Challenges of JRAIA and its Member Companies to Achieve Top Runner Targets for Room Air Conditioners under Energy Conservation Law

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1 Challenges of JRAIA and its Member Companies to Achieve Top Runner Targets for Room Air Conditioners under Energy Conservation Law Outline of JRAIA (The Japan Refrigeration and Air Conditioning Industry Association)! Established in 1949! Membership: 121 in all (75 regular members and 46 associate members)! Aim To contribute to development of the industry and to improvement of the living standards of the general public through innovating and standardizing refrigeration and air conditioning products and verifying their performance. November 8, 2012 Makoto Tono (Daikin Industries, Ltd.) JRAIA: The Japan Refrigeration and Air Conditioning Industry Association

2 !"#$ Outline of Presentation! JRAIA s role in working out energy-efficiency standards under the Top Runner Program! Challenges of JRAIA member companies to achieve energy-efficiency efficiency standards "Examples of their technological developments are shown.)! JRAIA s verification system for energy- efficient performance

3 1. JRAIA s role in working out Top Runner standards 7!!"#$%&'()*+,-./ !Organization to work out Top Runner standards" METI# Advisory Committee for Natural Resources and Energy Energy Efficiency Standards Subcommittee Working Group on Judging Standards for Air Conditioners Structure $Persons with relevant knowledge and experience $Users representatives%consumer organization, constructor & contractor organization, etc.) $Manufacturers representatives %JRAIA& 'METI (Secretariat!Top Runner standards for room air conditioners" )1st Top Runner standards *Evaluation index +,- *Classified by #Product type #Cooling capacity *Target year 2004 (partly 2007) ) 2nd Top Runner standards *Evaluation index.-/ *Classified by #Product type #Cooling capacity + indoor unit s dimensions *Target year 2010 (partly 2012)

4 2. JRAIA s role in working out Top Runner standards 7!!"#$%&'()*+,-./ !Evaluation standards for energy-efficient performance" Based on the fact that nearly 100% of room air conditioners shipped for the Japanese market are of inverter-type, APF was proposed as an energy-efficiency index, replacing COP. (APF : Annual Performance Factor#!As inverter-type models dominated the market, it became necessary to work out energy-efficiency evaluation standards suitable for the actual situations. APF was adopted as an energy-efficiency index of the 2nd Top Runner standards d!reflecting the market situations" Because of the housing conditions in Japan, there are many cases where indoor units have limited dimensions. With this in mind, a proposal was made to classify energy-efficiency standards based on dimensions of indoor units. To set target values of the 2nd Top Runner standards, classification was made between Indoor unit with free dimensions and Indoor unit with specified dimensions.

!. Mechanism of heat-pump type air conditioners (in case of heating) 3 Indoor heat exchanger, Fan motor Decompres sion

" 2 By taking in outdoor air of approx.7! and discharging cool air of approx.2!, heat energy that is equivalent to 5!

By compressing the acquired heat energy that is equivalent to 5!

5 !. Mechanism of heat-pump type air conditioners (in case of heating) 3 Indoor heat exchanger, Fan motor Decompres sion device Outdoor heat exchanger, Fan motor " 4 Circulating from " to 4 is the mechanism of heating operation. " 2 By taking in outdoor air of approx.7! and discharging cool air of approx.2!, heat energy that is equivalent to 5! is pumped up. Any substance possesses heat energy unless temperature falls beyond the lowest level (absolute temp -273!). By compressing the acquired heat energy that is equivalent to 5! into the state of high temperature and high pressure, heat energy is easily radiated. 3 4 Heat energy of high temperature is radiated into indoor-side. Compressor 2 By reducing pressure, heat energy is easily acquired.

6 !. Challenges to achieve energy-efficiency standards (Problem of rated COP)!Index for achieving energy-efficiency standards by 2004 Rated "#$ % Rated capacity &W' Rated power input &W' Rating conditions of JIS " 9612 (ISO 5151) Cooling Heating Indoor conditions DB/WB 27!&19!' 20!&15!' Outdoor conditions DB/WB 35!&24!' 7!& 6!' If the rated COP is used for inverter-type air conditioners (air conditioners with variable-speed compressor) as an energy-efficiency index, performance evaluation cannot fully be made in the actual usage. "#$ COP characteristics of inverter-type air conditioners (Cooling) Model B Model A Capacity increases Rated COP Indoor temp: 27! (constant) Rated COP is the same between Models A and B, however, A is higher ())*+*(,- than B in the actual use. 24! 35! Outdoor temp &!'

