Dixell CO2

KGH Congress 2018
#Controller #Transcritical #CO2 #Compressor
Title: Supermarket application of an advanced

management control system for a T-CO2 Compressor
Rack connected with Multiplexed Refrigerated Cabinets.
Beograd, 06/12/2018
STEFANO RIZZO - Export Sales Area Manager | Dixell Srl

Emerson Commercial & Residential Solutions
49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 1

49th International HVAC&R Congress and Exhibition, Belgrade, 5–7 Dec. 2018
Purpose
Dixell iProRACK 2.8
❑ In order to comply with the F-Gas Regulation and the phase-down of

fluorinated refrigerants, it becomes more and more important to
develop high efficient low GWP refrigeration systems.
❑ CO2 as natural refrigerants (GWP=1) is an effective replacement to

high GWP refrigerants.
❑ The use of CO2 as refrigerant, brings some challenges on systems

designs to guarantee the efficiency, often requiring more complex
systems to deliver comparable performance to HFC’s.
❑ Dixell iProRACK Control Solution helps CO2 applications, keeping high

performances of the system.

The CASE STUDY
T-CO2 system for a Supermarket in Wadalba (AUS)
T-CO2 Booster application with

Parallel Compression, Oil Management
and Adiabatic Cooling Expansion
iProRACK rel. 2.8

Supermarket Location and Features
Request of T-CO2 application in a potential warm area
SUPERMARKET
PROPRIETARY (Brand) Woolworths
Location Sydney (Australia)
City Wadalba
Dimension (m2) 2800 sqm trading area
Medium / High temperature line 201 kW
Low temperature line 34 kW

Climatic Profile Study to Design the Rack
Sydney, Climatic Zone Profile
Average Annual Temperatures

• Max: 21,7 °C
• Min 13,8 °C
Data source:
HIGH TEMPERATURES FOR FEW DAYS A YEAR, DRIVE TO AUXILIARY COOLING DEVICES

Climatic Profile Study to Design the Rack
Sydney, Climatic Zone Profile – possible System Solutions
A. To size all components of the System (Compressor Rack, Gas Cooler,

Compressors, etc) big enough to cover the worst ambient pick conditions.
B. To introduce a suitable System configuration, and an Auxiliary Cooling

Device enabled only when outside working conditions required it
(efficient solutions).

Supermarket – Refrigeration System Configuration
Controller: iProRACK release 2.8 is a modular system for T-CO2 applications
T-CO2 COMPRESSOR RACK FEATURES SUPERMARKET
MEDIUM temperature line
Total cooling capacity (kW) 201 kW (split across 1x HT rack + 1x MT rack)
2x T-CO2 RACKs
iProRACK release 2.8 is3acompressors (2 on/off + 1 VSD) each rack
Number of compressors
modular system for T-CO2 applications
LOW temperature line
Total cooling capacity (kW) 34 kW (booster configuration, 1x HT rack + 1x MT rack)
Number of compressors 2 compressors (1 on/off + 1 VSD ) each rack
PARALLEL compression line
Number of compressors 2 compressors (1 on/off + 1 VSD ) each rack

Other
Electronic Controller Dixell iProRACK Rel. 2.8

Adiabatic function Yes, controlled by Dixell iProRACK
Racks manufacturer HEATCRAFT – KIRBY

Supermarket – Refrigeration System Configuration
Controllers for showcases: XM600 series
SHOWCASES SUPERMARKET
MEDIUM / HIGH temperature line LOW temperature line
Number of cabinet(s) 56 cabinets + 8 cold-rooms Number of cabinet(s) 15 cabinets + 4 freezer rooms
Total KW 201 kW Total KW 34 kW

Dixell XM678D with integrated driver for Dixell XM678D with integrated driver for
Electronic Controller for Electronic Controller for
Ref. Cabinets
EEV stepper (1 per showcase and EEV stepper (1 per showcase and
Ref. Cabinets
1 per cold-room) 1 per cold-room)
83 x XM687D
83 x CH620
Showcases manufacturer HUSSMANN

Circuit Design and Configuration
Controller: iProRACK 2.8 configuration (according system design)
CONTROL PANEL:
✓ IPRC215D Rack Controller
including DxL SW Vs 2.8
GAS COOLER ✓ IPX215D 10DIN Expansion
✓ XEV20D + Battery Back-up
✓ VISOTOUCH User Interface
Adiabatic Cooling
Spray Nozzles
(controlled by
iProRACK 2.8)

PARALLEL COMPRESSION, a solution for warmer climates
Parallel compressors moving southern CO2 equator
Parallel compression:
❑ COP Improved
❑ Cost effective CO2 solution

for warmer climates
AIC10
✓ Parallel compression offers better performance because, moving CO2 from Flash Tank to Gas Cooler, makes
less compression work in comparison to the flash gas bypass cycle
✓ Parallel compressors are automatically activated when the controller detects consistent refrigerant mass flow
from By-Pass Valve (BPV) to MT suction line
✓ Flash Tank BPV (By-Pass Valve) kept on working, with higher pressure set point (safety purpose)

