Live from the Mobile Training Unit: CO2 refrigeration for Food Retail | Cooling United Live
Hello, and welcome to this session, where we will focus on our CO2 solutions within food retail. Today, we will start by focusing on our solutions for hyper markets, then we move on to our solutions for smaller stores such as discounters, then we'll focus on gas detection and last but not least we will present to you our brand new SFA10 for co2. We have convinced our great product managers to go out in the mobile training unit and do live presentations for you, so let's see if we can connect. Are you ready guys? Yeah thank you Anya, thank you very much yes we are indeed here in the training unit, Kalinsky and myself and we are going to introduce some of the new components, some of the updates for components that we have invested in recently for the for the CO2 solutions that we're offering so this includes both the multi ejector and also the updated pack controller. And the pack controller is what i'm going to talk about just now, so please follow me to the to the panel here, one of the many panels we have in the training unit. So inside we have the AKPC 782 installed,
and the 782 is the market leading CO2 controller and we are we are continuously investing into the 782 technology in terms of control methods and algorithms. The 782 is a is a highly flexible controller, so whether you have the smallest, simple mini booster with a few compressors and, you know, technology that fits your store that have come to the market 10 years ago or you're using the newest technology in terms of ejectors, and maybe with 10 or 12 compressors, then the 782 is flexible and it can be scaled in terms of number of compressors the technology you choose and also different options to cover your full application needs on the pack side. So as you define your your application the number of features increases and also the number of i o points and types of io's that you need also increases and this puts demands on the hardware.
And here on the left hand side you have the pack controller itself so this is a 782. and depending on which i o types and number of i o you need you expand your hardware with expansion modules, so here we have a 103 we have a 205 that offers different io types that fits with the specific application. So in this way both the hardware and the software is flexible We have a highly efficient solution we have invested in CO2 for for many years and we have refined this solution throughout the years and today CO2 is feasible in all climates throughout the technologies that we're offering.
Also in terms of reliability the Danfoss pack controllers are state of the art, so it's not just a cost efficient solution for you to buy but it's also a solution that you can trust in so the algorithms are efficient and they're also very robust, and that means that they can cover many different applications and they are also able to maintain cooling and overcome difficult periods with difficult operational conditions so that the cooling capacity of your store is maintained. The 782 features up to 12 compressors it has up to three suction groups so your MT, your LT and also your parallel intermediate compressors and that's all all integrated and coordinated in the 782. It masters the the high pressure control so in the gas cooler where you have more than 100 bar and the receiver pressure where we are creating the pressure for the for the rest of the evaporators.
In the high pressure gas cooler we have also very high temperature and this is one of the the keys to to obtaining a good efficiency, that is that you can also on top of the normal efficiency you can you can harvest the energy from the gas cooler and here also the 782 has a state-of-the-art built-in function where you can choose to have up to two heat recovery circuits that maintain your general heating and your your hot water and increase the whole efficiency of the of the installation. So this is the the 782 in terms of robustness, efficiency flexibility which are the one of the some of the trademarks of the of the 782. So thank you and over to you Anja. Thank you Brian, that was a good presentation it is clear that the controller is a vital part of the system but another vital part is of course the ejector.
Therefore, let's go back to the mobile training unit and see if Sjammick is ready. Hello, in this presentation i will focus on the CTM multi-ejector which is the vital part of the Danfoss multi-ejector solution. Historically the CO2 system efficiency has been a challenge in warm ambient conditions with the CTM multi-ejector the CO2 equator has been eliminated. This solution makes the CO2 refrigeration systems economically competitive with a standard HFC system no matter what is the ambient temperature. Please follow me, and let's have a look where the CTM is located in the mobile training unit. So here you can see the CTM multi-ejector which is a very special type. It contains the
liquid ejector, the low pressure ejectors and also the high pressure ejectors it is not something what is open for the regular sales, but in order to to run different types of applications and simulate different working conditions we are having this very specific version here. For the sake of simplicity and better understanding let's have a look on this standard transcritical system with IT compressors. The multi-ejector is located here between the gas cooler and the receiver. Here you can see that it's mounted in parallel with the high pressure valve but it is done in that way only for the training purposes. In a standard system the high pressure valve becomes redundant and the multi ejector takes over its functionality. It takes over its functionality and it gives much more it is designed in a way to lift some gas leaving the empty cases.
