Solutions For CO Retail Applications: High E Ciency Solutions

High
Eciency
Solutions.
Solutions for CO2 retail applications
carel.com
Content
1. WHY USE CO2 AS A REFRIGERANT?
1.1 Thermodynamic properties ................................................................5

1.2 Subcritical cycle.......................................................................................5
1.3 Transcritical cycle ....................................................................................5
2. SUBCRITICAL CO2 CASCADE
2.1 CAREL solution ........................................................................................7

2.2 System features ....................................................................................10
2.2.1 DSS: Double system synchronization ....................................................10
2.2.2 EEVS: Electronic Expansion Valve Synchronization ........................10
3. TRANSCRITICAL CO2 BOOSTER
12
3.1 CAREL solution .....................................................................................13

3.2 System features ....................................................................................15
3.2.1 DSS: Double system synchronization ....................................................16
3.3 Transcritical CO2 condensing units................................................16
4. SUBCRITICAL CO2: PUMPED
18
3.4 CAREL solution .....................................................................................18
5. COMMON COMPONENTS
20
Application note: Solutions for CO2 retail applications
1. WHY USE CO2 AS A REFRIGERANT?

Despite already having been utilised in the early 1900s, carbon dioxide
has only become widely used as a refrigerant in recent years. This is due to
increasing interest in natural uids, as well as legislation that, especially in
Europe, aims to limit the use of synthetic refrigerants.
Widely available, even as a waste product from other processes, CO2 is much
less expensive than traditional refrigerants. Together with this economic
advantage are other benets, such as low global warming potential (GWP =1,
no impact on the ozone layer), no dangers relating to toxicity or ammability,
and no need to recycle the gas at the end of system life.
1.2 Subcritical cycle

The simplest application of carbon dioxide as a refrigerant is in the subcritical
cycle: CO2 is used in a secondary low temperature loop, either vapour
compression (cascade system) or a pumped loop of liquid CO2.
Subcritical refrigeration process
bar
P 100
1.1 Thermodynamic properties

As well as the economic, political and environmental advantages listed
above, CO2 has several thermodynamic properties that in many dierent
applications can represent advantages and allow it to compete head-tohead with traditional refrigerants.
50
-5.5 C
29 bar
Subcritical
10
-35 C
11 bar
The primary cycle is managed using a traditional refrigerant, with the task of
keeping condensing temperature for the CO2 cycle below the critical point,
generally between -5 and -10 C.
1.3 Transcritical cycle

A CO2 cycle that exchanges heat with the outside can also be adopted. This
is referred to as the transcritical cycle, as in certain periods of the year outside
temperature will be near or above the critical point of 31.1 C.
Transcritical refrigeration process
bar
P 100
The main dierence between carbon dioxide and synthetic uids is that the
critical point is 31.1 C, a temperature that is easily reached in many dierent
parts of the planet. At critical point, the density of the liquid and saturated
gas are the same, while at higher temperatures there is no longer a boundary
between the two phases, and this is referred to as supercritical state.
Consequently, pressure and temperature are no longer related, meaning
measures need to be adopted to keep these under control, optimise heat
exchange and maximise eciency.
Fluid
CO2
R22
R134a
R410A
R404A
NH3
Critical
Critical Saturation Press. (bar) Volumetric latent heat
+30 C
Temp. (C) Press. (bar) -20 C
at -20 C (kJ/m3)
31.06
73.84
19.7
72.1
14592
96.15
49.9
2.4
11.9
2371
101.06
40.59
1.3
7.7
1444
71.36
49.03
4
18.9
3756
72.1
36.2
3.1
14.3
2820
132.25
113.33
1.9
11.7
2131
85 bar
50
-10 C
25,5 bar
10
The main dierence compared to a normal refrigeration cycle involves the

stage in which the compressed gas is cooled, which does not correspond to
constant condensing temperature as in the case of traditional cycles.
It can also be noted that operating pressures are very high, and this
represents the biggest challenge for the components in the installation, such
as compressors, valves and piping. Nonetheless, it should be stressed that
high pressure means smaller diameter pipes can be used, and pressure drop
and compression ratio are lower.
One property of CO2 is high volumetric latent heat, giving an important
advantage as concerns the heat exchangers, the number of circuits and
refrigerant charge.
Heat rejection condensing refrigerant
Heat rejection - transcritical CO2
Condensation normally takes place at constant pressure, with the gas