7 !. Challenges to achieve energy-efficiency standards!(introducing APF ")!"#$%&'( #) *&+*#$+, '&-)#-.+$%& )+%(#-!",/.+(& 0+(+ 1)#- %##,/$23 Seasonal Performance factor = Seasonal total load G JI Seasonal power consumptiong HI 4&-/#05 67$& 8 9:&'(; 8< =&2/#$5 >#?@#!:&( (&.' #$ /$0##-A*/0& 8BC!=##.5 6+'+$&*& +D&-+2& E##0&$ F#7*& \ Z[[ U V W X bcdefgch ijjkflm inonifpq G]^I `7/,0/$2,#+0 G]YI [ xyc xzc y{c a7(0##- (&.'&-+(7-& tuvw 1C3 _ 8LL MKL N O MLL P Q KL a%%7--/$2 '&-/#0 #) (/.& GRI GR-I L 8s 8B sm sk a7(0##- (&.'&-+(7-& tuvwgci 1C3 S =& &r7/-&0 %##,/$2 %+'+%/(@ U V W X _ U V W X 1?YF3 TLLL Na a%%7--/$2 '&-/#0 #) (/.& <LLL G]YRI L J 8s 8B sm sk a7(0##- (&.'&-+(7-& 1C3 tuvwgci \ Z[[ } ~ X 4#E&- /$'7( G]^I [ }~ X xyc xzc y{c tuvw a7(0##- (&.'&-+(7-& 1C3 _ 8LL MKL N O MLL P Q KL a%%7--/$2 '&-/#0 #) (/.& GRI GR-I L 8s 8B sm sk tuvwgci a7(0##- (&.'&-+(7-& 1CI S $&-2@ %#$*7.'(/#$ TLLL } ~ <LLL X G]YRI 1?YF3 L H 8s 8B sm sk a7(0##- tuvwgci (&.'&-+(7-& 1CI

8 !. Challenges to achieve energy-efficiency standards (Introducing APF ")!"#$ %&' &()*+,( -. /010 &' &. -.(,2 3)4 &56-,7-.8,.,489:,33-5-,.59 '+&.(&4(' ;<= #,43)4A&.5, $&5+)4 Seasonal total load (cooling + heating) Seasonal energy consumption (cooling + heating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

9 !. Challenges to achieve energy-efficiency standards (Technological development for performance improvement: Example ") Typical components of air conditioner!"#$%%& '()# (*+'),-(& Compressor Outdoor fan motor Four-way valve Inverter Indoor fan motor Decompression device Effects of components on performance /0001large2301small24 Rated performance Intermediate performance Mechanical efficiency!!!! Compressor Compression efficiency!!!! Decompression device Components Motor efficiency!!!!! Inverter (Compressor-driving controller) Indoor & outdoor heat exchangers Indoor & outdoor fan motors!!!!!!!!!!!! "!!! Electric Power Input.,$%%& '()# (*+'),-(& To improve APF, it is important to grasp the effects produced by each component on the rated and intermediate performance.

compression method Gas leakage is prevented by close contact Intermediate pressure Fixed scroll Orbiting scroll Running-in effect surface

10 !. Challenges to achieve energy-efficiency standards (Technological development for performance improvement: Example ") Compressor: its mechanical efficiency and compression efficiency High-performance scroll compressor Fixed scroll Orbiting scroll Automatic adhering compression method Gas leakage is prevented by close contact Intermediate pressure Fixed scroll Orbiting scroll Running-in effect surface treatment Gas leakage is prevented by close contact Motor Super-precision processing Running-in effect surface treatment Fixed scroll Orbiting scroll

compressor (1) DC motor adopting neodymium magnet

Orbiting scroll Stator with distributed windings!

