Johnson Controls Thermostats (24)
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With ongoing efforts from governments across the globe to reduce carbon emissions and with an ever greater focus on sustainability, it is vital that the HVAC sector does its part in becoming more environmentally conscious. And, while there have been steps to become more sustainable, there is a huge amount that still needs to be done to make sure that many of the targets that have been set are attainable. In buildings, both large and small, industrial heating accounts for roughly two thirds of industrial energy demand and around a fifth of global energy consumption. Figures like this show the need to have efficient and environmentally-friendly HVAC equipment in place to make the crucial steps towards reducing the contributions these systems make to our carbon footprint. High energy consumption in construction sector A 2019 report by The International Environment Agency (IEA) showed that the buildings and construction sectors combined were responsible for over 30% of global energy consumption and nearly 40% of carbon emissions. This is indicative of the steps the sector needs to take to play its role in a more eco-friendly society, some of which are already underway. However, much more needs to be done if the UK is to reach its goal of reaching net zero carbon emissions by 2050. As we envisage what a post-COVID world might look like, businesses and governments are continuing to put sustainability and lower carbon emissions at the forefront of their planning and the HVAC sector is certainly no exception. But with change in the sector a daunting prospect, decision-makers often don’t know where to start. Smart Technology use in HVAC systems Smart HVAC uses sensors that integrate with a building’s automation system With the constant growth and greater deployment of smart technologies within the HVAC sector, this is certainly a way that systems can become more efficient. Smart HVAC uses sensors that integrate with a building’s automation system. These sensors then collect information about conditions throughout the building. Heat waves are now a far more common occurrence in the United Kingdom. The Met Office estimates they are up to 30 times more likely and will be a bi-annual occurrence by 2050. It is important that any uptake in HVAC usage doesn’t lead to a drastic increase in emission generation. This is one of the areas where smart systems will become crucial. Many scientists have been unequivocal in their sentiment that heat waves are a cause of greater emissions and expect temperature records in the UK and Europe to be broken more regularly, so sites will need to be equipped to handle these conditions. Regulating temperature with hand-held devices With wireless systems now much more commonplace, temperatures can be controlled easily from hand-held devices. With these new technologies, those managing the systems can also benefit from remote monitoring and maintenance, reducing the need to travel to the site for yet another environmental incentive. To accompany the smart systems, equipment including smart thermostats can be installed to maximize HVAC efficiency. Other smart systems available to businesses include smart furnaces and air conditioning units that are far easier to operate than their traditional counterparts. Reducing unnecessary ventilation While global temperatures continue to rise, air conditioning usage has increased and has contributed to greater levels of energy usage. A huge amount of needless emissions are generated by unnecessary ventilation, contributing heavily to heat loss and overall energy wastage. Recirculation of air is a traditionally lower energy cost method of retaining heat and keeping emissions low, however, we must be mindful of the risks associated with recirculating air. The risk of circulating diseases is negated somewhat with heat recovery ventilation, which both removes the risk of disease spreading and improves energy consumption. Efficiency performance of new AC units Air conditioning units in particular contribute significantly to a building’s energy consumption Air conditioning units in particular contribute significantly to a building’s energy consumption, equating to 10% of the UK’s electricity consumption and as such it is important that we bear in mind ways to counteract the emissions this creates. Global energy demand for air conditioning units is expected to triple by 2050, as temperatures continue to rise year on year. The efficiency performance of new air conditioning units will be the key, when it comes to ensuring that escalating demand does not equate to greater emissions. Another issue for suppliers and manufacturers to address is differing rates of consumption for AC units in different countries, with units sold in Japan and the EU typically more efficient than those found in China and the US. Modularization Modular HVACs have also become increasingly popular in recent years. Modular HVACs are responsible for heating, cooling and distributing air through an entire building, with their increase in popularity largely down to their greater levels of energy efficiency, cost effectiveness, flexibility and substantial ease of installation and maintenance. Modular HVACs can be tailored specifically for workspaces and they often allow work to be done on the systems without disturbing the workforce, achieved primarily through rooftop placement. Commercial workspaces are larger and often require differing needs to residential properties and can cater to a wide range of the specific requirements of work and commercial spaces. As we strive for lower carbon emissions, it seems that this trend will continue and will become a key area in reducing emissions that HVACs have traditionally generated. System maintenance and training To meet government and industry requirements, many new buildings will require HVAC systems that can be maintained simply in order to perform in a more energy efficient way. Many companies are looking at ways to become climate neutral and significantly reduce their footprint Many companies are looking at ways to become climate neutral and significantly reduce their footprint. Companies are following the likes of German-based company, Wilo Group, who have announced they are committing to sustainable manufacturing by developing a new carbon neutral plant and HQ in the next few years. Lowering carbon footprint As we continue to move towards an ever more environmentally conscious society, it will be of paramount importance for companies, governments and the public to think about ways in which we can lower carbon emissions. Smart technologies will certainly be at the forefront of this, negating many needless journeys and making it easier for industries to adjust settings and tackle issues remotely. Greater levels of training will help equip us with the tools to make sure we are best placed to reduce emissions and be more sustainable as a result. While the steps outlined above do show some progress and measures we can take, there is far more that we can do as a sector to significantly reduce HVAC’s carbon footprint and once we have moved beyond the impact of the COVID-19 pandemic, this will surely be at the front of industry leader minds.