changing to the liquid phase, while in a transcritical cycle, the temperature of
the supercritical gas falls constantly.
As a result, the high pressure heat exchangers used are designed dierently
and in fact are called gas coolers rather than condensers.
Heat exchange is assisted by this specic property of carbon dioxide, as in
every phase of the cycle the two uids are much closer in temperature than
with traditional condensation. This advantage can be eectively exploited on
heat pumps to achieve higher eciency than traditional units.
As regards the eciency of the actual cycle itself, pressure at the gas cooler
outlet needs to be controlled.
Observing the p-h diagram, for a given gas cooler outlet temperature
(shown in blue in the gure), dierent cycles can be considered based on
heat exchanger pressure. It can be seen that, starting from the cycle drawn in
brown and increasing the pressure, there is an increase in output (hEVAP) that
exceeds the increase in compression work (hCOMP): eciency is therefore
higher. On exceeding the cycle pressure shown in green, the increase in
compression work exceeds the increase in cooling output, meaning a
reduction in eciency (cycle drawn in violet).
Therefore, for each gas cooler outlet temperature an optimum pressure can
be identied that maximises cycle eciency.
Fixed gas cooler outlet temperature
35 C
COP= 2,1
COP= 2,3
COP= 1,9
2. SUBCRITICAL CO2 CASCADE

This solution is ideal for using a natural refrigerant in places with high average
temperatures; subcritical CO2 cascade systems are normally used in hot
climates or as the rst stage in using CO2 as refrigerant.
Cascade systems comprise two circuits, one medium temperature (typically
R134a, R404a or NH3) and one low temperature (R744), connected via
one or more heat exchangers, normally plate exchangers, which on one
side condense the CO2 and on the other act as normal evaporators for the
medium temperature circuit.
Example of a subcritical CO2 cascade system
35 C
8 bar
R134a
E2V
-10 C
1 bar
E2V
E3V - E4V
-5,5 C
29 bar
R744
E2V
-35 C
11 bar
E2V
PROS
System relatively similar to a traditional installation (R404)
Operating pressure similar to traditional systems (max 45 barg)
Medium HFC gas content
System eciency better than standard HFC and can be used in all climates
CONS
If NH3 is not used, the installation is not completely green
If NH3 is used, the medium temperature compressor rack cannot be used
in all countries to serve the medium temperature showcases
2.1 CAREL solution

pRack pR300: compressor rack controller
pRack pR300 manages both the medium temperature and low temperature
compressor racks, with one or more controllers, depending on rack
dimensions. One instrument alone can manage LT and MT compressor
activation and safety (inverters, capacity control and compressors with
dierent capacities), medium temperature condensers (EC fans, inverters,
steps), any subcooling systems, synchronisation between the two systems
7
pRACK pR300
and communication with the electronic expansion valve driver on the

cascade system heat exchanger.
At most two plate heat exchangers are normally used to condense the CO2,
and the expansion valve can be managed using the built-in driver on pRack
pR300 or an external EVD EVO driver integrated into the system (RS485
eldbus communication).
Control diagram with one pRack board and one built-in driver
T
P
T
Text
PD L1
TD L1
VFD
PS L1
TS L1
MPXPRO
E2V
TGS
PE
T
E3V - E4V
pRACK pR300
P
T
PD L2
TGS
PE
TD L2
VFD
MPXPRO
PS L2
TS L2
E2V
TGS PE
pRack connections
symbol
description
Text
PD L1
TD L1
PS L1
TS L1
PE
TGS
PD L2
TD L2
PS L2
TS L2
Outside temperature
Line 1 (medium temperature) discharge pressure
Line 1 (medium temperature) discharge temperature
Line 1 (medium temperature) suction pressure
Line 1 (medium temperature) suction temperature
Heat exchanger evaporation pressure
Heat exchanger superheated gas temperature
Line 2 (low temperature) discharge pressure
Line 2 (low temperature) discharge temperature
Line 2 (low temperature) suction pressure
Line 2 (low temperature) suction temperature
probe type
NTC - HP
4-20 mA 0-18.2 barg
NTC - HF
4-20 mA 0-7 barg
NTC - HF
Ratiometric -1-9.3 barg
NTC HF
4-20 mA 0-44.8 barg
NTC HF
4-20 mA 0-44.8 barg
NTC - HF
MPXPRO & E2V: controller for multiplexed showcases and stepper electronic
expansion valve.
Given the speed of CO2 as a refrigerant, evaporator control is essential for
correct system operation. For this purpose, the CAREL E2V stepper electronic
expansion valve is important to ensure system stability. Featuring ultracap
technology, the MPXPRO + E2V system can guarantee complete closing in
the system without using additional solenoid valves.
remarks
For discharge temperature control (optional)

