APOLON RCWC-04D11 User manual

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 1
OPERATION MANUAL
PROVISION STORE
COMPRESSOR CONDESER UNIT
RCWC-04D11
Fresh/Sea water cooled

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 2

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 3
Hazards and precautions
Caution : Using the warnings and precautions in this manual
Read carefully!!!
Signs used in this manual
The Hazard sign attracts the attention to a certain procedure or practice which, if
not followed, may result to serious damage to people and property.
The Warning sign shows procedures which, if not followed, may result in serious
damage to the machine.
Important notes

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 4
Basic information
About the manual
This manual descri es the correct operation of compressor
condenser unit RCWC-04D11 and the coolers connected to it,
powered with 380V AC 50Hz.
This unit is equipped with a control panel for controlling the
regime, protections of the compressor ased on maximum current,
pressure of refrigerant outside the working area, cooling water flow,
control on the defrosting cycle of the evaporator, control on the fan
evaporator and the temperature in the refrigerated rooms.
This manual shall e read carefully. This is the only way to
ensure the correct operation of the unit.
This manual and its content, as well as any accompanying
documentation, are and will remain property of the manufacturing
company, which reserves all rights thereon. This manual may not e
copied, fully or partially, without a written permission from the
manufacturing company.
Description of the s stem
The compressor condenser unit RCWC-04D11 com ined with
forced air coolers is designed to cool up to two refrigerated room -
with up to +2°C in one of them and up to -18°C in the other.
Two compressor condenser groups have een mounted in the
chassis, where the dimensions of each one have een determined so
that it can supply the two refrigerated rooms. The first group is the
operating ones and the second one is ack-up.
Cooling takes place through evaporation of liquefied refrigerant in
the heat exchanger of the coolers, which are lown y fans. The
liquefied refrigerant (freon) is supplied to the coolers in a separate
copper pipe with  of 10 mm for each cooler. An expansion valve is
located in the cooler, where the agent is throttled, the pressure is
reduced and the heat is a sor ed and entered in the heat exchanger.
The evaporated freon in a gas condition goes to the inlet of the
compressor through a copper isolated pipeline with 22. With its
piston group, the compressor pressurizes the freon and the hot steam
enters the condenser, where it is cooled y the circulating water.

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 5
The condenser is a shell and tu e condenser, with the water
moving through the pipes and the freon cooling within its volume. The
direction of the water movement shall e correct in order to provide
for effective heat exchange.
It is a semi-hermetic piston compressor. The piston group is
directly coupled y the integrated electrical motor. The stator is
cooled y the freon that moves through it.
The compressor condenser unit is also equipped with an oil
separators for each compressor that separate the oil from the hot
steam and return it to the compressor.

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The receiver has integrated liquid separator, where the liquefied
refrigerant is uffered and where the liquid from the gas flowing to
the compressor is separated.
The control panel mounted on the chassis of the unit and
equipped with protective systems and contactors operates the
compressors, fans and defrosting.
System elements
1. Control panel
2. Compressor 1
3. Compressor 2
4. Condenser 2
5. Condenser 1
6. Pressure protection switch compressor 2(Pressostat)
7. Pressure protection switch compressor 1(Pressostat)
8. Gauges 2 LP, HP compressor 2
9. Gauges 1 LP, HP compressor 1
10. Receiver+Suction accumulator
1 2 3
4
5
7
6
9
8
10

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11. Ball valve gas pipe cooler (V11)
12. Ball valve gas pipe freezer (V10)
13. Ball valve gas pipe compressor 2 (V6)
14. Ball valve gas pipe cooler (V11)
15. Ball valve gas pipe freezer (V10)
16. Liquid injection solenoid (EV3 + V7)
17. Liquid cooler all valve+solenoid+sight glass (EV2+V8+SG2)
18. Liquid freezer all valve+solenoid+sight glass (EV1+V9+SG1)
19. Suction rottalock valve
20. Discharge rottalock valve
21. Compressor oil sight glass
11 12 13
14 15 16 17 18
19 20
21

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22. Receiver+Suction accumulator
23. Receiver liquid outlet rottalock valve (VT1)
24. Liquid filter-dryer (F1)
25. Liquid rottalock valve (VK2)
26. Low pressure suction line KP1 (P4, LPS2)
27. Compressor 1 protection pressostat KP17 (P1)
28. Low pressure gauge compressor 1
29. High pressure gauge compressor 1
30. High pressure suction line KP1 (P3, LPS1)
31. Low pressure gauge compressor 2
32. High pressure gauge compressor 2
33. Compressor 2 protection pressostat (P2)
25
2322
24

