Eason Cheng, Marketing Manager - REF APAC, at Refrigeration & HVAC Indonesia

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Innovative Cold Room Solutions
Efficiency, Reliability & IoT
Marketing Manager – REF APAC
Eason Cheng

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All over the world, we help our customers
to protect the environment
Electronic control solutions and humidification system for refrigeration, air
conditioning and heating applications

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Main system applications
Refrigeration: supermarket, c-store, restaurant chain, refrigerated warehouse…
HVAC: residential, commercial, industrial process, data centre

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Market trends & regulations
• Energy consumption
normatives
• Environmental impact
(natural refrigerants,
F-Gas…)
• IoT trend
End user needs
• Mantain high food quality
• Lower total cost of
ownership (savings &
reliability)
• Peace of mind
Installer needs
• High usability
• Simple installation (even for
CO2)
• Fast system configuration &
commissioning
• Reliability
What’s recognized for commercial cold rooms?
Main regulations, trends and market needs

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Cold Room CLASSIFICATION

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Depending on the thermal conditions of goods stored (fresh or frozen), cold rooms can be divided into:
• Medium temperature cold rooms
tipically T > 0°C → FRESH goods
(e.g. conservation of fresh fruit,
fresh meat/fish, cheese, vegetables)
• Low temperature cold rooms
tipically T < 0°C → FROZEN goods
(e.g. conservation of frozen foods,
typically enclosed in packages)

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Depending on installation, cold rooms can be divided into:
• Basic cold rooms with onboard
monoblock compressor/condenser/evap. (Stand-alone, small dimension)
• Cold rooms with remote condenser
(Stand alone, tipically one-to-one system: 1 condenser, 1 compressor, 1 evaporator)
• Centralised cold rooms without on-board compressor, with remote compressor rack
(from 2 to 6 compressors, 1 condenser serving multiple evaporators in multiple
cold rooms)

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COLD ROOMS DESIGN

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Cold room: Design
THERMAL WALLS
INSULATION
DOOR FRAME
HEATER (T<0°C)
PRESSURE
RELIEF
VALVE
SAFETY
FEATURES
FLOOR HEATER
(T<0°C)

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Cold room: Design
DOOR
EVAPORATING UNIT &
LAMINATION
LIGHTS
CONDENSING UNIT &
COMPRESSOR
PROBES

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DOOR
EVAPORATING UNIT &
LAMINATION
LIGHTS
CONDENSING UNIT &
COMPRESSOR
PROBES

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CAREL SOLUTION
FOR COLD ROOMS

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Coldwatch, gas leakage
Humidisk, MC
EVD Ice & HECU
Boss Family
Cella Range
HIGH
PERFORMANCES
and EASE OF USE
MODULAR
DESIGN
(additional
functions) SAFETY
DEVICES
HUMIDITY
CONTROL
SYSTEM
SINERGIES
SUPERVISOR
COMPATIBILITY
WIDE APPLICATION RANGE
EEV controls
3ph loads
management
Efficiency
Usability
Reliability
pGD1

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Cella Range benefits
• ENERGY SAVING
• STORED PRODUCTS
QUALITY
• ENVIRONMENT
SAFETY
• PERSONNEL
SAFETY
• FLEXIBILITY
• USABILITY

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Fare clic per modificare stile
- 1 and 4 relays
- 2 analog input
- 3 digital input
- 3 and 5 relays
- 2 analog input
- 3 digital input
- 6 relays
- 1 analog 0..10V output
- 5 analog input
- 3 digital input
- on/off EVD connection
- on/off EVD connection
- serial EVD connection
- serial 3PH connection

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SmartCella
MasterCella
UltraCella
- STANDARD SOLUTION
(complete features for
cold room control)
- FLEXIBLE (wide range
of models, RTC,
insulator)
Main controls - features
- BASIC FEATURES
- EXPANDABLE (modularity)
- EASY COMMISSIONING
(IR33+ platform based)
- ADVANCED SOLUTION
(big or specialistic installations)
- EXPANDABLE (modularity)
- UPGRADABLE (software)
- Double EEV management
- humidity management
- generic functions
- floating condensing
- Relays configuration
- DATALOGGING (usb)

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CAREL SOLUTION
FOR COLD ROOMS:
modularity

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Modularity
What do we mean with ″modularity″ ?
• Physical modularity:
• connection between control and module add-on
• Functional modularity:
•
between control and module,
max 500m (advanced functionality)
•
between control and module
(basic functionality)
RS485
ON / OFF
on/off connection
serial connection

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Modularity
Modularity adds more features to main control:
• Single/three-phase load management
(depending on loads number and power request)
• Power modules
allow to manage larger 1ph compressors or
larger 1ph-3ph heaters for defrost
• Ultra 3PH modules
direct control of all 3ph loads (compressor
included) or 3ph evaporator only.
• EEV management
grant more stability in refrigeration
cycle and additional energy saving
Ultra 3ph FULL Ultra 3ph EVAP
POWER module
EVD module

