Heat exchangers with 4 mm Ø tubes for high capacity density

A CO2 gas cooler equipped with photovoltaic panels and integrated energy storage system

Antibacterial photocatalytic filter for dual discharge
unit coolers

High transparency door

Reinforced fin with high corrosion resistance

Digitally animated mirror for collective spaces

Glass door with a high-resolution transparent screen for
commercial refrigerators and freezers

Thanks to the optimization of the circuits and the use of ½ "diameter tubes, the unit cooers of the Armónia series innovate the concept of “low AMMONIA charge ", because they guarantee excellent performance with a refrigerant charge / capacity ratio of 0.07 kg / kW, reducing the amount of ammonia in the evaporator by 67% compared to traditional solutions available on the market.

Through a specific selection of circuits and orifices, the Armónia series guarantees optimized unit cooler operation at a very limited number of recirculations, with the following benefits:

• reduction of ammonia charge in the unit cooler;
• reduction of ammonia volume in the entire system.

The added value of the Armónia unit coolers can be summarized as follows:

• increased safety levels;
• reduced costs;
• increased efficiency;
• extended application fields, within regulatory constraints.

[Comparison between a traditional unit cooler and LU-VE unit coolers with low refrigerant charge in terms of the refrigerant charge/capacity ratio.

* 5/8” TUBE DIAMETER; WAVY FINS; CROSS FLOW DESIGN

IoT technology for “Magic Mirrors”

Nidea^® is the result of close research collaboration between LU-VE Group and the Polytechnic University of Milan. The system has grown out of the necessity to optimize all the dynamics of the defrost process of unit coolers and avoid wasting energy and money, without reducing the functionality of the equipment.
The complex algorithm of Nidea^® is able to calculate and recognise the Optimal Defrost Point which is always variable.

LOWERS defrost energy consumption
LOWERS compressor energy consumption
LOWERS the level of dissipated heat
INCREASES the COP (coefficient of performance)

Nidea^® is the INTELLIGENT response to the waste involved in periodic and constant defrosting based on a logic of precaution. In a traditional system the cycle is activated independently of the real need for defrosting.

Nidea^® is equipped with two temperature sensors which determine the deactivation of the defrost cycle.

Nidea^®, thanks to its pressure sensor, calculates and registers the parameters to identify the time and duration of optimal activation.

Nidea^® registers and “reasons” in order to manage any  anomalies.

Nidea^® is adaptable and has a SELF CALIBRATING SYSTEM in order to automatically change the parameters and the set points in accordance with the current working condition.

The process of overmoulding which seals in the PCB (Printed Circuit Board) enables correct functioning in a humid environment up to a minimum temperature of -30°C.

With Nidea^® important energy savings compared to traditional defrosting (4 per day)

75%  less defrost cycles *
              With just one cycle per day!

30% reduction of energy costs of the total refrigerant plant *

* Data measured in real working condition of a plant.

The unit cooler can be equipped with Nidea^® including pre-mounted electronic expansion valve
In this case Extra savings up to 20%.

LU-VE EMERITUS®: 400% MORE CAPACITY THAN TRADITIONAL DRY COOLERS

EMERITUS® is the latest innovation developed for the LU-VE Exchangers family of dry coolers, condensers and gas coolers.
A resukt of collaboration with Milan Polytechnic, this technological innovation (patent pending) combines the advantages of the spray system with those of adiabatic pre-cooling, all assisted by a sophisticated control system.
The special features of this product make it particularly suitable for applications such as air conditioning and refrigeration. EMERITUS®, applied to CO₂ gas coolers, allows high COP of the plant to be obtained even in the hottest hours of the year, allowing a reduction of the geographical limit for the convenient construction of transcritical CO₂ plants ("CO₂ equator").

Advantages:

• CAPACITY: up to +400% compared to traditional dry ventilated exchangers
• COP INCREASE: reduction of DT1
• QUIET OPERATION: Noise reduction up to 6 dB(A)
• SAVINGS ON ELECTRICITY CONSUMPTION up to 60%
• REDUCTION OF FOOTPRINT up to 80%
• REDUCTION OF WATER CONSUMPTION up to 95% (compared to traditional cooling towers)
• AUTOMATIC WATER QUALITY CONTROL: equipped with sensors that continuously monitor the water quality
• PROTECTION: the finned pack is made of a new magnesium-aluminium alloy coated with a special treatment (ALUPLUS®) which guarantees high protection against corrosion
• INTELLIGENT CONTROL SYSTEM: with innovative and easy-to-use functions, the sophisticated software optimizes and drastically reduces electricity and water consumption

Zero Energy Glass

The new compact silencer, designed and tested in the LU-VE laboratories, dramatically reduces sound pressure level up to 6 dB(A).

