Powering the World's Most Visionary CO2 Heat Pump Systems with Fenagy and RLAY

When evaluating potential suppliers for the control panels of their large sustainable heat pumps, Danish OEM, Fenagy, had three critical requirements.

Powering the World's Most Visionary CO2 Heat Pump Systems with Fenagy and RLAY

When evaluating potential suppliers for the control panels of their large sustainable heat pumps, Danish OEM, Fenagy, had three critical requirements.

Summary

Founded in 2020, Fenagy A/S is a Danish OEM that specializes in large sustainable refrigeration and heat pump systems, designed to minimize environmental impact by using natural refrigerants like CO₂ and hydrocarbons. These systems integrate renewable energy sources, targeting industries such as District Heating, HVAC, and Data Centers. To support their rapid growth, Fenagy required a new supplier for control panels and enclosures, eventually choosing RLAY, a trusted CUBIC partner, to meet these demands.

Challenges

Solution

Fenagy partnered with RLAY, which provided a collaborative and innovative approach, along with expertise in series production. RLAY, utilizing the CUBIC Modular System and CUBIC Galaxy design software, enabled Fenagy to standardize control panel solutions while maintaining flexibility for quick adjustments. This partnership allowed for efficient series production, meeting Fenagy’s growing demand with high-quality, adaptable solutions.

Results

Fenagy experienced accelerated electrical development and innovation, enhanced by RLAY’s production capabilities and CUBIC’s support. The collaboration enabled quick adaptation to changing customer needs, ensuring Fenagy is well-positioned for continued growth and market leadership in sustainable heat pump systems.

Since its founding in 2020, Fenagy A/S has experienced remarkable growth. As a Danish OEM specializing in large sustainable refrigeration and heat pump systems, the company meets the rising demand for eco-friendly, energy-efficient solutions.

Not only do their advanced systems significantly reduce energy consumption, helping clients lower operational costs and minimize their carbon footprint. But using solely natural refrigerants like CO₂ and hydrocarbons, Fenagy ensures efficiency and minimal environmental impact compared to traditional synthetic alternatives. Powered by electricity, their systems further integrate renewable energy sources to limit reliance on fossil fuels making them truly the most visionary heating and cooling systems in the world.

Developed for industries such as District Heating, HVAC, and Data Centers, the systems require reliable power control for uninterrupted operation. As Fenagy has grown, so has their need for more capable electrical switchboards.

In late 2023, they identified CUBIC Partner, RLAY, as their new supplier for the control panel operating their H-2600 Heat Pump and stainless steel enclosures for the system’s evaporators.

About RLAY

With decades of experience, RLAY is a leading provider of industrial automation solutions in Denmark, specializing in electrical control panels and System solutions.

Since the mid-1970s, they have been a trusted partner of CUBIC, using the CUBIC Modular System for their designs. Their commitment to strategic partnerships ensures mutual growth and solutions marked by flexibility, honesty, and reliability.

The Challenges

In their search for a new supplier, Fenagy faced three critical challenges that a potential supplier would need to address:

"Our requirements changes quickly, and new control panel solutions must be constantly developed.

A new supplier must be able to support the development, deliver large quantities and easily adapt production to keep up with demand and growth at Fenagy."

- Niels Erik Bjerregaard, Electrical Engineer at Fenagy A/S.

Collaboration and Technological Support

In an industry where innovation drives success, staying ahead of the competition requires leading-edge technological development.

A new supplier needed to demonstrate a collaborative approach and possess the expertise to support the development of the electrical part of Fenagy’s solutions.

Capacity to Meet Escalating Demands

Due to Fenagy’s rapid growth and the increasing demand for sustainable refrigeration and heat pump systems, it was essential for a new supplier to have the capacity and capability to deliver large quantities.

This would enable Fenagy to meet market demands and sustain its growth path.

Flexible and Adaptive Production

Fenagy sought a supplier capable of quickly adjusting production processes to accommodate new developments and evolving requirements.

This flexibility is crucial to support Fenagy’s continuous innovation and adaptation in a dynamic market.

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The Solution

Having evaluated several candidates, Fenagy chose longtime CUBIC Partner, RLAY, as the top candidate due to their collaborative approach, expertise, flexibility, and great experience in series production. Within the first month of cooperation, the first delivery was completed and the relationship between Fenagy and RLAY quickly evolved into a valuable partnership.

Innovating through Strong Collaboration and Conceptualization

A crucial initial step in the process was to conceptualize ideas and requirements into a standardized control panel solution that allows for effective and adjustable series production.

Through sparring and constructive dialogue, RLAY’s extensive know-how has become an important asset in the ongoing development and innovation of control panels that perfectly fit Fenagy’s evolving requirements.

Partnering with RLAY also provided Fenagy with valuable sparring, training sessions, and additional tools from CUBIC to further enhance the development.

