Hecu Sistema - The REAL capacity modulation for C-Store

1. Target application
2. Regulations
3. User classes challenges
4. Hecu Sistema
5. Circuit schematics
6. Conclusions
Summary

Small stores, such as convenience
stores, service stations, small discount
supermarkets or corner shops, are a
segment with a higher rate of growth
than larger stores such as supermarkets
and hypermarkets.
This growth is the result of both new
openings and retrofits of existing
stores.
+ 27% Worldwide
growth rate per year*
Target application
400000
410000
420000
430000
440000
450000
460000
470000
480000
490000
500000
2014 2015 2016 2017
Total Condensing Unit * Elaboration of data sourced by PlanetRetail

The higher numbers of small format
stores are located in Asian region.
Thailand is one of the most important
country for the condensing unit market
with a growth rate higher than the
worldwide avarage.
+ 35% Thailand
growth rate per year*
Target application
* Elaboration of data sourced by PlanetRetail
20000
21000
22000
23000
24000
25000
26000
27000
28000
2014 2015 2016 2017
Thai Condensing Unit

CONVENIENCE-STORE: Also named corner shop, it is a small store that stocks a
range of everyday items such as groceries, snack foods, soft drinks. With a tipical
dimension around 80-120 square meter and an operational time of 24/7.
Refrigeration equipment tipical configuration is:
• 3 open front cabinets at medium temperature
• 1 plugin cabinet at low temperaure (ice cream products)
• 1 walkin room for beverages distribution
• 2 CDU: 1 to 3 for the cabinets and 1 to 1 for the walking room
Target application

Directive 2009/125/EC of the European Parliament and of the Council (Energy
Related Product, ERP, also called “Ecodesign”) defines the minimum level of
energetic performance for Condensing unit up to 50kW.
European regulation
The main pillar of the new EU 2014 F-Gas regulation is the reduction of emissions by
moving to lower GWP solutions. The aim is to reduce the total quantity of CO2
equivalent placed on the EU market by 79% before 2030.
E.N.EFFICIENCYREFRIGERANTS

American regulation
EPA rule 20 is selecting a list of refrigerant that will be not more available in the next
future divided by application.
R404A will be unacceptable for remote condensing units starting from January 2018.
REFRIGERANTS
The new regulations are setting the developments trends also
for the condensing units market focusing on energy efficiency
and low GWP refrigerants.

User classes challenges - OEM
Challenges
ENERGY
EFFICIENCY
Provide to the end user real reduction of
the consumptions and of the operating
costs
DIFFERENTIATION
New solutions to increase marketing
impact and line-up value
SUSTAINABLE
R&D
Solution pre-designed and pre-qualified
by suppliers and partners to reduce R&D
efforts and risks

User classes challenges - INSTALLER
Challenges
CUSTOMER
SATISFACTION
Provide to the end user a reliable
refrigeration system with low electrical
consumption
EASY
INSTALLATION
Short installation time, reduced cost and
clear guidelines for the best installation
practices
FAST
COMMISSIONING
Pre configuration and optimised units
for a fast start-up and fine tuning of the
system
SUSTEINABLE
MAINTENANCE
High level of system performance stable
along the time, avoiding problems
thanks to self tuning and preventive
maintenance

User classes challenges - RETAILER
Challenges
LOW OPEX
Decrease the energy consumption to
reduce the operating cost related energy
consumption and maintenance
FOOD
PRESERVATION
Maintain an optimal food quality and
avoiding food waste
ENVIRONMENT
RESPECT
Enforcement of corporate green policies
and reduction of carbon footprint

• an integrated refrigeration control system for CDU and
cabinets/cold rooms
• equipped with top DC inverter and modulating EEVs
technologies
• providing self-optimization for energy saving and food
quality
• enabling high end remote monitoring and benchmarking

• HIGH ENERGY EFFICIENCY
with advanced algorithm and floating setpoint
• RELIABILITY
with safety procedures and preventive actions
• FOOD PRESERVATION
with stable regulation
• EXTENSIVE USABILITY
with easy user interface, wizards and presetting
• REMOTE OPTIMIZATION
with store benchmarking, kpi and reports
User benefits

DC TECHNOLOGY
EEV TECHNOLOGY
Technical assets
NETWORK COORDINATION
REMOTE MONITORING

High efficiency system developed
together with SCI compressor and
their excellence in DC compressor
technology.
Real experiences
• 2 Laboratory operating for 2+
years
• 10+ Fieldtest running for 12+
months (6 in Thailand)

CAREL is investing with its Knowledge Centre in the continuous improvement
and learning of its staff to provide the best support to the customer.
Trainings and workshops are organized both in HQs, Regions and Subsidiaries
worldwide.
Picture from a a specific Hecu wokrkshop hosted by CAREL Thailand
Know-how