Mix it with the gas leaving the gas cooler and send it to the receiver at the medium pressure level in the next step the pre-compressed gas is taken by the IT compressors which operates more efficiently thanks to the lower pressure lift required. To sum up this part let me focus on the benefits for both OEMs and end users so the high pressure valve it becomes redundant so it is a clear saving for the for the OEM secondly you can use either less or smaller it compressors because they operate with pre-compressed gas. And the end users they will be happy to see lower energy consumption resulting in smaller energy bills and fast payback time. Let's go
back to the podium so we can look into different types of the ejectors which we have in our family. By using this two pager and answering questions about the ambient temperature and the system type, the store type and system size you can very easily determine which type of the multi ejector you should use. We have four different types: there is a low pressure type which is dedicated for booster systems, we have the high pressure multi ejector which is dedicated for parallel compression systems, there is a liquid one which is suitable for all types of trans-critical refrigeration systems and finally there is a combi block which is a combination of the high pressure valves and liquid valves. Inside of one aluminium block we have different sizes, there is a big one the CTM6 which can have either four five or six individual ejectors we have also smaller size like here that which is a CTM1 with one ejector inside there is also CTM2 which can have two ejectors. And what is important is that
irrespective from the size we have a built-in strainer which is very easily to access and to make a service. Please make sure that you will watch a presentation with my colleague Preben, who will present all the details how to make the the cleaning of the of this trainer. As a final words let me emphasize that the CTM multi-ejector and the AKPC782 pac controller, they were developed in order to take the CO2 refrigeration systems to the next level. Please try use it and experience a full benefit of the CO2 as the refrigerants thank you and back to studio. Thank you Shamik for that great presentation. Now we move over to our small store formats and introducing CO2 mini pack solution. Brian are you ready? Yeah thank you Anya and hi again everyone, and now we're going to talk about the mini pack solution of Danfoss.
consists of electronic components as well of mechanic components. This is an application area we have invested in in recent years and this is a market that has opened up since the new technology as well, as legislation and public opinion moves from traditional refrigerants to natural refrigerants. So we will talk about the mini pack solution and my focus today will be the the 572 in this session so the AKPC572 solution consists of a battery backup module the EKE2U.
It consists of two extension modules, EKE1P and it consists of the pac controller itself AKPC572 if you take the components in that order then the battery backup module is there for safeguarding the closure of the valves in case of a power outage. You don't want the high pressures in the in the refrigeration system to drift to locations that you are not in control of during a power outage. So if the if the power goes then the battery backup module will ensure the safe closing of the valve. Also the the status of the battery backup module is available in the pack controller,
so this means if the battery backup backup model is charging, if it's closing the valves, this information is available in the package pack controller as a as one solution you can say. In the same way we have the two valve drivers the EKE1P this is also a fully transparent module we use this to extend the io of the pack controller so here we have one stepper valve on one module stable valve on the other module and we also use utilizing some of the other ios to to to have sufficient input output on the solution. We have two modules and the way that the pack controller distinguish whether it's the one module or the other is simply that you apply a wire short circuiting on one of the analog input and this tells the module that now you are the the module that controls the gas bypass valve and the one without the short circuit controls the high pressure valve. So this is typically the only configuration you have to do of the KE1 modules that is to apply a short circuit then we have the the pack controller itself the AKPC572 this is built on the market leading algorithms and robustness that we know from the from the market leading in 782, so so here you will get the same level of efficiency, you'll get the the same level of safety of the system. Where we are distinguishing this solution from the 782 is that this is a dedicated solution and this is one of the ways we have made CO2 easy to work with and this is important in an application like this because typically we have smaller stores, you might have a different OEMs or installers service engineers that service a smaller installation compared to the traditional large installation and therefore it's very imminent that we have made CO2 easy to work with. You don't have to do revisits you don't have to spend a long time to do the
fine tuning of the different parameters so this was one of the key objectives with this solution It features, even if it's less flexible, it is a full booster pack so we can have three compressors on the MT we can have two compressors on the LT we have a full control of the gas cooler we have control of the receiver pressure and we also have a number of optional features like a heat recovery to increase the efficiency, de-super heater to increase the you know the capacity in very warm ambient, gas bypass as a safety feature and other functions that are optional. So this is all part of this solution got made available in very easy way. So let's have a look at at how the information is presented. There will be a session later on that demonstrates the wizard that we have applied here but i would just for the purpose of this session here i will show how we have made the application available and visible so that it's easy to get an overview. And here we have the 572 that is set up as a single booster system so we see the MT suction group and the key parameters around that as well as the temperature control around the gas cooler if we go to the next page then we see further details on the suction group we have details further details on the gas cooler opening degree of the valve the reference and so on. In terms of pressure and temperatures
