 431.64, 71 FR 71370.

3.2 MARKET A SSESSMENT

The f ollowing market assessment identifies the manufacturer trade association, domestic

manufacturers of commercial refrigeration equipment, manufacturer market share, regulatory

programs, and non­regulatory initiatives; defines equipment classes; provides historical shipment

data, shipment projections, and equipment lifetime estimates; and summarizes market

performance data.

3.2.1 Trade A ssociation

The A ir­Conditioning and Refrigeration Institute (ARI) is the trade association of

commercial refrigeration equipment manufacturers. On January 12, 2005, ARI developed an

agreement with manufacturers to establish the commercial refrigerator manufacturers division

(CRMD) within ARI as well as develop and implement a certification program for commercial

refrigerators, commercial freezers, and commercial refrigerator­freezers.

The C RMD was originally a separate trade organization founded in 1933. The industry it

serves includes supermarkets, food stores, convenience stores, restaurants, hotels, motels, food

processing establishments, and hospitals. The technical activities of CRMD include:

• Harmonization o f international equipment standards;

• Development o f industry performance standards for commercial refrigeration equipment;

• Updating o f industry guidelines for retail store fixture installation, design, energy

conservation, electronic case controls, and specifications for equipment installation;

• Maintaining l iaison with refrigerant suppliers and government agencies on environmentally acceptable chlorofluorocarbon (CFC) alternatives; and

• Providing i nput to government agencies concerning regulations affecting the industry.

3.2.2 Manufacturers a nd Market Share

Current A RI CRMD members are shown in Table 3.2.1, with parent companies shown in

parentheses, if applicable.

3­4Table 3.2.1 Commercial Refrigeration Manufacturers Division Members

Barker Company Hussmann ( Ingersoll Rand) Spartan S howcase

Beverage­Air Killion I ndustries Structural C oncepts Corp.

Columbus S howcase Co. Kysor/Warren ( Enodis) Tyler R efrigeration (Carrier, United

Technologies Corp.)

Continental R efrigerator Master­Bilt P roducts (Standex) Zero Z one

Federal I ndustries (Standex) McCall R efrigeration

Hill P hoenix (Dover Corp.) Southern S tore Fixtures

Source: C RMD manufacturers listed as of November 2006,

http://www.ari.org/sections/section_groups/CommercialRefrigerator/manufacturers.htm.

Non­ARI member commercial refrigeration equipment manufacturers are shown in Table

3.2.2, with parent companies shown in parentheses, if applicable.

Table 3 .2.2 Non­Air­Conditioning and Refrigeration Institute Member Commercial

Refrigerator Manufacturers

Amteko* Howard/McCray Silver K ing*

Arctic A ir Kelvinator True M anufacturing*

Arctic S tar* McCray* Turbo A ir

Arneg U SA* Refcon* Vogel*

Custom D eli* Regan­Pinnacle

Custom F abricators* Royal S tore Fixtures (Parisi)*

*Based o n ARI comment submitted to the Framework Document ( ARI, No. 7 Exhibit A at p. 1) b with the addition of

2 Silver King.

The following provides a brief listing of the manufacturers that produce self­contained

commercial refrigeration equipment without doors, remote condensing commercial refrigeration

equipment, and commercial ice­cream freezers.

The m ajority of the domestic market share of self­contained and remote condensing

commercial refrigeration equipment without doors is held by five major manufacturers. These

manufacturers are listed below, with their parent companies in parentheses, if applicable. 3

• Hill P hoenix (Dover Corporation)

• Hussmann C orporation (Ingersoll Rand)

• Kysor/Warren ( Enodis)

• Tyler R efrigeration (Carrier, United Technologies Corporation)

• Zero Z one

b A notation in the form “ARI, No. 7 Exhibit A at p. 1” identifies a written comment DOE has received and has

included in the docket of this rulemaking. This particular notation refers to a comment (1) by the Air­Conditioning

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.

3­5Although the above information applies to both self­contained and remote condensing

commercial refrigeration equipment without doors, only the self­contained refrigeration

equipment without doors is applicable under this rulemaking. True Manufacturing also

manufactures self­contained commercial equipment and has a large share of shipments of selfcontained commercial equipment without doors and commercial ice­cream freezers.

According t o 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

Although Appliance Magazine describes the data as “refrigerated display cases,” no precise

definition of refrigerated display case is provided and is therefore unclear as to what specific

types of equipment it covers–equipment that is self­contained versus remote condensing and

equipment with doors versus without doors. Only the self­contained equipment without doors

and remote condensing equipment are applicable under this rulemaking.

As o f 2004, Hussmann Corporation, a division of Ingersoll Rand, was the largest

domestic manufacturer, holding approximately 48 percent of the U.S. refrigerated display case

market. Like most industries, there exists a second tier of smaller but well­known

manufacturers. These other manufacturers make up the remaining 15 percent of U.S. market

share. Figure 3.2.1 illustrates the market share breakdown in the United States refrigerated

display case industry.

Other

Hussmann

48%

Tyler Refrigeration Hill Phoenix

15% Kysor/Warren

6% 15%

16%

Source: Appliance Magazine

, 28 th Annual Portrait of the U.S. Appliance Industry

, September 2005.

Figure 3.2.1 Domestic Refrigerated Display Case Market Shares

Companies c onsidered within the “Other” category are listed in Table 3.2.3, with parent

companies in parentheses, if applicable. Manufacturers of commercial ice­cream freezers are

listed in Table 3.2.4 with parent companies in parentheses, if applicable.

3­6Table 3.2.3 “Other” Domestic Refrigerated Display Case Manufacturers

Arneg USA Killion I ndustries True M anufacturing

Barker C ompany Master­Bilt P roducts (Standex) Turbo A ir

Columbus S howcase Co. Royal S tore Fixture (Parisi) Zero Z one

Federal I ndustries (Standex) Southern S tore Fixtures

Howard/McCray Structural C oncepts Corp.

Source: A ppliance Magazine

, 28 th Annual Portrait of the U.S. Appliance Industry

, September 2005.

Table 3.2.4 Commercial Ice­Cream Freezer Manufacturers

Arctic Air Hussmann ( Ingersoll Rand)* Structural C oncepts Corp.*

Beverage­Air* Kelvinator True M anufacturing

Columbus S howcase Co.* Kysor/Warren ( Enodis)* Tyler R efrigeration (Carrier,

United TechnologiesCorp.)*

Continental R efrigerator* Master­Bilt P roducts (Standex)* Zero Z one*

Delfield ( Enodis) McCall R efrigeration*

Hill P hoenix (Dover Corp.)* Silver K ing

* Based o n ARI comment submitted to the Framework Document (ARI, No. 7 Exhibit A at p. 1).

3.2.2.1 Small B usinesses

DOE i s considering the possibility that small businesses would be particularly impacted

by the promulgation of energy conservation standards for commercial refrigeration equipment.

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 industry is the largest that a for­profit

concern can be in that industry and still qualify as a small business for Federal Government

programs. These size standards are generally expressed in terms of the average annual receipts

or the average employment of a firm. For commercial refrigeration equipment, the size standard

is matched to NAICS code 333415, Air­Conditioning and Warm Air Heating Equipment and

Commercial and Industrial Refrigeration Equipment Manufacturing, and is 750 employees.

DOE w ill study the potential impacts on these small businesses in detail during the

manufacturer impact analysis, which will be conducted as a part of the notice of proposed

rulemaking analysis. Table 3.2.5 lists the small business commercial refrigeration equipment

manufacturers that DOE has identified.

Table 3 .2.5 Small Business Manufacturers of Commercial Refrigeration Equipment

Barker Company Royal S tore Fixture (Parisi) Structural C oncepts Corp.

Columbus S howcase Co. Regal­Pinnacle Turbo A ir

Killion I ndustries Southern S tore Fixtures Zero Z one

3­73.2.3 Regulatory P rograms

Both C anada and the State of California have efficiency standards in place for

commercial ice­cream freezers but not for the other equipment covered in this rulemaking (i.e.,

remote condensing commercial equipment and self­contained commercial equipment without

doors). In the case of remote condensing equipment, the Canadian Standards Association (CSA)

has established efficiency standards as part of its overall test standards. Australia has several

efficiency standards in place for all of the equipment covered in this rulemaking.

The f ollowing States have established appliance efficiency regulations: Arizona,

California, Connecticut, Maryland, Massachusetts, Minnesota, New Jersey, New York, Oregon,

Rhode Island, Vermont, and Washington. Of these, California is the only State that explicitly

regulates equipment covered in this rulemaking–commercial ice cream freezers and remote

condensing equipment with transparent doors.

