NOTICE D'INSTRUCTIONS OPERATING INSTRUCTIONS

Transcription

1 NOTICE D'INSTRUCTIONS OPERATING INSTRUCTIONS MONTAGE / MISE EN SERVICE / UTILISATION / MAINTENANCE INSTALLATION / COMMISSIONING / OPERATING / MAINTENANCE (à fournir à l utilisateur final pour compléter le dossier d exploitation requis pendant toute la durée de vie de l appareil) (must be given to the end user in order to complete the operating manual during the equipment service life) Groupe de Fluide DESP : 2 DIOXYDE DE CARBONE Groupe de Fluide DESP : 2 / PED fluid group : 2 Il est impératif de prendre connaissance de ces instructions dès réception de l appareil et avant toute intervention sur celuici. Notre service technique reste à votre entière disposition au pour toutes précisions supplémentaires. These operating instructions must be read at the delivery of the equipment and prior any operation on it. Our technical department is at your disposal for any additional information (Tel : ). This document is a translation of the French original version which prevails in all cases.

2 TABLE OF CONTENTS SAFETY 4-6 REGISTRATION OF YOUR CO2Y 7 GENERAL STARTUP INSTRUCTIONS 49 CAUTIONS FOR SAFETY 51 COMPONENTS 54 SCOPE OF APPLICATION 56 DIMENSIONS 57 HANDLING OF THE UNIT 58 SELECTION OF INSTALLATION LOCATION 59 REFRIGERANT PIPING WORK 61 COMMISSIONING 62 OPERATING 63 REFRIGERANT CIRCUIT DIAGRAM 64 ELECTRICAL CONNECTIONS 66 CONTROL CONNECTIONS 67 TERMINAL CONNECTION DIAGRAM 68 DESCRIPTION OF THE DISPLAY 70 MANUAL MODE FOR EVACUATION PROCEDURE 76 CONTROL FUNCTIONS 77 MAINTENANCE 78 WARRANTY CONDITIONS 81 ECODESIGN 83 APPENDIX 1: REFRIGERANT AND OIL CHARGING 84 APPENDIX 2 : ALARM LIST 87

3 SAFETY Reminder Carbon dioxide is a colorless and odorless gas, whose presence in excess in the atmosphere can lead to discomfort, such as headaches, difficulty concentrating, even with low levels of concentration and nausea in the case of greater than 1000 ppm. Carbon dioxide gas is heavier than air and is located at lowest point of spaces when they aren t ventilated. Machinery room must be equipped with a carbon dioxide detector as required by EN 378. In case of carbon dioxide evacuation (vacuum draw, etc ), it is important to have a connection through safety valves discharge pipes as required by EN 378. As professional, the installer must : define the operating conditions of the refrigeration equipment under his own responsibility regarding the design. This device needs to be incorporated in machines conforming to the Machines Directive. Its commissioning is only authorized if it has been incorporated in machines which fully satisfy the legal regulations. complete and adapt these recommendations, if necessary, by adding other safeties and /or controls according to the refrigeration equipment s operating conditions. have performed all the installing, commissioning and maintenance operations by qualified professionals and conforming with standards EN 378, EN 14276, EN 13136, EN 13313, EN and EN 60335, the EU directives, the safety rules generally recognized, sound engineering practice, the local regulations ; as well as those which may be set up, taking into account the evolution of the technology and the regulations. If the installation, the commissioning, the operating, the maintenance are not realised according to this operating instructions, the responsibility of Profroid cannot be involved. completely inform the customer on the control, maintenance and follow-up of the refrigeration equipment. The devices are delivered under pressurized nitrogen or dry air (make sure at reception that material is under pressure by using a pressure gauge) ; except dry cooler, brine air cooler. Respect the standard for transport and handling of pressure devices. Install device in a space with sufficient ventilation regarding standards and regulations because device is under pressure of nitrogen ; except dry cooler, brine air cooler. Very important : before performing any servicing operation on refrigeration equipment, the electric power supply must be turned off. The contractor or the company in charge of the installation shall be responsible for carrying out the required instructions. Profroid disclaims any responsibility for change(s) or repair(s) on its devices made without its prior agreement. The devices are exclusively intended for professionals, for refrigeration purposes and for their limits of use. The identification of device and his range of use are written on the name plate. The name plate is stuck on device. Name plates are located : on the coil for heat exchangers, on the frame for racks, on the housing for condensing units, on the receiver for liquid receiver sets and for liquid sub-assembly. The name plate is joined to this operating instructions (.pdf). The complete installation must be designed and used not to exceed the range of use. Device is designed for a maximum ambient temperature of 38 C (as standard configuration). The user or operator shall ensure the control and maintenance of the equipment with qualified professional complying with the instructions below, possibly completed by the installer. For these operations, the standards and directives mentioned above remain usefull. This is also available during the stop of the refrigeration installation. The average life cycle for the design of our devices is of a minimum of 10 years, provided if you follow our operating instructions. Profroid cannot be held responsible in case of violation to the recommendations of them. Pipings of Profroid equipment are made with different types : in copper, standard NF EN in steel, standard NF EN (type P265GH ; n ) in stainless steel, standard NF EN (type 304L X2CrNi18-9 ; n ) These pipings must be inspected regularly following standards, sound engineering practice and local regulations in the country of use. Some heat transfer fluids can be harmful or corrosive, and their uses must be realised in relation with their risks, if there is a leak on pipings. 4

