Profroid QuietCO2OL Series, QuietCO2OL LT Series, QuietCO2OL MT Series, QC MT30, QC MT50 Operating Instructions Manual
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OPERATING INSTRUCTIONS
COMMISSIONING / OPERATING / MAINTENANCE
(must be given to the end user in order to complete the operating manual during the equipment service life)
QUIETCO2OL
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 : + 33 4 42 18 05 00).
This document is a translation of the French original version which prevails in all cases.
/ PED fluid group : 2
Version 9110
Modifications since the version N° 051217
Pages
- Instruction on the refrigerant charge
P5
- Clarification on the system pressure
P6
- Addition of the water cooled units
(all the
document)
- Addition of some remarks on transportation
P 14
- Warning concerning the mounting of the liquid lines
P 16
- Commissioning Instruction on water cooled units
P 18-19-20
- Recommendation on the evaporator controller selection
P 24
- Clarification of the Controller settings
P 26
- Clarification for the gascooler cleaning instructions
P 32
- Update on the service instruction
P 33-34
- Clarification of the meaning of the colour code in the refrigerant and oil charge charts
P 38
- Instruction on oil filling
P 38
The following table aggregates all the main modifications since the last version
TABLE OF CONTENTS
SAFETY 1-3
GENERAL STARTUP INSTRUCTIONS 4-5
CAUTION FOR SAFETY 6-7
COMPONENTS 8-9
SCOPE OF APPLICATION 10
DIMENSIONS 11
HANDLING OF THE UNIT 12
SELECTION OF INSTALLATION LOCATION 13-14
REFRIGERANT PIPING WORK 15-16
COMMISSIONING 17-19
OPERATING 20
REFRIGERANT CIRCUIT DIAGRAM 21-22
ELECTRICAL CONNECTIONS 23-24
USER INTERFACE 25-27
DESCRIPTION OF THE DISPLAY 28-29
MANUAL MODE FOR THE VACUUM PROCEDURE 30
CONTROL FUNCTIONS 31
MAINTENANCE 32-34
WARRANTY CONDITIONS 35-36
ECODESIGN 37
APPENDIX 1: REFRIGERANT AND OIL CHARGE 38-42
APPENDIX 2 : ALARM LIST 43-44
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 60204 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 plat es 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 12735 and K65
in stainless steel, standard NF EN 10217-7 (type 304L – X2CrNi18-9 ; n° 1.4307)
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.
1
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.
If the appliance is installed in an area for which consideration of the external fire situation is mandatory, then the installer must make
the necessary arrangements.
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.
2
MAINTENANCE / RECYCLING
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.
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 theequipment.
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 13136 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.
RECYCLING
Before disassembling all or part of a device, make sure that the power supply has been switched off.
Recover for recycling by means of appropriate tools the refrigerant present in the unit or in the area of intervention after isolation
of it.
Collect all used oil and deposit it in the appropriate recycling centers. Remember to drain the oil
separator. Eliminate all or part of the device in a suitable recycling center
3
GENERAL STARTUP INSTRUCTIONS
Vacuum
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. Vacuum the
circuit 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 the vacuum procedure”.
Circuits dehydration
This operation must be carried out with all valves open (including solenoid
valves) with connection to a vacuum pump:
– to the low pressure side
– to 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. The compressors should 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.
4
GENERAL STARTUP INSTRUCTIONS
– Oil Charging must be done through the liquid service line during vacuum operation
Method of Charging
– Use Manifold Gauges and charging hoses for CO2 only.
– Use only refrigeration quality R744.
– When charging the refrigerant fix the flexible to the frame to avoid any risks
– Use a refrigerant scale to measure correct quantity charged into the system from
the R744 cylinders.
– 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. Frost at the bottom exterior of the cylinder is an evidence
that liquid R744 has 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 has been warmed up, the residual R744 can be
removed. In the meantime, another warm tank can be connected to the system to
continue the charging process.
– Do not charge liquid on compressor suction line. Only Gas.
– Charge the machine only in vapour phase. The charge should be done on the
suction line. Never charge the machine with liquid. Premature wear risk
when restarting.