Condensers and dry coolers with THE WHISPERER^® PLUS provide the following benefits:

• energy savings up to 19%
• reduction of sound pressure level at equal capacity
• increase of capacity at equal sound pressure level
• smaller unit footprint at equal capacity and sound pressure level
• elimination of warm air recirculation.

This is the integrated solution which combines big energy savings and respect for the environment. From today the direct expansion unit coolers are also available in the PLUG&SAVE version which includes the electronic valve and electronic control unit already fitted and wired up.

Important energy savings

Tests carried out in supermarkets in standard conditions have registered energy consumption reductions of up to 25% on the entire refrigeration system.

Absolute protection

The unit cooler is fitted with an electronic control unit (sealed into a special resin overmoulding) to regulate the valve. This is a construction technique developed for the automotive industry which guarantees performance even in the demanding operating conditions of low temperatures.

Saving installation time

The solution proposed by LU-VE drastically reduces the installation time of the electronic control units, which in traditional systems have to be positioned outside the cold room with a consequent increase of labour time.

Compatible with all systems and easy to programme

The PLUG&SAVE version of the unit cooler is compatible with any and all other electronic systems commonly used for the management of refrigeration plant. It can be used with 24 different refrigerants, including CO2 and the special working pressures required.

Pre-defined working parameters and Modbus connection

All working parameters are pre-defined and are simple to select on an easy-to-read display.
The only remaining setting actions required at the moment of installation are for:
- Refrigerant
- Superheating
- Function mode, choosing between high and low temperature.

NEW COIL GEOMETRY – Tube Ø 5mm
MINICHANNEL^® has been designed for reducing refrigerant charge and energy consumption, combined with high operating pressures.
Heat exchanger with special configuration of fins with “louvre” cuts which are positioned very closely together, capable of optimizing and increasing heat transfer performance, thanks also to the use of special high-efficiency tubes with internal grooves.

ADVANTAGES
• Very high level of solution flexibility
• Very wide range of tube-fin configuration (and consequent elimination of over-sizing for standard products)
• Unlimited range of possible applications. The same technology is applicable to condensers, evaporators, reversible heat exchangers (heat pumps), multi-circuit and cross flows, exchangers with different refrigerants (water and HFCs).
• Reduced weight (less copper, therefore reduced raw material costs) compared to traditional tube-fin solutions.
• Can be serviced and repaired on-site.

High energy saving doors

This compact silencer, designed and tested in the LU-VE laboratories,  dramatically reduces sound pressure level by up to 5 dB(A).
This significant result has been confirmed by tests carried out by TÜV of Munich.
Condensers and dry coolers with THE WHISPERER^® provide the following benefits:

 
• Reduction of sound pressure level at equal capacity 
• Increase of capacity at equal sound pressure level 
• Smaller unit footprint at equal capacity and sound pressure level
• Elimination of warm air recirculation.

Titan model door with LEDs integrated in the double glazing to illuminate the product

Doors with luminous text and logos integrated in the glass

Door with LEDs integrated in the double glazing to illuminate the product

The FHC design activity focused on research into new operating efficiency limits, using detailed fluid dynamic studies.
Long experimentation in the wind tunnel of the LU-VE laboratories led to the new directional JETSTREAMER^® grill which ensures uniform distribution of the air on the exchanger, greater air quantity, greatly extended use of the fan during the defrost stage and a particularly long air throw.
The graphs below show the typical curves of the fans of the F30C and F35HC ranges which use this sophisticated device. The illustrations are eloquent, demonstrating how careful research can be the best response to real application requirements. The air quantity increases compared to a traditional grill by respectively 4% (F35HC) and 9% (F30HC). The new JETSTREAMER^® also enables elevated heat exchange efficiency to be maintained during the frosting stage, as the air quantity remains close to the nominal value even with a significant load of frost on the fins. Such favourable behaviour has allowed a slight reduction of the fin spacing compared to the current SHC series, thus improving the overall efficiency of the product.

The air throw is also very elevated, with an increase of +28% for the F35HC series (compared to the previous S3HC) and +22% for the F30HC, due once again to the new JETSTREAMER^®.