As we look back at 2020, we are all reflecting on the year that was, and what we have learned from it. In the HVAC space, the year provided us with opportunities for growth and change, as we adjusted to our “new normal.” Here’s a look at some of the HVAC trends we see happening now taking hold as we head into 2021. Advancements and applications in indoor air quality - especially in HVAC space (SF / MF / CRE) 2020 was filled with starts and stops with regards to innovation. Covid-19 halted work in some facilities altogether earlier in the year. The pandemic has brought with it a re-energized interest in the air quality around us, especially in the public sector. There has been a newfound imperative in creating indoor air quality solutions that ensure that air is circulated, sanitized and purified to reduce the likelihood of the spread of sickness. This is a massive issue and 2021 will see growing efforts in these areas and the increased introduction of systems that will purify air quality. HVAC building systems Continued push toward energy efficiency (mainly SF but also CRE) Energy efficiency will be an ongoing issue into the foreseeable future. Once we have looked back at 2020’s carbon emission reductions (because fewer people were flying and driving) there will be no turning back. The same can be said for HVAC. Increased efficiency will continue to be an ongoing pursuit in 2021 and beyond. On average, HVAC appliances consume 48% of a household’s total energy usage. The latest generation of smart thermostats that use the newer 410A refrigerant have brought about reduced energy consumption by up to 35% optimizing how HVAC building systems are operated (reducing the possibility of leaving the AC on too long, and when it’s not necessary to use). convenience and energy savings Increase in supply chain management / platform services HVAC services such as those that collect and manage data including HVAC unit age, efficiency and condition at the property and portfolio level will continue to see increased adoption. These convenience and energy savings they provide is being seen in the multi-family and commercial space, especially with some building owners having been grounded by the pandemic in 2020. New construction had a role in expanding interest in HVAC asset tagging and helping it gain traction in the industry The data gathered by these services can be used in the future to predict HVAC system failures with significant accuracy before they happen. The convenience and potential cost savings acquired by implementing these services will continue to push their popularity into 2021. Additionally, it is interesting to note that new construction in 2020 had a role in expanding interest in HVAC asset tagging and helping it gain traction in the industry. Cataloguing HVAC assets ensures the follow up and guarantees that warranty registration holds and can help track future maintenance during a hold. At the time of sale, the current owner can present true data of the maintenance of these systems, which can increase the current value of the property and can also be used as a tool in negotiation. performing regular maintenance Remote monitoring can be the end to end solution that completes the action behind the alert (CRE mainly) Remote monitoring will continue to see adoption in 2021. Service providers will continue to rely less and less on clients identifying and reporting a problem a heating/cooling issue. The complaint from the tenant may come in some hours after the problem actually starts, and then by the time they get a service request completed, several hours more. And by the time the contractor is on the scene, it is likely more time has elapsed. Remote monitoring also results in regular maintenance, extending the lifetime of a HVAC system. By proactively performing regular maintenance, the overall costs of maintaining a system can be reduced by 40 percent, in addition to ensuring that units are always using the least amount of energy necessary. seamless customer experience Consolidation of HVAC services and equipment - the way people buy - turnkey integrated services One stop shopping for HVAC services and equipment gained popularity in 2020 One stop shopping for HVAC services and equipment gained popularity in 2020 and we will continue to see increased traction in 2021. There are many reasons why developers what to buy equipment directly from the manufacturer, such as convenience, working with a supplier because of its reputation, cost and guarantees on product and services. As more developers buy equipment directly, these manufacturers are responding by helping out with mechanical drawings. This process cuts down the supply chain, allows certainty that correct equipment is quoted, and saves money. The HVAC industry is also turning the corner in becoming more proactive in remediating failing assets and contractors are redoubling their efforts to provide a seamless customer experience increasing customer satisfaction for multi-family communities as well as other means of optimization of services that positively impact tenants, helping increase retention. HVAC providers that can manage the entire process from installation, to job request to invoicing, even reporting and tracking for each job, will be increasingly in demand in 2021.