and also for the receiver we have a graphical representation of the application so this is a daily use picture where you can very easily get an overview of how your application is running in the same way. We have made it very easy to set up the different types of denver valves so if you want to choose for instance the newest CCMT light valve then this is done easily through a drop down list where that is the only parameter that you have to set up and I think that's actually the next topic so back to you Anya. Thank you Brian now let's have a look at the valve side, we have our well-known CCMT range and the new extension the CCMT light let's have a look in the mobile training unit. Shaimick? Hello everyone in this part i will focus on the ccmt electric pressure regulating valves which are optimized for the CO2 refrigerations. Those valves have versatile applications firstly they can be used as the high pressure valve taking care of the pressure inside of the gas cooler you will also find them between the receiver and the compressors acting as the gas bypass valve and finally they can be also used as the expansion valves for evaporators. In this case we have the AKVP but they can be easily replaced by the ccmt CCMT valves.
Follow me and let's have a look on the family of the CCMT valves. there is a cc empty medium types from 2 up to 8 with a KV value of 0.8 cubic meter per hour and that is the maximum value for those valves. CCMT light that is the newest addition to our portfolio and exactly the same the being able to replace the CCMT Medium in terms of the capacity, because the maximum value which they are having it is also 0.8 cubic meters per hour. And finally there is a CCMT Large types from 16 up to 42 with a capacity from 1.6 up to 4.2 cubic meters per hour it is fully serviceable free in one concept, with a built-in filter. In this type which I have
today you will see that there is a mbs pressure transmitter integrated into the body but we also have a version without this MBS. And those valves are optimized for the systems above 100 kilowatts Coming back to our latest development and that is the CCMT Light, the valve is very robust accurate and easy to use. It is designed in a way to have high tolerance for dirt and debris what reduces the number of service related incidents and improves the long performance of the valve and the whole system. but in case there is a need to make a maintenance thanks to the fact that it is a cartridge design you can very easily take it apart clean all the all the internal components replace the o-rings or if necessary you can replace the whole actuator. We have 12 different code numbers with a different connection sizes and types which are very easily to be installed in the application and the installation time is very quick and easy because you can simply remove the product from the box and you can start the installation procedure, and for sure it saves a lot of time and energy for the OEMs. There is one more thing i would like to show you so please follow me. Brian. Here you can see the cross section of the CCMT Light. This valve has a linear opening curve
and there is no capacity jump at the very beginning. What is also important is that it is having a low hysteresis and thanks to that the pressure regulation is very accurate. And all those features are combined with a very quick operation of the valve, it takes only 2.1 seconds from open to close position please make a zoom on this part and you will see how quickly it operates it is still in the open position and now you've been able to see how fastly it closes what i can promise to you is that ccmt lite and ccmt family will grow so please watch out for the next releases thank you and back to studio. Thank you Shajmeck. Yes, we are very much looking
forward to the extension of our CCMT family now we will move over to something different, now we'll focus on gas detection for all stores. Over to you Brian. Yeah thank you Anya yes and i will talk about a different part of the refrigeration installation with namely the the gas detection system. And we have in '19 introduced the second generation of the gas detection product range, which offers new features and and state-of-the-art functions. So it's a wide product range which I've introduced to you and we have also installed the gas detector here in the mobile training unit, so we have here to the left of me we have a room and here we have a sensor head installed inside in the room and above the room we have with the remote cable we have the sensor electronics that is safeguarding the the room so to say. We also have the gas detector with
a built-in sensor and we have here monitoring the gas level here in the mobile training unit we have a unit with a built-in with a built-in sensor element. So the whole product range is offering peace of mind and that's really the the main value of the of the gas detection system. And on top of that, we have we have developed it so that it's something that fits the food retail and general commercial building industry, so that it's something that you can take out of the box, install electrically and then in in most cases you actually can connect the power and you have your monitoring system and gas detection system up and running. The peace of mind is delivered out of the box you can say, firstly because we have a pre-calibrated sensor and this comes with a calibration certificate that has a certain validity or duration that it's valid, and if we take a CO2 then the validity of the certificate is actually five years. And that is quite remarkable for for gas detection systems like this. When it comes to to the expiration of the of the validity of the of the calibration then