The evolution of the spray system has led to the development of products with ever greater performance. The WATER SPRAY SYSTEM^® was unveiled in 2000, capable of using untreated water for a limited number of hours per year. WET AND DRY^® was introduced in 2003; thanks to its use of water filtered with an inverted osmosis cycle, it could operate for a greater number of working hours. Finally in 2006, DRY AND SPRAY^® was launched; this innovative system, thanks to its new nozzle configuration, can function using softened water for up to 900 hours per year
The LU-VE spray systems can be used on condensers, dry coolers and large capacity gas coolers.
The use of LU-VE spray systems instead of cooling towers has several important advantages:

• water consumption limited to brief periods of the year;
• absence of stagnant water and consequent elimination of risks arising from water impurities and environmental contamination (eg legionella);
• shorter plant payback time;
• low energy consumption;
• low noise level;
• possibility of free cooling;
• no evaporation clouds

The advantages compared to traditional dry coolers are:

• substantial reduction of energy consumption (up to 1/3);
• important air flow reduction (up to 1/3);
• important reduction of overall dimensions (up to 1/3);
• quieter running;
• possibility of cooling to a temperature below that of the ambient air dry bulb.

The new patented structure, fully tested on vibrating platforms, has many advantages such as:

• greater product rigidity;
• reduced unit weight;
• better and more uniform air circulation;
• minimum performance loss if one fan stops.

The evolution of the spray system has led to the development of products with ever greater performance. The WATER SPRAY SYSTEM^® was unveiled in 2000, capable of using untreated water for a limited number of hours per year. WET AND DRY^® was introduced in 2003; thanks to its use of water filtered with an inverted osmosis cycle, it could operate for a greater number of working hours. Finally in 2006, DRY AND SPRAY^® was launched; this innovative system, thanks to its new nozzle configuration, can function using softened water for up to 900 hours per year
The LU-VE spray systems can be used on condensers, dry coolers and large capacity gas coolers.
The use of LU-VE spray systems instead of cooling towers has several important advantages:

• water consumption limited to brief periods of the year;
• absence of stagnant water and consequent elimination of risks arising from water impurities and environmental contamination (eg legionella);
• shorter plant payback time;
• low energy consumption;
• low noise level;
• possibility of free cooling;
• no evaporation clouds

The advantages compared to traditional dry coolers are:

• substantial reduction of energy consumption (up to 1/3);
• important air flow reduction (up to 1/3);
• important reduction of overall dimensions (up to 1/3);
• quieter running;
• possibility of cooling to a temperature below that of the ambient air dry bulb.

This distributor, designed to guarantee maximum performance of the heat exchanger in different operating conditions, ensures:

• greater operational stability: balanced distribution of the refrigeration fluid to make the evaporator run smoothly and reliably;
• less frost: uniform distribution of the fluid guarantees uniform frost deposition on all fin surfaces, permitting less frequent defrosting.

Maximum capacity in all working conditions, especially for new refrigerants with a high ratio of gas to liquid after the expansion valve.

The evolution of the spray system has led to the development of products with ever greater performance. The WATER SPRAY SYSTEM^® was unveiled in 2000, capable of using untreated water for a limited number of hours per year. WET AND DRY^® was introduced in 2003; thanks to its use of water filtered with an inverted osmosis cycle, it could operate for a greater number of working hours. Finally in 2006, DRY AND SPRAY^® was launched; this innovative system, thanks to its new nozzle configuration, can function using softened water for up to 900 hours per year
The LU-VE spray systems can be used on condensers, dry coolers and large capacity gas coolers.
The use of LU-VE spray systems instead of cooling towers has several important advantages:

• water consumption limited to brief periods of the year;
• absence of stagnant water and consequent elimination of risks arising from water impurities and environmental contamination (eg legionella);
• shorter plant payback time;
• low energy consumption;
• low noise level;
• possibility of free cooling;
• no evaporation clouds

The advantages compared to traditional dry coolers are:

• substantial reduction of energy consumption (up to 1/3);
• important air flow reduction (up to 1/3);
• important reduction of overall dimensions (up to 1/3);
• quieter running;
• possibility of cooling to a temperature below that of the ambient air dry bulb.

This coil suspension system, patented by LU-VE in 1999, totally eliminates tube contact with the structure of the condenser or dry cooler and ensures complete protection of tubes in the coil during transport, installation and operation.