Minnesota a nd Vermont do not regulate commercial refrigeration equipment at all.

Arizona, Oregon, Rhode Island, and Washington regulate certain types of commercial

refrigeration equipment. However, these States specifically exclude commercial ice­cream

freezers, remote condensing commercial equipment and self­contained commercial equipment

without doors.

Connecticut, M aryland, Massachusetts, New Jersey, and New York regulate certain

commercial refrigeration equipment, but make no mention of commercial ice­cream freezers.

Connecticut and Maryland also make no mention of remote condensing commercial equipment

or self­contained commercial equipment without doors. New York and Maryland legislation

does not include remote condensing commercial equipment and self­contained commercial

equipment without doors. New Jersey makes no mention of remote condensing commercial

equipment, but does include self­contained commercial equipment without doors. However, no

standards are currently in place for this equipment.

3.2.3.1 California

California En ergy Commission (CEC) Appliance Efficiency Regulations (effective July

1, 2006) establish efficiency standards for commercial ice­cream freezers, but not for the other

types of equipment covered in this rulemaking (i.e., remote condensing commercial equipment

and self­contained commercial equipment without doors). The maximum allowed daily energy

consumption (kilowatt hours (kWh) per day) for commercial ice­cream freezers vary based on

the door type (i.e., solid or transparent) and volume (V). There are two different standard levels

with two different effective dates of January 1, 2006 and January 1, 2007 as shown in Table

3.2.6.

3­8Table 3.2.6 California Energy Commission Efficiency Regulations for Commercial IceCream Freezers

Equipment Type Type o f

Door Maximum D aily Energy

Consumption [kWh] Maximum D aily Energy

Consumption [kWh]

Effective J anuary 1, 2006 Effective J anuary 1, 2007

Reach­in c abinets, pass­through

cabinets, and roll­in or rollthrough cabinets that are icecream freezers Solid 0.398 V + 2.28 0.39 V + 0.82

Transparent 0.940 V + 5.10 0.88 V + 0.33

V

= Volume in ft 3

Source: Appliance Efficiency Regulations, July 2006, CEC­400­2006­002­REV1, section 1605.3, Table A­7.

The CEC regulations also have a design requirement for lighting in remote condensing

commercial equipment with transparent doors, self­contained commercial equipment without

doors, and remote condensing commercial equipment without doors. This design requirement

mandates that the internal illumination 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 the State of California.

The t est methods used for determining compliance with the CEC regulations are

American National Standards Institute/Association of Home Appliance Manufacturers

(ANSI/AHAM) HRF­1­1979, Household Refrigerators, Combination Refrigerator­Freezers, and

Household Freezers

, for volume measurements; ANSI/ASHRAE Standard 117­1992, Method of

Testing Closed Refrigerators, for energy consumption measurements of self­contained

commercial refrigerators, commercial freezers and commercial refrigerator­freezers with doors;

and ANSI/ASHRAE Standard 72­1998, Method of Testing Open Refrigerators

, for energy

consumption measurements of self­contained commercial refrigerators, commercial freezers, and

commercial refrigerator­freezers without doors. The energy consumption tests are conducted

with the following integrated average product temperatures (IAT) (because the CEC standards

for refrigerators and freezers are only for those equipment with doors and a self­contained

condensing unit, only the IAT for commercial ice­cream freezers is germane here):

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

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

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

• Ice­Cream C abinet: ­5 ° F ± 2 ° F (­20.6 ° C ± 1.1oC)

3.2.3.2 Canada

The N atural Resources Canada (NRCan) Office of Energy Efficiency has energy

efficiency standards for self­contained commercial “reach­in” refrigerators, freezers, and

refrigerator­freezers with solid/opaque doors or transparent doors, and are based on California’s

regulations. 7 Because NRCan considers commercial ice­cream freezers a type of self­contained

commercial “reach­in” freezer, these regulations apply to commercial ice­cream freezers.

The a pproach taken by Canada differs from that of California. The Canadian standards,

rather than specifying the type of equipment covered, define commercial refrigerators,

3­9commercial freezers, and commercial refrigerator­freezers in a manner that identifies only those

units that are not covered by standards. In addition, manufacturers of commercial refrigerators

and commercial freezers without doors are required to report the rated energy use 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 117­1992, Method of Testing

Closed Refrigerators, with the following specifications for the IAT:

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

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

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

• Ice­Cream C abinet: ­5 ° F ± 2 ° F (­20.6oC ± 1.1oC)

The t wo tiers of performance standards for self­contained commercial freezers (under

which ice­cream freezers are classified) will take effect April 1, 2007 and January 1, 2008,

respectively. As shown in Table 3.2.7 below, maximum daily energy consumption depends on

door type and volume.

Table 3 .2.7 Canadian Efficiency Regulations for Commercial Ice­Cream Freezers

Equipment

Type Type o f Door Volume

( V)

[Liters] Maximum D aily Energy

Consumption (E)

Effective April 1, 2007

[kWh] Maximum D aily Energy

Consumption (E)

Effective January 1, 2008

[kWh]

Self­contained Opaque < 3 40 E

= 7.62 E

= 7.07

commercial

f reezers Opaque ≥ 3 40 E

= 0.0141 V + 2.83 E

= 0.0141V + 2.28

Transparent

­ E

= 0.0332 V + 5.10

­

Source: A mendment 9 to the Energy Efficiency Regulations published in Canada Gazette Part II, November 15,

2006.

3.2.3.3 Canadian S tandards Association

CSA is a n independent standards­setting agency that establishes test procedures and

efficiency standards that are typically adopted by the Canadian government. The Canadian

standard CAN/CSA C657­04, Energy Performance Standard for Refrigerated Display Cabinets

(Merchandisers)

, applies to remote condensing commercial equipment with and without doors,

and self­contained commercial equipment with and without doors, except as covered by CSA

C827­98 (R2003). Commercial refrigerators and commercial freezers with doors (including

commercial ice­cream freezers) are covered in a separate test procedure and standard, CSA

C827­98 (R2003), Energy Performance Standard for 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 minimum energy performance standards (MEPS)

(the changes to the standard make it extremely difficult to compare levels between the 1995 and

updated standards).

The C SA C657­04 standard divides commercial refrigeration equipment into seven

classes and several sub­classes. Classes and MEPS levels from CSA C657­04 are summarized in

Table 3.2.8 below. For equipment with a remote condensing unit, the MEPS use a pre3­108 determined remote condensing unit efficiency to determine daily energy use.

Table 3 .2.8 Canadian Standards Association Equipment Classes and Efficiency Ratings

Class IAT*

( °F) Temperature Open/Closed Deck Number o f

Air

Curtains Angle o f Air

Curtain

from

Vertical MEPS

2 004

(kWh/ft

per day)

1 41.0 medium open single/multi 1 0­30° 4.0

2 41.0 medium open single/multi 1 30­60° 2.9

3 41.0 medium open single/multi 1 60­90° 1.6

4 0.0 low open multi 2 o r 3 0­30° 9.4

5 0.0 low open single 1 60­90° 4.6

6a 41.0 low/medium closed multi single v ent with glass 2.3

6b 0.0 Same a s 6a 6.1

7a 41.0 medium closed single/multi glass n/a 2.6

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

* IAT

= the average temperature of all test packages as recorded during testing.

Source: CSA C657­04, Energy Performance Standard for Refrigerated Display Cabinets (Merchandisers).

3.2.3.4 Australia

Australia h as required efficiency standards for commercial refrigeration equipment as of

October 1, 2004. 9 The standards apply to both remote condensing and self­contained

commercial equipment primarily used for the storage of chilled and frozen food. The minimum

energy performance standards are set out in Australian Standard (AS) 1731.14­2003 as total

energy consumption per total display area (TEC/TDA) in kWh/day/meter 2 (m 2 ) for various

equipment types. The Australian standards categorize equipment by the following criteria:

• Remote o r self­contained condensing unit

• Lit s helves or unlit shelves

• Number o f shelves

• Solid d oor or glass door

• Fan c oil or gravity coil

• High, m edium, or low temperature

The s tandards also specify minimum energy performance by M­package temperatures

(temperature of a load package) for self­contained cabinets. The test procedures used to measure

energy consumption are specified in AS 1731­2003.

3.2.4 Non­Regulatory I nitiatives

DOE r eviewed several voluntary programs promoting energy­efficient commercial

refrigeration equipment in the United States, including the Environmental Protection Agency

(EPA) ENERGY STAR program for solid­door commercial refrigerators and commercial

freezers, the Consortium for Energy Efficiency (CEE)’s initiative for commercial refrigeration

3­11equipment, and the Federal Energy Management Program (FEMP)’s procurement program for

energy­efficient commercial refrigerators and commercial freezers. DOE also reviewed various

rebate programs offered by local utilities.

