The future of residential heat pumps: efficiency, safety and native integration
The market is recovering. Complexity is increasing
The European heat pump market is stabilising towards steady growth, driven by upcoming EU regulations on decarbonisation and the electrification of energy consumption. For manufacturers and installers, this scenario brings complex challenges: adapting to the new F-GAS and Cybersecurity regulations, and safely managing low-GWP natural refrigerants (such as R-290 propane), which are highly flammable.
To overcome this challenge, simply assembling the best hardware components is not enough: integration makes the difference. Perfect synergy is required between the control electronics and the software logic managing the entire refrigeration circuit.
The complete CAREL solution
CAREL offers an integrated and modular ecosystem, specifically designed around the needs of air-to-water and water-to-water heat pump manufacturers. From refrigeration cycle management to indoor comfort, every element is designed to integrate seamlessly with the others.
Supporting new refrigerants
All our products and components are A3 Ready, ATEX or hermetic. This approach reduces potential ignition sources within the unit and enables faster, simpler development of systems using highly flammable refrigerants such as R-290. Final unit certification is quicker, and the leakage tests required by EN 60335-2-40 can be omitted if all components comply with these requirements.
High-efficiency synergistic control
Our inverters manage variable-speed DC compressors, optimising their loads, reducing on/off cycles (increasing component lifetime while lowering overall operating costs) and reducing noise levels in residential environments.
Ready-to-use application software
The application developed with STone optimises the coordination of high-efficiency systems. The modular software already includes the logic required to manage both the refrigeration circuit and the indoor environment, ensuring maximum comfort. A technological foundation designed to help manufacturers achieve high performance from the outset, reducing integration complexity while remaining fully customisable thanks to the STone ecosystem.
Further strengths
New three-phase inverter with integrated active PFC
The new CAREL three-phase inverter from the PSD2 series, featuring integrated active PFC technology, represents a key element of the high-efficiency offering for next-generation heat pumps.
Active power factor correction continuously manages the current drawn from the grid, reducing THDi harmonic distortion and maintaining a power factor (PF) close to 1, while complying with the most stringent EMC regulations (IEC 61000-3-2) across the entire operating range.
The electronic and mechanical architecture is significantly simplified, reducing the need for dedicated external solutions such as filters and ferrites.
Plug-and-Play LINbus connectivity
Thanks to the strategic collaboration with Grundfos, the new vertical controllers for residential heat pumps natively integrate the LINbus protocol, ensuring immediate compatibility validated during R&D. No additional hardware is required, commissioning is simplified, and direct access to operating data is provided.
Active safety for detecting refrigerant leaks
The new GLD mini with dual alarm relay NDIR technology is essential for continuously monitoring installations using flammable refrigerants and taking units to an even higher level of safety.
Smartphone-assisted commissioning and maintenance
Through a display with integrated Bluetooth and the APPLICA app, installers and service technicians can perform diagnostics, commissioning and guided troubleshooting directly from their smartphone. Diagnostics become faster and interventions simpler.
STone Virtual Loop: test software before building the machine
With STone Virtual Loop, the new tool parts of STone ecosystem, the behaviour of the heat pump can be emulated through mathematical models right from the early design stages and without the need for physical prototypes. Developers can run and validate machine software on a PC, analyse unit behaviour and identify potential issues and bugs without having to wait for laboratory testing timelines.
The result?
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Reduced need for physical prototype testing and less time spent in the laboratory |
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Faster development of new product ranges and evolution of existing ones |
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Significant cost reductions for both new projects and products already in the portfolio |
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Support for onboarding new company personnel by enabling testing in a safe environment |
Design the next generation of heat pumps safely and effectively
With CAREL, hardware and software are designed to work together optimally, and the new programming environment supports the unit throughout its entire lifecycle. From safety with A3 refrigerants and refrigeration circuit management, using inverters that enable highly efficient compressor control, to indoor environment management. Third-party integration, connectivity and virtual testing software complete the offering, reducing complexity, accelerating development and bringing solutions to market faster.
