THE OLPP™ ON ICE

Quiet Insulated Cabinets: Quiet insulated cabinets in outdoor condensing units are designed to minimize noise generated by the operation of the units while providing protection against environmental factors.

Suction-to-Liquid Heat Exchange Accumulator: The Suction-to-Liquid Heat Exchange Accumulator protects the compressor, preventing liquid slugging and prolonging its operational life. It boosts efficiency through improved heat transfer and decreased superheat setpoints, resulting in energy savings. Functioning as a flow stabilizer, it maintains system consistency during varying loads. Moreover, it regulates refrigerant temperature, minimizing the chance of compressor overheating, thus enhancing system reliability and overall performance.

VFD on Compressors: Variable Frequency Drives (VFDs) control electric motors' speed, ensuring precise refrigeration alignment with varying load requirements. By applying VFDs to Chiller compressors, Sensori™ adjusts the compressor's speed and capacity according to the system's cooling demands. This achieves energy savings, precise control, and reduced stress on the compressor.

PID Control for Compressor Staging: Proportional-integral-derivative (PID) control regulates processes. In compressor staging, PID control of temperatures, pressures, flow, and speed manages multiple compressors' on/off cycling to match the cooling demand more precisely. Monitoring and controlling these processes optimize the performance of the compressors and ensure they operate within their intended ranges – gaining better efficiency and longevity.

Reduced Discharge Superheat: Discharge superheat refers to the temperature difference between the refrigerant gas leaving the compressor and its saturation temperature at the corresponding pressure. Lower discharge temperatures naturally result in reduced discharge superheat. With lower discharge superheat, there is less extra heat being generated by the system. This contributes to better performance and efficiency of the refrigeration system.

Cooler Running Compressors: Cooler running compressors experience less wear and tear, require less energy, and maintain optimal operating conditions for the compressor and the refrigerant. This results in improved system efficiency, reduced energy consumption, and longer equipment life.

Enhanced Compression Efficiency: The compression ratio measures how hard a compressor must work. Since compressing refrigerant requires energy input, a lower compression ratio means the compressor works more efficiently. Compression ratios tend to be lower when compressor discharge temperatures are kept low, leading to improved efficiency, reduced energy consumption, and lower operational costs over the system's lifespan.

Extra Pass Subcooled Loop in Condenser: Adding an extra pass subcooled loop in the condenser involves routing refrigerant through an additional loop that facilitates further cooling of the refrigerant beyond its saturation point. This results in increased subcooling, where the liquid refrigerant's temperature is lower than its saturation temperature at the given pressure. Increased subcooling has multiple benefits, including improved system capacity, efficiency, and refrigerant control.

Outdoor Unit: Placing the chillers outside the facility eliminates the need for an indoor mechanical room. This outdoor arrangement simplifies operations, liberating valuable indoor space for other purposes. Furthermore, outdoor configurations offer the flexibility of potential future relocation if needed.

Secure Remote Access: Sensori™ offers comprehensive diagnostics for compressors, evaporators, and all linked components. With secure remote access, technicians can monitor, configure, and troubleshoot the system from any location using smartphones, touchscreens, or computers. This enhances flexibility and efficiency and offers complete system protection thanks to automatic email notifications and effective alarm management.

Automation System: The automation system, using variable frequency drives (VFDs), helps the brine pump, condenser, and compressors adjust their operation based on sensor data, adapting to changing conditions. This reduces the compressor's on/off cycles and ensures a steady temperature difference across the evaporator, keeping ice temperature fluctuations under 1°F. Adjusting refrigeration in line with demand reduces mechanical strain and energy consumption, regardless of occupancy.

Built-in System Logging: System logging involves recording operational data and events of the refrigeration system over time. Graphing these logs helps analyze system performance, identify anomalies, and make informed decisions about maintenance and optimization.

Crash Cooling Function: The crash cooling feature has digitalized temperature control with pre- programmed settings and push-button operation. When initiated, it rapidly cools the ice to a predetermined setpoint, automatically resetting afterward to maintain the desired temperature. This technology is crucial for ensuring consistent ice conditions and eliminating human error.

Full Floating Head Control: A "floating head" control strategy adjusts the condensing pressure setpoint based on the outdoor ambient temperature. As the outdoor temperature changes, the adaptive control of Sensori™ adjusts the condensing pressure to maintain efficient heat rejection. This helps prevent overcooling or undercooling of the refrigerant for significant energy savings and optimizes system performance.