3.2.4.1 ENERGY STAR

The EP A’s ENERGY STAR labeling program has specifications for self­contained soliddoor commercial refrigerators and commercial freezers, including commercial ice­cream

freezers. 10 This program does not apply to remote condensing commercial equipment or selfcontained commercial equipment without doors. To meet the ENERGY STAR criteria for

commercial ice­cream freezers, the maximum energy consumption allowed is as follows:

• Maximum En ergy Consumption ≤ 0.39V + 0.82 kWh/day

where V is the internal volume in cubic feet (ft 3 ).

The t est method used in the ENERGY STAR program is the ANSI/ASHRAE Standard

117­1992, Method of Testing Closed Refrigerators

. The energy consumption tests are conducted

with an IAT of ­5 ° F ± 2 ° F for commercial ice­cream freezers. The ENERGY STAR program

has no explicit mention of a test method for the measurement of internal volume.

3.2.4.2 Consortium f or Energy Efficiency

The C EE has a Commercial Kitchen Initiative for solid door and glass­door reach­in

commercial refrigerators and commercial freezers. 11 This program is based on ENERGY STAR

levels and only applies to self­contained commercial equipment with doors and is therefore not

relevant to this rulemaking. The program specifies standard levels in terms of maximum daily

energy use in kWh/day for various door types.

3.2.4.3 Federal E nergy Management Program

FEMP h as established purchasing specifications for energy­efficient equipment,

including commercial ice­cream freezers. 12 Federal purchasers are now required by EPACT

2005 to purchase equipment that is ENERGY STAR­qualified or FEMP­designated. This

equipment is in the upper 25 percent of energy efficiency in its class. The coverage of the FEMP

program is identical to the ENERGY STAR program, and is therefore not relevant to this

rulemaking.

3.2.4.4 Rebate P rograms

Several r ebate programs for commercial refrigeration equipment are offered by local

utilities, including Efficiency Vermont, the Energy 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 V ermont, an organization offering technical assistance and financial incentives

to encourage energy efficiency in the State of Vermont, offers rebates for the installation of stripcurtain covers for commercial refrigeration equipment without doors. The cash incentive is $6

per foot of display case that is covered by the curtain. 13

3­12The Energy Smart Grocer Program is funded by California utility ratepayers under the

auspices of the California Public Utilities Commission. Eligible participants include grocery and

convenience stores, food processors, and refrigerated warehouses operating in PG&E, SCE, or

SDG&E electric service territories. The program offers rebates for the use of night covers on

commercial refrigeration equipment without doors, upgrades to more efficient case lighting, and

the replacement of older equipment without doors with new high­efficiency equipment or new or

refurbished reach­ins. 14

Sierra Pacific Power and Nevada Power offer incentives promoting the installation of

energy efficient commercial refrigeration equipment through the Nevada Sure Bet Program.

These rebates are available to the utilities’ commercial, industrial, and institutional customers. In

addition to other refrigeration rebates, the program offers $4 per linear foot for the installation of

night covers on commercial refrigeration 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 efficiency commercial refrigeration

equipment. 16

Roseville Electric has a “Custom” Rebate program, which includes commercial

refrigeration equipment, in which the customer is paid for energy efficiency projects that reduce

peak kW; however, no rebates are paid on kWh savings. In this type of rebate the customer, or

their engineer, would present the project scope, including what equipment is currently installed,

what is proposed, and how the proposed equipment goes beyond what would be considered

standard for today’s replacement. Engineering calculations would be provided to show kW and

kWh savings. Roseville Electric would evaluate the customers’ proposal and advise if the

project is eligible for rebates and at what level. Typically these are paid at $400/kW, but may be

less if significant third party engineering work is required to verify the peak load reductions. 17

PG&E, SCE, and SDG&E offer rebates to business customers for retrofit refrigeration

projects through the Express Efficiency Refrigeration Program. The program provides $9 per

linear foot for night covers installed on existing commercial refrigeration equipment without

doors to all business customers. The program also gives incentives for the installation of glass

doors on existing equipment without doors. This rebate is applicable to both self­contained

commercial equipment and remote condensing commercial equipment. The rebate provides $200

per door installed on an otherwise open low­temperature display case and $150 per door installed

on a medium­ temperature display case. 18, 19, 20

3.2.5 Equipment C lasses

Commercial r efrigeration equipment can be divided into various equipment classes

categorized by physical characteristics that affect the efficiency of the equipment. Most of these

characteristics affect the merchandise that the equipment can be used to display, and how that

merchandise can be accessed by the customer. 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 angle of the door or air curtain (i.e., horizontal, semivertical,

or vertical) and the type of condensing unit (i.e., remote or self­contained). The following list

3­13shows the key physical characteristics of commercial refrigeration equipment that DOE

identified in its Framework document:

1. Operating Te mperature

• Medium t emperature (38 °F, refrigerators)

• Low temperature ( 0 °F, freezers)

• Ice­cream t emperature (­15 °F, ice­cream freezers)

2. Door T ype

• Equipment w ith transparent doors

• Equipment w ith solid doors

• Equipment w ithout doors

3. Orientation ( air­curtain or door angle)

• Horizontal

• Semivertical

• Vertical

4. Type o f Condensing Unit

• Remote c ondensing

• Self­contained

An a lternate organization of equipment classes for commercial refrigeration equipment

was proposed by ARI 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 w ithout doors (air­curtain angle of 0 to 10° from the vertical),

• semivertical w ithout doors (air­curtain angle of 10 to 80° from the vertical),

• horizontal w ithout doors (air­curtain angle of 80 to 90° from the vertical),

• vertical w ith doors,

• horizontal w ith doors, and

• service o ver­counter.

One e quipment family proposed by ARI, “service over­counter,” was not included in the

DOE organization of equipment classes and is unique in that it is designed to display products,

but access to the products is from the backside of the cabinet. This equipment is designed to

merchandise products for which access is typically provided only to sales personnel. DOE feels

that this equipment family is necessary, as this type of equipment provides a different utility to

the end­user than any of the other proposed classes.

As w ith DOE’s equipment class organization, ARI’s organization differentiates

equipment by operating temperature. In addition to the three temperatures proposed by DOE

(medium, low, and ice cream), ARI proposed a third temperature category: an “application”

temperature. ARI explained that the application temperature category would allow

manufacturers to test equipment at some temperature other than the three proposed by DOE, for

models that could not be tested at one of those temperatures.

3­14DOE examined the shipment data provided by ARI (see section 3.2.6) to determine the

relative magnitude of equipment that operates at an application temperature compared to

equipment that operates at one of the three temperatures proposed by DOE. Excluding

equipment for which EPACT 2005 amended EPCA to set standards (self­contained commercial

refrigerators and commercial freezers with doors), there were 170,949 units of remote

condensing and self­contained equipment shipped in 2005 (shipments of commercial

refrigerator­freezers were not reported, but are considered very small). Of the total shipments,

only 1.7 percent were self­contained and remote condensing equipment that operate at 45 ° F,

20 ° F, 10 ° F, or ­30 ° F (application temperatures), and 98.3 percent were of self­contained 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 were predominately remote condensing equipment. There were 1,834 units

of remote condensing wine chillers shipped in 2005. Comparatively, in 2005 there were 85,001

units of remote condensing refrigerators that operate at 38 ° F.

DOE’s t est procedure for commercial refrigeration equipment, (see chapter 2) requires

that all equipment, including equipment designed to operate at application temperatures, be

tested at one of the three rating temperatures: 38 ° F for refrigerators, 0 ° F for freezers, and ­15 ° F

for ice­cream freezers. Given the relatively low shipment volumes of equipment that operates at

application temperatures, as well as DOE’s understanding that some of this equipment already

can operate and be tested at one of the standard rating temperatures and that manufacturers might

be able to redesign other equipment in relatively minor ways to have these capabilities, DOE

believes this requirement will not place an unreasonable burden on manufacturers. In addition, if

necessary, manufacturers could seek waivers from the DOE test procedure, pursuant to 10 CFR

431.401. For these reasons, DOE does not intend to develop separate standards for equipment

that operates at application temperatures.

DOE i s proposing to organize its equipment classes in a manner similar to ARI, and used

the six ARI equipment families as a starting point to develop its list of equipment classes. The

“vertical with doors” equipment class and the “horizontal with doors” equipment class were split

into two each based on having either transparent doors or solid doors. Table 3.2.9 shows the

eight commercial refrigeration equipment families DOE is proposing.