4 INSTALLATION The loading and unloading operations must be performed with adequate handling equipment (forklift, crane, etc.) using possible lifting points provided for this purpose. The qualified professional should be certified and will wear individual safety equipment (protective gloves, glasses, safety shoes, etc.) ; operators will never circulate under the load during lifting operations. During handling, the operator will ensure a good balance to prevent the equipment from swinging. Make sure that the equipment or its accessories have not been damaged during shipping and no parts are missing. If devices are used in a seismic area, then the installer must apply all necessary rules. Enough free space all around the refrigeration equipment should be provided to facilitate maintenance operations. The heat exchangers must be installed in locations free of any external dust or other pollutants from the neighbourhood which could obstruct or clog the coils. If devices are used in a corrosive area (sea side, pollutant gas, etc.), make sure that appropriate anticorrosion protection has been provided. Make sure that pipings are connected to the appropriate pressurized equipment (EN378-2). All connecting pipings must be correctly supported and clamped. For the connection of pipings, protect sensitive components located around the permanent assemblies to be made. Before any intervention, the operator must obstruct all the openings of the circuit (+ pressurization under nitrogen) ; except dry cooler, brine air cooler. Discharge pipings (outlets of safety valve for example) must be installed in view to protect people and apparatus from leakage of refrigerant. Make sure that flexible hoses are not in contact with metal parts. The products added for thermal and /or acoustic insulation must be neutral with respect to support materials. The protection devices, pipings and accessories must be protected against unfavourable effects from the environment. Make sure that access and emergency exit ways are not obstructed to comply with the local regulations. COMMISSIONING Prior to electrically connect the facility, make sure that the AC power line voltage and frequency ratings correspond to the indications on the identification plate and the power voltage is within a tolerance of + 10 % with respect to the rated value. Specific protection is provided according to the neutral system. Any on-site wiring must comply with the legal standards in force in the country of installation (including grounding). Before turning on a device, make sure that : - the electric connections have been correctly made - the clamping screws of the various terminals are correctly tightened Check the possible presence of locking devices of compressor antivibration elements, and remove them, if they exist. OPERATING Do not use the refrigeration equipment or components for any utilization other than that for which it is designed. Comply with the special manufacturers recommendations contained in the manufacturers operating instructions. It is strictly prohibited while the device is running to remove the guards and panelling provided by the manufacturer to protect the user and ensure his safety. When operating, surface temperatures above 60 C and /or below 0 C may be reached. During any servicing operation, the personnel should be extremely careful while working on the device. Profroid is not informed to real use of partly completed machines ; their integrations and use must comply to Machines Directive and recommendations of this operating instructions. Results of design calculations, checks, and test reports in relation with low voltage directive are archived. MAINTENANCE The device must be checked and inspected into service, regularly, by a qualified and approved personal, following rules. The device will be subject to preventive maintenance (EN 378) : - external visual inspection of device, - checks of device during running, - checks of device corrosion. 5

5 Before working on pressurized components, shut down the facility and wait until the equipment is at the ambient (room) temperature. Before removing the guards and panelling, turn off the device. Set it aside and make sure that no power is present. Do not use piping to access on the equipment or to store something on the equipment. The replacement of a safety valve must be made by the same brand of the original one. If there is modification of type and /or brand, then the professional in charge of the replacement will do a calculation sheet following EN and /or ask Profroid some elements. Handle regularly the device valves in view to avoid theirs blocking on. If a personal in charge of maintenance closed a blocked valve, this personal will must avoid the possible increase of pressure in the part of device which is isolated. The periodic technical checks must be made following frequencies determined by standards, sound engineering practice, end user and installer. Report periodic checks and analyze the data. In case of abnormalities or inconsistencies, determine the cause and correct it. In case of hanged units (evaporator as an example), it is necessary to define an exclusion zone on the ground, to avoid the presence of persona under the equipment. It is important to ensure that the hinge mechanisms of moving parts are operational before all manipulations (drain pan, door, fans mounted on hinges, ). In general, when opening any moving parts it is necessary to accompany them or slow their opening speed to avoid casing deformations. Lockable fan switch aren t safety accessories. 6

6 ENREGISTREMENT DE VOTRE CO2Y REGISTRATION OF YOUR CO2Y 7

7 GENERAL STARTUP INSTRUCTIONS Evacuation To avoid inclusion of air or moisture in the refrigerant circuit, be sure to execute vacuum drying of the entire circuit before charging refrigerant by using a vacuum pump. Execute evacuation after securely carrying out airtight/pressure testing. > When performing vacuum drying, make sure that valve EC1 and EC3 are fully open, please refer to chapter Manual mode for evacuation procedure. Dehydration of circuits This operation must be carried out with all valves open (including solenoid valves) with connection to a vacuum pump: of the low pressure side of the high pressure side The quality of drying should not be judged by the speed at which the level of vacuum is reached but on the effective time it is held (24 hours at 0.7 mbar is a good standard). The total increase in pressure after that period should not be more than 2.6 mbar. The residual moisture in the system should be less than 10 ppm. When the installation is under vacuum, an insulation check of the motor should not be carried out nor should the compressors be started before at least 1 bar of fluid pressure is reintroduced. This is to prevent motor winding damage. Refrigerant and Oil Charging Calculate the refrigerant and oil charge prior to charging (refer to appendix 1). Execute refrigerant charging immediately after evacuation. Charge refrigerant R744 (CO2 refrigerant). Do not mix with other refrigerant. Always use refrigerant grade R744, moisture content must be below 10 ppm. 49