High energy efficiency - ROI
Real time continuous energy optimization
through network communication with refrigerated unit (MPX PRO)
Higher refrigeration efficiency at partial load operation
with DC / BLDC technology and power+ drive
Minimum energy waste
with precise oil and liquid injection using CAREL E2V expansion valves
Return Of Investment

Several fieldtest are confirming
up to 35% energy saving comparing to ON-OFF solution.
This saving is giving a
ROI of the solution of 10-14 months*
* based on Bangkok field test

focus on real time optimization
• Continuous modulation of the suction
pressure set point
• Avoided or reduced ON-OFF cycles
• High efficiency and stability with
CAREL Power+
• Stable product temperature
• Continuous modulation of the
superheat set point
• High efficiency and stability with CAREL
EEV electronic expansion valve
Real time continuous energy optimisation
through network communication with refrigerated unit (MPX PRO)

SMOOTH LINES
1. If the control temperature is
approaching the set point
2. SH set point is increased
3. To reduce cooling capacity to the
refrigerated unit
DECREASE
ON-OFF CICLES
INCREASE
ENERGY EFFICIENCY

FLOATING SETPOINT CALCULATION:
1. Request of each evaporator
2. Power of each evaporator
3. Defrost status of the each evaporators
DECREASE
COMPRESSOR SPEED
INCREASE
ENERGY EFFICIENCY

We will now examine three different situations involving a system made up of
• 1 condensing unit
• 3 showcases (3000 W, 2000 W, 1000 W)

There is cooling demand from all
the refrigerated units.
The largest (3000 W) has the
highest demand.
The set point of the condensing
unit moves rapidly to the minimum
value so as to provide maximum
cooling capacity.

All the temperatures of the
refrigerated units are below
the set point.
The set point of the condensing
unit moves rapidly to the maximum
value , providing less cooling
capacity and more energy saving

focus on refrigeration efficiency
A BLDC compressor can
precisely meet system
cooling request…
Higher refrigeration efficiency at partial load operation
with DC / BLDC technology and power+ drive
… giving maximum efficiency
in terms of performance and
COP compared to other
available technology.

focus on injection
Minimum energy waste
with precise oil and liquid injection using CAREL E2V expansion valves
Liquid injection by
electronic valve
reduces the
amount of
refrigerant needed
to lower the
discharge
temperature.
By installing an advanced oil
separator with double level
sensor, the E2V valve control
algorithm makes sure the
exact quantity of oil required
by the system is injected.
Injection of pure oil only,
avoiding mixing with hot gas
that causes energy
inefficiency.
The oil/liquid injection algorithms ensure only the actual quantity needed by the
system is injected, avoiding energy inefficiencies:

System reliability - OIL
Speed Boost
through power+ drive and DC compressor
Oil recovery washing
using CAREL E2V expansion valves
Better oil flow and easy installation
with multisplit-style pre-insulated piping

System reliability – OIL
focus on speed boost
Speed Boost
through power+ drive and DC compressor
Oil speed boost function forces the compressor to run at a fixed speed for a settable
time to recover the oil lost all long the refrigerant circuit.
OIL BACK BY HIGH COMPRESSOR SPEED

focus on speed boost
Oil recovery washing
using CAREL E2V expansion valves
Oil recovery washing function forces the Cabinet superheat set point at 0K for a
settable time to recover the oil lost all long the refrigerant circuit (washing cycle).
During washing cycle speed compressor is fixed.
OIL BACK BY EVAPORATOR FLUSH

focus on multisplit piping
Not critical in case of low compressor speed.
Flowing to the compressor, the piping maintain the same diameter small enough to
ensure that the oil mixed with the refrigerant can come back to the CDU
No installation problems when working at heights
• Advanced oil injection solution
• Network communication with showcases to clean the evaporators
• Speed boost function
• Multi-split piping
Better oil flow and easy installation
with multisplit-style pre-insulated piping

• HIGH RELIABILITY(OIL
RETURN) with high
refrigerant speed
• LOW EFFICIENCY
with high pressure drops
• LOW RELIABILITY (OIL
RETURN) with low
refrigerant speed
• HIGH EFFICIENCY
with low pressure drops
Pipe sizing guidelines will target the highest
possibile energy saving without risks
focus on multisplit sizing

CAREL strongly believe in the great potential of DC technology and want to offer in the
market the most reliable and efficient driving of these compressors.
Depth qualification tests done by CAREL with compressor suppliers allows the
customer to obtain a perfect control and several safety procedures to always run the
compressor at the best conditions.
System reliability - QUALIFICATION
Optimal compressor driving with CAREL Power+
by in depth qualification procedure

Extensive usability – HMI
Intuitive programming with advanced PGD user terminal
and service tool
Easy tuning and optimization
using wizard procedure
Fast and easy commissionig
Super-fast commissioning
through automatic pre-configurations and easy
Service menu