3­15Table 3.2.9 Commercial Refrigeration Equipment Families

Equipment Family Designation Description

Vertical O pen VOP equipment w ithout doors and an air­curtain angle greater

than or equal to 0° and less than 10°

Semivertical O pen SVO equipment w ithout doors and an air­curtain angle greater

than or equal to 10° and less than 80°

Horizontal O pen HZO equipment w ithout doors and an air­curtain angle greater

than or equal to 80°

Vertical C losed Transparent VCT equipment w ith hinged or sliding transparent doors and a

door angle less than 45°

Vertical C losed Solid VCS equipment w ith hinged or sliding transparent doors and a

door angle greater than or equal to 45°

Horizontal C losed Transparent HCT equipment w ith hinged or sliding solid (opaque) doors and

a door angle less than 45°

Horizontal C losed Solid HCS equipment w ith hinged or sliding solid (opaque) doors and

a door angle greater than or equal to 45°

Service O ver Counter SOC equipment w ith sliding or hinged doors intended for use

by sales personnel and fixed or hinged glass for displaying

merchandise

Within each of these eight equipment families are 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 efficient than self­contained

because of the use of large, multiplex compressor rack systems that feed multiple pieces of

equipment. Remote condensing equipment cannot be easily relocated, due to the refrigerant

piping required, whereas self­contained equipment is more mobile, requiring only an electrical

outlet for operation.

The o perating temperature of the equipment also has a significant impact on utility and

energy use, and can be medium (M), low (L) or ice­cream (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 is a necessary

distinction. The larger temperature differences and thermodynamic behavior of refrigerants

means that equipment with lower operating temperatures runs less efficiently than equipment

with higher operating temperatures.

For o pen cases, vertical represents an air­curtain angle of <10 ° from the vertical,

semivertical represents an air­curtain angle of ≥10 ° and <80 ° from the vertical, and horizontal

represents an air­curtain angle of ≥ 80 ° from the vertical. DOE could not identify an existing

industry definition of air­curtain angle, but developed a preliminary definition for consideration.

DOE is considering defining air­curtain angle as “the angle between a vertical line and the line

formed by the points at the center of the discharge air grille and the center of the return air grille,

when viewed in cross­section.”

3­16For closed cases, vertical represents a door angle of <45° from the vertical, and

horizontal represents a door angle of ≥45° from the vertical. DOE did not receive stakeholder

feedback on how to define the door angle for equipment with doors, but is considering defining

door angle as “the angle between a vertical line and the line formed by the plane of the door,

when viewed in cross­section.”

Using a ll combinations of equipment families, operating mode and temperature, 48

equipment classes are possible, as illustrated in Table 3.2.10. However, self­contained

equipment with doors that operate at a medium temperature, low temperature, or both, already

had standards established in EPACT 2005. Therefore, these ten equipment classes are not

included in this rulemaking and are indicated by asterisks in Table 3.2.10.

DOE a lso developed a lettering system to simplify discussion of equipment classes. The

lettering designation for a particular equipment class consists of the lettering abbreviations for

the equipment family, operating mode and temperature, separated by periods. A complete list of

equipment classes with lettering designations is shown in Table 3.2.10, organized by family,

operating­mode, and temperature.

3­17Table 3.2.10 Commercial Refrigeration Equipment Classes

Equipment Family Equipment

F amily

Designation Equipment

F amily Image Operating

M ode

Designation Temperature

D esignation Equipment C lass

Designation

M (38°F) VOP.RC.M

RC L ( 0°F) VOP.RC.L

Vertical Op en VOP I ( ­15°F) VOP.RC.I

M ( 38°F) VOP.SC.M

SC L ( 0°F) VOP.SC.L

I ( ­15°F) VOP.SC.I

M ( 38°F) SVO.RC.M

RC L ( 0°F) SVO.RC.L

Semivertical Op en SVO I ( ­15°F) SVO.RC.I

M ( 38°F) SVO.SC.M

SC L ( 0°F) SVO.SC.L

I ( ­15°F) SVO.SC.I

M ( 38°F) HZO.RC.M

RC L ( 0°F) HZO.RC.L

Horizontal O pen HZO I ( ­15°F) HZO.RC.I

M ( 38°F) HZO.SC.M

SC L ( 0°F) HZO.SC.L

I ( ­15°F) HZO.SC.I

M ( 38°F) VCT.RC.M

RC L ( 0°F) VCT.RC.L

Vertical C losed VCT I ( ­15°F) VCT.RC.I

Transparent M ( 38°F) VCT.SC.M*

SC L ( 0°F) VCT.SC.L*

I ( ­15°F) VCT.SC.I

M ( 38°F) VCS.RC.M

RC L ( 0°F) VCS.RC.L

Vertical C losed Solid VCS I ( ­15°F) VCS.RC.I

M ( 38°F) VCS.SC.M*

SC L ( 0°F) VCS.SC.L*

I ( ­15°F) VCS.SC.I

M ( 38°F) HCT.RC.M

RC L ( 0°F) HCT.RC.L

Horizontal C losed HCT I ( ­15°F) HCT.RC.I

Transparent M ( 38°F) HCT.SC.M*

SC L ( 0°F) HCT.SC.L*

I ( ­15°F) HCT.SC.I

M ( 38°F) HCS.RC.M

RC L ( 0°F) HCS.RC.L

Horizontal C losed HCS I ( ­15°F) HCS.RC.I

Solid M ( 38°F) HCS.SC.M*

SC L ( 0°F) HCS.SC.L*

I ( ­15°F) HCS.SC.I

M ( 38°F) SOC.RC.M

RC L ( 0°F) SOC.RC.L

Service O ver Counter SOC 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 e quipment classes have standards established by EPACT 2005 and are therefore not covered under this

rulemaking.

3­183.2.6 Shipments

As pa rt of its comments on the Framework Document (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, since not all major manufacturers

are represented by ARI. c However, because these data cover the vast majority of the remote

condensing equipment sold, and because no other detailed data were available, the ARI shipment

data became the basis of DOE’s analysis.

Table 3 .2.11 shows 2005 annual shipments for each category of commercial refrigeration

equipment by equipment class. The ARI data included 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 shipments of equipment at the three temperatures

considered in this rulemaking (38°F, 0°F, and ­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 reported by ARI.

Most notably, True Manufacturing, which DOE understands has a large market share of self­contained equipment

with doors and ice­cream freezers.

3­19 cTable 3.2.11 Air­Conditioning and Refrigeration Institute Shipments of Commercial

Refrigerators and Freezers by Equipment Class

Equipment

Family Equipment

F amily

Designation Operating

M ode

Designation Temperature

D esignation Equipment

C lass

Designation ARI

S hipments**

M (38°F) VOP.RC.M 38743

RC L ( 0°F) VOP.RC.L 0

Vertical Op en VOP I ( ­15°F) VOP.RC.I 0

M ( 38°F) VOP.SC.M 6512

SC L ( 0°F) VOP.SC.L 0

I ( ­15°F) VOP.SC.I 0

M ( 38°F) SVO.RC.M 29552

RC L ( 0°F) SVO.RC.L 0

Semivertical SVO I ( ­15°F) SVO.RC.I 0

Open M ( 38°F) SVO.SC.M 9750

SC L ( 0°F) SVO.SC.L 0

I ( ­15°F) SVO.SC.I 0

M ( 38°F) HZO.RC.M 4541

RC L ( 0°F) HZO.RC.L 14278

Horizontal O pen HZO I ( ­15°F) HZO.RC.I 0

M ( 38°F) HZO.SC.M 838

SC L ( 0°F) HZO.SC.L 1738

I ( ­15°F) HZO.SC.I 0

M ( 38°F) VCT.RC.M 2767

RC L ( 0°F) VCT.RC.L 38483

Vertical C losed VCT I ( ­15°F) VCT.RC.I 0

Transparent M ( 38°F) VCT.SC.M* 43374*

SC L ( 0°F) VCT.SC.L* 2472*

I ( ­15°F) VCT.SC.I 1898

M ( 38°F) VCS.RC.M 49

RC L ( 0°F) VCS.RC.L 2

Vertical C losed VCS I ( ­15°F) VCS.RC.I 43

Solid M ( 38°F) VCS.SC.M* 4*

SC L ( 0°F) VCS.SC.L* 4202*

I ( ­15°F) VCS.SC.I 470

M ( 38°F) HCT.RC.M 0

Horizontal

C losed

Transparent HCT RC 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 9056

M ( 38°F) HCS.RC.M 37

RC L ( 0°F) HCS.RC.L 0

Horizontal HCS I ( ­15°F) HCS.RC.I 0

Closed S olid M ( 38°F) HCS.SC.M* 39761*

SC L ( 0°F) HCS.SC.L* 4109*

I ( ­15°F) HCS.SC.I 0

M ( 38°F) SOC.RC.M 9312

RC L ( 0°F) SOC.RC.L 9

Service O ver SOC I ( ­15°F) SOC.RC.I 0

Counter

SC M ( 38°F) SOC.SC.M* 1108*

L ( 0°F) SOC.SC.L* 0*

I ( ­15°F) SOC.SC.I 0

* These e quipment classes have standards established by EPACT 2005 and are therefore not covered under this

rulemaking.

