Top power at higher energy efficiency

Marmo NV, a meat processing company in Belgium, focused on energy efficiency when renovating its refrigeration system. They partnered with Sabcobel, an experienced cooling systems company, who chose Phoenix Contact’s speed starters for fan speed regulation. The renovated system utilized CO2 as the evaporating refrigerant minimized refrigerant quantity and repurposed residual heat for hot water generation. Sabcobel’s expertise in creating cold chains for the food industry ensured a successful installation at Marmo.

Compact design saves space in control cabinets

Marmo has 60 chillers in their production area, each with a specific setpoint controlled by a system. Phoenix Contact’s speed starters regulate the three-phase AC fans’ speed, ensuring employee comfort and consistent temperatures. The system includes an air boost function in each room, allowing employees to increase air speed when needed. This flexible fan speed control system prioritizes energy efficiency while enhancing comfort. The compact design of the speed starters was a key factor in their selection, as they require minimal space in the control cabinet. These modules offer functionalities that bridge the gap between motor starters and frequency converters, operating on three-phase power with a maximum power rating of 1.5 kilowatts.

Flexible I/O system for connecting the chillers to the central PLC

The refrigeration system at Marmo is efficiently controlled by a central PLC unit connected to distributed I/O islands through the Profinet protocol. This setup offers cost savings and improved efficiency.

The system includes 11 distributors responsible for controlling the 60 chillers in various rooms. These distributors are connected to the central PLC using the Profinet network. To manage the I/O islands effectively, Marmo opted for the Axioline Smart Elements I/O system from Phoenix Contact. This choice was driven by the system’s compact design and flexibility. The installation incorporates a significant number of digital and analog inputs and outputs, including RTD cards for temperature sensors, pressure measurement, and gas detection. The use of Smart Elements modules on a backplane enables seamless communication via Profinet network.

furthermore, one notable advantage of the distributed I/O system is its transparency to the central PLC. This simplifies the management and monitoring process for the system, making it easier to control and maintain.

Remote monitoring for in-service support

Implementing the new refrigeration system during production was a challenge, but the user-friendly Smart Elements modules with Phoenix Contact’s tool-free Push-in connection technology proved beneficial. Also, Maintenance Manager Tim Steegmans appreciated Sabcobel’s support and the system’s industrial approach for operational reliability. Remote monitoring and remote reset capabilities in speed starters enabled efficient assistance from Sabcobel’s specialists.

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