8 GENERAL STARTUP INSTRUCTIONS Method of Charging Use Manifold Gauges and charging hoses for CO2 only. Use only refrigeration quality R744. Use a refrigerant scale to measure correct quantity charged into the system from the R744 cylinders. Oil Charging must be done through the liquid service line during vacuum operation Close the vacuum pump and break the vacuum with vapor R744 until 7-10Bar to avoid dry ice formation. Dry ice may block hoses and pipes and charging will be impossible. Charge vapor in both suction and liquid line. Control that the expansion valve at the evaporator(s) is active. Control both electronic pressure transmitters and manifold Gauges for correct pressure readings. As vapor is drawn from the R744 cylinders, pressure and temperature inside the cylinder will decrease. Frosting on the bottom exterior of the cylinder is evidence that some R744 liquid evaporated inside. The reduction in pressure also causes a slower flow rate of vapor into the system. Once the flow from the cylinder has slowed to a low level, the cold cylinder should be disconnected and allowed to warm. After the cylinder warms, additional R744 can be removed. In the meantime, another warm tank can be connected to the system to continue the charging process. Add liquid R744 only into the liquid line. Do not charge liquid on compressor suction line. Only Gas. Overfilling the system may cause malfunction and compressor damage. Sight glass does not indicate correct R744 level if 100% full. Control superheat management is inside min-max superheat settings. ¾ level in the sight glass is ok. Simulate transcritical conditions when charging in low ambient conditions by blocking the air flow into the condenser/gas cooler in order to control correct charging level. Run the unite and simulate thermostat cut off, defrosting cycle or manual pump down in order to control correct operation and R744 charge. In case of leakage detection and repair: empty the system completely and refill according to the first filling charge. 50

9 CAUTIONS FOR SAFETY As professional, the installer must: Define the operating conditions of the refrigeration equipment under his own responsibility regarding the design. This device needs to be incorporated in machines conforming to the Machines Directive. Its commissioning is only authorized if it has been incorporated in machines which fully satisfy the legal regulations. Complete and adapt these recommendations, if necessary, by adding other safeties and /or controls according to the refrigeration equipment s operating conditions. Have performed all the installing, commissioning and maintenance operations by qualified professionals and conforming with standards EN 378, EN 14276, EN 13136, EN 13313, EN and EN 60335, the EU directives, the safety rules generally recognized, sound engineering practice, the local regulations; as well as those which may be set up, taking into account the evolution of the technology and the regulations. If the installation, the commissioning, the operating, the maintenance are not realised according to this operating instructions, the responsibility of Green & Cool cannot be involved. Completely inform the customer on the control, maintenance and follow-up of the refrigeration equipment. The units have been designed for 80/80/80/120bar pressure and are equipped with discharge safety pressure switches set at 120 bar. Any system that is designed with PS < 74 bar (R744 critical point) can risk overpressure when it stops. When installing a CO2Y unit to a system using a lower design pressure, the installer is responsible for the protection of this system (for example by installing a safety valve). 51

10 CAUTIONS FOR SAFETY The devices are delivered under pressurized nitrogen or dry air (make sure at reception that material is under pressure by using a pressure gauge). Respect the standard for transport and handling of pressure devices. Install device in a space with sufficient ventilation regarding standards and regulations because device is under pressure of nitrogen; except dry cooler, brine air cooler. Very important: before performing any servicing operation on refrigeration equipment, the electric power supply must be turned off. The contractor or the company in charge of the installation shall be responsible for carrying out the required instructions. Green & Cool disclaims any responsibility for change(s) or repair(s) on its devices made without its prior agreement. The devices are exclusively intended for professionals, for refrigeration purposes and for their limits of use. The identification of device and his range of use are written on the name plate. The name plate is stuck on device. Name plates are located: on the coil for heat exchangers, on the frame for racks, on the housing for condensing units, on the receiver for liquid receiver sets and for liquid sub-assembly. The name plate is joined to these operating instructions (.pdf). The complete installation must be designed and used not to exceed the range of use. Device is designed for a maximum ambient temperature of 43 C (as standard configuration). The user or operator shall ensure the control and maintenance of the equipment with qualified professional complying with the instructions below, possibly completed by the installer. For these operations, the standards and directives mentioned above remain useful. This is also available during the stop of the refrigeration installation. The average life cycle for the design of our devices is of a minimum of 10 years, provided if you follow our operating instructions. Green & Cool cannot be held responsible in case of violation to the recommendations of them. Pipings of Green & Cool equipment are made with different types : in copper, standard NF EN in steel, standard NF EN (type P265GH ; n ) in stainless steel, standard NF EN (type 304L X2CrNi18-9 ; n ) These pipings must be inspected regularly following standards, sound engineering practice and local regulations in the country of use. Some heat transfer fluids can be harmful or corrosive, and their uses must be realized in relation with their risks, if there is a leak on pipings. 52

11 CAUTIONS FOR SAFETY Do not use other than the designated refrigerant (for charging, adding or recharging) Refrigerant gas leak may cause suffocation. Piping, equipment components and tools should be appropriate for use with R744 (CO2 refrigerant). Use of unsuitable components or those designed for HFC refrigerant may cause serious incidents such as equipment failure and rupture of the refrigerant cycle. Securely place the cover on the electrical box and enclosure panel. Incomplete attachment may lead to penetration of water and living creatures, meaning potential current leak and fire/electrical shock. Do not change the set values of the safety device. Using the refrigeration unit with changed values may cause failure of the safety stop function and lead to a burst or fire. When abnormal operation is detected, or before starting disassembly or repair, turn off the main power switch. Specified components must be used for repair. Use of non-specified components may cause failure of the safety stop function and lead to burst or fire. Incorrect moving may cause fall or dropping of the refrigeration unit, and cause injury. Request a specialty operator for disposing the refrigeration unit. Make sure that access and emergency exit ways are not obstructed to comply with the local regulations. Protect all electrical live parts from rain or snow if doing maintenance with unit under voltage 53