Refrigerant Adaptability: Based on a zero-leak rate, the advanced low-pressure design uses non-flammable, non-toxic, low Global Warming Potential (GWP) next-generation HFO refrigerants – prioritizing both the environment and personal safety. The highly adaptable system can seamlessly transition to future low-pressure refrigerants with a simple setting change in the control panel and requires no equipment or operation changes.

Scheduled Set Back: The scheduled setback feature allows ice-making systems to operate at reduced capacity during off-peak hours or when the facility is idle, a strategy tailored to the facility's preferences. This approach can result in energy conservation and a decrease in operational expenses.

Slab & Infrared Sensors: Both slab and infrared sensors are optional components, and both are being actively logged to provide more comprehensive information for making decisions about ice conditions. The system is preconfigured to accommodate up to four slab and two infrared sensors, offering flexibility in sensor selection. Users can utilize all available sensors or opt for a customized combination based on their specific needs.

Increased Safety: The advanced chiller design integrates low-pressure, next-generation HFO refrigerants, markedly improving safety compared to ammonia systems. This design removes the necessity for extra human safety equipment and leads to cost savings through streamlined piping, architectural needs, and specialized training.

VFD on Brine Pump: VFDs match the brine pump operation with the ice surface needs for improved process control and regulation. They allow the pump motors to adjust their speed according to the cooling demand, ensuring efficient brine circulation and optimizing flow rate. VFDs can slow down the pump motors when the demand is low, such as during reduced ice usage or when maintaining ice temperature. This reduces energy consumption and ensures that the brine circulation matches the actual cooling requirements for better efficiency and consistent ice quality.

Evaporator Heat Exchanger: Incorporating a titanium plate heat exchanger in the chiller system significantly enhances its energy efficiency. This advanced technology improves heat transfer efficiency, enabling the system to perform better while using smaller refrigerant and brine volumes. In contrast to traditional setups with large barrels that hold substantial amounts of brine, the heat exchanger plate optimizes the flow process, eliminating the need for excess brine that remains unused. This results in a much more efficient and resource-saving operation for the chiller system.

Suction-to-Liquid Heat Exchange Accumulator: The Suction-to-Liquid Heat Exchange Accumulator protects the compressor, preventing liquid slugging and prolonging its operational life. It boosts efficiency through improved heat transfer and decreased superheat setpoints, resulting in energy savings. Functioning as a flow stabilizer, it maintains system consistency during varying loads. Moreover, it regulates refrigerant temperature, minimizing the chance of compressor overheating, thus enhancing system reliability and overall performance.

Centralized Humidity Control: The indoor packaged dehumidification unit is easily managed through an interactive HMI screen, offering full scheduling capabilities, access to graphing, threshold settings, alarms, and viewing history.

PID Control for Compressor Staging: Proportional-integral-derivative (PID) control regulates processes. In compressor staging, PID control of temperatures, pressures, flow, and speed manages multiple compressors' on/off cycling to match the cooling demand more precisely. Monitoring and controlling these processes optimize the performance of the compressors and ensure they operate within their intended ranges – gaining better efficiency and longevity.

VFD on Compressors: Variable Frequency Drives (VFDs) control electric motors' speed, ensuring precise refrigeration alignment with varying load requirements. By applying VFDs to compressors, Sensori™ adjusts the compressor's speed and capacity according to the system's cooling demands. This achieves energy savings, precise control, and reduced stress on the compressor.

Reduced Discharge Superheat: Discharge superheat refers to the temperature difference between the refrigerant gas leaving the compressor and its saturation temperature at the corresponding pressure. Lower discharge temperatures naturally result in reduced discharge superheat. With a lower discharge superheat, the system generates less extra heat. This contributes to better performance and efficiency of the refrigeration system.

Enhanced Compression Efficiency: The compression ratio measures how hard a compressor must work. Since compressing refrigerant requires energy input, a lower compression ratio means the compressor works more efficiently. Compression ratios tend to be lower when compressor discharge temperatures are kept low, leading to improved efficiency, reduced energy consumption, and lower operational costs over the system's lifespan.

Cooler Running Compressors: Cooler running compressors experience less wear and tear, require less energy, and maintain optimal operating conditions for the compressor and the refrigerant. This results in improved system efficiency, reduced energy consumption, and longer equipment life.

Secure Remote Access: Sensori™ offers comprehensive diagnostics for compressors, evaporators, and all linked components. With secure remote access, technicians can monitor, configure, and troubleshoot the system from any location using smartphones, touchscreens, or computers. This enhances flexibility and efficiency and offers complete system protection thanks to automatic email notifications and effective alarm management.