Inverter driven air conditioning is more energy efficient, cheaper to operate and more profitable to install than its non-inverter driven equivalent. Here Neil Ballinger, head of EMEA at automation parts supplier EU Automation, explains how HVAC engineers can maintain the inverters in their customer’s aircon units. Do you remember cross country at school? It was exhausting; miles of seemingly pointless jogging and sprinting and, if the teacher was not looking, walking. If you were unlucky enough to be born before modern safeguarding measures were introduced, it probably also meant getting lost in the nearest woods.Why isn’t every installation an inverter driven unit, instead of the traditional single stage or dual stage models? My PE teacher, who seemed particularly vicious at the time, but in retrospect just knew about sports science than most, used to make us do something called fartlek as well. This meant long distance runs, incorporating elements of speed training by mixing up sprints with jogs and walks. The worst bit was starting to run again after a walk. That is exactly how the motor in your customer’s air conditioner feel if the units you fit are not inverter controlled. The motor has to act just like a runner doing fartlek — it sprints continuously, operating at full speed until the thermostat tells it the room is cool, then it stops. When the room gets warm, it starts again, powers immediately up to full speed and repeats the process indefinitely. Just like a teenage cross-country runner, it is the starting and stopping that is the tough bit. Furthermore, the unit probably doesn’t have to run at full speed to keep the room at the correct temperature, if the motor were inverter controlled it would speed up and slow down as the temperature fluctuates. Why isn’t all aircon inverter driven? We all know that inverter driven aircon is better than its non-inverter driven cousins. It can provide heating as well as cooling and the lifetime cost of use is less for the customer — because their energy bills stay low. The cost of installation is also higher because it is a more complex job, so it works out better for the contractor. It’s a win-win. The research firm Technavio even lists it as one of the key technologies driving growth in the HVAC market in its annual reports every year. So, the only question is, why isn’t every installation an inverter driven unit, instead of the traditional single stage or dual stage models?When contractors contact EU Automation to buy automation parts, for the units they maintain, they have given us another reason: maintenance Cost is a factor, but when contractors contact EU Automation to buy replacement motors and inverters, and other automation parts, for the units they maintain, they have given us another reason: maintenance. As HVAC engineers, we are not necessarily specialists in power electronics, and this makes inverter maintenance daunting. Microcontrollers and IGBTs (Insulated Gate Bipolar Transistors) are not beyond us by any means, but they can be intimidating. Personally, I would back an electrical or heating engineer over an electronics specialist in a problem-solving contest all day long; but that doesn’t solve the problem at hand. Furthermore, while we are experts in air conditioning brands, and know our Daikins and Grees from our Mitsubishis and Fujitsus, we don’t necessarily have contacts at the inverter manufacturers. Amtech, Danfoss, Vacon and Yaskawa are all names we know, but the local dealer for any of them is probably not in your phone book. This is especially true if the unit you need is from a first-generation inverter driven aircon unit and well over a decade old. While we are experts in air conditioning brands, and know our Daikins and Grees from our Mitsubishis and Fujitsus, we don’t necessarily have contacts at the inverter manufacturers Maintenance techniques While inverter maintenance can be daunting, it isn’t difficult. The tools you will need most often are nothing more than a rag and a spanner, while the more esoteric kit is stuff you probably carry anyway, a laptop, vacuum and