12 COMPONENTS CO2Y Air Cooled : 54

13 COMPONENTS CO2Y Water Cooled : MT Versions LT Versions 55

14 SCOPE OF APPLICATION CO2Y Series Product GMCC Toshiba CO2Y 50MT CO2Y 30MT CO2Y 67MT CO2Y 100MT CO2Y 75LT CO2Y 167LT Refrigerant system Ambient Optional: Water system (applicable for liquid-cooled condenser) On/off cycle period Refrigerant Oil type (brand) Alternative oil Evaporating temperature Suction superheating Discharge gas temperature Inverter operation Nominal Revolution Temperature Relative Humidity Inlet liquid temperature Liquid mass flow Pressure loss in the liquid side for the BPHX R744 PAG PAG oil VG100 PZ100S PAG100 FUCHS -20 C to +5 C 20K or below +120 C or below RPS 70 RPS -32 C to -20 C -15 C 43 C (the ambient temperature can be -30 C if polar kit heater is installed) 10% 90% -8 C to 38 C (nominal +7 C / +12 C) Variable according to capacity. 50 kpa or below 5 min or longer for on/off cycles 56

15 DIMENSIONS Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Dimensions CO2Y MT Air cooled CO2Y LT Air Cooled CO2Y Water Cooled CO2Y CO2Y CO2Y CO2Y CO2Y CO2Y MT30 MT50 MT67 MT100 LT75 LT167 CO2Y MT CO2Y LT Fig 1 Fig 3 Fig 2 Fig 4 Fig 5 Fig 6 Length (mm) Width (mm) Std : 811 PK : Depth (mm) Weight (kg)

16 HANDLING OF THE UNIT Carry-in Operation - Make sure that the equipment or its accessories have not been damaged during shipping and no parts are missing. - Carry the refrigeration unit gently by keeping the vertical position as much as possible. - Absolutely avoid a lay-down position of the refrigeration unit. The loading and unloading operations must be performed with adequate handling equipment (forklift, crane, etc.) using possible lifting points provided for this purpose. - The qualified professional should be certified and will wear individual safety equipment (protective gloves, glasses, safety shoes, etc.) ; operators will never circulate under the load during lifting operations. FORKLIFT - When carrying the refrigeration unit by a forklift, use a packaging wood base or pallet for maintaining the refrigeration unit in the vertical position. CRANE When carrying the refrigeration unit by a crane, use a packaging wood base or pallet for maintaining the refrigeration unit in the vertical position. Make sure that the unit is safely secured to the lifting straps. During handling, the operator will ensure a good balance to prevent the equipment from swinging. 58

17 SELECTION OF INSTALLATION LOCATION The CO2Y Air Cooled is intended for outdoor installation 1200 mm 250 mm 500 mm 500 mm Vibration should be reduced by a platform or anti-vibration pad for avoiding transmission of vibration to the floor and wall. To avoid falling, secure the refrigeration unit by using anchor bolts. (Use all securing positions) The refrigeration unit must be installed with an inclination angle 1 or below. If devices are used in a seismic area, then the installer must apply all necessary rules. Enough free space all around the refrigeration equipment should be provided to facilitate maintenance operations. The heat exchangers must be installed in locations free of any external dust or other pollutants from the neighborhood which could obstruct or clog the coils. If devices are used in a corrosive area (sea side, pollutant gas, etc.), make sure that appropriate anticorrosion protection has been provided. 59

18 SELECTION OF INSTALLATION LOCATION NO air from a second unit shall be directed towards the gas cooler of another one! In the case of face-to-face installation, keep a minimum of 2000mm distance between the units mm 60

19 REFRIGERANT PIPING WORK Selection of Refrigerant Piping Size The connection piping size for refrigeration unit is, in principle, as shown below, but each installation should be determined by calculating pressure loss of the piping and refrigerant flow speed and making sure no problem occurs in the cooling capacity and oil return. As refrigeration unit using CO2 refrigerant incurs pressure higher than when using traditional refrigerants, it is necessary to choose adequate materials. Make sure that piping s are connected to the appropriate pressurized equipment (EN378-2). Product Suction line (R744) Liquid line (R744) PS Water line (Water Cooled CO2Y) MT30 9,52 mm (3/8") 9,52 mm (3/8") 80 bars 28,57 mm (1"1/8) MT50 9,52 mm (3/8") 9,52 mm (3/8") 80 bars 28,57 mm (1"1/8) MT67 9,52 mm (3/8") 9,52 mm (3/8") 80 bars 31,62 mm (1"3/8) MT100 9,52 mm (3/8") 9,52 mm (3/8") 80 bars 31,62 mm (1"3/8) LT75 9,52 mm (3/8") 9,52 mm (3/8") 80 bars 28,57 mm (1"1/8) LT167 12,7 mm (1/2") 9,52 mm (3/8") 80 bars 28,57 mm (1"1/8) Selection of refrigerant piping can be done by using the Green & Cool pipe selection tool. ( Prevent contamination of foreign objects such as dust, metal powder, oxide scale, etc. Since the compressor consists of high precision components, contaminants generate scratches on the sliding surfaces, thereby increasing gas leak, deteriorating performance, and causing excessive wear and seizure. Flow nitrogen gas during welding. Piping inside and outside must be clean. 61

20 REFRIGERANT PIPING WORK Refrigeration network connection Before any work is done on the refrigeration circuit, the holding charge must be removed. The piping used must be of copper refrigeration quality in accordance with PED 2014/68/EC and EN All piping must be correctly supported and fixed and should in no case be allowed to restrict the operation of the gas cooler unit. For the connection of piping, protect sensitive components located around the permanent assemblies to be made. The products added for thermal and /or acoustic insulation must be neutral with respect to support materials. The protection devices, piping s and accessories must be protected against unfavorable effects from the environment. Reverse-trap Evaporator higher than unit. P-trap Suction line Evaporator lower than unit. Suction line 5 m max height difference P-trap 62