Can be used as backup for PE
For suction superheat control (optional)

MPXPRO & E2V

8
EXV: Electronic expansion valve

The crucial aspect of this type of installation is the cascade heat exchanger,
normally a plate heat exchanger, that condenses the CO2. Two heat
exchangers are sometimes used in order to improve control at low loads
and increase safety, and are normally controlled by EXV stepper electronic
expansion valves (in these applications PWM electronic valves cannot
guarantee optimum performance).
In such applications, as well as traditional suction superheat control, there is
direct integration with the low temperature compressor rack if the driver is
built into the controller, or via serial communication if an external EVD EVO
driver is used.
Due to the nature of the refrigerant, the condensed liquid CO2 needs to be
monitored to ensure good performance
EXV electronic expansion valves
Control diagram with two pRack boards and one built-in driver
T
P
T
Text
PD L1
TD L1
MPXPRO
VFD
E2V
P
PS L1
TS L1
T
pRACK pR300 L1
TGS
PE
E3V - E4V
pRACK pR300 L2
P
T
PD L2
TGS
PE
TD L2
VFD
MPXPRO
PS L2
TS L2
E2V
TGS PE
pRack connections for L1

symbol
description
Text
PD L1
TD L1
PS L1
TS L1
Outside temperature
symbol
description
PE
TGS
PD L2
TD L2
PS L2
TS L2

probe type
remarks
NTC - HP
4-20 mA 0-18.2 barg
NTC - HF
4-20 mA 0-7 barg
NTC - HF

probe type
remarks

NTC HF
4-20 mA 0-44.8 barg
NTC HF
4-20 mA 0-44.8 barg
NTC - HF

2.2 System features

2.2.1
DSS: Double system synchronization
System for communication between the medium temperature and low

temperature compressor racks.
The low temperature circuit cannot operate correctly if the medium
temperature circuit is not working, therefore communication between the
two systems is essential to synchronise operation and modify operation
when needed.
Specically, the following are possible
start the medium temperature rack when the low temperature rack is
operating, both during start-up and in normal operation
shut down the low temperature rack when the medium temperature rack
is not working correctly
avoid simultaneous compressor starts on the dierent systems to reduce
peaks in energy consumption
2.2.2
EEVS: Electronic Expansion Valve Synchronization
System for communication between the low temperature rack (pRack pR300)
and electronic expansion valve driver on the plate heat exchanger, either
built-in on pRack pR300 or external (EVD EVO)
The low temperature rack can in this case tell the driver of any changes
in cooling capacity and thus modulate evaporator capacity based on CO2
condensing pressure, without requiring additional probes and ensuring ne
and precise condensing pressure control. Exchanging information between
the compressor rack and the heat exchanger can also augment traditional
superheat control with factors that are vital for this type of installation,
such as variation in low temperature rack cooling capacity and trend in CO2
condensing pressure.
Safety procedures are featured in the event of conditions in which system
stability cannot be guaranteed.
Available for both one and two heat exchangers.
If one or more individual drivers is used, the condensing pressure probe can
be connected directly to the EVD EVO driver; in this way, valve control will be
directly aected by a safety procedure that tends to open the valve when CO2
condensing pressure is too high. In this case, the CO2 condensing pressure
probe connected to pRack is optional.
This function can be used in the following congurations:
pRack pR300 with built-in driver and just one heat exchanger
pRack pR300 with one individual external EVD EVO driver
pRack pR300 with two individual external EVD EVO drivers
10
Control diagram with one pRack board and one individual external driver
featuring high CO2 pressure protection.
P
T
Text
PD L1
TD L1
VFD
PS L1
TS L1
MPXPRO
E2V
TGS PE
T
EVD EVO
RS485
E2V
pRACK pR300
P
T
TGS PE
PD L2
PD L2
TD L2
VFD
MPXPRO
PS L2
TS L2
E2V
TGS PE
pRack connections
symbol
description
Text
PD L1
TD L1
PS L1
TS L1
PD L2
TD L2
PS L2
TS L2
Outside temperature
EVD EVO connections

symbol
description
PD L2
PE
TGS
11

probe type
NTC - HP
4-20 mA 0-18.2 barg
NTC - HF
4-20 mA 0-7 barg
NTC - HF
4-20 mA 0-44.8 barg
NTC HF
4-20 mA 0-44.8 barg
NTC - HF
probe type
4-20 mA 0-44.8 barg

