Smart concept, smart control: The “eChiller” replaces chemicals with pure water

100 percent water as cooling agent, 80 percent energy saving: The “eChiller” is unique worldwide in the scalable power range of 20 to 300 kW, and provides a lasting solution for the challenges currently facing the cooling industry as a result of new legal requirements, uncertain price developments for traditional cooling agents and rising energy costs. An all-round smart concept – thanks to Berghof’s control technology. At Gardena, the renowned manufacturer of intelligent systems for garden irrigation and maintenance, the “eChiller”, which recently won an award from the European Commission, has proven itself over the past year to be highly energy efficient and low maintenance.

Birds of a feather flock together: Both Efficient Energy GmbH, the inventor and manufacturer of the “eChiller”, and at Berghof Automation and Control Solutions, the control specialists of the Berghof corporate group, are passionate about seeking out new things. It’s no wonder that experts on both sides are excited about this innovation. This is undoubtedly one of the reasons why the design-in phase for this project was unusually short, at only a few weeks: “We spent many years working hard and meticulously on revolutionising cooling technology before we ended up with the ‘eChiller’, and we therefore wanted to launch the product on the market as quickly as possible once it was ready”, stressed Dr.-Ing. Jürgen Süß, CEO of Efficient Energy GmbH, which developed the “eChiller”, that has recently won the „European Business Awards 2018-2019“ from the European Commision in the category „The Product and Services Award“, and is now successfully manufacturing it in series production. Initially, the company put all of its energy into the development of compression cooling technology and planned to control the “eChiller” using a simple microcontroller. We quickly noticed, however, that this made it difficult for us to exploit the full energy savings potential that our idea offered,” recalls Dr.-Ing. Süß.

 

 

 

 

 

 

 

Smart concept: The “eChiller”, which recently won an award from the European Commission, is the only cooling machine in series production to offer water as a cooling agent in the power range of 20 to 300 kW.

Based on CODESYS

An employee at Efficient Energy then made a crucial step: “He made us excited about the advantages of programmable controls (SPS) based on ‘CODESYS’. Together with the specialists at Berghof, we manged to control the heat-emitting chain very successfully and to optimise our energy use”, says Dr.-Ing. Süß, thanking the company for their successful cooperation together. The result can be clearly seen: According to Efficient Energy, the “eChiller” is four times more energy efficient than standard systems. And, thanks to its smart control concept, it can be adapted flexibly and precisely to the wishes of the individual customer. Berghof’s SPS can be adapted to any circumstances. This high degree of flexibility is made possible by its sophisticated standard portfolio, all of which uses the conventional and tried-and-tested “CODESYS” system. The advantage for customers: Berghof thus has extensive experience in components, descriptions, user experience, accessories, software, performance and much more.

 

 

 

 

 

 

 

Smart control: Thanks to a programmable “CODESYS” control system made by Berghof, the “eChiller” is controlled reliably along the entire heat-emitting chain.

Intelligent automation solution

As one of the first users of “CODESYS”, Berghof has many years of experience in application creation. The current control platform, based on modern processors, offers a broad portfolio of different components. This portfolio ranges from the compact “B-Fortis CC-Slim” box control and all-in-one “B-Fortis CC-Prime” controls with a number of interfaces and IOs, to the “B-Primis DC-Classic and DC-Prime” panel SPS and the “B-Primis ET-Classic and ET-Prime” web terminals. The Berghof controls’ high level of performance makes them perfectly suited to CNC applications with SoftMotion. The portfolio also contains safety control and cloud services solutions, fully integrated into “CODESYS”. This broad portfolio allows Berghof to offer solutions tailored to specific customers using tried-and-tested methods. The company provides whatever support is necessary throughout all phases of project implementation. This means that even employees with limited experience are able to implement their requirements with confidence. The result: high-quality projects are carried out swiftly with proven components, providing security for system engineering and end users alike.

 

 

 

 


Impressive flexibility:
Berghof’s SPS can be adapted to any circumstances. This high degree of flexibility is made possible by its sophisticated standard portfolio, all of which uses the conventional and tried-and-tested “CODESYS” system. The advantage for customers: Berghof thus has extensive experience in components, descriptions, user experience, accessories, software, performance and much more.

Used by the market leader Gardena

A good example of this is the collaboration with Gardena, the renowned manufacturer of intelligent systems for garden irrigation and maintenance: For one of the company’s factories in Gerstetten near Ulm, where Gardena produces around 1.5 million plastic components per day for its own use and for countless renowned customers, the company’s bosses are looking for a cooling solution for a plastic extruder machine to manufacture pipes for its sprinkler systems that is as energy-efficient and environmentally-friendly as possible. One thing presented a particular challenge: To guarantee that the pipes are as high-quality as possible, the temperature must always lie within a very narrow temperature range. “This means that we not only have the ‘water instead of chemicals’ and high energy savings benefits of the ‘eChiller’ to extol, but can also highlight the very precise control via the SPS points”, Dr.-Ing. Süß is delighted to announce. Pleasant side effect: Efficient Energy can control SPS simply via remote access to carry out system diagnoses or software upgrades for Gardena. The “eChiller” has been up and running at Gardena for around one year, and has proven itself to be successful under daily, round-the-clock operation. No small wonder that things bode well for Gardena continuing to rely on the “eChiller” for its temperature control needs in future, as far as possible anyway.

 

 

 

 

 

 

Satisfied customer: At Gardena, the renowned manufacturer of intelligent systems for garden irrigation and maintenance, the “eChiller” has been up and running at Gardena for around one year, and has proven itself to be successful under daily, round-the-clock operation.

 

 

 

 

 

Seamless operation: No small wonder that things bode well for Gardena continuing to rely on the “eChiller” for its temperature control needs in future, as far as possible anyway (here Efficient Energy sales engineer Peter Kaden, left, in conversation with Mr Roginic, head machine operator at Gardena Manufacturing in Gerstetten, near Ulm).