refrigeration & retail controllers solutions for compressor racks prack the advanced solution for compressor racks carel.com

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1 refrigeration & retail controllers solutions for compressor racks prack the advanced solution for compressor racks carel.com

2 prack the power of simplicity prack is the complete offering from CAREL for the control and management of centralised compressor racks The ideal solution to respond to a variety of market requirements, as regards high number of inputs and outputs for control needs; innovative management algorithms for energy savings; compatibility with main control market standards; multiple integration/supervision possibilities The prack platform now features two versions prack pr100: standard solution for multiplexed systems, manages piston, scroll or screw compressors, with one or two suction lines, including cascade or booster with synchronisation between systems (DSS). prack pr100t and pr200t: evolution of the pr100 version, designed to manage transcritical CO 2 systems, both booster and cascade, includes management of high pressure valves with configurable algorithms, oil management and gas cooler. User simplicity Developed with special focus on being easy to use, prack features numerous details, procedures and tools to help users use the controller. Energy saving prack features ESS Energy Saving Suite, a group of functions designed for energy saving that can also be applied together with the supervisory system. System optimisation Management of modulating devices to guarantee maximum efficiency in the control of operating pressure and consequently ensure greater system stability.

3 prack Wizard Ib03 Compressors config. Compressors type: RECIPROCATING Compressors number: 4 prack Main menù 1/9 I/O A. Unit Status B. Inputs/Outputs C. Compressors Comp.Reg. Regulation by: Regulation type: Cab01 PRESSURE NEUTRAL ZONE Ain Config. Suction press.probe PLB1 B1 4-20mA 3.16 barg Max.value: Min.value: Calibration: 7.0 barg -0.5 barg 0.0 barg Wizard Procedure to guide the user step-by-step through the initial configuration of prack. By simply responding to the questions displayed automatically by the tool, prack can independently set the main parameters required for the unit to start safely. Pre-configurations Series of configurations for each application already featured inside the instrument. By simply choosing one of the applications described in detail in the special Quick Guide, prack can independently set the main parameters required for the unit to start safely. B7/ID5 Easy operation Easily accessible information, guided self-configuration procedures, easy browsing inside the menus to minimise commissioning and service times Smart key Programming key to copy the complete configuration of the instrument, making it easily transportable to other instruments running the same application. Display The graphic LCD makes the user interface extremely functional. Browsing the various menus is very intuitive and simple, all the information is grouped into functional areas to make browsing even faster. The display is therefore always simple and fast to use. prack manager SW program for storing and managing different configurations. With prack manager users can also save their own settings directly from the instrument, modify them on a PC and copy them to other instruments, simply and intuitively. prack manager also allows the SW to be updated and real time connection to verify unit operation during commissioning. Tdis B4 F1 NO3 F2 NO4 C1 NO1 B5/ID3 Psuct B3 C2 NO2 B6/ID4 Psuct B1 NO5

4 prack flexibility and configurability Just one device that responds to the needs of both small and large compressor racks. prack can adapt operation to the type of systems and the specifications of the electrical panel. Two lines Two suction lines, one condenser line prack allows complete management of an entire low-medium temperature installation with just one controller. As well as traditional configurations with one suction line and one condenser line, now up to two suction lines and two condenser lines can be managed, either split or shared. DSS Multi-board The flexible prack architecture allows multiple controllers to be connected together and make up part of a system that manages up to two complete circuits. These configurations increase the number of inputs and outputs available for implementing special control functions and allow a dedicated instrument to be installed near the system being controlled, avoiding unnecessary wiring costs. LT Two suction lines, two condenser lines MT MT DSS: Double system synchronization DSS For booster or cascade systems, the low temperature and medium temperature circuits communicate with one another so as to optimise operation of the entire system. Communication between the lines speeds up system response to sudden variations in operating conditions. LT