NTC HF
remarks

Can be used as backup for PD L2
remarks
3. TRANSCRITICAL CO2 BOOSTER

Transcritical CO2 booster systems are the most promising solutions for using
natural refrigerants in retail contexts, above all in climates that are not too
hot.
They generally feature three sections with dierent pressures::
high pressure: the section from the medium temperature compressor
discharge to the HPV valve (in red)
intermediate pressure: the section from the HPV valve to all the expansion
valves (in orange)
medium pressure: the section from the medium temperature evaporators
downstream of the expansion valve to the suction side of the medium
temperature compressors (in light blue)
low pressure: the section from the low temperature evaporators
downstream of the pressure regulating valves to the suction side of the
low temperature compressors (in blue)
A basic traditional installation is shown in the gure below. Dierent variants
can be found on the market, above all using plate heat exchangers to increase
system eciency and/or assist correct operation. These are not normally part
of system operating logic, and are not covered in this document.
Example of a transcritical CO2 system
40 C
120 bar
R744
-10 C
26 bar
HPV
E3V - E4V
2 C
35 bar
E2V
E2V
E2V
-35 C
11 bar
E2V
In general, the gas is drawn in by the medium temperature compressors at

a pressure of around 26 barg (maximum pressure 40-60 barg), and at the
compressor discharge normally passes through a heat recovery system (of
varying complexity), essential for overall unit eciency, and the gas cooler. In
this section, operating pressure essentially depends on outside temperature,
and may vary from minimum values of around 40-45 barg, based on the type
of compressors used, to 120 barg, the maximum safety valve pressure. The
name gas cooler refers to the fact that, in certain climatic conditions, it may
not manage to condense the CO2, which consequently reaches the high
pressure valve in the form of a dense gas. The high pressure valve (HPV) is the
heart of this type of installation, making sure it works eciently and in the
most favourable conditions at any given moment; consequently, it lowers
the operating pressure of the receiver downstream to 35-40 barg so as to
condense the CO2. Receiver pressure is managed by the regulating valve
(RPRV), which works by bypassing the system so as to maintain constant
receiver pressure.
Receiver pressure is managed by the regulating valve (RPRV), which
works by bypassing some of the gas so as to maintain constant receiver
pressure. From the receiver, the liquid ows to all the medium and low
temperature showcases; it is then expanded by the expansion valves on
the low temperature evaporators and then drawn in by the LT compressors
and subsequently remixed with the gas from the medium temperature
evaporators and the receiver pressure regulating valve (in this section,
maximum pressure may range from 25 to 60 barg).
12
These gases - at dierent temperatures - are then drawn in by the medium

temperature compressors. The most common variants include:
gas cooler for low compressor discharge temperature
plate heat exchangers between the gas from the RPRV and the liquid line,
with the dual purpose of subcooling the liquid at the evaporators and
osetting the heating eect of the RPRV valve
plate heat exchangers between the suction side of the medium
temperature compressors and the gas cooler outlet, with the dual purpose
of assisting mixing between the dierent gases on the compressor suction
side and further cooling the gas exiting the gas cooler
PROS
system that completely uses natural refrigerants (CO2)
various studies have shown higher eciency than any other type of
installation (traditional R404a or subcritical CO2) at average outside
temperatures less than 15C
technology becoming standardised, costs are falling
CONS
high pressures involved (up to 120 barg)
systems are normally more complex than traditional ones
not yet completely applicable to hot climates, low eciency
3.1 CAREL solution