**Source: ARI, No. 7 Exhibit B at p. 1.

3­203.2.6.1 Appliance M agazine Data

Appliance M agazine publishes historical and forecasted shipments of refrigerated display

cases, which are shown in Table 3.2.12 and Table 3.2.13. As mentioned earlier, Appliance

Magazine describes the data as representing refrigerated display cases but does not provide a

precise definition of the equipment. It is unclear what types of equipment this term covers–

whether it is equipment that is self­contained or remote condensing, or equipment with doors or

without doors. For this rulemaking, only the self­contained equipment without doors and all

remote condensing equipment are applicable.

Table 3 .2.12 Historical Shipments of Refrigerated Display Cases

Year Unit S hipments

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: A ppliance Magazine

, 53 rd Annual Statistical Review

, May 2006.

Table 3.2.13 Statistical Forecasts of Refrigerated Display­Cases Shipments

Year Unit S hipments

2007 181,000

2008 185,000

Source: A ppliance Magazine

, 54 th Appliance Industry Forecasts

, January 2006.

It is unclear what is responsible for the sharp decline in unit shipments between 2000 and

2001 reported by A ppliance Magazine

. A similar decline is reported in other market literature,

followed by an increase in shipments predicted by 2008. 21 It is believed 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 quarter of 2001. Financial reports by CRE manufacturers discuss depressed

investment and uncertainty in the retail food industry during the period from 2000 to 2005 as

contributing factors to low sales of commercial refrigeration equipment. There may also be

other explanations including possible changes in what equipment is included in “refrigerated

display cases” by Appliance Magazine

.

3.2.6.2 Current I ndustrial Reports

The U .S. Census Bureau’s Economic Census of Manufacturing Industry Series and its

Current Industrial Reports (CIRs) publish statistics on the quantity and value of shipments for

those companies with shipments over $100,000 in value. 22,23 There are eight categories for

3­21­­ display cabinets and display cases, including “reach­ins”. These are sub­divided into reach­in,

closed display, and open display. As is evident from the tables provided below, the data reported

in the CIRs are not complete (i.e., shipments data are not provided for most sub­categories). d

The data also indicates some very large changes in the value of shipments between 1992, 1997

and 2002.

Table 3 .2.14 shows shipment data for open refrigerated display cases, which include both

self­contained units without doors and remote condensing units without doors. It is not possible

from Table 3.2.14 to determine which shipments are for self­contained units and which are for

remote condensing units as the census data reports these together in all reported data. Only the

self­contained open refrigerated display cases and remote condensing open refrigerated display

cases are applicable in this rulemaking.

Table 3 .2.14 Shipments of Open Refrigerated Display Cases (Remote Condensing and SelfContained)

Number of

Type Open o r

Closed Temperature Survey Y ear Companies w ith

Sales over Shipment

Q uantity Shipment

V alue

$100,000 (1000's) ($1000)

Display C ase

One Level Open Normal 2002 6

­ 89,622

1997 13

­ 140,259

1992 12

­ 142,268

Display C ase

Multi Level Open Normal 2002 9

­ 341,472

1997 11 58.6 258,310

1992 9

­ 151,760

2002 6

­ 11,538

Display C ase Open Frozen F ood 1997 7 20.4 90,213

1992 8 61,776

Source: U .S. Census, Current Industrial Reports, http://www.census.gov/cir/www/index.html; U.S. Census,

Economic Census, Manufacturing Industry Series 1997, EC97M­3334D,

http://www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing Industry Series

2002, EC02­31I­333415 (RV), http://www.census.gov/econ/census02/

Table 3.2.15 shows shipment data for closed refrigerated display cases, which include

both self­contained units with doors and remote condensing units with doors. It is not possible

from Table 3.2.15 to determine which shipments are for remote condensing units. Only the

remote condensing closed refrigerated display cases are covered in this rulemaking.

d 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.

3­22Table 3.2.15 Shipments of Closed Refrigerated Display Cases (Remote Condensing and

Self­Contained)

Number of

Type Open o r

Closed Temperature Survey Y ear Companies w ith

Sales Over Shipment

Q uantity Shipment

V alue

$100,000 (1000's) ($1000)

2002 11

­ 50,601

Display C ase Closed Normal 1997 15

­ 91,892

1992 14

­ 43,576

2002 8

­ 20,618

Cabinet Closed Frozen F ood 1997 9

­ 112,873

1992 6 38,171

Other 2002 7

­ 58,549

Display

C ases Not s tated Low T emp. 1997 6

­ 43,150

1992 9 9.6 39,629

Source: U .S. Census, Current Industrial Reports, http://www.census.gov/cir/www/index.html; U.S. Census,

Economic Census, Manufacturing Industry Series 1997, EC97M­3334D,

http://www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing Industry Series

2002, EC02­31I­333415 (RV), http://www.census.gov/econ/census02/

For the data in Table 3.2.14 and Table 3.2.15, the following two commercial refrigeration

equipment sub­categories are not included:

• Commercial r each­in refrigerators and reach­in vertical display cabinets for normal

temperature applications (not intended for frozen foods, etc.) including self­contained

and remote units.

• Commercial r each­in refrigerators and reach­in type vertical display cabinets for lowtemperature applications, including self­contained and remote units.

Table 3 .2.16 shows shipment data for commercial reach­in (vertical) cabinets (including

self­contained units and remote condensing units). These cabinets can have either solid or

glazed doors. It is not possible from Table 3.2.16 to determine which shipments are for remote

condensing units and which shipments are for self­contained units. Only the remote condensing

reach­in cabinets are covered in this rulemaking.

3­23Table 3.2.16 Shipments of Commercial Reach­In Cabinets (Remote Condensing and SelfContained)

Number of

Type Open o r

Closed Temperature Survey Y ear Companies w ith

Sales Over Shipment

Q uantity Shipment

V alue

$100,000 (1000's) ($1000)

Display

C abinets

­ 2002 21 381.7 465,553

Not f or Not Normal 1997 29

­ 439,081

Frozen

F oods Specified

1992 31 165.8 224,018

Display

C abinet Not

Sp ecified Low

T emperature 2002 16

­ 259,105

1997 24

­ 307,605

1992 24 59.5 219,544

Source: U .S. Census, Current Industrial Reports, http://www.census.gov/cir/www/index.html; U.S. Census,

Economic Census, Manufacturing Industry Series 1997, EC97M­3334D,

http://www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing Industry Series

2002, EC02­31I­333415 (RV), 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 analyses, not enough detail is provided in the data

to provide specific assessments for shipments within each of the three primary categories

covered in this rulemaking (i.e., commercial ice­cream freezers, self­contained commercial

equipment without doors, and remote condensing equipment).

3.2.7 Equipment L ifetimes

DOE r eviewed available literature and consulted with experts on commercial

refrigeration equipment in order to establish typical equipment lifetimes. The literature and

individuals consulted estimated a wide range of typical equipment lifetimes, as shown in Table

3.2.17.

Individuals w ith previous experience 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 remodeling (typically every 10 years or so).

Consultation with one distributor suggested that U.S. tax depreciation schedules (which allow

depreciation over a 5­year period for retail fixtures, including commercial refrigerators and

commercial freezers) 24 are one driver for regular replacement of commercial refrigeration

equipment in the United States.

Some l iterature reviewed suggested longer lifetimes of up to 20 years or more for

commercial refrigeration equipment. Many of the studies cited 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 lifetime of the compressor racks. 25 However,

consultation with experts in the field suggested that smaller, independently owned grocery stores

were more likely to keep equipment longer than larger chain stores.

3­24Several industry experts suggested there is a significant used/refurbished equipment

market. However, the size of the used market relative to the new market was not determined.