11 !. Challenges to achieve energy-efficiency standards (Technological development for performance improvement: Example ") Compressor: Motor efficiency High-performance scroll compressor (1) DC motor adopting neodymium magnet (2) Stator with concentrated windings Fixed scroll Orbiting scroll Stator with distributed windings!traditional technology) Stator with concentrated windings!developedp technology) (3) Stator/rotor stack thickness becomes largesized (4) Core shape optimizing current waveform Motor

12 10. Challenges to achieve energy-efficiency standards (Technological development for performance improvement: Example!) Compressor-driving controller (Inverter) Microcomputer for control (1) Reduction of motor loss by driving sine wave (2) Low torque motor, which shows high efficiency in the intermediate performance range, can stably be driven up to high-speed.!control of pressure rise at converter!control of vector at inverter Compressor motor Compressor-driving control system

11. Challenges to achieve energy-efficiency standards (Technical development for performance improvement:

) Indoor heat exchanger Traditional technology Folding-type heat transfer fin & Single diameter heat transfer

heat transfer tube New technology Integral form heat transfer fin & different diameter heat transfer tube 6.

13 11. Challenges to achieve energy-efficiency standards (Technical development for performance improvement: Example!) Indoor heat exchanger Traditional technology Folding-type heat transfer fin & Single diameter heat transfer tube! heat transfer tube Air-velocity distribution is bad! heat transfer tube New technology Integral form heat transfer fin & different diameter heat transfer tube 6.35 heat transfer tube With air-velocity distribution uniformed, performance of heat transfer is improved. Flow-velocity is so high that heat exchange can not be fully made. Simulation of airvelocity distribution 0 4m/s Simulation of airvelocity distribution 0 4m/s

Electronic-control expansion valve!"#$%%&'( )$&*+',-&$. #'/0/%123'4 0/ 1(5*/%'( /$ %"1% #'-#06'#1%0$2 373&' 312 /"$.

14 12. Challenges to achieve energy-efficiency standards (Technological development for performance improvement: Example!) Decompression device Capillary tube Maximum efficiency is achieved only at the rated point. Performance lowers at other operating points. Electronic-control expansion valve!"#$%%&'( )$&*+',-&$. #'/0/%123'4 0/ 1(5*/%'( /$ %"1% #'-#06'#1%0$2 373&' 312 /"$. %"' +180+*+ '--030'237 ')'2 1% $%"'# $9'#1%026 9$02%/ %"12 %"' #1%'( 9$02%: ;<= In case of cooling operation Intermediate COP (COP at intermediate capacity) Electronic-control expansion valve Room temp: 27! (constant) Rated COP Capillary tube Capacity increases 24! 35! Outdoor temp>!?

15 13. Challenges to achieve energy-efficient standards (Trends in seasonal energy consumption)

16 14. Verification system of energy-efficient performance!history of Japan Air Conditioning and Refrigeration Testing Laboratory" # August 1978: Established originally as JRAIA Testing Laboratory # October 1980: Room air conditioner certification program started # October 1983: Package air conditioner certification program started # October 2004: Certified to ISO/IEC for laboratory accreditation # February 2011: Separated from JRAIA, Japan Air Conditioning and Refrigeration Testing Laboratory started as a third-party institute!outline of Certification Program" Enter the Program Factory assessment Verification of testing facilities Self-certification of products by participants Type registration of self-certified products Entry is allowed for those manufacturing/selling in Japan Assessment of quality control system Renewed every two years Viewing available Production Random sample test $% Order issued for improvement Improved by participants Certification seals are affixed to products. The following are certified based on JIS. &Cooling capacity &Heating capacity &APF Certified results are kept fair by obtaining approval from the committee, including members from outside (persons with relevant knowledge and experience, etc.).

HCH6. Product Specifications

HCH6. Product Specifications HCH6 Product Specifications HIGH EFFICIENCY 16 SEER TWO- STAGE HEAT PUMP WITH OBSERVERt COMMUNICATING CONTROL SYSTEM 2 THRU 5 TONS SPLIT SYSTEM 208/230 Volt, 1- phase, 60 Hz REFRIGERATION CIRCUIT S Copeland