a Fluke meter. Before you start, remember that while we tend to refer to an inverter as an inverter, the manufacturers themselves, and many of the sources of information online, often refer to them as VSDs (Variable Speed Drives), VFDs (Variable Frequency Drives) or just plain old drives. As a result, when you are searching online for a video to explain something, it’s worth using all three of those terms, alongside the inverter manufacturer’s name and the problem to make sure you get the right result.While inverter maintenance can be daunting, it isn’t difficult When you do move on to maintenance, step one is simple; make sure that the unit is free of dust. This is as easy as vacuuming the heatsink with an ESD (Electrostatic Discharge) vacuum cleaner when you perform routine maintenance or investigate a problem. While you are checking for build up of dust and daily grime, check the filters. They will probably have to be replaced during annual maintenance, but high use might mean they need to be replaced more often. The control panel itself should be well ventilated and free of dust as well, if it isn’t it can overheat, which is the number one cause of inverter damage and the most common reason contractors contact us for replacement units. Before you put your vacuum and duster away, you should make sure that the inverter unit’s location is clean and as sheltered from the elements as possible. Because it’s normally situated on a roof, it’s not going to be perfect, but the units are designed to take a limited battering. That doesn’t mean it’s okay for them to be covered in leaves, surrounded by rubbish or immediately beneath the guttering outlet though! Before you put your vacuum and duster away, you should make sure that the inverter unit’s location is clean and as sheltered from the elements as possible Get out the spanner Once you’ve finished these steps, you are done with dusting for now, it’s time to get out your screwdriver and your spanner. Step one is to make sure the fans on the inverter are operating normally, without noise and with nothing blocking their rotation. The fan keeps the internal components running effectively, just as it does on PC, and if its function is impaired the capacitors will overheat and the inverter will fail.When you install or maintain an inverter on an air conditioning system, it is a sensible precaution to back up the drive parameters to your laptop The next job is to grab your spanner and make sure the power terminals are on tight. Loose connections cause arcing, overheating and even melting of components and are easily checked during any kind of maintenance and repair. While we are still in the realms of the work your apprentice can do with their eyes closed, you should also make sure that the inverter’s removable LCD control pad is stored sensibly and not continually attached to the drive. If it remains attached, there is a chance the display will stay on permanently, which means that when you need it to diagnose a problem, it will probably already be burnt out. Break out the laptop When you install or maintain an inverter on an air conditioning system, it is a sensible precaution to back up the drive parameters to your laptop. It takes minutes and is normally done by using the removable LCD control. In fact, it’s often as simple as selecting ‘PARs’ and then ‘BACKUP’ from the menu. If you struggle, there are lots of videos on YouTube, like this one, which explain the process for each drive. As a result, if the inverter ever does need replacing, you can whip out your backed up parameters and order a new or refurbished one easily, before reloading the parameters to the replacement and getting up and running in no time. Your customers will think you are a power electronics genius, as well as a HVAC expert, and they will be loyal for life; especially of you save them on a hot day! If you follow these simple measures, you will find that the inverters in your customer’s air conditioning units last much longer and no motors will have to run the equivalent of a cross country, thanks to a lack of inverter control.