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 9
Commissioning
The first start-up of the equipment shall e done y an authorized
service center or person. Failure to comply with this rule will
automatically revoke the warranty.
Refer to the schematic diagram if you are unclear on the
refrigerant installation.
Preliminary check
The checks mentioned elow shall e performed efore
commissioning:
• Check the terminals and grounding for tight fitting to the
connecting terminals, as well as the other connections to the
contactors and control terminals. Also check whether the main
switch oard is in an open /off/ position.
• Check whether any voltage of the phases is elow or a ove the
permissi le one and that the im alance does not exceed 7%.
• Connection to the water unit of the condenser.
• Connection of sensors or other external devices to the control
terminals/accident alert, etc./.
• Check the components of the external water main system
(pump, user equipment, filters, supply to cisterns and tanks, if any) for
correct installation ased on the manufacturer's instructions.
• Check the integrity of the hydraulic systems, ensure that the
liquid is availa le with no leaks.
• Check that the pumps rotate in the correct direction and that the
liquid is in circulation for at least 1 hour for each pump. Then clean the
filters at the suction side of the pumps.
•
Regulate the water flow ased on the unit requirements

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 10
First start-up (after continues stop)
1. The power supply of the unit is switched off.
2. All valves are closed and the unit has the necessary quantity of
refrigerant.
3. The compressor condenser group that will e operating is selected.
4. The water valves of the selected condenser open so that cooling
water can pass through it (it is sufficient that it operates only with V1
or V3 stop valves. Valve V2 and V4 are regulated for water flow).
5. The ypass water valve VB1 or VB2 opens (water diagram).
6. The suction valves of the respective compressor VR2 or VR4 close.
The picture elow shows the status of the rotalock valve. First picture
- closed valve, second picture - maximum open valve with closed
service port, third picture - open valve with open service port.
7. The discharge valve of the selected compressor VR1 or VR3 opens
8. Valve V1 or V2, respectively, opens
9. All switch along the front panel of the control panel are switched off
10. The power supply is switched on and all fuses in the panel are
switched on (Power supply pilot lamp light).
11. Wait for the compressor crankcase heaters to warm up. Up to 20 min
after the power supply, the crankcase around the heater will warm
up.
If the compressor has not warmed up sufficiently /minimum warm up time - 2 h/,
do not switch the unit on. Check the good working order of the heater and its
contact diagram.
12. Ensure that the compressor is heated to more than 10 degrees a ove
the am ient temperature y touching it!
13. Visually check whether there is oil in the compressor crankcase oil
glass!

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If no oil level is detected on the sight glass, do not undertake running
of the compressor! Add oil of the same rand or a compati le one.
14. After the compressor is heated, the suction valves of the freezer and
cooler (V10 and V11) open
15. The liquid valves of the cooler and freezer V9 and V8 open
16. The liquid valve of the condenser VK1 or VK2 opens, so that the
service port remains open, it sensing the pressure of the liquid for
the water regulating valve.
17. The switches of the cooler and freezers are turned on
18. The compressor selected via the refrigerant valves is started from the
switch of the control panel
19. The compressor needs to start operating and its amperemeter and
gauges shall e o served. The operating current must e less than
7.5A and the high pressure must e lower than 20 ar.
20. The compressor shall switch off ased on low pressure
21. Valve V5 or V6 opens
22. Valve VR2 or VR4 starts to open slowly. The compressor shall start
working. The valve shall e used to maintain low pressure of 3.0 ..
3.5 ar at the compressor inlet until the full opening of the valve.
In case of warm cham ers, the pressure may e higher. In this case,
only the freezer may e switched on and then add the cooler.

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The compressor shall run and decrease in the cham er temperature
should e o served.
23. After 5-10 min of operation, the valve for liquid injection V7, oil return
valve V3 or V4 must e open.
24. The ypass valve of the water regulating valve must e close and
check the high pressure does not exceed 20 ar.
25. After reaching the set temperature, only liquid with no u les shall
e visi le on the sight glasses of the refrigerators.
If there are u les, refrigerant should e added
Adding oil!
Only if the oil in the compressor is insufficient and system is
charged with refrigerant.
a) Switch off the power supply from the main power switch.
) The suction valve of V5 or V6 closes
c) Switch off the operation switch of the Compressor On/Off,
freezer On/Off and cooler On/Off, and supply power from the
main power switch.
d) Run the compressor at short intervals through the Test utton
until the low pressure reaches 0.2-0.4 ars. (if pressure ecomes
lower than 0.0 ar, open the suction valve V5 or V6 slightly, until
the pressure is increased to over 0.0 ar.)
e) In case of positive pressure (0.2-0.4 ars), connect the service
hose to the low pressure service port located on the low
pressure valve VR2 or VR4 and close the valve with 1 turn.
Ensure that gas is released from the other end of hose.
f) Insert the hose in the container with oil you will add. There
should e u les.
g) By pressing the test utton for a short time, make the low
pressure negative - vacuum (-0.5 ars). Vacuum sucks oil to the
compressor.
h) Wait until the oil reaches the desired level (2/3) of the sight
glass.
i) When reaching the level, unwind the rod of the compressor
valve VR2 or VR4 until the port is fully open and the service port
is closed
j) Disconnect the hose from the service port and put the protective
cap
k) Open valve V5 or V6 and start compressor
l)