Those consulted generally agreed that the salvage value of used equipment was very low

compared to the initial purchase price. This is due to both cosmetic concerns and the custom

nature of much of the equipment. Additionally, the difficulty in collecting used equipment of the

same “look” for planned display case line­ups was cited as another reason for the low price of

used equipment. A survey in the Pacific Northwest reported that for small, independent grocery

stores (<20,000 square feet) and for independently 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 fraction was approximately 11 percent. None of

the large grocery chains surveyed had plans to purchase refurbished equipment.

Table 3 .2.17 Estimates for Commercial Refrigeration Equipment Lifetimes

Life Reference

15 y ears “New Y ork Energy $martSM Program Cost­Effectiveness Assessment

December 2 004, NYSERDA 26

5­7 years

(Large Chains) Verisae 27

15 years

(Smaller chains and independent

grocers. May go up to 20 years) Verisae 28

7­15 years Mark E llis & Associates 29

, New Zealand Minimum Energy Performance

Standards for Commercial Refrigeration Cabinets

15 y ear Foster­Miller ( 2001) 30

15­20 years EPA ( 2001) 31

15 years Arthur D

. Little (ADL) (2002) 32

9­10 years

(9 years with doors, 10 years

without doors) CEC 2004 33

5­15 years (Typical 10 years) Hansen 2 006 34

10 years PG&E 2 004 3

7­10 years (remote condenser) Intergovernmental P anel on Climate Change (IPCC) 2001 35

8­12 years (self contained)

7 y ears Fisher 1 991 36

3.2.8 Market Pe rformance Data

DOE c onducted a survey of existing remote condensing refrigerated equipment from

major manufacturers and compiled a performance database. The primary source of information

for the database was equipment data sheets that were publicly available on manufacturers’

websites. From these data sheets, equipment information such as total refrigeration load,

evaporator temperature, lighting power draw, defrost power draw, and motor power draw

allowed determination of calculated daily energy consumption (CDEC) according to the test

procedure in ARI Standard 1200­2006, Performance Rating of Commercial Refrigerated Display

Merchandisers and Storage Cabinets. Figure 3.2.2 through Figure 3.2.5 show CDEC values as a

function of TDA for select remote condensing equipment classes. Figure 3.2.6 shows the

relationship between air­curtain angle (measured from the vertical) and CDEC/TDA for the

VOP.RC.M, SVO.RC.M, and HZO.RC.M equipment classes.

3­25Figure 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

3­26Figure 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

3­27Figure 3.2.6 Market Performance Data for the VOP.RC.M, SVO.RC.M, and

HZO.RC.M E quipment Classes: Comparison of Air­Curtain Angles

3.3 TECHNOLOGY ASSESSMENT

The pu rpose of the technology assessment is to develop a preliminary list of technologies

that could potentially be used to improve the efficiency of commercial refrigeration equipment.

The following assessment provides descriptions of technologies and designs that apply to all

equipment classes; designs that apply to equipment without doors only; and technologies and

designs that apply to self­contained equipment only.

3.3.1 Technologies a nd Designs Relevant to All Equipment Classes

The f ollowing technologies and designs are relevant to all equipment classes: higher

efficiency lighting, higher efficiency ballasts, remote ballast location, higher efficiency

expansion valves, higher efficiency evaporator fan motors, evaporator fan motor controllers,

higher efficiency evaporator fan blades, increased evaporator surface area, low pressure

differential evaporators, anti­sweat heater controllers, insulation increases or improvements,

defrost mechanism, and defrost cycle control.

3.3.1.1 Higher E fficiency Lighting

Commercial r efrigeration equipment often includes lighting to illuminate the contents.

Some commercial refrigeration equipment also includes an illuminated sign on the exterior of the

unit. Higher­efficiency lighting leads to energy savings in two ways: less energy is used directly

for lighting, and less heat energy is dissipated into the refrigerated case by the lamp. Efficiency

3­28in lighting is commonly measured as efficacy (lumens/watt), or the quantity of light output

(lumens) per electrical energy input (watts, W).

Recently, t he commercial refrigeration industry has been moving toward using T­8

fluorescent lighting in all cases. T­8 lighting is substantially more efficacious than T­12 lighting,

and is predominantly used with electronic ballasts, which are more efficient than magnetic

ballasts commonly used in T­12 lighting. The industry is also increasingly interested in T­5

lighting, although T­5 lighting systems are not significantly more efficacious than T­8 systems.

An e ven more recent trend is the use of light emitting diode (LED) technology. Although

LEDs are less efficacious than fluorescent technology, they are more directional than linear

fluorescent bulbs, allowing for comparable product illumination with less total wattage. There

have been recent advancements in LED efficacy as well as the adoption of LED technology by

large food retailers. 37 Research by the Lighting Resource Center indicates that lighting display

cases using LEDs were found desirable by consumers. LEDs are predicted to steadily increase in

efficacy and decrease in cost as technology improves. 38

3.3.1.2 Higher E fficiency Lighting Ballasts

Higher e fficiency lighting ballasts reduce energy consumption by requiring less electrical

power to operate, and by reducing waste heat generation, which contributes to case heat load.

Most i lluminated display cases in supermarkets use fluorescent lighting with magnetic

ballasts, which use inductance to modulate power flow to fluorescent lamps. Magnetic ballasts

have significant electrical resistance losses. Electronic 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. In addition, fluorescent lamps operate more efficiently at the higher frequency

provided by electronic ballasts.

In a ddition to the direct reductions in electrical power consumption, heat generated by the

lighting and the lighting ballast contribute to the case heat load. By increasing ballast efficiency,

the compressor load is also reduced.

3.3.1.3 Remote L ighting Ballast Location

Because l amp ballasts may be located remotely from the fluorescent lamps they power,

they may be located within the display case cabinet but outside of the refrigerated space,

reducing heat load and case energy consumption.

3.3.1.4 Higher E fficiency Expansion Valves

Expansion v alves are refrigerant metering devices whose purpose is to 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 liquid­vapor mixture. The low

temperature of the refrigerant leaving the expansion valve creates the driving force to move heat

out of the refrigerated space and into the evaporator.

3­29The most basic type of expansion device is a capillary tube, which may be found in small

self­contained commercial refrigeration equipment. The capillary tube is a long, thin piece of

pipe that creates a pressure drop in the refrigerant 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 worst­case conditions, and therefore may operate at

reduced efficiency during normal operation.

The t hermostatic expansion valve (TXV) is common in remote condensing commercial

refrigeration equipment. This device uses an orifice to reduce the pressure of the entering

refrigerant and a sensing bulb to monitor and maintain 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 efficient than the capillary tube device under varying

conditions. However, a TXV will likely not provide significant energy savings over a properly

sized capillary tube under steady­state conditions.

The e lectronic expansion valve (EEV) is similar to the TXV, but uses an electronic

control system to optimize refrigeration­system performance under all operating conditions.

Because it does this with greater flexibility than that allowed by a TXV, an EEV theoretically

allows for increases in energy efficiency under varying conditions. However, as with the TXV,

an EEV will likely not provide significant energy savings over a properly sized capillary tube or

over a TXV under steady­state conditions.

3.3.1.5 Higher E fficiency Evaporator Fan Motors

Evaporator f an motors are fractional horsepower in size, are responsible for moving air

across the evaporator 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

conditions. Higher efficiency evaporator fan motors reduce energy consumption by requiring

less electrical power to generate motor shaft output power.

Electric m otors operate based on the interaction 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 reversed in a brushless motor. The electromagnetic interactions

between these two magnets cause the rotor to rotate.

The s implest type of electric motors—single­phase electric motors—suffer from a serious

shortcoming. Single­phase 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 single­phase motors is the way

in which they handle this start­up problem.

Nearly a ll inexpensive fan motors are of either the shaded­pole or the permanent split

capacitor (PSC) variety, and the same is most likely true for standard commercial refrigeration

equipment fan motors (fan motors not marketed as “high efficiency”). In both cases, the

electromagnet consists of windings of electrical wire through which current is driven. In a

shaded­pole 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 generated by the un­shaded

3­30portion induce rotation when the motor is powered. Because the imbalance between the shaded

and unshaded portions of the magnet remains throughout operation, however, shaded­pole

motors are inefficient, with typical motor efficiencies less than 20 percent. 39 Shaded­pole motors

are, however, electrically simple and inexpensive.

In a PSC motor, a smaller, start­up winding is present in addition to the main winding.