Air coolers with turbulent fins and tubes with internal helical 2.0 ribs

Condensers with turbulent fins and tubes with internal helical grooving

At the beginning of the 60s heat exchangers were made with flat fins and smooth bore tubes. The studies and experiments carried out by Contardo during this period into the definition of the calculation system for heat exchanger capacity dependent on its various working conditions, permitted the imposition of fundamental criteria to enhance the capacity of unit coolers and fan-type condensers.
The first positive results in terms of increased external coefficient and capacity of the heat exchangers were obtained with special incisions on the fins. These cuts interrupted the laminar movement of the air flow, producing turbulence. Over the years, this technology has been further refined by LU-VE, designing specific high efficiency fins for air evaporators and fan-type condensers.
The optimum combination of fins with special turbulators and internally helically grooved tubes gives LU-VE unit coolers a capacity increase of up to 73% compared to traditional technology units. This innovative technology for special fins and tubes is now a feature of the most advanced equipment produced in every part of the world.

At the end of the 50s an extraordinary product appeared: the air cooled condenser designated “tubeless”, so-called because it is the fins themselves which form the “tube” by means of high funnel collars inserted one into the other and copper brazed in a controlled atmosphere furnace.
This guarantees the highest coefficient of thermal conductivity in that the refrigerant passes through the fins themselves.
The special internal configuration of the “tubeless” condenser accounts for three concurrent actions:

• it increases the turbulence in the flow of refrigerant;
• it increases the primary exchange surface in that the internal corrugated wall is more extensive than a smooth bore tube;
• it reduces the thickness of the liquid film adhering to the internal surface; this film hinders the condensation of the remaining vapour

These high efficiency condensers are particularily appreciated by the market which demands about a million of them every year. Their special features include:

• high thermal exchange;
• reduced internal volume;
• high resistence to corrosion;
• consistent performance over time;
• totally clean interior thanks to fin collar brazing in a neutral atmosphere at
  1150 °C;
• high mechanical resistence;
• excellent matching of fan motors to condensers to give top performance, quiet running and reduced energy consumption;
• greatly reduces the amount of space taken up.

The following types of condensers are currently in production:
STN
STFT
STVF

Traditionally, to protect the fins of heat exchargers installed in locations with aggressive atmospheres, copper and aluminium fins of increased thickness were used. This led to a significant increase in weight and cost of the heat exchanger. At the beginning of the 70s the Research Laboratories of Contardo, in collaboration with an important producer of sheet aluminium, developed a new efficient and competitive system for the protection of fins, called ALUPAINT^®.

Corrosion resistance tests in marine and industrial atmospheres were carried out by the following test laboratories:

Metaalinstituut TNO (The Netherlands);
Istituto di Ricerca e Collaudo Masini (Italy).

Towards the end of the 70s, with the objective of increasing the performance of heat exchangers with special turbulance fins even more, successful experiments were done using a new technique to increase the coefficient of the internal exchange.
This very interesting result was obtained by inserting special aluminium spirals into the tubes at the initial part of the circuit.
This system eliminated the laminar, stratified movement of the refrigerant, distributing it over the entire surface of the tubes.
This fundamental breakthrough in the technology of heat exchange was achieved by LU-VE at the end of the 80s with a world first in the refrigeration field: the construction of air evaporators and fan-type condensers with internal helically grooved tubes.
The optimum combination of fins with special turbulators and internally helically grooved tubes gives LU-VE unit coolers a capacity increase of up to 73% compared to traditional technology units. This innovative technology for special fins and tubes is now a feature of the most advanced equipment produced in every part of the world.

Differentiated fin pitch

The defrosting of air evaporators was originally done by running water over the fin block. This was effective but required a connection to the mains water supply and great care in the construction of the cold rooms.
In the 50s, in order to simplify construction of the equipment, especially that used in low temperature rooms, unit coolers began to be produced with electric defrost, obtained by fitting an electric heater in the plate of the fin pack. This new system, simple and functional, was widely used principally in low temperature rooms with small unit coolers.
A weak point and source of many problems was the difficulty in making the soldered junction between the electric cables and the heater terminal. Constructors tried various solutions such as using small junction boxes with seals or rubber covers. All these were more or less susceptible to damage caused by the processes of continual heating and cooling in the defrost cycle. This would lead to subsequent malfunction.
A technological turning point which ensured the reliability of electric defrost was reached by Contardo at the beginning of the 60s with the design of an electric heater with a power supply cable vulcanized to the stainless steel plate. The following effects followed:

• complete reliability of the junction between the power supply cable and the heater;
• manufacture of pre-cabled heaters ready to be inserted into the fin block, as the diameter of the vulcanized part is the same as the diameter if the heater element.

Nowadays, nearly all unit coolers with electric defrost on the market have electric heaters connected using the terminal vulcanization technique.