Johnson Controls, the global pioneer for smart, healthy, and sustainable buildings announced it has surpassed a milestone by filing 200 U.S. utility patent applications for innovations surrounding its OpenBlue Central Utility Plant offering and related energy optimizing product offerings. Additionally, it received its 90th U.S. patent grant for innovations related to OpenBlue Central Utility Plant product and energy optimization innovations. Central Utility Plant is a key component of the newly announced OpenBlue NetZero Buildings as a Service offering. Energy optimization The most recent grants, U.S. Pat. No. 11,061,424, awarded July 13th, 2021, and U.S. Pat. No. 11,036,249, awarded June 15, 2021, includes innovations which allow for a building energy optimizer to predict regional peak demand time periods. Peak regional demand (associated with both high cost and high emissions) predicted by the Johnson Controls system can be used to optimize energy performance based on the probability that any given period of time will be a peak contribution period. Making buildings sustainable “The innovations are being driven by our customers, who have expressed an urgent need to reduce their carbon footprint and make their buildings smarter, healthier and more sustainable --, especially as the world, navigates climate change,” said Karl Reichenberger, Johnson Controls vice president of Intellectual Property. A recent Net Zero Pulse Survey among a large group of building professionals shows the acceleration of net-zero goal setting; over 90% have significant goals to reduce carbon emissions and energy consumption by 2030 and beyond. Building management CUP automatically generates and implements optimization decisions, controlling equipment from manufacturers Johnson Controls’ OpenBlue Central Utility Plant (CUP) can monitor thousands of building variables, using information from connected equipment and external sources such as weather forecasts and utility rates. This allows customers to fully optimize their building management systems. CUP automatically generates and implements optimization decisions, controlling equipment from a variety of manufacturers. “This type of intelligence allows for Johnson Controls to help our customers solve large-scale problems that are unique to the built environment in a way that can both curb carbon emissions and their costs,” said Terrill Laughton, vice president, and general manager, Energy Optimization, Johnson Controls. CUP benefits More than 40 Johnson Controls customers have already purchased CUP, allowing them to reduce energy costs, increase productivity, ensure equipment reliability and reduce greenhouse gas emissions. For example, at Children’s of Alabama, a pediatric medical center in Birmingham, Johnson Controls designed and built – and now operates and maintains – a new central utility plant. Johnson Controls also developed an innovative plant simulator that allowed the medical center to significantly cut capital expenditures. As a result, Children’s of Alabama has reduced its natural gas use by 69% and is saving $250,000 annually, with the potential to save $450,000 a year over the life of a 25-year contract with Johnson Controls. $3 billion investment in engineering, R&D Over the past five years, Johnson Controls has invested close to $3 billion in engineering, research, and development and has increasingly been awarded patents by global patent offices. These innovations reflect R&D investments in OpenBlue and other digital offerings, including air quality, energy optimization, and sustainability of services, systems, and equipment. “Johnson Controls is on an important journey -- transforming from an industrial company to a digital buildings technology company powered by software, connectivity, data, and artificial intelligence,” said Michael Ellis, executive vice president and chief customer and digital officer, Johnson Controls. “We are enabling our customers to achieve new values in sustainability and energy enhancements through building platforms, allowing customers to optimize their building management systems.” Global innovation portfolio Johnson Controls is separately investing in additional property related to OpenBlue Digital Twin and Clean Air Beyond the energy optimization portfolio, Johnson Controls is separately investing in additional intellectual property related to OpenBlue Digital Twin and OpenBlue Clean Air. Johnson Controls was also named a Clarivate Top 100 Global Innovator™ in 2021 for the sixth straight year. The 10th edition of the annual report from Clarivate Plc, a global pioneer in providing trusted information and insights to accelerate the pace of innovation, identifies companies at the pinnacle of the global innovation landscape by measuring their ideation culture that produces patents. As a pioneer in the building's space for more than 135 years, Johnson Controls has been a pioneer in sustainability. It is ranked in the top 12% of climate leadership companies globally by CDP and was recently named again to the World's Most Ethical Companies® in Honoree List and one of Corporate Knights' Global 100 Most Sustainable Companies.
