Simple retrofit boosts significant efficiency potential
At Geochang Refrigeration’s ice factory, two air-cooled condensing units maintain a temperature between –5°C and –10°C for ice storage in the cold room. The factory manufactures and distributes ice, essential for various industries, including food preservation.
The heart of both condensing units is a BITZER ECOLINE 4-cylinder reciprocating compressor. After several years of operation, the operator aimed to achieve even more energy-efficient system operation. Seasonal and hourly load fluctuations caused frequent start-stop cycles of the compressors, making it difficult to maintain a stable temperature. To achieve more stable operation and thus save energy, modernisation was necessary.
To address this, they partnered with Samyoung Machinery and DL Refrigeration. Together, they decided to start by upgrading the compressor of one of the condensing units with advanced capacity control to increase energy efficiency.
Retrofitting made easy
The BITZER PERFORMANCE KITS for ECOLINE reciprocating compressors that were not supplied ex-works with the IQ MODULE CM-RC-02 made it easy for installers to carry out the retrofit. BITZER Korea supported its customer with the on-site retrofit of the compressor.
In this project, the ENERGY KIT variant of the PERFORMANCE KIT was used, which allows the mechanical capacity control VARISTEP to be retrofitted without complex modifications to the switch cabinet. The ENERGY KIT is mounted on the terminal box of the existing compressor in a very short time. The wiring of the capacity control is then carried out directly via the module and the compressor. Thanks to VARISTEP, the compressor capacity can be precisely adjusted to the actual cooling demand. ‘Thanks to the BITZER ENERGY KIT, retrofitting the capacity control took less than three hours. No complex rewiring in the switch cabinet was necessary,’ says Mr. Kim, Technical Director at Samyoung Machinery. On-site power consumption measurements over 24 hours showed about a 15% reduction in power usage after system optimisation with the ENERGY KIT.
Optimised data management
In addition to intelligent compressor operating and protection functions, the ENERGY KIT allows the BITZER ECOLINE reciprocating compressor to be connected to useful digital services. With the BEST SOFTWARE or the BEST app, for example, the operating data of the compressors can be displayed in real time on a laptop or smartphone via Bluetooth or Modbus interface. ‘We have access to real-time data from the compressor at all times, which helps us with analyses. This allows us to intervene quickly if necessary or carry out preventive maintenance measures,’ says Mr. Park, Field Service Manager at Samyoung Machinery.
The customer is very satisfied with the project. They have trusted BITZER compressors and the support from BITZER staff for many years. The retrofit of the VARISTEP capacity control via the ENERGY KIT optimised compressor operation, thereby reducing energy consumption and lowering long-term operational costs.
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