Control diagram with one pRack board and built-in twin driver
T
THR
T
TD L1
TGC PGC
VFD
PS L1
TS L1
Text
HPV
PREC
E3V - E4V
E2V
MPXPRO
pRACK pR300T
T
TD L2
TGS
PE
MPXPRO
VFD
E2V
PS L2
TS L2
T
TGS PE
pRack pR300T connections

symbol
description
Text
PGC
TGC
THR
PREC
PS L1
TS L1
TD L2
PS L2
TS L2
13
Outside temperature
Gas cooler pressure
Gas cooler outlet temperature
Heat reclaim temperature
Receiver pressure
probe type
NTC - HP
4-20 mA 0-150 barg
NTC - HF
NTC - HF
4-20 mA 0-60 barg
4-20 mA 0-44.8 barg
NTC - HF
NTC HF
4-20 mA 0-44.8 barg
NTC - HF
remarks
For heat recovery system control (optional)

pRack pR300T: controller for transcritical CO2 compressor racks

pRack pR300T provides complete management - in single or multi-board
congurations - of both small and medium-large transcritical CO2 systems.
One instrument alone can manage LT and MT compressor activation and
safety, any heat recovery systems, the gas cooler, the oil recovery system, the
high pressure valve (HPV) and receiver pressure regulating valve (RPRV).
The HPV and RPRV valves can be managed directly by pRack pR300T
with built-in driver or with external EVD EVO driver. Both instruments are
compatible with all valves available on the market.
pRack pR300T
MPXPRO & E V : controller for multiplexed showcases and stepper

electronic expansion valve
Given the speed of CO2 as a refrigerant, evaporator control is essential for
correct system operation. For this purpose, the CAREL E2V stepper electronic
expansion valve is important to ensure system stability. Featuring ultracap
technology, the MPXPRO+E2V system can guarantee complete closing in the
system without using additional solenoid valves.
2
EXV: Electronic expansion valve

Standard CAREL EXV stepper expansion valves have a maximum pressure of 45
barg, and therefore can be normally used (as expansion valves on showcases
and RPRVs) in all systems where maximum receiver pressure is 45 barg.
In cases where maximum receiver pressure is higher than this value, the
E2V*CS* series can be used, designed specically for transcritical CO2
applications with a maximum pressure of 140 barg.
These valves can also be used as high pressure valves (HPV) and receiver
pressure regulating valves (RPRV) on small compressor racks.
MPXPRO & E2V
EXV electronic expansion valve
Control diagram with two pRack boards and built-in twin driver
Text
T
THR
T
TD L1
TGC PGC
VFD
PS L1
TS L1
HPV
PREC
E3V - E4V
E2V
pRACK pR300T L1
MPXPRO
pRACK pR300T L2
TD L2
TGS
PE
MPXPRO
VFD
E2V
PS L2
TS L2
T
TGS PE
14
pRack pR300T connections for L1

symbol
Text
PGC
TGC
THR
PREC
PS L1
TS L1
description
Outside temperature
Gas cooler pressure
Receiver pressure
pRack pR300T connections for L2

symbol
description
TD L2
PS L2
TS L2
probe type
NTC - HP
4-20 mA 0-150 barg
NTC - HF
NTC - HF
4-20 mA 0-60 barg
4-20 mA 0-44.8 barg
NTC - HF
remarks
probe type
NTC HF
4-20 mA 0-44.8 barg
NTC - HF
remarks
3.2 System features

The HPV valve control algorithm on pRack pR300T is managed based on the
gas cooler outlet temperature TGC and gas cooler pressure PGC. Depending on
operating conditions, the system can work in:
transcritical operating conditions (line 1), in which the instrument
controls the HPV valve so as to maintain the best set point and maximise
compressor rack COP
subcritical operating conditions (line 3), in which instrument attempts to
maintain a certain level of subcooling
transition operating conditions (line 2), in which the instrument attempts
to keep the transition from transcritical to subcritical as smooth as possible,
considering that the refrigerant in such situations is neither in the liquid
nor gas phase.
RPRV valve management aims to maintain constant pressure inside the