5 prack Ain Config. Suction press.probe PLB1 B1 4-20mA 3.16 barg Max.value: Min.value: Calibration: Digital in Liquid level alarm PLB1 ID07 Status Close Logic NC Function Not active Input/output configuration 7.0 barg -0.5 barg 0.0 barg All the inputs and outputs on prack feature completely configurable attributes. This makes prack perfectly adaptable to systems developed using pco sistema family devices and the majority of systems developed using other instruments. Generic functions prack features up to 10 completely configurable functions that can be used to satisfy specific market requirements. By using free analogue inputs or system variables, the system can be customised with specific logic directly from the user interface, without having to customise the product. Safety prack not only features traditional safety systems such as compressor alarms (up to 4 digital inputs available for each compressor), common high and low pressure switches, high condensing pressure prevention etc., as available on previous controllers for compressor racks, but also several new safety systems: backup pressure probes, only if the main probes fail; discharge temperature monitoring on each compressor; ChillBooster as protection against high condensing pressure protection against low suction superheat sign-of-life for activation of backup systems anti-liquid return output double alarm priority internal log; internal configuration backup SET SET+DIFF Refrigerant leaks In reply to the F-gas regulations on the refrigerant leaks, prack can directly manage the refrigerant leak sensors through a report to a supervisor or dedicated outputs.

6 prack energy saving prack offers several different possibilities to increase efficiency and reduce overall energy consumption of the compressor rack. Set point compensation Possibility to modify the system working set point based on time schedules. Independent reduction of energy consumption at night and in winter. Modulating suction set point Using the PlantVisorPRO or PlantWatchPRO supervisory system, the CAREL system can recognise the current operating status of the entire installation and independently adapt its operating conditions to the actual demand from the field. Modulating condensing pressure set point prack can adapt its operation based on outside conditions by simply adding an outside temperature probe. The condensing pressure set points are automatically modified so as to minimise compressor energy consumption. ESS Energy Saving Suite MPXPRO Energy saving maximised by using MPXPRO with the CAREL E 2 V expansion valve on showcases and in cold rooms. ChillBooster prack manages ChillBooster, the evaporative cooling system for air-cooled condensers, maximising performance during operation at high summer temperatures and minimising energy consumption. Ideal for CO 2 gas coolers, ChillBooster can be activated as the last condenser stage or as an emergency procedure. Heat Recovery prack manages the heat exchanger fitted upstream of the condenser to recover heat for domestic hot water production, by monitoring the refrigerant temperature entering the condenser. Once activated by digital input, scheduler or when high condensing pressure prevention is activated, the operating conditions of the condenser can be adjusted to maximise system efficiency. Economizer / Liquid injection Ideal for scroll and screw compressors, prack can also manage liquid injection and economizer systems, by monitoring the discharge temperature and operating conditions of each individual compressor to increase compressor efficiency, reducing discharge temperature and maximising overall system COP.

7 prack system optimisation prack optimizes compressor rack operation by applying available modulating devices, as well as control and rotation algorithms to stabilise operating pressure. Types of compressors prack manages all types of compressors currently available on the commercial refrigeration market. Piston maximum 12 compressors on each line; pre-configured capacity steps; different sizes (max 4); up to 4 configurable digital alarms for each compressor; first compressor with inverter. Scroll maximum 12 compressors on each line different sizes (max 4) up to 4 configurable digital alarms for each compressor first compressor Emerson-Copeland digital scroll (management algorithm based on macroblock approved by Emerson - Copeland ). Control and rotation prack ensures optimum management of compressors and fans by applying three distinct control functions and four types of rotation. Control proportional: suitable for simple on-off control (above all fans); dead band: above all for compressors, ensures stable pressure within a set range and allows staggered on and off times; proportional Integral: suitable for compressors and fans, above all modulating devices (inverter, digital scroll, EC fans), ensures very fine control and thus stable operating pressure. off zone SET on zone Pres Rotation FIFO: First in first out, used to balance the number of starts between compressors, normally applied to compressors that have the same capacity; LIFO: Last in first out, used to give priority to the first compressors over the last, normally applied to compressors with different capacities; TIME: used to balance operating hours between devices, normally applied to compressors that have the same capacity; CUSTOM: defined by the user, used to give priority to some devices over others based on specific needs. Pres SET SET t Screw pre-configured Bitzer, Refcomp, Hanbell models; pulsing valves managed by SSR (Solid state Relays, optoelectronic devices with a very high number of switching cycles); step - stepless - inverter management; dedicated starting procedures; internal star delta / part winding starting; envelope monitoring and safety procedures.