Focus on user terminal
Intuitive programming with advanced PGD user terminal
and service tool
• Different access profiles make it possible to quickly
find the parameters for each type of user.
• Navigation is simplified thanks to the menu divided by
function and type of parameters
• Availability with both PGD and pLD PRO terminal

focus on wizard
Easy tuning and optimization
using wizard procedure
• Fast condensing unit configuration using the wizard start-
up procedure.
• Pre-setting of the main unit parameters, such as set
point and alarm thresholds, based on the selected type of
refrigerant.
• Pre-setting of the probes that are essential for control in
each type of application

Extensive usability - PRESET
• Fast commissioning with automatic pre-
configuration for connection between
condensing unit and showcases.
• Optimized and extensively modifiable
default values.
• Control parameters optimized for
showcases fitted with MPXPRO
controllers.
Super-fast commissioning
through automatic pre-configurations and easy Service menu

Optimal food preservation
Wide modulation range of DC compressors
with advanced algorithms and strong components synchronization
Optimum food temperature

20 rps 120 rps
16,7 % 100 %
MIN MAX
ON
OFF
MAX
MIN
Continuous switching of ON/OFF
compressors
Thanks to wide modulation range, DC
compressors will run at the optimum speed to
match the cooling requirement
ON/OFF compressor
DC compressor
Wide modulation range of DC compressors

on a traditional condensing unit:
• Set point is fixed by the unit with the
highest demand
• ON/OFF thermostat
with Hecu Sistema:
• Set point is dynamic and change
according to real conditions
• Smooth line thermostat
with advanced algorithms and strong components synchronization

Remote optimization
Continuous optimization and preventive maintenance
Continuous optimization and stores
comparison
LOCAL supervisory system as unique point of access to the system
REMOTE monitoring system for systems comparison and business
intelligence within all stores

• Analysis
• Reports
• Dashboard
• Benchmark
From row data into Valuable information in
order to help key people to take the right
strategical decision
Energy Consumption
Maintenance
Food waste
1. CONTROL
2. ANALYSE
3. REACT
with the possibility to control the system, analyse the performance and react to optimise it
Continuous optimization and preventive maintenance
Remote optimization

• Alarms monitoring and notification – Avoid food waste
• Local / Remote trouble shooting and graph analysis – Remote maintenance
• Advanced level of refrigeration system – Refrigeration efficiency
• Local report data analysis and temperature – Food quality performance
• More than 20 variables logged and saved - Analytics layer increase
LOCAL supervisory system as unique point of access to the system
Remote optimization

Daily Data
Generation
Data collection
Store Analytic
Dashboard, Report and K.P.I automatically
updated in order to support Decision
Makers to create the right plan for an
efficiency improvement.
REMOTE monitoring system for systems comparison and business
intelligence within all stores
Remote optimization

Store temperature K.P.I. in order to identify in a very simple way the
stores/units with issues and to focus the service and maintenance actions.
Remote optimization
focus on KPI

Energy consumption comparison, distribution and trends also in relation
with other informations (temperature, humidity,…) to compare the
perfomances of different stores
Remote optimization
focus on energy analysis

Circuit schematics
A medium temperature system can
be managed as shown in the
diagram alongside.
pRack Hecu can control:
• 1 BLDC compressor
• 1 optional backup compressor
• EEV, solenoid or capillary oil
injection valve
• EEV or solenoid liquid injection
valve
• Up to 2 fans
• Serial communication with up to
5 MPXPRO controllers
MEDIUM TEMPERATURE

LOW TEMPERATURE
A low temperature system can be
managed as shown in the diagram
alongside.
pRack Hecu can control:
• 1 BLDC compressor
• 1 optional backup compressor
• EEV, solenoid or capillary oil
injection valve
• EEV vapour injection valve
• Up to 2 fans
• Serial communication with up to
5 MPXPRO controllers
Circuit schematics

ALTERNATIVE AND OPTIONAL DEVICES
pRack Hecu can manage
a solenoid valve as an
alternative to the EEV
valve for liquid injection.
pRack Hecu can manage
solenoid or capillary valves as
alternatives to the electronic
expansion valve for oil injection.
Circuit schematics

ALTERNATIVE AND OPTIONAL DEVICES
Circuit schematics
High service level with backup compressor
activated only in the event of alarms or
malfunctions on the main compressor. The
system continues operating and service
response times are less critical.

Conclusions
• Considerable energy saving results obtained by DC technology and
advanced control algorithms
• Significant reductions in operating costs for the user, and
consequently an estimated return on investment (ROI) of 12 months
• Optimum food preservation with more stable product temperature
• Lower operating noise, making this technology ideal for
installations in residential areas
• Wide range of remote monitoring systems in order to optimize
system performance, carry out preventive maintenance and analyze
energy consumption
• Guided configuration procedures and a vast choice of standard
settings that maximize usability

CAREL Hecu sistema components

Hecu Sistema - The REAL capacity modulation for C-Store

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