CO2 Solutions

Optimizing CO2 refrigeration systems with Dixell Copeland’s complete control solution: XM700, iProRack and XWEB
With the growing adoption of CO2 as a refrigerant, companies are looking for solutions to maximize the efficiency of their installations while minimizing environmental impact. As a natural refrigerant, CO2 offers a sustainable alternative, but to fully exploit its benefits, advanced management tools are required. The trio of XM700, iProRack and XWEB offers a complete solution for CO2 installations, combining intelligent control, remote monitoring and energy optimization. This article takes an in-depth look at how each component contributes to the optimization of CO2 systems.

XM700: advanced management of multiplexed refrigerated cabinets

The XM700 is at the heart of refrigerated cabinet management in a CO2 system. This controller has been developed to offer maximum flexibility while improving the energy efficiency of multiplexed systems. Here are some of its key features, which are particularly relevant to CO2 installations:

Adaptive overheating management

One of the most important features of the XM700 is its ability to dynamically manage superheat according to the state of the compressor group. This system is capable of synchronizing evaporator superheat with the operating conditions of the transcritical compressor unit. In CO2 systems, this optimizes compressor suction temperature, reducing energy consumption while increasing overall system efficiency.

Reduced defrosting time

Thanks to the Optimized Defrost Duration (ODD) algorithm, the XM700 is able to shorten evaporator defrost times by up to 20%. This is particularly beneficial in CO2 installations, where defrosting can sometimes cause significant energy losses if left unchecked. The ODD detects precisely when the evaporator is fully defrosted and automatically terminates the process, limiting defrosting to the bare minimum.

Comprehensive load management

In addition to temperature and overheating management, the XM700 offers comprehensive load management for components such as fans, lighting and heaters. These loads can be modulated according to the real needs of the installation, reducing energy consumption while maintaining optimal temperature conditions for product preservation.

Intuitive user interface

Another advantage of the XM700 is its ease of use. It features a modern web interface, accessible via PC, tablet or smartphone. This interface enables technicians to monitor the status of refrigerated cabinets in real time, modify parameters, and even perform firmware updates remotely. This greatly simplifies maintenance and configuration operations, reducing downtime and associated costs.

Compatibility with natural refrigerants

The XM700 is designed to be compatible with natural refrigerants such as CO2 (R744), propane (R290) and isobutane (R600a). This compatibility enables users to integrate the controller into a wide range of applications without having to modify the existing infrastructure, while complying with environmental requirements.

iProRack: advanced compressor management and CO2 plant optimization

The iProRack is a powerful, modular solution specially designed for CO2 transcritical systems. Here are the main features often required in modern refrigeration systems.

Compressor management

iProRack can manage up to 12 compressors for the MT (medium-temperature) line and 12 compressors for the LT (low-temperature) line, including two inverter-driven compressors for each line. This ensures maximum flexibility and enables variable refrigeration requirements to be met by adjusting compressor performance.

Parallel compressors

In addition to the MT and LT lines, iProRack also supports up to 6 compressors for the parallel line, including two with inverter. This feature is particularly useful in hot climates, where compressor efficiency is essential to maintain optimum performance.

Compressor protection

Each compressor benefits from up to 3 safety protections, guaranteeing long-term reliability and reducing the risk of unexpected breakdowns or failures.

Oil injection management

iProRack features oil injection management based on both oil level and differential pressure. This extends compressor life and optimizes lubrication, even under difficult operating conditions.

High-pressure valve management

iProRack enables high-pressure valve management via the XEV20D driver or an analog output, ensuring optimum pressure management in the gas cooler, guaranteeing safe and efficient operation.

Flash gas valve management

The flash gas is also controlled via the XEV20D driver or an analog output, providing precise regulation to avoid overpressure or loss of efficiency in the system.

Heat recovery

iProRack can manage one or two heat recoveries for hot water and heating systems. This allows excess heat to be reused, improving the overall energy efficiency of the system.

Gas cooler bypass

Gas cooler bypass management is a key feature for improving energy efficiency during heat recovery. By bypassing the gas cooler, thermal energy can be used more efficiently.

Compatibility with adiabatic systems

Thanks to advanced management of the gas cooler fans, iProRack is compatible with adiabatic systems, increasing COP (coefficient of performance) by lowering condensation temperatures.

Liquid and hot gas injection

iProRack offers liquid injection to better control compressor discharge temperature, and hot gas injection to optimize suction superheat management. These features guarantee stable operation and better protection of key system components.

Discharge temperature management with liquid injection

iProRack can use a PWM signal to regulate liquid injection via a stepper valve, precisely controlling compressor discharge temperature and improving compressor life.

Management of auxiliary functions

iProRack can manage up to 8 auxiliary functions via temperature sensors and digital inputs, enabling additional management of liquid levels, fan control or regenerative exchangers.

De-superheaters

iProRack can integrate up to 3 de-superheaters, reducing the temperature of hot gases after compression.

Compatibility with XeCO2 system

The XeCO2 system enables iProRack to work with flooded evaporators, guaranteeing optimum use of the evaporator surface and increased efficiency in hot or high-humidity environments.

Compressor Guard function

The Compressor Guard feature protects compressors against liquid backflow, preventing hydraulic shocks that could damage compressors in the long term.

Optimized inverter control

iProRack includes optimized inverter control, dynamically adjusting compressor speed to meet fluctuating cooling demands, ensuring maximum energy efficiency.

XWEB: Supervision, control and optimization

XWEB is an advanced supervision system for remote monitoring and control of all CO2 plant components. It offers a simple, intuitive web interface, giving site managers, technicians and operators rapid access to critical information.

Advanced connectivity and remote access

XWEB provides connectivity via Ethernet and Wi-Fi, making it easy to access plant data remotely from any device (smartphone, tablet or PC). This connectivity is particularly useful for maintenance technicians, who can monitor the status of installations and intervene rapidly in the event of an alarm or malfunction, without having to be physically present on site.

Data management and optimization algorithms

One of XWEB’s strengths is its ability to collect and analyze data in real time. It uses advanced optimization algorithms, such as CRO (Compressor Rack Optimization), to adjust compressor operation according to actual system requirements. This reduces energy consumption while guaranteeing a stable temperature in refrigerated zones.
XWEB also offers intelligent management of floating condensation and dew point management for display cabinets, helping to reduce power consumption of equipment such as anti-fog heaters.

Safety and alarms

XWEB features a highly responsive alarm management system. In the event of a problem (overheating, gas leak, compressor fault), the system immediately sends an alert by email or SMS to technicians, facilitating rapid intervention and reducing risks to stored products.

Remote updating and parameter backup

Another advantage of XWEB is the ability to update field controllers (such as the XM700 and iProRack) remotely, without the need to physically visit the site. This keeps systems up to date with the latest features and security patches, while reducing maintenance costs. What’s more, XWEB enables all device configurations to be backed up, making it easy to return to service in the event of a failure or reset.

Performance visualization and reporting

XWEB also provides real-time visualization of plant performance, with detailed reports enabling operators to quickly identify areas for improvement. Whether monitoring temperatures, energy consumption or analyzing trends, the system offers complete visibility of the plant.

The combination of XM700, iProRack and XWEB technologies provides a complete, high-performance solution for CO2 installations.

This trio not only maximizes energy efficiency, but also ensures intelligent, secure system management, with remote supervision that greatly simplifies maintenance and performance monitoring. For companies seeking to optimize their facilities while reducing their environmental footprint, these solutions offer a suitable, scalable response.

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