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 13
Adding refrigerant!
If the refrigerant quantity is insufficient, refrigerant should e
added.
In normal operating conditions and tempered cham ers, the low
pressure should e around 1.0-2.5 ars and the high pressure
should not exceed 21 ars.
Insufficient refrigerant is esta lished y checking the sight
glasses of the liquid for u les .
If you are not sure a out presence of liquid in the glasses, you
can stop the cham er while the compressor is operating and see
whether there are u les on the sight glass.
a) Connect the service hose to the liquid port of refrigerant
ottle and the low pressure service port (SP1) of the KV1 valve at
the valves panel.
Sp1

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 14
) The hose connected to the cylinder will ecome slightly loose
a out 5 sec /the sound of gas release is heard/, the hose is tightened
and the valve is closed.
c) When the compressor is operating, open the cylinder liquid
valve — start charging. The cylinder should e positions so that liquid is
released from its valve.
During charging with liquid, there is a hazard of a hydraulic
shock, therefore the compressor must e operating and the
refrigerant must e added efore the liquid separator.
d) During charging, the presence of u les at the glasses of
the liquid, the high pressure and the compressor current should e
monitored.
e) Charge till sight glasses are full with liquid.
f) After finishing with the charging, close the cylinder valve and
disconnect hose.
Charging the system with refrigerant and
oil!
If the system is completely empty of refrigerant and/or oil.
The system must e charged with oil and/or refrigerant in case of an
accident or commissioning of the system.
Pre-check the system for nitrogen leaks.
a) Power supply must e stoped.
) Open all valves of the system and connect the service gauges
to service ports SP3 of valve V10 and service port SP5 of valve V9.
c) The solenoid valves shall e forced open (with a magnet or y
using electricity).
d) A vacuum pump is connected to the middle port of the
gauges, their valves are opened and the vacuuming is switched on.
e) The system should e vacuumed for at least 8 hours.
f) If it is necessary to add oil, connect a service hose to the
service port of the compressor VR2 or VR4 and su merge the other
end in the oil container. The vacuum in the system sucks the oil from
the container to the compressor. Disconnect the service hose from
the compressor after reaching the desired level. Leave to vacuum for
at least 1 more hour.
g) After you have vacuumed, start adding the refrigerant.
h) Close the valves of the service gauges

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i) Close solenoid valves
j) Connect the refrigerant cylinder at the place of vacuum pump.
k) Open the cylinder valve and position the cylinder so that it
works with liquid.
l) Open the high pressure valve of the service gauges and pour
liquid to the unit through service port SP5 (or SP4).
f you charge a unit that has stopped, you must pour the refrigerant in
the receiver and the unit liquid pipe. Ensure that no liquid enters the
compressor during charging.
m) The quantity of refrigerant is indicated on the plate of the unit.
If necessary, add refrigerant in operating condition.
n) Start unit
Changing the filter dehydrator
Changing the filter dehydrator is necessary in case of system
depressurization, repairs on the compressors or if the filter
permea ility is reduced.
When the system is operating and the filter dehydrator is
clogged, the liquid pipe after the filter is cooled. The difference
etween the temperature at the filter inlet and outlet shall not exceed
2K.
The method for changing the filter dehydrator when the system
is operating is descri ed elow
a) Close the outlet of the receiver valve VT1.
) Wait until the operating compressor is switched off.
c) By using the utton test, suction the low pressure to 0.2 ars.
Repeat several times until the pressure is kept at 0.2 ars.
d) Close the liquid line valves V7, V8 and V9
e) Unwind the filter from the pipes and from the stand and
replace with a new one. This procedure shall e performed rapidly in
order to prevent entry of air into the system. Install filter in right
direction.
f) Valves VT1, V7, V8, V9 open and the system is started.