21 COMMISSIONING Do not use other than the designated refrigerant (for charging, adding or recharging). Prior to electrically connect the facility, make sure that the AC power line voltage and frequency ratings correspond to the indications on the identification plate and the power voltage is within a tolerance of + 10 % with respect to the rated value. Specific protection is provided according to the neutral system. Any on-site wiring must comply with the legal standards in force in the country of installation (including grounding). Before turning on a device, make sure that: the electric connections have been correctly made the clamping screws of the various terminals are correctly tightened Check the possible presence of locking devices of compressor antivibration elements, and remove them, if they exist. 63

22 OPERATING Do not use other than the designated refrigerant (for charging, adding or recharging). Do not use the refrigeration equipment or components for any utilization other than that for which it is designed. Comply with the special manufacturers recommendations contained in the manufacturers operating instructions. It is strictly prohibited while the device is running to remove the guards and panelling provided by the manufacturer to protect the user and ensure his safety. When operating, surface temperatures above 60 C and /or below 0 C may be reached. During any servicing operation, the personnel should be extremely careful while working on the device. Green & Cool is not informed to real use of partly completed machines; their integrations and use must comply with Machines Directive and recommendations of these operating instructions. Results of design calculations, checks, and test reports in relation with low voltage directive are archived. Water cooled CO2Y features The cooling fluid of the Water Cooled CO2Y must either be water or a mixture of water and MEG (maximum MEG concentration: 40%). The inlet temperature of this fluid must be in a -8 C/+38 C range. The nominal range is between +7 C and +12 C. The water circuit is equipped with a ball valve which allows regulating the bypass of the gascooler. A thermostatic control valve allows controlling the water flow which passes through the intercooler on the LT versions. This valve operates by measuring the temperature of the refrigerant on the CO2 outlet of the heat exchanger. When dimensioning the water circuit, the installer must take into account the pressure losses of the water pipes and the exchanger(s). The following table shows a rough estimate of the pressure losses depending on the water flow : Fluid EG 35% H2O H2O EG 35% Inlet water ( C) Outlet water ( C) -8 C -4 C +7 C +12 C +15 C +20 C +30 C +35 C Flow (m 3 /h) Pressure loss (kpa) Flow (m 3 /h) Pressure loss (kpa) Flow (m 3 /h) Pressure loss (kpa) Flow (m 3 /h) Pressure loss (kpa) MT30 1, , ,86 9 0,92 11 MT50 2, , , ,57 13 MT67 2, , , ,03 13 MT100 4, , , ,82 22 LT75 1, ,9 10 0,88 8 0,91 10 LT167 2, , , ,

23 CO2Y Air Cooled REFRIGERANT CIRCUIT DIAGRAM 65

24 CO2Y Water Cooled : REFRIGERANT CIRCUIT DIAGRAM 66

25 ELECTRICAL CONNECTIONS Caution Electrical compartment contains live terminals, please ensure supply is isolated before removing the cover. Any person accessing this part of the unit should be suitably trained and competent. Before carrying out any maintenance work, disconnect the drive and the external control circuits from the power supply by moving the main system switch to off. Once power has been disconnected from the drive, wait at least 5 minutes before disconnecting the electrical cables. Power supply Max. absorbed current without evaporators (Air cooled) Max. absorbed current without evaporators (Water cooled) CO2Y 30MT 230 V / Single phase / 50 Hz + G CO2Y MT series CO2Y CO2Y 50MT 67MT CO2Y 100MT 400 V / 3ph /50 Hz N + G CO2Y 75LT 230 V / Single phase / 50 Hz + G CO2Y LT series CO2Y 167LT 400 V / 3 ph / 50 Hz N + G 13,3 A 20,7 A 27,2 A 18,5 A 18,4 A 31,4 A 12,5 A 19,9 A 26,4 A 16,5 A 17,6 A 31,4 A If consumers are powered from the condensing unit using the available circuit breakers, select the main power supply by adding the actual consumer input current to the above values General information The machine is designed in accordance with EN Supplying cable must be connected on terminal of main switch. All cabling on site must conform to the legal standards in force in the relevant countries and to EN

26 CONTROL CONNECTIONS The specificities of water cooled versions are shown in blue. Please refer to the electrical wiring diagram supplied with the CO2Y for more detailed information. If an MTXPro/Ultracella controller is installed, the communication with the Fieldbus has to be established. 68 If another controller is installed, the communication has to be established with the dedicated output of the ECU70.

27 TERMINAL CONNECTION DIAGRAM Please consider that the EC motor is installed on Water Cooled versions (0-10V three way valve). MT Versions 69

28 TERMINAL CONNECTION DIAGRAM LT Versions 70

29 DESCRIPTION OF THE DISPLAY Types of display There are three fundamental types of display shown to the user: Main display Menu display Screen for display/setting the parameters USER PASSWORD: 1502 Main display The software on board prack Hecu automatically returns to the main mask 5 min after the last button was pressed. An example of the main mask is shown in the figure, highlighting the fields and icons used. 1. Time and date 2. Main values 3. Unit status (unit off) compressors and fan status (unit on) 4. Active alarm signal and manual operation 5. Access further information mask (menu branch A.a) by pressing Note the information shown on the main mask varies according to the system configuration and type of control value used (pressure, temperature) 71