8 NEW pr100t and pr200t evolution of the prack platform prack is available in the pr100t and pr200t version for managing transcritical CO2 systems, both booster and cascade pr100t and pr200t can independently manage a transcritical CO2 compressor rack, completely controlling double temperature (LT-MT) systems, either cascade or booster. The intrinsic features of prack make the solution flexible and adaptable to the specific part of the application, with the same platform providing a compact solution on one board for managing small systems, but also multi board solutions for managing more complex compressor racks that require a high number of inputs and outputs. HPV: High receiver pressure prack controls the back pressure valve used to regulate gas cooler pressure. The algorithms to optimise system COP can be configured by expert users so as to satisfy all market requirements. Backup procedures are available in the event of system malfunctions or probe errors. RPRV: Receiver pressure regulating valve prack uses a special algorithm to control flash gas valves and thus maintain receiver pressure at the set point. Control is continuous and settable. Safety procedures are available in the event of system malfunctions, excessive pressure or probe errors. Integration between HPV and RPRV control brings operating synergies that ensure system safety. ChillBooster Recovery procedures Backup with single board Hardwired fault synchronisation with case controllers PlantVisorPRO 2 also for case controller synchronisation via serial line Adiabatic cooling system for air condensers Activation by high condensing pressure or as last control stage High efficiency with high outside temperatures during summertime Compressor management Coupling and timings Speed drive Safety envelopes Double system synchronization (DSS) Multiple rack synchronisation Optimised stage start/stop Safety startup Subcooler Gas cooler integration Scheduled or on demand Gas cooler Oil management Optimised fan management Speed drive (EC, VFD) Cooling Injection Separator

9 prack pr100t and pr200t, just one platform to manage transcritical CO2 systems. Flexibility and scalability to satisfy all needs. Oil management An independent oil cooling system can be managed for each compressor, including temperature monitoring, separation and accumulation with suitably filtered levels, and injection into the compressors using special valves (including pulsing valves). This function, now integrated into prack, means compressor oil management can also be monitored and logged. NEW pr200t additional features 16/02/2011 Touch User Interface advanced graphical functions datalogging, trends and real animated gauges customisable masks pgdtouch series (range from 4 to 13 ) Stepper valves direct drive Transcritical 40 barg 17/01/2010 Modbus Device Modbus Devices Management Management Complete management of EC fans through Modbus RS485 direct connection Direct communication with a common RS485 serial line Complete and individual monitoring of working conditions and power consumption Improved interactions with compressor rack controller Pre-configured optimisation Customisable algorithm Safety procedures Receiver pressure regulating valve (RPRV) Control based on receiver pressure Safety procedures High pressure alarm complete fan management of EC through Modbus RS485 direct connections direct communication with a common RS485 serial line complete and individual monitoring of working conditions and power consumption improved interaction with compressor rack controller gas cooler cleaning Multi language up to 4 languages built-in MT LT booster system diagram Heat recovery Superheat control Subcooling improvement 30.5 C 90 barg built-in driver with Ultracapacytor technology up to two valves management High pressure valve (HPV) 12:33