The current Biden Administration’s renewed focus on climate change has expedited the phasedown of high-GWP refrigerants, kicked off by the passage of the American Innovation and Manufacturing (AIM) Act, part of the December 2020 COVID stimulus bill. As the AIM Act phase-down schedule progresses, higher-GWP HFC refrigerants, while viable, have the potential to have a limited useful life and ultimately be eliminated. In response to pending changes, Johnson Controls has announced it will use R-454B, a mildly flammable refrigerant, in order to exceed key regulatory requirements. Key environmental goals This is a significant step toward Johnson Controls reaching key environmental, social and governance (ESG) goals, including: helping customers achieve a 16 percent reduction in emissions by 2030 and achieving net-zero carbon emissions before 2040, says the company. The decision was made as the HVAC industry is preparing to phase out high-GWP refrigerants Johnson Controls has selected R-454B to replace R-410A in all its ducted residential and commercial unitary products, as well as air-cooled scroll chillers, after extensive research, testing and evaluation of capacity, efficiency, safety, availability, longevity, global warming potential (GWP), ozone depletion potential (ODP) and other metrics. The decision was made as the HVAC industry is preparing to phase out high-GWP refrigerants, such as R-410A, which are now being formally addressed by the Environmental Protection Agency (EPA) through the recently passed AIM Act. Commercial unitary products The EPA’s pending regulations could stipulate that manufacturers begin producing equipment utilizing low-GWP refrigerants prior to Jan. 1, 2025, for residential and light commercial unitary products and Jan. 1, 2024, for new chiller products. The mild-flammability (A2L) aspect of new refrigerants, including R-454B, requires that safety standards and individual state building codes must first be updated prior to the introduction of these refrigerants into the market. The process to update codes and standards is well under way and should be completed for many jurisdictions prior to the Jan. 1, 2025, proposed transition date for stationary HVAC equipment (e.g., unitary). Extensive, multi-year research and testing has been conducted by ASHRAE, AHRTI and others to ensure A2Ls can be safely deployed. Proper training will be critical to ensure the safe use, transportation and storage of A2L refrigerants. Refrigerant transition dates Existing R-410A equipment built prior to the EPA’s proposed manufacturing cutoff dates can be sold Johnson Controls is committed to ensuring the safe transition to R-454B by providing in-depth training for its contractors and technicians prior to the pending refrigerant transition dates, according to the company. The pending mandates from the EPA and the California Air Resources Board (CARB) for refrigerants with less than 750 GWP will likely only apply to the sale of new residential and commercial unitary equipment as well as air-cooled scroll chillers. Existing R-410A equipment built prior to the EPA’s proposed manufacturing cutoff dates can be sold and installed indefinitely, so there will be little to no impact on contractors and customers from a R-410A equipment standpoint. Once EPA completes the allocation phase of the AIM Act, it will next address reclaim and service practices; therefore, contactors could see future mandates on the use of reclaimed refrigerants as well as enhanced requirements for leak detection and record keeping. Refrigerant management practices “R-454B is more compatible with existing R-410A equipment, requires less charge and can reduce HVAC systems’ energy use by up to 5%,” says Chris Forth, Executive Director of Regulatory, Codes and Environmental Affairs, Ducted Systems, Johnson Controls. “These similar operating characteristics will make for a smoother transition for distributors, wholesalers, contractors and owners, resulting from the commonality of critical system components and their very similar operating pressures and temperatures.” These similar operating characteristics will make for a smoother transition for distributors" “It’s vital that contractors and equipment owners establish proper refrigerant management practices and invest in available flammable refrigerant training,” Forth adds. More specifically, Johnson Controls recommends that contractors review the AHRI Safe Refrigerant Transition Task Force best practices and complete the ACCA A2L refrigerant training before new equipment enters the market (updated ASHRAE 15.2P training is expected by the end of 2021). flammable refrigerants implementation Johnson Controls also recommends that contractors strengthen their current refrigerant management practices: Ensure technicians are EPA section 608-certified for the equipment they will be servicing, train technicians not to mix different recovered refrigerants in the same cylinder, implement robust refrigerant tracking and documentation practices and establish a reliable supply chain for R-410A reclamation before 2025. Johnson Controls has been engaged in the safety standards and building codes development process from the beginning of the low-GWP, flammable refrigerants implementation. Johnson Controls engagement included safety standards such as ASHRAE 34,15; the pending 15.2P standard; as well as UL 60335-2-40 and UL 60335-2-89. ASHRAE safety standards R-454B offers the best outlook for long-term viability as phasedown regulations continue “Our first priority has been and will continue to be safety, and thus, we help sponsor and engaged in the research and testing efforts conducted through the Air-Conditioning, Heating and Refrigeration Technology Institute (AHRTI) and ASHRAE,” says Forth. Johnson Controls also engaged in the adoption of the UL and ASHRAE safety standards via the national model codes, such as the International Code Council (ICC) and the International Association of Plumbing and Mechanical Officials (IAPMO). Choosing R-454B is a long-term play for Johnson Controls. If the EPA AIM Act phase-down falls below the current 750 GWP limit proposed for stationary AC/unitary equipment, some A2L refrigerants could be phased out quickly, whereas the choice by Johnson Controls to utilize R-454B could, under the same scenario, be viable until 2034. With the lowest GWP of all EPA SNAP-approved refrigerants (GWP of 466), R-454B offers the best outlook for long-term viability as phasedown regulations continue, says the company. Aggressive efficiency standards The HVAC industry is in constant flux. For an OEM that means continually introducing innovative, new features into systems, developing new products that meet aggressive efficiency standards and, in this case, environmental regulations to phase out high-GWP refrigerants. “Transitions of this scale are not new to Johnson Controls, but it does require flexibility and equipment redesigns to utilize R-454B,” says Forth. “However, because the properties (pressures, temperatures, etc.) of R-454B are very similar to the existing R-410A, the actual performance testing did not present the same degree of challenge as past transitions. Johnson Controls has been at the forefront of environmental protection,” says Forth. “Today, our commitment to sustainability is stronger than ever, and it is reflected in the choices we make every day.”