receiver around a set point; in extreme conditions it may modify the
operating conditions of the HPV so as to ensure the system as a whole
operates correctly.
The oil recovery system manages oil levels in the separator, controls the
receiver injection solenoid valve, as well as the pressure dierence from
compressor rack suction pressure, and also manages the injection of oil into
the various compressors, with alarms triggered if injection is not sucient.
An important factor in system operation, this function can also be used
with the electromechanical oil recovery systems that are widely available
on the market to simply monitor and log system operation for subsequent
verication.
15
HPV
RPRV
The heat recovery system is very important for overall system eciency,
and is managed so as to maximise the amount of heat recovered, modifying
operation of both the gas cooler of the high pressure valve.
Chillbooster: evaporative cooling system for CO2 gas cooler
Especially suitable for installations in temperate climates, where the outside
temperature exceeds 30 C just a few days a year, this is a simple evaporative
cooling system that can decrease the outside temperature perceived by the
gas cooler by between 5 and 15 C.
An optimum way to improve the eciency of a transcritical system in hot
temperatures, it integrates perfectly with pRack pR300T so as to ensure
operation only in critical conditions or as a safety measure.
discharged air
Chiller
hot summer air
ChillBooster
Tap and filter are

recommended
hot summer air
chillBooster
3.2.1
DSS: Double system synchronization
cooled hair
cooling/atomizing nozzles
System for communication between the medium temperature and low

temperature compressor racks.
The low temperature circuit cannot operate correctly if the medium
temperature circuit is not working, therefore communication between the
two systems is essential to synchronise operation and modify operation
when needed.
Specically, the following are possible
start the medium temperature rack when the low temperature rack is
operating, both during start-up and in normal operation
shut down the low temperature rack when the medium temperature rack
is not working correctly
avoid simultaneous compressor starts on the dierent systems to reduce
peaks in energy consumption
3.3 Transcritical CO2 condensing units
For small applications, CAREL can oer a complete and integrated solution
using E2V*CS stepper valves, suitable for these types of units and featuring
much simpler assembly than the larger solutions available on the market.
Carel E2V*CS CO2 valves have maximum operating pressure 140 barg and 90
bar dierential, and can be used in these types of applications with capacities
up to 40 kW.
This compact solution comprises a single controller tted with built-in driver
and ultracap for direct management of E2V*CS valves used as HPVs and
RPRVs. The scalability of the pRack platform allows the same user interface
to be used for these types of applications, with special focus on installation
costs and simple operation.
16
Control diagram with one pRack boards and built-in twin driver
Text
T
THR
T
PGC
TGC
TD L1
HPV
VFD
PS L1
TS L1
P
P
PREC
E2V
MPXPRO
pRACK pR300T
TGS
T
TD L2
PE
MPXPRO
VFD
E2V
P
PS L2
TS L2
PE
TGS
T
symbol
Text
PGC
TGC
THR
PREC
PS L1
TS L1
TD L2
PS L2
TS L2
17
description
Outside temperature
Gas cooler pressure
Receiver pressure
probe type
NTC - HP
4-20 mA 0-150 barg
NTC - HF
NTC - HF
4-20 mA 0-60 barg
4-20 mA 0-44,8 barg
NTC - HF
NTC HF
4-20 mA 0-44,8 barg
NTC - HF
remarks

4. SUBCRITICAL CO2: PUMPED

Not as widely used as traditional cascade subcritical systems, these aim to
limit the use of HFC refrigerants only to the equipment room. The medium
temperature showcases are supplied with pumped liquid CO2 while the low
temperature showcases are tted with expansion valves. The CO2 is cooled by
a dedicated chiller (NH3 or R134a) inside a tank, normally with a tube bundle
evaporator.
In addition to traditional systems, these also include pumps that circulate the
liquid CO2 to the medium temperature evaporators, where it is not expanded,
but rather is simply superheated, returning to the receiver in the semi-liquid
phase.
Example of pumped subcritical CO2 system
35 C
8 bar
R134a
E3V / E4V
-10 C
1 bar
-5,5 C
29 bar
R744
E2V
-35 C 11 bar
E2V
PROS
low non-natural refrigerant content;
possibility to use ammonia (NH3), limited to the equipment room only;
completely green installation inside the store display area.
CONS
very sensitive to pumping system piping size;
additional pump energy consumption.
3.4 CAREL solution