Differential oil control
Accurate oil differential pressure control
✓ To ensure a good lubrication to all compressors, a

pressure differential oil control has been adopted
✓ 5 bar differential pressure between oil receiver and

flash tank
✓ Oil injection valve between oil separator and oil

receiver is used
✓ Safety functions: in case of low oil signal from the oil

receiver sensor, VSD compressors increase the speed

Adiabatic Cooling Control Function
To control the high ambient temperature pick
✓ Adiabatic System: ON when Gas Cooler outlet Temp overcome 36°C, OFF when GC outlet Temp goes below 28°C
✓ During "normal" operation GC Differential Temp (GC Outlet Temp - Operative Ambient Temp) is close to 2K (GC design)
✓ With Adiabatic Cooling Expansion, the net cooling effect is around 8.4K (close to the 9K from system design)
✓ The fans locked at fixed speed

Conclusions
Adoption of advance technical solutions and integrated controller, expand T-CO2 application areas
✓ CO2 (GWP=1) as effective replacement to high GWP refrigerants; GREEN solutions.
✓ The adopted technical solutions, like parallel compression and adiabatic cooling expansion,
have made CO2 systems working also in warmer areas, moving CO2 Equator southern
✓ iProRACK thanks to the integrated logic, can synchronize, coordinate and manage efficiently
different CO2 system design, from simple to complex configurations.
✓ Tests in real working conditions (Wadalba case study is an example) highlighted the efficiency
of the application developed by Dixell-Emerson and used in the iProRACK controller.

iProRACK System Configurations
Overview of iProRACK controller family and CO2 plant features
System Configurations available Features
1 Circuit 1, medium temperature line
2 Circuit 2, low temperature line
3 Booster
4 Gas Cooler
5 Bypass valve
6 Parallel compression
7 Heat Reclaims (Tap water and Floor heating)
8 Hot Gas Injection
9 Liquid Injection
10 De Super heater
11 Oil injection
12 Adiabatic function
13 HVAC cooling control

V2IPR Visotouch
IPRC215D

V2IPR Visotouch
IPRC215D IPX206D IPX215D XEV20D

V2IPR Visotouch
IPRC215D IPX206D IPX215D XEV20D
Battery
Battery
backup
backup

V2IPR Visotouch
IPRC215D IPX206D IPX215D XEV20D XEV20D
Battery Battery
Battery Battery
backup backup
backup backup

V2IPR Visotouch
Battery Battery
Battery
backup Battery
backup
backup backup

V2IPR Visotouch
Battery
Battery Battery
Battery
backup
backup backup
backup

iProRACK Touch Interface
One touch to move between the circuits
Synoptic
Navigation bar
always available

Thank you


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KGH Congress 2018

#Controller #Transcritical #CO2 #Compressor

Title: Supermarket application of an advanced

STEFANO RIZZO - Export Sales Area Manager | Dixell Srl

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 1

❑ In order to comply with the F-Gas Regulation and the phase-down of

❑ CO2 as natural refrigerants (GWP=1) is an effective replacement to

❑ The use of CO2 as refrigerant, brings some challenges on systems

❑ Dixell iProRACK Control Solution helps CO2 applications, keeping high

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 2

T-CO2 Booster application with

iProRACK rel. 2.8

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 3

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 4

Average Annual Temperatures

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 5

A. To size all components of the System (Compressor Rack, Gas Cooler,

B. To introduce a suitable System configuration, and an Auxiliary Cooling

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 6

T-CO2 COMPRESSOR RACK FEATURES SUPERMARKET

MEDIUM temperature line

Total cooling capacity (kW) 201 kW (split across 1x HT rack + 1x MT rack)

Total cooling capacity (kW) 34 kW (booster configuration, 1x HT rack + 1x MT rack)

Number of compressors 2 compressors (1 on/off + 1 VSD ) each rack

PARALLEL compression line

Number of compressors 2 compressors (1 on/off + 1 VSD ) each rack

Electronic Controller Dixell iProRACK Rel. 2.8

Racks manufacturer HEATCRAFT – KIRBY

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 7

MEDIUM / HIGH temperature line LOW temperature line

Number of cabinet(s) 56 cabinets + 8 cold-rooms Number of cabinet(s) 15 cabinets + 4 freezer rooms

Total KW 201 kW Total KW 34 kW

Showcases manufacturer HUSSMANN

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 8

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 9

❑ Cost effective CO2 solution

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 10

✓ To ensure a good lubrication to all compressors, a

✓ 5 bar differential pressure between oil receiver and

✓ Oil injection valve between oil separator and oil

✓ Safety functions: in case of low oil signal from the oil

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 11

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 12

✓ CO2 (GWP=1) as effective replacement to high GWP refrigerants; GREEN solutions.

different CO2 system design, from simple to complex configurations.

of the application developed by Dixell-Emerson and used in the iProRACK controller.

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 13

System Configurations available Features

1 Circuit 1, medium temperature line

2 Circuit 2, low temperature line

7 Heat Reclaims (Tap water and Floor heating)

8 Hot Gas Injection

13 HVAC cooling control

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 14

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 15

IPRC215D IPX206D IPX215D XEV20D

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 16

IPRC215D IPX206D IPX215D XEV20D

49. Međunarodni kongres i izložba o KGH, Beograd, 5–7.12.2018 17

IPRC215D IPX206D IPX215D XEV20D XEV20D