30 DESCRIPTION OF THE DISPLAY Screen for displaying/setting the parameters An example of visual for displaying/setting the parameters is shown in the figure, also highlighting the fields and icons used: 1. Parameters 2. Screen identifier 3. Menu The display identifier details the menu branch and the mask: the first character indicates the menu branch, while the two alphanumeric digits identify the order of the mask inside the menu. For example mask Bab01 is the first mask in menu B.a.b Parameters setpoints Label Description Unit Min Max Setpoint Cab03 Compressor pressure setpoint barg Cae24 Suction high pressure alarm threshold (absolute) barg 60.0 Cae25 Suction high pressure alarm diff. barg Cae26 Suction low pressure alarm threshold (absolute) barg 10.0 Cae27 Suction low pressure alarm diff. barg Caf17 Minimum on time compressor s Caf17 Minimum off time compressor s Caf17 Minimum time to start same compressor s Cag52 Max speed rps Cag52 Min speed rps Cag57 High discharge temp. : Limit C Cag57 High discharge temp. : Alarm C Dab03 Gascooler setpoint C Dae06 High gas cooler pressure alarm threshold barg Dae07 Low gas cooler pressure alarm threshold barg Phb28 Maximum HPV safety setpoint barg Phb28 Minimum HPV setpoint barg Fhb22 Regulation CO2 receiver pressure setpoint barg 55.0 (MT) (LT) Risk of condensation if CO2 receiver pressure set below 55 bar on MT versions 72

31 DESCRIPTION OF THE DISPLAY Navigation To navigate inside the menu tree, use the following buttons. 73

32 DESCRIPTION OF THE DISPLAY Menu tree Level 1 Level 2 Level 3 Description a. Main info Information of the different operational states A. Unit Status b. Setpoint Setpoint modification c. On/Off Regulation on/off a. Digital Inputs Configuration and status of the digital inputs a. Status b. Analog Inputs Configuration and status of the analog inputs c. Digital Outputs Configuration and status of the digital outputs B. Inputs / Outputs d. Analog Outputs Configuration and status of the analog outputs C. Compressors D. Condensers E. Evaporator F. Other functions b. Manual Management a. Digital Outputs Manual management of the digital outputs b. Analog Outputs Manual management of the analog outputs c. BLDC Output Manual management of the BLDC output c. Test a. Digital Outputs Factory test of the digital outputs b. Analog Outputs Factory test of the analog outputs a. I/O status Configuration and status of the compressor s inputs/outputs b. Regulation Parameters of the compressors regulation c. Working hours Maintenance threshold and running time of the compressors d. Energy Saving Not used e. Alarms Configuration of the LP/HP security of the compressors f. Configuration Hardware configuration of the system g. Advanced Advanced configuration of the system a. I/O status Configuration and status of the gascooler s inputs/outputs b. Regulation Parameters of the gascooler s regulation c. Driver EVD Not used d. Energy saving Energy saving, HP floating, winter time difference e. Alarms Configuration of the LP/HP security of the gascooler f. Configuration Hardware configuration of the system g. Advanced Advanced configuration of the system a. I/O status Configuration and status of the evaporator s inputs/outputs b. Configuration Controller type connected (MPXPRO/Ultracella) c. Regulation Not used d. Driver EVD Not used a. Oil b. Defrost c. Economizer d. Injection e. Heat reclaim a. I/O status Configuration and status of the inputs/outputs of the oil management b. Settings Oil management configuration a. I/O status Configuration and status of the defrost inputs/outputs b. Regulation Defrost configuration c. Info Remaining time before the next defrost cycle a. I/O status Not used b. Settings Not used a. I/O status Configuration and status of the inputs/outputs of the liquid injection b. Settings Liquid injection limit and differential a. I/O status Not used b. Settings Not used 74

33 DESCRIPTION OF THE DISPLAY Menu tree Level 1 Level 2 Level 3 Description F. Other functions f. Generic functions g. ChillBooster h. Transcritical a. Clock a. Thermostats Configuration up to 5 thermostats (digital outlets) b. Modulations Configuation up to 2 modulating thermostats (analog outlets) c. Alarms Digital inlets alarms configuration d. Scheduler Not used e. I/O status Configuration and status of the inputs/outputs of generic functions a. I/O status Not used b. Settings Not used a. I/O status Configuration and status of the inputs/outputs of the transcritical mode b. Settings Transcritical mode settings c. EVO Settings EVO, HP valves and liquid receivers definition a. Scheduler Hourly/weekly scheduling b. Adjustment Internal clock setup (date and time) Language setting of the regulator (English only at the b. Langage moment) G. Settings c. BMS Adress and communication speed setup d. Fieldbus Communication port setup of the Fieldbus e. Passwords Access passwords and access level modification (password modification is discouraged) a. Data logging Suction and discharge pressure data recording on the alarms H. Safety b. Prevent Offload mode activation for high temperature or high pressure levels c. Alarm configuration Security setup I. Info Software version and BIOS a. Preconfigurations Not used b. Wizard Regulator setup erasure and back to pre-configuration menu L. Setup c. Quick Not used configurations d. Defaults Regulator setup erasure and factory reset 75

34 MANUAL MODE FOR EVACUATION PROCEDURE Password management Insert password: user = 1502 Press enter to continue. Main menu Use arrows up/down to access the necessary masks. Select B. Inputs/Outputs and press enter. Inputs/Outputs Select Manual management and press Enter to continue Use this function ONLY to manually open EC1 and EC3 valves during evacuation of the unit I/O Manual Select Analog outputs and press Enter to continue Press enter to enable L1-Suction Press enter to enable L1-Discharge Use arrows and enter to set the timeout (15 min). Once the specified time has been reached, both L1-Suction and L1-Discharge manual management will be disabled. Once the evacuation procedure is done, either wait for the timeout to end or go back to this menu to disable manual management Press enter to continue. Manual management of HPV (EC1) valve Use this function during evacuation of the unit for both MT and LT models. Use arrows and press enter to change to 100 %. Manual management of RPRV (EC3) valve. Use this function during evacuation of the unit, only for MT models. Use arrows and press enter to change to 100 %. WARNING: do not operate EC3 on LT models, risk of compressor starting. Press escape to go back to start menu. 76