pRack pR300: compressor rack controller
This manages both the chiller compressors - based on the CO2 pressure inside
the receiver - and the low temperature compressors, applying the same
synchronisation functions between the two systems. One important aspect
in this type of system is coordinated operation of the medium temperature
rack with the tube bundle evaporator controller, to prevent problems of low
pressure.
Receiver pressure control is the main task, given the quantity of refrigerant
inside and consequently its signicant inertia, and therefore it is essential to
activate the compressors based on receiver pressure; medium temperature
compressor suction pressure will therefore only be monitored for safety
reasons, to prevent problems of low pressure.
pRack can also manage simple pumping systems with or without inverter
pRACK pR300
18
Control diagram with two pRack boards
Text
P
T
TD L1
PS L1
EVD EVO
T
PD L1
TS L1
PREC
pRACK pR300 L2
T
pRACK pR300 L1
E2V
MPXPRO
Light
E2V
TS L2
PS L2
MPXPRO
MPXPRO
Light
MPXPRO
pRack pR300 connections on L1
symbol
description
Text
PD L1
TD L1
PS L1
TS L1
PREC
Outside temperature
Condensing pressure line 1 (medium temperature)
CO2 receiver pressure
pRack pR300T connections on L2

symbol
TD L2
PS L2
TS L2
description
EVD EVO connections

symbol
description
PREC
PE
TGS
MPXPRO and MPXPRO light

MPXPRO for the low temperature showcases with electronic expansion valve,
and MPXPRO light for medium temperature showcases where no electronic
expansion valve is required, rather simply refrigerant management based on
demand from the showcase.
Compatible with the full option version, MPXPRO light standardises wiring
and installation.
19
probe type
NTC - HP
4-20 mA 0-18.2 barg
NTC - HF
4-20 mA 0-10 barg
NTC - HF
4-20 mA 0-10 barg
probe type
NTC HF
4-20 mA 0-44.8 barg
NTC - HF
probe type
4-20 mA 0-44.8 barg
NTC HF
remarks

For low pressure alarm control
For medium temperature compressor control
remarks
remarks
EVD EVO and EXV drivers

Management of the tube bundle evaporator is critical in this type of
application, the size of the evaporator, the inertia of the load and the proximity
of the compressors require very ne control that needs to adapt quickly to
compressor activation or deactivation, respond gradually to changes in load,
not ood the compressors and protect against low suction pressure alarms.
The functions of the EVD EVO driver and the low superheat, low suction
pressure and high CO2 condensing pressure protection must therefore be
correctly calibrated based on the features of the installation (number and
type of compressors, evaporator and receiver size, whether receivers are used
on the suction side, system dynamics)
Driver EVD EVO e EXV
5. COMMON COMPONENTS
In addition to the solutions already described, CAREL Retail sistema oers a
series of other products that are essential for system management.
PVPRO: supervisory system
Single point of access to the entire system, this allows ne tuning, continuous
monitoring and logging of data, communication with the outside and alarm
management.
Remote or local access with various functions to optimise system operation
and increase safety:
Floating suction pressure: optimises the compressor rack suction pressure
set point based on actual system requirements
Dew point broadcast: to modulate showcase anti-sweat heaters using the
dew point reading inside the store
Parameter control: to monitor vital system operating parameters, even
oine, preventing accidental modications
Energy: to monitor system energy consumption, create scheduled reports
clearly showing system performance
KPI (Key performance indicators): for a quick and eective overview of the
operation of the dierent units and clearly establish where action needs
to be taken
Recovery procedure: together with the compressor rack, to interact
directly with all the unit controllers in the event of rack malfunctions and
schedule restart to get the system up and running again
DPWL: gas leak sensors

Available for all types of refrigerant, the CO2 leak sensor in particularis very
important for installations both in equipment rooms and inside the store
itself. Directly interfaceable with the electronic controllers via analogue
signals or the supervisory system via Modbus RTU, these constantly monitor
the level of CO2 in the room and quickly identify any gas leaks that may be
harmful to humans.
CO2 is in fact heavier than air and can cause asphyxiation, in the event of leaks
it tends to accumulate at oor level, therefore the sensors should be installed
around 30-40 cm from the oor and near the refrigeration units.
PVPRO: supervisory system
DPWL: gas leak sensor
20
VFD: inverters
Available for both compressors and fans, the CAREL VFD range of inverters
covers all applications, including CO2, and together with the pRack range
allows ner control of evaporation pressure.
VFD: inverter
Probes and transducers

Vast range of temperature probes and pressure transducers, available in
various types, completely covering all applications with natural refrigerants
4-20 mA pressure probes: recommended on compressor racks
Ratiometric pressure probes: recommended on showcases and in cold
rooms
NTC and pT1000 temperature probes
NTC and pT1000 clamp-on temperature probes: recommended for
installation on pipes
Probes and transducers
pLoads: load control