Automation System: The automation system, using variable frequency drives (VFDs), helps the condenser and compressors adjust their operation based on sensor data, adapting to changing conditions. This reduces the compressor's on/off cycles and ensures a steady temperature difference across the evaporator. Adjusting refrigeration in line with demand reduces mechanical strain and energy consumption, regardless of occupancy.

Built-in System Logging: System logging involves recording operational data and events of the refrigeration system over time. Graphing these logs helps analyze system performance, identify anomalies, and make informed decisions about maintenance and optimization.

Crash Cooling Function: The crash cooling feature has digitalized temperature control with pre-programmed settings and push-button operation. When initiated, it rapidly cools the ice to a predetermined setpoint, automatically resetting afterward to maintain the desired temperature. This technology is crucial for ensuring consistent ice conditions and eliminating human error.

Refrigerant Adaptability: Based on a zero-leak rate, the advanced low-pressure design uses non-flammable, non-toxic, low Global Warming Potential (GWP) next-generation HFO refrigerants – prioritizing both the environment and personal safety. The highly adaptable system can seamlessly transition to future low-pressure refrigerants with a simple setting change in the control panel and requires no equipment or operation changes.

Scheduled Set Back: The scheduled setback feature allows ice-making systems to operate at reduced capacity during off-peak hours or when the facility is idle, a strategy tailored to the facility's preferences. This approach can result in energy conservation and a decrease in operational expenses.

Increased Safety: The advanced chiller design integrates low-pressure, next-generation HFO refrigerants, markedly improving safety compared to ammonia systems. This design removes the necessity for extra human safety equipment and leads to cost savings through streamlined piping, architectural needs, and specialized training.

Slab & Infrared Sensors: Both slab and infrared sensors are optional components, and both are being actively logged to provide more comprehensive information for making decisions about ice conditions. The system is preconfigured to accommodate up to four slab and two infrared sensors, offering flexibility in sensor selection. Users can utilize all available sensors or opt for a customized combination based on their specific needs.

Extra Pass Subcooled Loop in Condenser: Adding an extra pass subcooled loop in the condenser involves routing refrigerant through an additional loop that facilitates further cooling of the refrigerant beyond its saturation point. This results in increased subcooling, where the liquid refrigerant's temperature is lower than its saturation temperature at the given pressure. Increased subcooling has multiple benefits, including improved system capacity, efficiency, and refrigerant control.

Outdoor Unit: Placing the chillers outside the facility eliminates the need for an indoor mechanical room. This outdoor arrangement simplifies operations, liberating valuable indoor space for other purposes. Furthermore, outdoor configurations offer the flexibility of potential future relocation if needed.

Full Floating Head Control: A "floating head" control strategy adjusts the condensing pressure setpoint based on the outdoor ambient temperature. As the outdoor temperature changes, the adaptive control of Sensori™ adjusts the condensing pressure to maintain efficient heat rejection. This helps prevent overcooling or undercooling of the refrigerant for significant energy savings and optimizes system performance.

VFD on Brine Pump: VFD controlled brine pumps to adjust their speed according to the cooling demand, ensuring efficient brine circulation and optimizing flow rate. VFDs can slow down the pump motors when the demand is low, such as during reduced ice usage or when maintaining ice temperature. This reduces energy consumption and ensures that the brine circulation matches the actual cooling requirements for better efficiency and consistent ice quality.

Evaporator Heat Exchanger: Incorporating a titanium plate heat exchanger in the chiller system significantly enhances its energy efficiency. This advanced technology improves heat transfer efficiency, enabling the system to perform better while using smaller refrigerant and brine volumes. In contrast to traditional setups with large barrels that hold substantial amounts of brine, the heat exchanger plate optimizes the flow process, eliminating the need for excess brine that remains unused. This results in a much more efficient and resource-saving operation for the chiller system.

Reduced Maintenance and Moving Parts: A simplified system with fewer complexities, moving parts, and less complicated piping architecture requires less maintenance. The fewer components, the less chance there is for mechanical failures. This leads to lower maintenance costs, reduced downtime, and improved operational reliability.

Digital Integration: The Sensori-integrated OLPP undergoes meticulous design and engineering, integrating the SCADA system, IPC, GateManager, and HMI. It replaces conventional mechanical pressure controls with advanced digital controls, digitizing the entire system. This transformation enhances accuracy and responsiveness, eliminating the reliance on mechanical components prone to degradation over time, thereby mitigating maintenance issues. The digitalization process enables precise control of all components within the system.