In particular, the CUBIC Galaxy design software, which integrates perfectly with their existing electrical CAD software, has been valuable. Transitioning from 2D to 3D design has enabled Fenagy to fully leverage Digital Twin principles and has been key in the conceptualization process.

"Together, we have developed a standardized concept that allows for series production with the possibility to make adjustments based on the end-user's preferences. Both RLAY's knowledge and CUBIC's support and Galaxy software is playing an important role in this process."

- Niels Erik Bjerregaard, Electrical Engineer at Fenagy A/S.

Efficient Series Production

An anticipated need for 70 control panels and nearly 450 customized stainless steel enclosures within the first year emphasizes Fenagy’s focus on production capacity in their selection of a new supplier. With a modern 4,500 m² panel workshop and expertise in series production, RLAY is perfectly positioned and fully equipped to effectively meet Fenagy’s requirements.

Being a CUBIC Partner, allow RLAY to integrate the many advantages of the CUBIC Modular System to further enhance efficiency in their series production. Utilizing they system’s standard parts, simplifies and accelerates assembly at RLAY to support large volumes and ensure consistent quality and shorter lead times. This capability enables RLAY to consistently support Fenagy in meeting the growing market demand.

"The CUBIC Modular System gives great flexibility and makes us more competitive. It supports our abilities in series production and allows us to efficiently meet high-volume demands while maintaining consistent quality and fast delivery times."

- Lars Farsø, CEO at RLAY.

Flexible Solutions

Fenagy has customers across various industries, each with unique requirements, making it essential for the standardized control panel solution to be easily adjustable. By utilizing the CUBIC Galaxy design software and digital twin principles, Fenagy can easily make adjustments to the standardized control panel solution in cooperation with RLAY.

This approach allows RLAY to be proactive and easily make quick, precise changes in the series production, ensuring that the final product meets specific customer requirements while maintaining efficiency and high performance.

Supported by the unique flexibility of the CUBIC Modular System, the same principles apply to the continued development of the control panel. Any future tweaks and updates to the design can quickly be reflected in RLAY’s production.

The Concept

Explore the details of the standardized Control Panel solution for Fenagy’s H-2600 Heat Pump.

Technical Specifications

Control Panel

Type of Switchboard: Back to back Control Panel and MCC
Dimensions (W*H*D): 1968 x 2040 x 1200 mm
Voltage: 3x400V
Frequency: 50Hz
Ampere: 2000A
Busbar: Copper
Short Circuit: 50 kA for 1 sec
Protection: IP54

Customized Stainless EVAP

Type of Switchboard: Stainless Control Panel
Dimensions (W*H*D): 800 x 1000 x 200 mm
Voltage: 3x400V
Frequency: 50Hz
Protection: IP66

The Results

By selecting RLAY, Fenagy has achieved exactly what was intended by designating a new supplier. The electrical development has been accelerated by RLAY and CUBIC’s support, while RLAY’s production enables them to continue their extraordinary growth path.

Key Outcomes

Teaming up with RLAY has accelerated Fenagy’s electrical development. The collaborative approach between Fenagy, RLAY, and CUBIC will continue to be a key asset in the innovation of Fenagy’s electrical parts.

RLAY’s series production capabilities and use of the CUBIC Modular System, provide Fenagy with the flexibility to quickly adjust to evolving technical and customer requirements while maintaining production efficiency.

RLAY’s ability to shorten lead times and meet high production demands ensures Fenagy is well-prepared to meet current and future market demands and continue its growth journey.

The Results

Key Outcomes

RLAY’s ability to shorten lead times and meet high production demands ensures Fenagy is well-prepared to meet current and future market demands and continue its growth journey.

Collaborative workflow

Follow the full product journey from production at CUBIC to installation on site.

CUBIC Production

The standard parts of the CUBIC Modular System needed for the control panel are produced at CUBIC’s factories in Denmark, Poland, India, and China. The customized stainless steel enclosures are made in Brønderslev, Denmark at the CUBIC headquarters.

1 Flatpack Shipment

The CUBIC Modular System components are delivered as flatpack.

The customized EVAP’s are shipped fully welded and pre-equipped on pallets.

2 Frame Assembly at RLAY

Series production of the frames of the control panels at RLAY.

3 Mounting Plate Assembly at RLAY

Mounting plates are being mounted with hardware in the series production at RLAY.

4 Finalized Control Panel

The fully assembled and tested control panel in RLAY’s production before shipment to Fenagy.

5 Control Panel Arriving at Fenagy

The control panel arrives at Fenagy before being mounted on the H-2600 Heat Pump system.

6 Mounting on H-2600 Heat Pump

The control panel gets mounted on the H-2600 Heat Pump system and final tests are made.

7 Installation on Site

The finalized Fenagy H-2600 Heat Pump system with the CUBIC Modular System control panel is installed on site.

8 Finalized Solution

The finalized H-2600 Heat Pump system is fully set up and ready to provide optimal performance in accordance with customer-specific operation needs.

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