Device for controlling loads based on system energy consumption, this
activates and/or deactivates the dierent loads only when possible.
Integrated into pRack pR300, it reduces compressor rack cooling capacity
when necessary.
pLoads: load control
pChrono: scheduler
Device for scheduling the activation of lights, pumps and any other devices
inside the installation, so as to maximise energy savings not only in the
refrigeration system, but also the air-conditioning and building management
systems.
pChrono: scheduler
21
22
23
+4000018EN - 1.0 - 01.10.2012

CAREL INDUSTRIES Hqs 2012 all rights reserved. CAREL INDUSTRIES reserves the right to modify the features of its products without prior notice.
Headquarters ITALY
Sales organization
CAREL INDUSTRIES HQs
CAREL Asia
www.carel.com
CAREL HVAC/R Korea

www.carel.com
CAREL Czech & Slovakia

www.carel-cz.cz
CAREL Australia
www.carel.com.au
CAREL Russia
www.carelrussia.com
CAREL Korea (for retail market)

www.carel.co.kr
CAREL China
www.carel-china.com
CAREL India
www.carel.in
CAREL Ireland
www.carel.com
CAREL South Africa

www.carelcontrols.co.za
CAREL Sud America

www.carel.com.br
CAREL Thailand
www.carel.co.th
CAREL Deutschland
www.carel.de
CAREL U.K.
www.careluk.co.uk
CAREL Turkey
www.carel.com.tr
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www.carelfrance.fr
CAREL U.S.A.
www.carelusa.com
Via dellIndustria, 11
35020 Brugine - Padova (Italy)
Tel. (+39) 0499 716611
Fax (+39) 0499 716600
carel@carel.com
CAREL Iberica
www.carel.es
All trademarks hereby referenced are

the property of their respective owners.
CAREL is a registered trademark of CAREL
INDUSTRIES in Italy and/or other countries.
CAREL INDUSTRIES 2010 all rights reserved
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Solutions For CO Retail Applications: High E Ciency Solutions

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Solutions for CO2 retail applications

1.1 Thermodynamic properties ................................................................5

2. SUBCRITICAL CO2 CASCADE

2.1 CAREL solution ........................................................................................7

3. TRANSCRITICAL CO2 BOOSTER

3.1 CAREL solution .....................................................................................13

3.3 Transcritical CO2 condensing units................................................16

4. SUBCRITICAL CO2: PUMPED

3.4 CAREL solution .....................................................................................18

Application note: Solutions for CO2 retail applications

1. WHY USE CO2 AS A REFRIGERANT?

1.2 Subcritical cycle

1.1 Thermodynamic properties

1.3 Transcritical cycle

The main dierence compared to a normal refrigeration cycle involves the

Heat rejection - transcritical CO2

Condensation normally takes place at constant pressure, with the gas

Fixed gas cooler outlet temperature

Application note: Solutions for CO2 retail applications

2. SUBCRITICAL CO2 CASCADE

2.1 CAREL solution

and communication with the electronic expansion valve driver on the

Application note: Solutions for CO2 retail applications

For discharge temperature control (optional)

For discharge temperature control (optional)

MPXPRO & E2V

EXV: Electronic expansion valve

EXV electronic expansion valves

pRack connections for L1

Heat exchanger evaporation pressure

For discharge temperature control (optional)

Ratiometric -1-9.3 barg

For discharge temperature control (optional)

2.2 System features

DSS: Double system synchronization

System for communication between the medium temperature and low

EEVS: Electronic Expansion Valve Synchronization

Application note: Solutions for CO2 retail applications

EVD EVO connections

Line 2 (low temperature) discharge pressure

4-20 mA 0-44.8 barg

For discharge temperature control (optional)

3. TRANSCRITICAL CO2 BOOSTER

In general, the gas is drawn in by the medium temperature compressors at

These gases - at dierent temperatures - are then drawn in by the medium

3.1 CAREL solution

pRack pR300T connections

For heat recovery system control (optional)

For suction superheat control (optional)

pRack pR300T: controller for transcritical CO2 compressor racks

MPXPRO & E V : controller for multiplexed showcases and stepper

EXV: Electronic expansion valve

MPXPRO & E2V

EXV electronic expansion valve

Application note: Solutions for CO2 retail applications

pRack pR300T connections for L1

pRack pR300T connections for L2

3.2 System features