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.