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• For contractors
Potential value source: the installation is flexible, can be
upgraded in the future.
Installation cost saving: compared to a standard installation,
shorter power cables are required with a
3-phase module installed near the 3-phase load.
• For wholesalers
Easy stock management: each WS can still satisfy a wide range of
request with a reduced number of part numbers in stock.
Benefits - Modularity

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Cold rooms offer - Modularity
YouTubeUltracellavideo

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• New concept:
additional modules grant new features (electronic valve management, power
management, 3-phase loads management).
• Ease of use:
every module can be managed by the main control display (Ultracella).
• Flexible installation:
the installation position of main control and module can be chosen to optimise
both usability and installation convenience.
• Differentiating offer:
competitors must offer a specific product for each specific installation. Usually
competitors cannot upgrade an existing control with further functions.
Features - Modularity

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CAREL SOLUTION
FOR COLD ROOMS:
EEV management

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Application example: EEV
CASE STUDY EEV vs TEV
• Application: Low temperature cold room 90m3 for meat storage (set -20°C), evaporator: 5,5kW with heater defrost 3PH 5kW, 4 fans 200W 1PH, refrigerant
R404a
• Controls: UltraCella + EVD module with display (I/O connection, no serial)
• Supervisor: PVP2
• Energy measurement: emeter 3PH ! measurement of all loads of cold room
• Switch EEV/TEV: each 3 days by UltraCella AUX relay handled by PVP2 Technology switch
• Condensing management
- EEV ! condensing fans at maximum speed ! condensation as low as possible
- TEV ! fan speed is regulated by internal controller

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1 year result (Apr’15 - Mar’16): 13,31% of energy saving (considering total consumption):
-TEV: estimated consumption in 1 year ! 22.699kWh
-EEV: estimated consumption in 1 year ! 19.678kWh ! -3.021kWh ! saving 362€ (0,12€/
kWh)
Saving can be improved further by floating suction & variable speed evaporator fans.
13%Minimum 1 year granted saving
€ 30,00
Application example: EEV
One yearpayback

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EEV management
Which driver can be used
in cold room applications?

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ExV Sistema: components
1. EEV
2. EVD Driver
3. Pressure transducer
4. NTC probe
Superheat =
Suction gas temperature – evaporation saturated
temperature (pressure)
Protection for liquid going
into the compressor
Keep Evaporator running in best
condition

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ExV Sistema
• If SH < Setsurr
• If SH > Setsurr
LIQUID
GAS
Liquid into CMP
(CMP damages)
closing
LIQUID
GAS
Low portion of
evaporator used
(low efficiency)
opening
EVD regulates based on SH and SetSH (~10°K)

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EVD Module
• EVD Module is a special EVD Evo that can be phisically connected to the main cold
room controller (Smartcella or Ultracella)
• Can be configured and managed by Ultracella display throught RS485 SERIAL
connection, or run in ON/OFF mode (by compressor status)
• Available with or without Ultracap
on/off
serial
NTC and
pressure probe
connections
Ultracap
Serial
connection
Transformer
+ power
supply
EEV
connections
Relay
connections

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EVD module with Ultracap
• Ultracap grants enough energy to close
the EEV (protecting the CMP from liquid
flood) upon an energy blackout
• Ultracap doesn’t require maintenance or
periodical check

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EVD Ice
• EVD Ice is a special EEV driver that can be installed on the evaporator.
• Can be configured and managed by Ultracella display throught RS485
SERIAL connection, or run in ON/OFF mode (by compressor status)
• Available with or without Ultracap
SERIALNTC probe
Pressure
probe
Ultracap connection
EEV stator
pre-wired
Serial
connection
Power supply
Zero welding
Zero wiring
ON/OFF

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Depending on driver position
EVD EVO
EVD Ice
on/off on/off
on/off on/off
serial
serial
No modularity
SmartCella MasterCella UltraCella
on/off connection serial connection

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CAREL SOLUTION
FOR COLD ROOMS:
cella range accessories & features

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Supervisors
boss
• Built-in Wi-Fi
• Max 300 devices
boss mini
• Advanced
• Built-in Wi-Fi
• 50 devices
• Micro HDMI
• Basic
• ethernet port
• 30 devices
Browsable from
mobile devices

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boss range – Instant messaging
The new cutting-edge alarms management
boss offers the possibility to send a message in
case of alarm, using an instant messaging APP:
“Telegram” (similar to WhatsApp).
The message contains:
• alarm info (site name, description, timestamp…)
• screen-shot of the last 3 hours trend of the devices in
alarm condition
Same message can be send to a chat group for having a better
team coordination / time reaction.

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RemotePRO is an advanced Enterprise Solution for the:
• data analysis
• stores benchmark
• service maintenance improvement
• energy consumption reduction
boss range – centralization

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Personnel safety
Coldwatch
• Safety system for personnel trapped in
cold rooms.
• To be installed in cold rooms with a
volume of more than 10 m3, operating at
sub zero temperature.
Gas Leakage Sensor
• Allows prompt identification of gas
leaks, avoiding having to shut the
unit down.
• Guarantee the safety of personnel in
the vicinity.