35 CONTROL FUNCTIONS Protective functions Compressors stops when: High pressure exceeds 108 bar. Restarts with manual reset. Low pressure is below 15 bar. Automatic reset. BLDC Power + Alarm. See display information. Compressor auto reset. 5 times before alarm becomes manual. Compressor out of envelope alarm. Compressor auto reset. 5 times before alarm becomes manual. EC Gas cooler fan is protected by internal temperature sensor. Automatic reset. All alarms are visible after pressing the flashing red warning triangle. Hold down to reset. Example here: suction pressure probe broken or disconnected. Alarm list A complete list of controller alarms can be found on appendix 2. 77

36 MAINTENANCE Warning This unit restarts automatically. Before any intervention on the unit, operator must make sure that the main switch is safely secured. Recommendations If the unit is stopped for long periods of time, the fan motors should be run for at least two hours each week. Every month, carry out an operating check on: Cleanliness of coil Refrigerant level Minimum every year: Clean the gas cooler Instructions or recommendations appearing in the various technical advice notes and manufacturer's service manuals should be followed precisely. Please contact our Technical Department for any additional information. Cleaning Coils should preferably be cleaned with: Compressed air By brushing with non-metallic materials Avoid all aggressive detergents which may cause eventual corrosion. Replacement parts References of replacement parts are given by After sales department ( ). Operating instructions for maintenance For all maintenance operations, the following instructions must be followed: Unit door must only be opened after the main switch has been cut-off and the fans have stopped completely. The safety HP can be accessed when the door is opened. Then, access to service ports for connecting the pressure gauge is possible. 78

37 MAINTENANCE 79

38 MAINTENANCE 80

39 WARRANTY CONDITIONS OF THE REFRIGERATION UNIT No charge warranty period is 1 year from the date of installation of the refrigeration unit. However, the coverage of the no-charge warranty is the failed component by supplying a replacement component. Any failure caused by the following reason is considered chargeable even during the warranty period. Failure caused by not conforming to the use condition specified in this installation instructions Model selection or equipment installation design was incorrect. When our company has determined that the failure was generated by an error in combining refrigeration unit models, incorrect control components such as solenoid valve, or designing a refrigeration cycle without conforming to the prohibited items, caution items, or instructed items indicated in the installation instructions and on the product. When a problem exists in the installation work. When damage or breakage was generated by incorrect handling during installation work. When the failure is judged as being caused by contaminants (debris, metal powder, etc.) entering in the cycle during the installation or piping work. When the failure is judged as incorrect wiring work during installation and piping work. When the personnel related to our company pointed out incorrect work but no improvement was made. Accident caused by violating laws and regulations. When the system was operated by knowing large vibration or operation sound. When a problem was generated by a weak foundation or weak base frame. When operational failure was caused in the check valve or solenoid valve due to incorrect brazing of piping connection. Accident was generated by locally modifying our company s product specification, or moving the equipment. Accident caused by contamination of debris in the electric components (hole drilling for installing additional components). Accident generated by not complying with the specified installation location, operating ambient temperature or operating voltage. Accident generated by locally modifying the company s product specification, performing accompanying work or moving the location, or accident generated without using the protective devices included in the product. Accident generated by incorrect operating environment or maintenance/inspection. 81

40 WARRANTY CONDITIONS OF THE REFRIGERATION UNIT Accident caused by installing in an environment containing oil (including machine oil), water, salt (coastal area, etc.). Accident caused by incorrect installation location (insufficient airflow, special environmental condition such as water pressure, chemical substances, etc.). Accident caused by adjustment error of control equipment, etc. Accident caused by short cycle operation (each operation and stop for five min or shorter). Incorrect maintenance (not noticing gas leak). Error in repair work (wrong component, missing component, wrong attachment). Accident caused by overcharging or shortage of refrigerant, and insufficient refrigeration oil (starting failure, motor cooling failure, lubrication failure). Accident caused by defrosting failure. Accident caused by abnormal voltage. When air or water is judged being contaminated in the cycle. Accident caused by failure of power source caused by loose terminal of wiring. Failure of the motor or electric component caused by abnormal power voltage drop (220 V or below) when starting after power failure and switching to emergency power source. Failure of the motor or electrical component caused by abnormally high voltage applied to the source such as lightening, or excessive noise such as arc spark, etc. Accident caused by unspecified voltage condition, or accident caused by applying distorted voltage of a general-purpose inverter. Accident caused by using a ground fault interrupter not specified by our company. Accident caused by not conforming to the range of evaporating temperature, ambient temperature, and operating voltage specified for this product. Accident caused by fire, earthquake, flood, lightening or other natural disaster. When the product is operated on a vehicle, vessel, or transport means (vibration, impact, momentary power failure, oil surface securing, etc.). Accident caused by the installation or operation largely deviated from the common sense general practice of installation, operation, adjustment, or maintenance is not warranted. In addition, secondary damage caused by the accident of the refrigeration machine, such as damaged food items or loss of sales opportunity, is not compensated. Therefore, each user shall have an alarm system for avoiding the secondary damage, or consult with our agent for protective measures such as damage insurance. Manufactured in France by PROFROID CARRIER S.C.S 178, rue du Fauge - ZI Les Paluds - B.P Aubagne Cedex - France International : Tel. (33) Fax (33)