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 16
Pump down
If the system is not operating for a long time, it is recommended to
collect the refrigerant in the system receiver.
a) Close VT1
) Start system (freezer, cooler and compressor on)
c) Wait until the compressor is switched off. It may e
necessary to wait for more than one switch off of the compressor
until the pressure is esta lished.
d) Valves V7, V8, V9, V10, V11 close.
Starting after pump down. Valves V7, V8, V10, V11 are opened and
the unit and cham ers are switched on.
If the power supply has een off for more than 6 hours, you need to
wait for the compressor crankcases to warm up /min. 2 h/.
Changing the compressors
a) Switch off the cham ers.
) If the operating compressor is upright, wait until it stops and
switch it off from the key
c) If you want to stop compressor 1, close valves VK1 and V5,
or, respectively, valves VK2 and V6 for compressor 2.
d) Close the water valve of the condenser you want to stop V1
or V2 (water diagram)
e) If compressor 1 will e switched on, open valves VK1 and V5.
For compressor 2, open VK2 and V6
f) Open the water valve of the respective condenser V1 or V3
(water diagram)
g) Start the selected compressor from the switch
h) Start cham ers

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 17
Control panel of RCWC-04D11
1. Ampermetre compressor 1
2. PL/pilot ligt/ Liquid injection
3. Ampermetre compressor 2l
4. PL power supply
5. Freezer controller XR70
6. Cooler controller XR70
7. PL compressor 1 run
8. Switch Off/On compressor 1
9. PL Compressor 2 run
10. Switch Off/On compressor 2
11. PL freezer cooling
12. Switch freezer Off/On
13. PL cooler cooling
14. Switch Off/On cooler
15. PL Compressor 1 high pressure alarm
16. PL Compressor 1 overload alarm
17. PL Compressor 2 high pressure alarm
18. PL Compressor 2 overload alarm
19. PL defrost freezer
20. Button manual defrost freezer
21. PL defrost cooler
22. Button manual defrost cooler
23. PL Compressor 1 low pressure alarm
24. PL Compressor 1 high temperature
25. PL Compressor 2 low pressure alarm
26. PL Compressor 2 high temperature
27. PL freezer evaporator fan running
28. PL cooler evaporator fan running
29. PL condenser 1 cooling water no flow
30. Button test compressor 1
31. PL condenser 2 cooling water no flow
32. Button test compressor 2
33. PL freezer fan motor overload alarm
34. PL cooler fan motor overload alarm
35. Compressor 1 run hours
36. Compressor 2 run hours

Operation manual RCWC-04D11 OM-RCWC-04D11 2014 18
Alarms
Compressor high pressure
The pressure of the operating compressor is two high, the pressure
protection switch compressor is triggered
• Lack of cooling, clogged condenser, high temperature of the
cooling water
• The unit is overfilled with refrigerant
o Manual reset (unmount the cap of the pressure
protection switch compressor, green reset utton)
Compressor low pressure
The pressure of the operating compressor is too low, the pressure
protection switch compressor is triggered
• Insufficient refrigerant
• Clogged filter dehydrator
• Lack of lowing of the evaporator
o Automatic reset - pressure protection switch
compressor
Compressor high temperature
The temperature of the operating compressor engine is high
• Clogged filter
• Insufficient refrigerant
• Damaged high temperature module (located in the
compressor electrical ox)
• Damaged refrigerant injection system
• Damaged TEX valves of the evaporators
Automatic reset - after power interruption
Compressor overload
The working current of the operating compressor is high
• High pressure
• Unsuita le power supply
• Damaged compressor
o Manual reset - motor protection
Cooling water no flow
Lack of water flow through the operating condenser
• The water pump is not working
• Damaged water regulation valve
• Closed valves

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• Damaged sensor for detecting the differential difference of
water through the condenser
Automatic reset — Delta pressure switch
Fan motor overload
High current of the evaporator fans
• Unsuita le power supply
• Blocked fan /propeller/
• Damaged motor of the fan
Manual reset — Motor protection
Compressor cooling system
The compressor cooling is performed y injection of liquefied
refrigerant into the suction collector of the compressors. See diagram
of refrigerating system EV3, V7.
The EV3 solenoid is operated y a controller in electrical oard
IN1, which monitors the temperature of the heads of the two
compressors with sensors Dt1 and Dt2, type Pt1000.
The IN1 controller has pulse with modulation outlet that operates
the EV3 valve. When the head temperature reaches 100 degrees,
liquid is injected.
Within the range etween 100°C and 110°C, the length of the
injection impulse changes from 1 sec to 10 sec with period of 10 sec.
Example: in case of 103°C, there is 3 sec. of liquid injection and 7
sec. pause.
ettings of the operating mode of the
refrigerating chambers
The operating mode of the refrigerating cham ers is regulated y
the XR70 controllers for each cham er.
The cham ers are switched on from the Off/On switch.
The defrost cycle is controlled from XR70 and can e forced from
Manual defrost /at the control panel/, which will end automatically.