the sensor will actually give a small warning message so that you are aware that you need to to do the calibration,and when the calibration is due you can choose to follow the semi-automated calibration process where you are guided through some steps to do the calibration or you can choose simply to to buy a new sensor element. You can actually open the gas detection unit, you can unplug the the sensor element while the power is on and then you can plug in the new sensor element and it will it will start detecting the gas based on the new element so it's it's easy like this. One of the other features that is offering peace of mind is a safe entry function. So you can choose to to activate a function which means that when you enter the room you can you can you can activate the function and that actually simulates an alarm of the system. So before you enter a room for instance you can do this on a daily basis you can do it on a weekly basis depending on the the safety measurements and standards of the end user.
You press and hold a button and after some seconds it will simulate an alarm and then you can actually see that the warning unit of the gas detection system is actually activating and that means that the safety chain of the gas detection system is is well functioning. The whole DDS is not certified according to functional safety or similar standards but it's actually developed in in a compliant, co2 compliant, development process and that means that the way that the product is designed and structured gives the highest safety in the industry. We have both a critical alarm relay which has a threshold which depending on the gas allows you to work a certain number of hours in the environment even if you have reached the critical level so it is a safe critical level but we also have a warning level that allows you to to get a pre-warning and and have a separate alarm relay for this function. The whole range consists of just five sensor elements but between these five sense elements we actually cover more than 30 refrigerants and that means that one DDS will actually cover a range of refrigerants which means that the logistics and the inventory that you that you hold in your stock is reduced. Also the whole range all the GDS's are equipped for for communication they come with a modbus communication capability. It's an open modbus you can choose to integrate it with the Danfoss system manager make it part of your refrigerant refrigeration system and here in the mobile mobile training unit we have done just that so here we have a graphical representation of of a pack and we can see here the icon of the gas detection system, and right now we have 481 ppm in this mobile training unit. So that is how you can you can monitor the gas detection you can
follow the level you can do data logging and you can do analysis of your gas detection system. Oo that's a quick introduction to the DDS so back to you Anya. Thank you Brian. Now we move over to something completely different it is our brand new SFA safety valve we are just launching it now, today actually. So let's move over in the mobile training unit and get it all straight from Jacob, the product manager. Are you ready Jacob. Yes i am thank you Anya. Hello and I would like to today to present the two new products at danfoss safety valve SFA10 coming together with a DSV changeover valve products, which are designed according to industrial standards. It's applicable for capacities which is medium low charge industrial systems but also CO2 transcritical small to medium sized systems. With the industrial design that we are introducing here
we are addressing some of the most common issues in in the co2 transcritical systems, with leaks with sudden reliefs and lost charges, something that annoys everyone in the industry I think. It's applicable for your suction accumulators it's applicable for LT empty suction lines but also LT discharge lines up to a certain capacity of course, you can calculate that with our with the use of our Coolselector 2 calculation software at least once it's introduced to the market by the end of the year Safety valves are subject to inspection every one to six years. It really depends on where you are in the world, but every one to six years it's required that you actually access the valve that you do an inspection and also a pressure verification of the set pressure. Of course you can also decide to replace, it scrap it, and also to repair. It it's not widely in
CO2 transcritical systems to actually keep the products alive but with this valve we are introducing the possibility to actually repair and keep the product alive rather than throwing it away. To make that safe as required in the EN378 we're introducing also the DSV changeover valve where you have the possibility to mount two SFAs and you can then switch the port here close one open another making sure that you always have one safety valve in operation while yours can service or replace or whatever on the other one. To make that even more safe we also have made sure that you know in which direction to turn the spindle once you want to open for instance or shut port B you would have to turn it clockwise and opposite. But let's look a bit into the product and see what it means in terms of industrial reliable and durable design there's a number of critical components inside which basically define the function of the valve First of all you have the spring. The spring is the one applying the pressure
to the seat or through the cone, ensuring you have the exact right opening pressure this we have made in a slightly bigger size compared to the competitors you have in co2 systems you can also see it that the the bonnet is slightly bigger compared to competition. And the main reason for that is that we would don't want to stress the springs because with the more stress you have, the more relaxation you also have on the springs and with relaxation you actually have a set pressure which is dropping over time and we don't like that. We want the set pressure to be steady at least until you have the next service or inspection. Secondly you want the valve to be tight many other brands are using different kind of sealing methods it can be flat sealing it can be a hard teflon etc. Our experience is with safety valves that these have to be that the o-ring give you the best solution, the o-ring is by far due to the elasticity of the product the best material in order to compensate you know small differences on the on the on the cone or or the seat of the of the valve. In addition in our design we also sealing, it's difficult to see here, but we are sealing on the top and the inside of the seat.