The start­up winding is electrically 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 start

up winding and that generated by the main winding induce rotation. Because of the capacitor,

however, the current to the start­up winding is cut off as the motor reaches steady state. Because

of this, PSC motors are more energy efficient than their shaded­pole counterparts, with motor

efficiencies ranging from 50 to 70 percent. Like shaded­pole motors, PSC motors are produced

in large quantities and are relatively inexpensive. 40 Commercial refrigeration equipment fan

energy efficiency can be substantially improved by replacing shaded­pole motors, in the models

that use them, with PSC motors.

A third t ype of electric motor, the electronically­commutated permanent magnet (ECM)

motor (also known as the brushless permanent magnet motor), is more energy­efficient than

either shaded­pole or PSC motors. ECM motors, which are sold in high volumes, are threephase electric motors with efficiencies even greater 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 F an Motor Controllers

Evaporator f an motor controllers allow fan motors to run at variable speed to match

changing conditions in the case. During periods of frost build­up, fan motor power requirements

increase; during the post­defrost period, power requirements decrease. Matching the fan speed

to all conditions ensures more stable 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 different ambient humidity and temperature levels.

3.3.1.7 Higher E fficiency Evaporator Fan Blades

High e fficiency evaporator fan blades, or tangential evaporator fans, move air more

efficiently, yielding energy consumption savings by reducing the required fan shaft power. The

evaporator fans typically used in commercial refrigeration equipment have sheet metal blades.

The blades are typically supplied by a fan blade manufacturer and mounted to the motor by the

equipment manufacturer. These fan blades are not optimized for commercial refrigeration

equipment. Evaporator fans may have lower efficiencies due to the higher required pressure

drops, for which sheet metal fans are not well suited. Required fan shaft power could be reduced

if the fan blades were optimized for each given application.

Tangential f ans also provide an opportunity to decrease equipment energy consumption. 41

Tangential fans utilize a vortex builder to generate a uniform airflow over a large surface. This

makes them better suited to evaporator and condenser fans, which need to distribute airflow over

a large coil surface area. A single long tangential fan can meet the airflow requirements for an

entire refrigerated cabinet, while requiring a single high­efficiency fan motor.

3­313.3.1.8 Increased Evaporator Surface Area

The evaporator is a refrigerant­to­air heat exchanger composed of metals with high

thermal conductivity such as aluminum and copper. It is responsible for evaporating and

superheating the entering refrigerant liquid­vapor mixture while extracting heat from the air in

the refrigerated space. The internal heat­exchanging surfaces in contact with refrigerant are

commonly referred to as “refrigerant­side” while the external heat­exchanging surfaces in

contact with the air are referred to as “air­side.”

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 drive 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 refrigeration load and the thermal

characteristics of the evaporator as shown in Equation 3.1:

Q DAT

− SET = Δ T = Eq. 3.1

UA

where

Q is the total refrigeration load [Btu/h],

U is the heat transfer coefficient of the evaporator [Btu/ ° F/ft 2 ],

A is the area of the evaporator [ft 2 ], and

ΔT is the temperature difference between the discharge air temperature and evaporator

temperature [ ° F].

Increasing t he area of the coil will decrease the necessary ΔT and therefore decrease the SET.

This results in an increased compressor energy efficiency ratio (EER) and lower compressor

energy consumption.

Enhancements t o the refrigerant­side surface area of the evaporator typically include

rifled or diamond­pattern tubing and increased number of tube passes. Enhancements to the airside surface area include increased fin pitch (decreased fin spacing), fin patterns (wavy or zigzag), and increased numbers of tube passes.

Increasing t he overall size of the coil in one or more dimensions without changing other

aspects of the coil is another way to increase the 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 P ressure Differential Evaporators

Decreasing t he air­side pressure drop of an evaporator coil allows for the use of lowerpower 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” which can completely block airflow through portions of the coil.

3­323.3.1.10 Anti­Sweat H eater Controllers

Anti­sweat h eating controllers match the on­time of anti­sweat heaters to the anti­sweat

heating requirements imposed by the ambient humidity, reducing energy consumption when

ambient humidity is low. Anti­sweat heating is necessary to prevent moisture condensation on

surfaces of display cases, the temperatures of which can be below the ambient dew point.

Freezer­door g askets are a typical example of such a surface. Anti­sweat heaters on

freezer­door gaskets are typically always on, but the installation of controls that sense ambient

humidity levels can turn off the heater when anti­sweat heating is not required, reducing

electricity consumption. Such control requires measuring the local dew point or relative

humidity, and measuring external surface temperatures. A particular heater can be turned on

when the temperature of a particular surface falls below the dew point, or the heaters can be

cycled with on­times increasing with dew point. Reducing anti­sweat heater on­time will also

yield additional energy savings in case heat load reductions, since anti­sweat heaters contribute

to case heat load.

In a ddition, it is possible that electric anti­sweat heaters could be replaced by a hot­gas

line running around the doorframe. Although manufacturers have claimed that this is a difficult

technology to implement, it has seen widespread and successful use in residential freezers.

3.3.1.11 Improved o r Thicker Insulation

Either i ncreasing the insulation thickness or reducing insulation conductivity will reduce

the energy consumption of commercial refrigeration equipment. Typical insulation thickness for

refrigerated display cases ranges from 1.5 to 2 inches. Blow­in polyurethane foam is used for

most cases. The impact of an increase in insulation thickness and insulation quality is limited for

open cases by the fact that a large portion of the cooling load is due to infiltration.

Improved­technology po lyurethane foam insulation has a 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 cell­size consistency. Use of the better foam would reduce

case wall load, assuming no wall thickness change.

The i mportance of case volume suggests that technologies that would allow reduction in

insulation thickness while maintaining thermal resistivity (R­value) would be of interest.

Vacuum panels could provide such performance. Vacuum panels are airtight panels sealed with

glass or plastic, which are evacuated to eliminate a conduction path. They are generally filled

with supporting powder that prevents collapse of the external seal. Much work needs to be done

to demonstrate the reliability of vacuum panels to show that they will perform for many years

without leaking and losing their insulating value. Additionally, current­technology vacuum

panels do not provide the necessary structural rigidity between sheet metal panels that is possible

with foamed­in­place polyurethane insulation.

3.3.1.12 Defrost M echanism

As t he air in the refrigerated space is cooled, water vapor condenses on the surface of the

evaporator coil. In refrigerators and freezers, where the evaporator coil is below 32°F, this water

3­33freezes as it collects, forming a growing layer of frost. The frost reduces cooling performance by

increasing the thermal resistance to heat transfer 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 a re several methods available for defrosting the evaporator coil: off­cycle defrost,

electric defrost, and hot­gas defrost. Off­cycle 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 the frost. Electric defrost is used where the

air temperature is not high enough to defrost the coil, and where defrost must occur quickly to

prevent any significant rise in product temperature. Electric defrost involves melting frost by

briefly turning on an electric resistance heater, which is in contact with or near the evaporator

coil.

Hot­gas d efrost is only applicable to remote condensing systems and involves the use of

the hot compressor discharge gas to warm the evaporator from the refrigerant side. Electricity

usage is reduced in comparison to the electric defrost method because available heat, which

would otherwise be rejected in the condenser, is used. The hot gas defrost system requires more

complicated piping and control than electric defrost. An additional drawback is the thermal

stress inflicted upon the refrigerant piping by the alternating flow of hot gas and cold refrigerant.

3.3.1.13 Defrost C ycle Control

Defrost­cycle c ontrol involves management of the initiation and termination of defrost

cycles, and thereby the frequency and duration of defrost cycles. In the past, defrost cycles were

completely scheduled, and initiation and termination were timer­controlled. Cycles were

initiated at regular intervals, and terminated after a fixed amount of time. Cycle frequency and

duration were then unrelated to actual frost conditions. 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 worst­case scenario, and the cycle duration long enough to ensure

complete defrost in the worst­case scenario. Timer­based defrost can lead to unnecessarily

frequent and long defrost cycles.

The c urrent practice involves scheduled cycle initiation, determined by a timer, and

demand­based cycle termination, determined by temperature sensors. Defrost cycles are still

initiated at regular intervals, but are terminated when the coil temperature reaches a value

indicating complete defrost. Partial demand­based defrost saves energy relative to fully

scheduled defrost by limiting cycle duration, but cycle frequency can still be high.

Fully d emand­based defrost would eliminate unnecessary defrost cycles. Two methods

currently exist for carrying out demand­based defrost—measurement of cross­coil airtemperature drop and optical detection of frost buildup. Problems with these methods are

associated with possible reduction of airflow for reasons other than coil frosting: dust collection,

evaporator fan problems, varying product fill levels, and external flow disturbances.