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Food Safety and Quality
• HACCP is a management system in which food safety is
addressed through the analysis and control of biological,
chemical, and physical hazards.
• Constant monitoring of proper storage temperature
conditions.
• It applies on the whole Cold Chain.
• ALARMS
(immediate reaction)
• DATA LOGGING
up to 2 selectable
parameters
(long term analisys)

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Humidity management
Humidisk
• Centrifugal humidifier
• Small/medium size
cold rooms
Humisonic
• Ultrasonic humidifier
• Small/medium size
cold rooms
MC multizone
• Compressed air
humidifier
• Medium/large cold
rooms
All the humidifier can be driven by UltraCella

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visit
www.carel.com

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New system for DC Technology cold rooms:
• Custom solution, co-engineered with OEMs,
to support their market strategy
• refrigerant neutral (CO2, HFO, HFC)
• based on Carel Hecu, Ultracella,
EVD Ice long lasting experience
DC technology in cold rooms: food quality and energy-saving
Carel NEW solution: DC Cella SPLIT
Cold room controlCondensing unit with Evaporator with
Cabling and
accessories
Unique design &
services

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DC technology in cold rooms: food quality and energy-saving
OEMs opportunities
Every OEM DC Cold Room bundle is unique:
• exclusive OEM technology and
OEM know-how for CDU and evaporator
• different bundle composition,
depending on OEM unique services,
values and accessories
• Custom Carel HW, SW and pre-setting
to enhance OEM bundle performances
• powered by Carel DC Technology

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DC technology in cold rooms: food quality and energy-saving
Carel NEW solution: DC Cella SPLIT
EVAPORATOR
with embedded EVD Ice
All electronic expansion valve benefits with:
- Zero field welding
- Zero field wiring
- Up to half less pulldown time vs thermostatic
expansion valve
CONDENSING UNIT with
embedded HECU
- Maximum system performances with
variable capacity
- Optimal temperature control
- Real-time energy optimisation
COLD ROOM CONTROLLER
DC Cella
- Fast & easy wizard commissioning
- High configurability for wide
applications range
- Built-in datalogging functions

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DC technology in cold rooms: food quality and energy-saving
Solution benefits: higher products quality preservation
Time
Temperature[°C]
DC Technology (green) works with measured average temperature limited in a narrow range (set
±1°C) thanks to smoothline logic → more than 80% of the time (defrost included).
On/off systems (red) in the same range share only less than 50% time.
Set= 2°C
2°C
3°C

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Higher energy savings
• HFC: up to +25% average energy saving vs
traditional on/off solutions.
• CO2: up to +15% average (20% peak) energy
saving vs AC inverter semi-hermetic
technology.
• Smart defrost logics
DC technology in cold rooms: food quality and energy-saving
Solution benefits: high performances
Higher acoustic comfort
• less pipes vibrations
• less noise
thanks to DC Technology compressor and
modulating speed CDU fans.
* Depending on CDU acoustic insulation
up to

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DC technology in cold rooms: food quality and energy-saving
Solution benefits: installation & commissioning time saving
* Starting point: 90m3 cold room with walls and door only
3~
Factory
fitted &
tested!
3ph
solution
ready2go!
Quicker commissioning
& pulldown.
No re-tune needed!

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DC technology in cold rooms: food quality and energy-saving
Solution benefits: reliability & monitoring
Reliability
System-approach grant total control on all
system devices:
• Serial communication backup logic
• Preventive alarms logic
• Compressor envelope management
• Advanced oil return management
Monitoring
Complete local and remote monitoring activities
on the whole system:
• Less need for periodical check and field
visits
• Installer can provide premium monitoring
services thanks to advanced IoT capabilities

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Less complexity
• bundle pre-qualified
• factory-fitted & tested components
• Error-proof special cable connections
DC technology in cold rooms: food quality and energy-saving
Solution benefits: usability
Easy installation, even with CO2
• System pre-configured
• Intuitive, step-by-step wizard commissioning
• All system devices status quickly accessible
from main cold room control

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DC technology in cold rooms: food quality and energy-saving
References
Pictures courtesy of
Bottleshop in Bangalow (AU)
Seafood shop in Cairns (AU)

51. This document and all of its contents are property of CAREL. All unauthorised use, reproduction or distribution of this document or the information contained in it, by anyone other than CAREL, is severely forbidden.
• DC Cella can enable additional benefits to OEMs cold room unique solutions, like:
– Seamless installation
– Reliability
– Performances
• DC Cella can overcome perceived difficulties related to DC technology and CO2
while complying with:
– energy consumption normatives
– environmental impact regulations
• DC Cella solutions are powered by CAREL DC Technology
• More DC Technology applications available @ CAREL, HALL 5 stands 306-308
DC technology in cold rooms: food quality and energy-saving
Conclusions