Refrigeration units work in a series of cycles. This is when the unit starts and stops to maintain the required storage temperature. Air cycles (on/off) typically produce a minimum of 12 cycles per hour and, in some open display cases, 20 cycles per hour.
Refrigeration units usually monitor circulating air temperature in order to decide when to switch on and off. However, circulating air temperature tends to rise quickly, far more quickly than food temperature and, as a result, refrigeration works harder than necessary to maintain stored products at the right temperature. This in turn leads to excessive electricity consumption and undue wear and tear on the equipment.
How the eCube works
How Refrigeration Units Work
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The eCube consists of a food simulant contained in a double-skinned enclosure. The food simulant mimics food temperature at around 10mm below the surface. It is like having your thermostat regulating the temperature by the temperature of the yogurt, instead of the air temperature. Due to its specific design, the eCube ensures that refrigeration keeps food at the correct temperature.
When fitted to the thermostat sensor, which controls the compressor, the eCube significantly reduces the frequency of the refrigeration cycles as they are now based on food temperature rather than fluctuating air temperature.
By using the eCube as a cycle control mechanism, refrigeration cycles last longer but can be reduced by as much as 80%.
For example, a Dairy Case air cycles 3 minutes on, 2 minutes off = 12 cycles per hour. With an eCube fitted, the cycles change to 8 minutes on, 7 minutes off = 4 cycles per hour. This equates to a 66.7% reduction in starts.
As the start-up of a refrigerator compressor uses 3 times more power (i.e. start-up 12 amps, run 4 amps) considerable energy savings are achieved. In addition, the more efficient refrigeration cycle leads to a more efficient unit, which then leads to a colder storage area. Consequently, by re-adjusting the thermostat back to its normal temperature settings, there are further substantial
energy savings, without compromising food safety and quality.
Here are just some of the reasons to retrofit your refrigeration system with an eCube:
- Significant energy savings (reduced electricity bills and Demand
- Charges/Climate Change Levy Charges)
- Considerable noise reduction
- Reduced wear and tear on equipment, leading to extended life of equipment;
- Fewer breakdowns
- Fewer sensor failures (as sensors are protected inside the eCube)
- Safer food and less product spoilage
- Reduced environmental pollution
- One-time retrofit product requiring no further attention or maintenance once fitted
- Lower temperatures achieved without heat induced defrost cycles.
Benefit to Longer Duty Cycles
Benefit of longer on-cycles
Normal air cycles will operate as the air temperature attains the set point of the thermostat. This will generate several on/off cycles, without having very much effect on the food temperature (i.e. several 3 minute cycles). However, with the eCube fitted, this changes to 10 minute on-cycles, resulting in a positive food temperature reduction by cooling the food quicker. This, in turn, leads to safer food. In effect, installing the eCube leads to more efficient use of the refrigerator system, lower energy consumption and safer food. The longer on-cycle creates a more efficient refrigeration cycle i.e. longer runs at maximum benefit (compare it to fuel consumption and efficiency in a car on a stop start urban road, or a longer stretch of motorway driving at a steady 70 miles an hour).
Benefit of longer off-cycles
A longer off-cycle allows pressure equalization between the high and low pressure parts of the refrigerant system. This results in a softer start from a cooler system, thus avoiding compressor trip caused by high pressure or an unbalanced system i.e. lower amperage clean start obtains maximum efficiency far quicker (with a further energy saving). The electrical starting component and devices used on refrigeration equipment have an engineered life span, so less maximum power use of these components extends the reliability of the components, thereby reducing refrigeration failure. The eCube extends the life of the starting devices and, in turn, the refrigeration equipment. In time, this leads to fewer breakdowns and engineer call outs.
Refrigeration Control Systems
Food monitoring based on food temperature and not air temperature is now a widely accepted principle of refrigerated storage.
In response to EU food safety legislation, the eCube was originally designed to accurately monitor refrigerated food storage temperatures. This is achieved by using a food substitute contained within an enclosure that enables a microprocessor temperature sensing probe to be contained within a food grade food substitute.
With its variable size cable termination, the eCube fits modern refrigeration controls without changing the manufacturer’s specification (i.e. the eCube is fitted to the sensor inside the evaporator in the refrigerated return air). Once in place, contained within the enclosed evaporator, the eCube requires no further attention or maintenance.
Energy Savings using the eCube
It was realized soon after the eCube had been used for temperature monitoring that it could also deliver substantial energy savings when fitted to a refrigeration unit thermostat.
By using the eCube as a device to control food storage temperature, a more efficient refrigeration cycle is attained. Currently air cycles (on/off) typically produce a minimum of 12 cycles/hour and, in some open display cases, 20 cycles/hour. By using the eCube as a cycle control mechanism, refrigerated cycles can be reduced by as much as 80%.
Example: Dairy case air cycles 3 minutes on, 2 minutes off equals 12 cycles/hour. With the eCube fitted, cycles change to 8 minutes on and 7 minutes off; this equates to 4 cycles/hour, a 66% reduction in starts. As the start-up of a refrigerator compressor uses three times more power (i.e. 12 Amps is required for start-up and 4 Amps for run), power consumption is reduced by 16 to 22%.
This product must be installed by a component installer. Contact Synapse International for ordering information!