Enhanced Leak Prevention: A simplified and sealed system design inherently reduces the opportunities for refrigerant leaks. This is not only environmentally responsible but also helps you comply with regulatory requirements and saves costs on replacement refrigerants.

Redundant Control: Using several smaller compressors with VFD controls introduces redundancy by distributing the load, providing operational flexibility, isolating potential issues, improving energy efficiency, and offering scalability. This approach enhances the overall reliability and resilience of the system in the face of varying demands and potential equipment failures.

Industrial Personal Computer (IPC): Monitors and enhances the operation of refrigeration equipment to maintain the desired temperature and other environmental conditions. To achieve this, IPCs leverage sensors and data analysis to make immediate adjustments to the refrigeration system, thereby guaranteeing efficient and uniform performance.

Plug & Play: The IPC plays a crucial role by automatically collecting and consolidating data into comprehensive user screens. Systems arrive pre-programmed and ready for installation, allowing users to access essential data immediately. The automated process simplifies the user experience, making critical information readily available without the complexities of manual configuration.

Pushing Data: Systems are equipped with sensors and controllers that collect data related to temperature, humidity, pressure, compressor status, door openings, and other relevant parameters. These data collection points serve as the source of information, which is then pushed to a secure server (GateManager) and made accessible for reporting and historical analysis. The live data guarantees the well-being and functionality of the system, while historical data serves as a valuable asset for evaluating the system's performance and identifying trends.

Email and Alarm Management: Automatic email notifications & alarm management alert users & maintenance personnel about critical system events. This enables timely responses to issues, reducing downtime & potential product loss.

Complete System Diagnostics with Operating Envelope: With access to detailed diagnostics for compressors, evaporators, and all connected components, Sensori™ is invaluable for maintenance and troubleshooting. It identifies issues early, prevents downtime, and optimizes performance. An envelope of optimal operations is defined with AI and maintained with Machine Learning, allowing the system to self-assess and adjust.

Energy Management: All systems are equipped with an integrated energy profile from the outset, eliminating the need for later add-ons. This integrated approach ensures complete transparency regarding the equipment's energy consumption, allowing for precise and informed energy management.

Gatemanager software is a web-based user interface designed to gather information from the system and transmit the data through a secure server. It establishes an encrypted connection between the equipment and personal computers or smart devices and allows data to flow between them. Technicians can then remotely access and view real-time data, enabling them to monitor, adjust, and protect equipment as if they were on-site. This system facilitates efficient and secure remote equipment management and enhances operational control.

Connects Over LAN (Local Area Network): Sensori Control doesn't exclusively rely on Internet Protocol (IP) for its functionality. It is designed to operate even without an IP connection, utilizing its own Local Area Network (LAN). This capability enables Sensori Control to establish communication, share data, and operate within a confined network environment independent of external networks like the Internet or a Wide Area Network (WAN). This means Sensori still facilitates communication and shares essential data for efficient equipment performance when internet connectivity is limited or unavailable.

WAN (Wide Area Network): Once processed, relevant data is distributed or sent over a Wide Area Network (WAN). WAN connections are crucial for remote accessibility, as they provide the infrastructure for devices to communicate and interact over large distances, including accessing resources and systems remotely with cell phones or computers.

No IT personnel Required: No elite skill sets are needed to manage systems well. The simplified setup and automatic configuration of Sensori™ reduce the complexity of implementing remote access and control. The system is easily connected via standard Ethernet or 12-wire cables for data transmission, plug-and-play monitoring, and control. Not requiring dedicated IT personnel makes the system more accessible and reduces associated labor expenses.

Cloud Storage: Instead of being stored on a local computer or on-premises servers, data is uploaded to these servers over the internet. The accessibility of cloud storage ensures that data from equipment can be securely stored and accessed from anywhere with an internet connection, promoting collaboration and enabling real-time decision-making. Additionally, cloud services incorporate robust backup and redundancy measures, safeguarding equipment-generated data against potential loss.

Accessibility: Thanks to GateManager's VNC (virtual network computing), a direct connection makes login access possible on smart devices. Devices linked to the WAN, accessible from anywhere with internet connectivity, can retrieve processed data. These devices can include computers, smartphones, tablets, and other connected hardware. Complete machine control, including programming and information access, is available. Remote adjustments to setpoints and monitoring can be quickly executed when necessary for temperature or pressure changes, ensuring comprehensive system protection.

Centralized Heat Control: Operators can easily access setpoints, alarms, graphing tools, and historical data to fine-tune settings, leading to more precise and efficient temperature control through real-time monitoring and analysis. Zone heating modules.