And let's say we have the higher pressure coming in here on the downside here or the upstream side that pressure is actually helping us to keep the o-ring in good shape because we are sealing against the inside of the seat. And keeping the o-ring in the right shape rather than trying to make it into a very strange shape and even popping it out that actually help us to keep the valve tight and also in place we don't pop the o-ring out and because with that you would have definitely have a sudden relief. Finally you want to have a perfect reseating once you have the product relieving which is quite common in CO2 systems due to the nature of of CO2 and standstill you want a perfect re-seating again the o-ring here will help us a lot because you can have a little impurity coming from the system and the product is actually capable of taking at least to some extent these particles and still ensure a tight seating. Making a safety valve is basically not that difficult, Making one prototype that works is not difficult, what matters to you as a customer that is definitely that you have a manufacturer who can manufacture one valve after another and still they are performing as specified. That requires you have a very good quality assurance in your production. In our design we know exactly how our tolerances should be so that we ensure that we are always in within the tolerances in our operation. And this we have told and shared of course to our suppliers that they have to fulfill and supply parts with a very narrow tolerance and what is called a high CPK value. If you want you can also have the product certified by TUFF
not only the product design but also that the set pressure or pressure setting of the valve is actually done correctly and is is verified by TUFF at the same time you they also check that all the materials are actually fulfilling the requirements to a pressure bearing product. So, how can we make a difficult or product that is you know quite sensible easy to service how can we do that well the concept is that we introduce this as our service part. This is what we have pre-assembled for you we have made sure that this o-ring is at actually fitting 100 and is in the correct place and the only thing you have to do would be to assemble the product like i'm doing now. Into the valve, mount the seats with sufficient torque of course, and then you can do your adjustment of your spring make sure that it's to the right set pressure. Butt this has to be done by a accredited service provider that can
ensure and measure that it is the exact correct set pressure. So he will also be the person who is actually verifying the set pressure so can also of course set pressure setting when you have replaced the the cone and the o-ring. So all in all we're talking about a reliable product you don't have to replace one valve after another you know even more frequent than required because you kind of have lost confidence in the product. This product is reliable until the next inspection is due. It's as you saw before also repairable and by that we are introducing definitely a sustainable solution. And as our captain here on the background is saying the SFA10 will sail for years without losing its course and i hope now that you understand a little what we are referring to when we are phrasing things like this so that is designed according to to industrial standards. The product is
available for sales with pressure setting up to 65 bar around november 2020 this year so in very short time you can buy the products as singles it means that you can buy it as separate code numbers but we also introducing a an attractive code number where you can purchase one changeover valve together with two safety valves in one code number. So you can follow the introduction of the product on our Dever site and of course you will also hear much more about it on our social medias at that time around november so that was the product here and back to you and thank you. Thank you Jacob for that great introduction to the new safety valve that was all we had to present to you guys today about CO2, but tomorrow we'll have a session focusing on applications and hands-on. Now the product managers and i will go into a
chat room to be able to answer your questions so hope to see you all there thank you.