Johnson Controls, the globally renowned company for smart, healthy, and sustainable building solutions, has significantly upgraded the testing lab facilities at its residential HVAC manufacturing plant in Wichita, Kan. upgrading HVAC testing facility The nearly US$ 15 million investment includes the addition of seven test chambers, automated testing and model shop equipment, and a new building, which adds 2,000 more square footage space, bringing the plant’s total testing facilities to 100,000 square feet total. Every product that the Wichita factory designs and manufactures undergo multiple rigorous tests at the lab, in order to ensure it operates safely and efficiently across a wide range of conditions, for years to come. Highly accelerated life testing (HALT) of equipment New advanced technology makes it possible for the lab team to better accommodate product development While Johnson Controls voluntarily performs highly accelerated life testing (HALT), which subjects equipment to extreme environmental conditions that replicate five years in the field, there is other testing that the government requires for all residential HVAC systems to ensure product safety, efficiency, and environmental sustainability. The additional space and new advanced technology make it possible for the lab team to better accommodate product development and testing for the vast number of systems that Johnson Controls produces for its YORK, Luxaire, Coleman, Champion and Fraser-Johnston brands, many of which are part of Johnson Controls' OpenBlue connected suite of technologies. Optimized testing process The following lab updates optimize the testing process to help ensure product reliability and performance: Seven 20 x 60-foot test chambers join nine existing cells used in the design and development phase to test, rate and qualify heating and cooling products for agency approval. These test chambers control temperatures within two-tenths of a degree for all rating points. This level of control provides confidence when rating equipment for SEER and EER. The additional cells will accommodate more equipment, which will help systems become available more quickly. A new automated heating lab and test stands allow technicians to setup and pre-program test stations. Compared to older, manual methods, automated testing of heating equipment, such as gas furnaces, is more efficient and precise to confirm reliability. Advanced model shop equipment, which includes a new water jet, bender, and press machine, allows model makers to precisely cut and form sheet metal to make prototype parts more quickly and efficiently. This will accelerate prototype testing and refinement so products can enter production faster. A spacious transit table building with rain capabilities gives technicians much greater control, during transit and rain tests. The new area offers better mounting, which makes installing systems for testing easier, while the enclosure improves precision during rain tests and accommodates a new high-pressure pump for recently required wind-driven rain testing for extreme conditions, which also reinforces Johnson Controls' commitment to quality. performance and reliability “When visitors tour the lab, they are simply overwhelmed by the extensive steps that we take to ensure each and every system developed in the labs are tested to ensure performance and reliability,” said Doug Dorrough, Director of Lab Operations, Johnson Controls. Doug adds, “The greater efficiency and unprecedented quality we can now achieve with this major investment will bring our premier products to market sooner and provide homeowners with enduring comfort and peace of mind.” Lab upgrades coincide with new efficiency standards The upgrades coincide with new efficiency standards, including the 2023 Department of Energy (DOE) efficiency standards and environmental sustainability requirements, including the Environmental Protection Agency’s (EPA) low-global warming potential (GWP) refrigerant transition that will be required of all HVAC equipment manufactured by January 1, 2025. The expanded lab will better accommodate product development and testing schedules to ensure that each product meets or exceeds all requirements, as well as the high-quality standards Johnson Controls holds for its equipment. Johnson Controls will continue to invest in and expand the testing facilities in Wichita, Kan. over the next several years with new equipment and additional facilities to accommodate new product development and testing.
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