– Overfilling the system may cause malfunction and compressor damage.
– Sight Glass on the liquid line does not indicate correct R744 level if 100% full.
Control superheat management is inside min-max superheat settings. ¾ of filling
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.
5
CAUTION 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 60204
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 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 < 80 bar can represent a risk of overpressure when it stops.
When installing a QUIETCO2OL unit into a system using a lower design pressure, the installer must
protect this system against risk of overpressure (for example by installing a safety valve) and modify
the control settings accordingly.
6
CAUTION 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
7
COMPONENTS
Fan
Electrical compartment
Filter drier
Service valve
liquid line
Sight glass
Compressor
HP safety pressure switch
EC1 HP Control valve
EC3 Control valve
intermediate pressure
Gas cooler
HP service valve
Service valve
Suction line
LP/HP Pressure
transducer
Shut-off valves liquid line
- QUIETCO2OL air cooled :
MT Version
8
COMPONENTS
3-ways valve
Plate Heat Exchanger
By-pass valve (gas cooler)
Sight glass
Filter drier
Service valve suction line
Compressor
EC1 HP Control valve
HP service valve
LP/HP Pressure transducer
Service valve liquid line
EC3 Control valve
intermediate pressure
Regulating thermostatic
valve
Plate Heat Exchanger
(intercooler)
3-ways valve
Plate Heat Exchanger
By-pass valve (gas cooler)
Sight glass
Filter drier
Service valve liquid line
Service valve suction line
LT compressor
Parallel compressor
EC1 HP Control valve
Oil separator
HP service valve
Solenoid valve
Pressostat de sécurité
+
Transducteur de pression HP/BP
MT Version
LT Versions
- QUIETCO2OL water cooled :
8
SCOPE OF APPLICATION
Produit
QUIETCO2OL serie
Compressor model
GMCC
Toshiba
QC
50MT
QC
30MT
QC
67MT
QC
100MT
QC
75LT
QC
167LT
Circuit du
fluide
frigorigène
Refrigerant
R744
Oil(Supplier)
Alternative oil
PAG
PZ100S
PAG VG100
PAG100 FUCHS
Evaporating
temperature
-18°C à +5°C
-32°C à -18°C
Suction
superheating
20K or below
Discharge gas
temperature
+120°C or below
Inverter
operation
45–100 tr/s
25–100 tr/s
45–100 tr/s (LT)
25-100 tr/s (MT)
Nominal
Revolution
70 rps
Ambient
Temperature
-15°C* / + 43°C (the ambient temperature can be -30°C if polar
kit heater is installed)
Relative
Humidity
10% – 90%
Allowed fluids
Water, Water-glycol (MPG / MEG – 60% maxi)
Water circuit
(water cooled
version)
Water inlet
temperature
-8°C to 35°C (nominal +7°C / +12°C)
Water mass
flow
Variable (depend on the capacity)
Pressure drop
(water side)
50 kPa or below
On/off cycle period
5 min or longer for on/off cycles
Liquid line temperature standard
receiver pressure settings
55 Bar (19°C)
35 Bar (0°C)
* Depending on the ambient temperature the use of the Polar kit should follow the following recommendations:
Ambient Temperature < -15°C Mandatory
Ambient Temperature < +5°C Recommended
10
DIMENSIONS
QUIETCO2OL MT serie
Air cooled
QUIETCO2OL LT
Serie Air cooled
QUIETCO2OL serie
Water cooled
QC
MT30
QC
MT50
QC
MT67
QC
MT100
QC LT75
QC LT167
QC MT
QC LT
Fig 1
Fig 3
Fig 2
Fig 4
Fig 5
Fig 6
Dimensions
Length
(mm)
1200
1200
1200
1200
1200
1200
Depth
(mm)
360
390
690
811
390
690
Height
(mm)
1028
1430
1028
1638
1028
1028
Weight (kg)
125
130
160
185
185
210
175
250
Fig 1 Fig 2
Fig 3
Fig 4
Fig 5 Fig 6
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.
12
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