41 ECODESIGN Air cooled version : Rated P A max Q COP SEPR MT Evap. Temp. =-10 C LT Evap. Temp. =-32 C Amb. Temp. Ta= +32 C (kw) Annual electric. consum. (kwh/a) Rated COP Seasonal energy perfom. ratio COP Validity SEPR VALIDITY MT30 2, ,76 YES MT50 4, ,76 YES MT67 6, ,47 YES MT100 8, ,47 YES LT75 2, ,89 YES LT167 6, ,82 YES Calculations made in «step capacity control mode» 83

42 APPENDIX 1 : REFRIGERANT AND OIL CHARGING This appendix gives the instructions for charging the unit with R744 and additional oil. The following assumptions have been made in order to calculate both charges: - 90% filling factor for gascooler in partload. - Min/Max level in receiver: 10% / 80%. - Liquid line and suction line diameter following the specifications page % filling factor for the evaporator. Here s an example of how to determine the required charges: - In this case, an MT67 unit has to be installed with a 7dm 3 evaporator and a 20m pipe. The following diagrams gives the corresponding R744 and oil charge : - Start on the crossing point of the unit (MT67) and the length of the pipe (20 meters), - Draw a horizontal line from this point which crosses the evaporator volume line, - Draw a vertical line from the crossing point of both lines and read both CO2 charge (at the bottom) and additional oil charge (at the top). - In this particular example, the R744 charge equals 7.8 kg and an additional oil charge of 60 ml is required. The installer also has to consider the zone of this crossing point for charging restrictions: - Green zone : No restrictions - Yellow zone : Warning : Do not pump down the liquid line into the unit, or the receiver could be overfilled and cause compressor damage by liquid floodback. Close the liquid line valve to avoid this issue. - Red zone : Not allowed. The diagrams for the different models are shown in the next pages: 84

43 APPENDIX 1 : REFRIGERANT AND OIL CHARGING 85

44 APPENDIX 1 : REFRIGERANT AND OIL CHARGING 86

45 APPENDIX 2 : ALARM LIST Code Description écran Reset Delay Action ALU02 Regulation probe(s) missing Automatic Not present Shutdown unit ALA01 Discharge temperature probe broken or disconnected Automatic 60 s Related functions disabled ALA02 Gascooler pressure probe broken or disconnected Automatic 60 s Related functions disabled ALA03 External temperature probe broken or disconnected Automatic 60 s Related functions disabled ALA04 General function probe A in board 1 broken or disconnected Automatic 60 s Related functions disabled ALA05 General function probe B in board 1 broken or disconnected Automatic 60 s Related functions disabled ALA06 General function probe C in board 1 broken or disconnected Automatic 60 s Related functions disabled ALA07 General function probe D in board 1 broken or disconnected Automatic 60 s Related functions disabled ALA08 General function probe E in board 1 broken or disconnected Automatic 60 s Related functions disabled ALA24 Suction pressure probe broken or disconnected Automatic 60 s Related functions disabled ALA25 Suction temperature probe broken or disconnected Automatic 60 s Related functions disabled ALA43 Gascooler outlet temperature probe broken or disconected Automatic 60 s Related functions disabled ALB01 Low common suction pressure by pressostat Num.autom.reset: / in min Semiautomatic Config. Shutdown compressor ALB02 High common condensing pressure by pressostat Man./Autom Config. Shutdown compressor ALB03 Low gascooler pressure alarm Automatic Config. Fan forcing at 0% ALB04 High gascooler pressure alarm Automatic Config. Fan forcing at 100% (5 min.) and shutdown compressor ALB07 Fans common overload Automatic Config. - ALB15 High suction pressure alarm Automatic Config. - ALB16 Low suction pressure alarm Automatic Config. - ALC01 Alarm 1 compressor 1 Man./Autom. Config. Shutdown compressor ALC02 Alarm 2 compressor 1 Man./Autom. Config. Shutdown compressor ALC05 Alarm comp. backup Man./Autom. Config. Shutdown compressor ALG01 Clock board error Automatic - Related functions disabled ALG02 Extended memory error Automatic - Related functions disabled ALG11 High thermostat alarms Function: 1-5 Man./Autom. Config. - ALG15 Low thermostat alarms Function: 1-5 Man./Autom. Config. - ALG19 High modulating alarms Function : 6-7 Man./Autom. Config. - ALG23 Low modulating alarms Function : 6-7 Man./Autom. Config. - ALG27 Generic normal alarms Function : 8-9 Man./Autom. Config. - ALG28 Generic serious alarms Function : 8-9 Man./Autom. Config. - ALP01 Power + nβ disconnected Automatic Not present Related functions disabled ALP03 Compressor start failure (tempt.: / max:) Semiautomatic Not present 5 tries, Shutdown compressor ALP05 High discharge gas temperature Automatic Not present Shutdown compressor ALP06 Low pressure differential (insufficient lubrication) Automatic Config. Shutdown compressor ALT01 Compressors working hours Manual Not present - ALT15 Low superheat alarm Settable Config. Shutdown compressor ALT17 Warning setpoint HPV gascooler press. too different from current setpoint Automatic Config. Related functions disabled ALT18 HPV alarm high receiver pressure Automatic Not present Related functions disabled ALW01 Warning high pressure prevent Automatic Config. Related functions disabled ALW05 Warning Fans inverter Automatic Not present - ALW10 Warning Low superheat Automatic Not present - ALW15 Warning an error occured during auto-configur. Automatic Not present - ALW16 Warning Invalid activation of oil level inputs, check the connections Automatic - - ALW24 Power + n Device Offline Semiautomatic 2 s Shutdown compressor ALW25 Power+ n Semiautomatic Not present Shutdown compressor ALW26 Compressor start failure (tempt. : / max.: ) Semiautomatic Not present - ALW27 Envelope alarm Zone Semiautomatic Not present Shutdown compressor 87