3­343.3.1.14 Thermoacoustic R efrigeration

Thermoacoustic r efrigeration is a technology that uses high­amplitude sound waves in a

pressurized gas to pump heat from one place to another. A device consisting of a series of small

parallel channels, referred 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 l ongitudinal standing sound wave causes the gas particles to oscillate back and forth

parallel to the walls of the stack. The alternating compression and rarefaction 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 that of the nearby stack wall, heat is transferred

from the gas to the stack wall. If the local temperature of the gas drops below that of the stack

wall, heat is transferred from the wall to the gas.

Prototypes o f thermoacoustic refrigerators have been demonstrated for commercial

refrigeration applications. A prototype thermoacoustic refrigeration unit designed for an icecream freezer has been measured to be as efficient as the vapor compression unit it replaces.

This technology is expected to improve in efficiency with further development of heat

exchangers and other subsystems. It is also likely that efficiency in many applications could

improve because thermoacoustic refrigerators are well suited to proportional control, where the

cooling capacity can be continuously controlled so that the output can be adjusted accurately for

varying load conditions. Although, this technology currently does not improve upon the

efficiencies of conventional refrigeration technology, thermoacoustic refrigeration has the

environmental benefit of being refrigerant­free.

3.3.1.15 Magnetic R efrigeration

Magnetic r efrigeration utilizes the magneto­caloric effect where magneto­caloric

materials like gadolinium absorb heat from their surroundings when entering a magnetic field,

then reject heat to their surroundings when exiting a magnetic field. When magneto­caloric

materials are circulated through magnetic fields and combined with heat exchangers to transfer

heat, they can be used to remove heat from a refrigerated space and reject heat to the

surroundings.

This r efrigeration technology could be used in any possible application where cooling,

heating or power generation is used today. Because of the early stage of development, many

technical issues need to be addressed for this technology to be commercially viable.

3.3.1.16 Electro­hydrodynamic E nhanced Heat Transfer

Electro­hydrodynamic ( EHD) enhanced heat transfer is the result of applying a highvoltage electrostatic potential field across a heat transfer fluid, such as a refrigerant or refrigerant

mixture. The applied field destabilizes the 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 phase­change processes (e.g., boiling and

condensation).

3­35This phenomenon is typically used to electronically control the capacity of a heat

exchanger by raising the applied voltage to increase the heat transfer. This can lead to improved

efficiencies by using smaller capacity equipment, most of the time without EHD, and then

utilizing the EHD effect during peak loads. EHD can replace, or work in conjunction with,

enhanced surface heat exchangers. To use EHD, an electrical voltage (from a few volts to

thousands of volts) is applied to the heat transfer device. However, because the heat transfer

fluids are typically dielectric (of low electrical conductivity), even high voltages produce very

little current. This low current helps keep the power (voltage x current) and the associated

energy penalty low.

3.3.1.17 Copper R otor Motors

Making t he critical components of an induction motor's rotor (e.g., conductor bars and

end rings) out of copper instead of aluminum, which is the common current practice, improves

the energy efficiency of the motor. The greater conductivity of copper results in lower resistance

heating losses in the rotor and thus lower losses in the motor. Further improvements in the

design and fabrication of copper motors, such as optimization of the steel laminations, could

further increase the efficiency of copper motors over aluminum motors.

3.3.2 Designs R elevant Only to Equipment without Doors

The f ollowing design option is relevant only to equipment without doors: air­curtain

design.

3.3.2.1 Air­Curtain D esign

Refrigerated d isplay cases without doors allow consumers easy access to products while

maintaining temperatures that ensure food safety. The absence of doors necessitates the use of a

circulated air curtain to keep cold air inside the case. The refrigeration load for these cases is

dominated by infiltration, or the entrainment of warm and moist air into the curtain. This

infiltration adds both sensible and latent heat to the case, as well as depositing additional

moisture on the evaporator coil, which must be removed through defrosting.

Improved a ir­curtain 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 prior to the air curtain discharge grill to

shape the velocity profile using a honeycomb grill to align the airstreams and encourage laminar

flow. Improvements to the velocity profile and discharge air grill may enhance the performance

of the air curtain and reduce the infiltration load.

3.3.3 Technologies a nd Designs Relevant Only to Self­Contained Equipment

The f ollowing technologies and designs are relevant only to self­contained 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.

3­363.3.3.1 Higher E fficiency Compressors

Several t echnologies exist to increase the efficiency of commercial refrigeration

equipment compressors. High efficiency reciprocating and scroll compressors, sometimes

incorporating variable­speed motors, all have higher efficiencies than the traditional

reciprocating compressors commonly used in commercial refrigeration equipment.

Scroll c ompressors compress gas in a fundamentally different manner from traditional

compressors—between two spirals, one fixed and one rotating. High efficiency reciprocating

compressors are as efficient, or more efficient, than scroll compressors. However, some

drawbacks exist including noise, cost and reliability, compared to scroll compressors.

Variable­speed c ompressors are implemented through the use of an electronic control on

the compressor motor, which allows the motor to operate at different speeds. Variable­speed

compressors reduce energy consumption in three ways (but it should be noted that it typically

increases efficiency over a broad operating range but does not inherently increase maximum

efficiency at the compressor rating point):

1. When r efrigerant flow is reduced during part­load operation, the condenser and

evaporator (designed for full flow conditions) are more effective and thus more

efficient. Temperature drops decrease, resulting in reduced pressure rise across the

compressor, which also improves efficiency.

2. Close m atching of load eliminates the cycling that occurs with single­stage

compressors. Maintaining a constant pressure is more efficient because losses at

higher pressure rise are greater than gains at lower pressure rise.

3. During t he off­cycle, the pressure in the system equilibrates. At the intermediate

pressure, refrigerant vapor will condense in the cold evaporator rather than the

condenser. Essentially, some of the heat rejection load is rejected to the evaporator

during this time, reducing overall system performance. Variable speed operation

would eliminate or significantly reduce compressor off­time and the related

inefficiencies.

3.3.3.2 Liquid S uction Heat Exchangers

The g oal of a liquid suction heat exchanger is to further cool the flow of liquid refrigerant

entering the expansion valve using the flow of gaseous refrigerant leaving the evaporator, thus

providing sub­cooling for the entering liquid by super­heating the exiting suction vapor. Hotter

suction vapor is less susceptible to heat gains in the return piping to the compressor rack. The

compressor work is increased, 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 and hotter vapor limits the use of this method in some situations.

The possibility for these problems and the potential gains of liquid suction heat exchangers

depend on the several factors, including evaporator temperature, type of refrigerant used, and

system pressures.

3­373.3.3.3 Increased C ondenser Surface Area

Like t he evaporator, the condenser is a refrigerant­to­air heat exchanger composed of

metals with high thermal conductivity such as aluminum and copper. It is responsible for

condensing and sub­cooling the entering refrigerant vapor while rejecting heat from the

refrigerant to the ambient air.

Depending o n the requirements of the equipment, the condenser will have a saturated

condenser temperature (SCT) that is about 10°F warmer than the ambient air. As with

evaporator coils, increasing the area of the condenser coil will decrease the necessary ΔT across

the coil and therefore decrease the SCT, resulting in increased compressor efficiency (increased

EER).

Enhancements t o the refrigerant­side surface area of the condenser typically include

rifled or diamond­pattern tubing and increased number of tube passes. Enhancements to the airside surface area include increased fin pitch (decreased fin spacing), fin patterns (wavy or zigzag), and increased numbers of tube passes.

Increasing t he overall size of the coil in one or more dimensions without changing other

aspects of the coil is another way to increase the area. However, most applications limit the

amount of coil size increase in order to maintain 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 E fficiency Condenser Fan Motors

Condenser f an 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 conditions. 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 F an Motor Controllers

Condenser f an motor controllers allow fan motors to run at variable speed, to match

changing conditions in the case. Matching the 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 steady­state conditions, there is no energy

savings benefit with condenser fan motor controllers.

3.3.3.6 Higher E fficiency Condenser Fan Blades

High e fficiency condenser fan blades, or tangential condenser fans, move air more

efficiently, yielding energy consumption savings by reducing the required fan shaft power. The

condenser fans typically used in commercial refrigeration equipment have sheet metal blades.

The blades are typically supplied by a fan blade manufacturer and mounted to the motor by the

3­38equipment manufacturer. These fan blades are not optimized for commercial refrigeration

equipment. Required fan shaft power could be reduced if the fan blades were optimized for each

given application.

Tangential f an also provide an opportunity to decrease commercial refrigeration

equipment energy consumption. Tangential fans utilize 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. A single long tangential fan can meet the airflow

requirements for an entire condenser, while only requiring one high­efficiency fan motor.

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