10 Technical specifications Comparison between inputs and outputs on the various sizes analogue inputs digital inputs analogue outputs digital outputs DIN compact 4 4 (sh.) 2 4 (sh.) 1 PWM 1 0 to 10 Vdc 5 2 SSR (24 Vac) 6 small 3 2 (sh.) 8 2 (sh.) 4 0 to 10 Vdc 6 2 SSR (24 Vac) 13 medium 6 2 (sh.) 12 (24 V) 2 (230 V) 2 (sh.) 4 0 to 10 Vdc 11 2 SSR (24 Vac) 18 large 6 4 (sh.) 14 (24 V) 4 (230 V) 4 (sh.) 6 0 to 10 Vdc 14 4 SSR (24 Vac) 18 extra large N.O. 6 2 (sh.) sh.= configurable as analogue or digital input 12 (24 V) 2 (230 V) 2 (sh.) 4 0 to 10 Vdc 25 4 SSR (24 Vac) 18 Below are the specifications in detail of all the inputs and outputs on each size Compact NTC, 0 to 1 V 0 to 10 V, 0 to 5 V, 0 to 20 ma, 4 to 20 ma NTC, 0 to 1 V, PT1000 NTC, 0 to 1 V, 0 to 10 V, 0 to 5 V free DI NTC, free DI free DI PWM 0 to 10 V N.O. N.O./ N.C. SSR B1, B2 B3, B4 B5, B6 B7, B8 ID1, ID2 DO1, DO2 DO3 to DO7 Y1 Y2 Small NTC, PT1000 free DI B1 to B3 B4, B5 ID1 to ID8 DO1 to DO6 DO7, DO8 Y1 to Y4 NTC, 0 to 1 V, 0 to 10 V, 0 to 5 V, 4 to 20 ma DI, 24 Vac/Vdc 0 to 10 V N.O. N.O./N.C. SSR

11 Medium NTC, PT1000 free DI NTC, 0 to 1 V, 0 to 10 V, 0 to 5 V, 4 to 20 ma DI, 24 Vac/Vdc DI, 24 Vac/Vdc, 230 Vac 0 to 10 V N.O. N.O./ N.C. SSR B1 to B3 B4, B5 B6 to B8 ID1 to ID12 ID13, ID14 DO1 to DO6 DO7 DO8 DO9 to DO11 DO12 DO13 Y1 to Y4 Large NTC, PT1000 free DI NTC, 0 to 1 V, 0 to 10 V, 0 to 5 V, 4 to 20 ma DI, 24 Vac/Vdc DI, 24 Vac/Vdc, 230 Vac 0 to 10 V N.O. N.O./ N.C. SSR B1 to B3 B4, B5 B6 to B8 B9, B10 ID1 to ID12 ID13, ID16 ID17, ID18 DO1 to DO6 DO7 DO8 DO9 to DO11 DO12 DO13 DO14, DO15 DO16 to DO18 Y1 to Y6 Extra-Large NTC, PT1000 free DI NTC, 0 to 1 V, 0 to 10 V, 0 to 5 V, 4 to 20 ma DI, 24 Vac/Vdc DI, 24 Vac/Vdc, 230 Vac 0 to 10 V N.O. N.O./ N.C. SSR B1 to B3 B4, B5 B6 to B8 ID1 to ID12 ID13, ID14 DO1 to DO6 DO7 DO8 DO9 to DO11 DO12 DO13 DO14, DO15 DO16 to DO29 Y1 to Y4

12 Codes available Models with RS485 serial interface: Size Code Description Compact PRK100X3B0 prack pr100 compact, built-in white pgd 1, RS485 2SSR, connector kit PRK100X3BK prack pr100 compact, external white pgd 1 with connection cable, RS485 2SSR, connector kit. Small PRK100S3B0 prack pr100 small, built-in white pgd 1, RS485 2SSR, connector kit PRK100S3BK prack pr100 small, external white pgd 1 with connection cable, RS485 2SSR, connector kit Medium PRK100M3B0 prack pr100 medium, built-in white pgd 1, RS485 2SSR, connector kit PRK100M3BK prack pr100 medium, external white pgd 1 with connection cable, RS485 2SSR, connector kit Large PRK100L3B0 prack pr100 large, built-in white pgd 1, RS485 4SSR, connector kit PRK100L3BK prack pr100 large, external white pgd 1 with connection cable, RS485 4SSR, connector kit Extra large NO PRK100Z3B0 prack pr100 XL NO, built-in white pgd 1, RS485 4SSR, connector kit PRK100Z3BK prack pr100 XL NO, external white pgd 1 with connection cable, RS485 4SSR, connector kit Models without RS485 serial interface Size Code Description Compact PRK100X3A0 prack pr100 compact, built-in white pgd 1, 2SSR, connector kit PRK100X3AK prack pr100 compact, external white pgd 1 with connection cable, 2SSR, connector kit Small PRK100S3A0 prack pr100 small, built-in white pgd 1, 2SSR, connector kit PRK100S3AK prack pr100 small, external white pgd 1 with connection cable, 2SSR, connector kit Medium PRK100M3A0 prack pr100 medium, built-in white pgd 1, 2SSR, connector kit PRK100M3AK prack pr100 medium, external white pgd 1 with connection cable, 2SSR, connector kit Large PRK100L3A0 prack pr100 large, built-in white pgd 1, 4SSR, connector kit PRK100L3AK prack pr100 large, external white pgd 1 with connection cable, 4SSR, connector kit Extra large NO PRK100Z3A0 prack pr100 XL NO, built-in white pgd 1, 4SSR, connector kit PRK100Z3AK prack pr100 XL NO, external white pgd 1 with connection cable, 4SSR, connector kit Models without serial interface Code Description PRK100X0A0 prack pr100 compact, no terminal, 2SSR, connector kit PRK100S0A0 prack pr100 small, no terminal, 2SSR, connector kit PRK100M0A0 prack pr100 medium, no terminal, 2SSR, connector kit PRK100L0A0 prack pr100 large, no terminal, 4SSR, connector kit PRK100Z0A0 prack pr100 XL, no terminal, 4SSR, connector kit Accessories Code PGD1RK0FX0 CONV0/10A0 CONVONOFF0 PCOS CVSTDUTLF0 CVSTDUMOR0 PCOSO0AKY0 PCOSO0AKC0 S90CONN002 S90CONN000 S90CONN001 SPKT*R* e SPKC00* SPK*C*, SPK1*, SPK2*, SPK3* NTC* NTC*HT* Description pgd 1 user terminal for prack pr100 Module for converting a PWM output to a linear 0 to 10 V and 4 to 20 ma analogue output Module for converting a 0 to 10 V analogue output to an SPDT digital output RS485 serial connection card USB/RS485 serial converter with telephone connector USB/RS485 serial converter with 3 pin terminal Smart key (programming key) PC Smart Key USB converter Terminal connection cable l= 0.8 m Terminal connection cable l= 1.5 m Terminal connection cable l= 3 m 0 to 5 Vdc ratiometric pressure probes 4 to 20 ma active pressure probes NTC temperature probes -50T90 C NTC temperature probes -0T150 C CAREL INDUSTRIES 2011 all rights reserved. CAREL INDUSTRIES reserves the right to modify the features of its products without prior notice EN Headquarters ITALY Sales organization Affiliates CAREL INDUSTRIES HQs Via dell Industria, Brugine - Padova (Italy) Tel. (+39) Fax (+39) carel@carel.com CAREL Asia - CAREL Australia - CAREL China - CAREL Deutschland - CAREL France - CAREL Iberica - CAREL India - CAREL HVAC/R Korea - CAREL Russia - CAREL South Africa - CAREL Sud America - CAREL U.K. - CAREL U.S.A. - CAREL Czech & Slovakia - CAREL Korea (for retail market) - CAREL Ireland - CAREL Thailand - CAREL Turkey - 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.