Green&Cool CO2Y 50MT User manual

CCU-CO2Y
Outdoor Type Refrigeration Unit
(Non-fluorocarbon Refrigeration Unit
with CO2 Refrigerant)
– Installation
– Commissioning
– Operating
– Maintenance
Operation
Instructions

Thank you very much for purchasing Green & Cool
products.
Please read this instruction booklet and correctly comply
with the explanations.
In particular, please read “General start up instructions”
(page 4) and "Cautions for safety" (page 5) for ensuring
safe operations.
Please retain this instruction booklet in a safe place.
Registration of your product 3
General start up instructions 4
Cautions for safety 5-7
Components 8
Scope of application 9
Dimensions 10
Handling of the unit 11
Selection of installation location 12-13
Refrigerant piping work 14-15
Refrigerant circuit diagram 16
Electrical connections 17
Control connections 18
Description of the display 19-31
Maintenance 32-34
Warranty 35-36
Table of content
2

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Registration of your CO2Y
Text som beskriver
förfarandet saknas

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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 pages 26-27.
Refrigerant Charging
– Calculate the refrigerant charge prior to charging, the system design allows to
a maximum of 3,8L of refrigerant.
– Execute refrigerant charging immediately after evacuation.
– Charge refrigerant R744 (CO2 refrigerant).
– Do not mix with other refrigerant.
– Always use refrigerant grade CO2, moisture content must be below 10 ppm.
Method of Charging
– Close the vacuum valve of the manifold gauge set exclusively for CO2
refrigerant, and separate the vacuum pump.
– To prevent dry ice formation, systems should first be charged with R744
(CO2) vapor to a pressure above the triple point of 4,16 bar.
– Open the joint valve attached to the service piping and Liquid line service
port, and charge liquid state refrigerant.
– Note: Do absolutely not charge liquid refrigerant from the low
pressure side (low pressure service port).
– Avoid overcharging, maximum charging is 3,8 kg
– When the liquid refrigerant no longer goes into the refrigeration unit, close the
liquid line service port and start the refrigeration unit in cooling operation to
adjust refrigerant quantity by charging gas in to the suction line service port.
– After completing refrigerant quantity adjustment, close the refrigerant cylinder
valve and check that the low pressure and high pressure service ports have
been closed.
General startup instructions

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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.
Cautions for safety

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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 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 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 D equipment are made with different types :
in copper, standard NF EN 12735
in steel, standard NF EN 10216-2 (type P265GH ; n° 1.0425)
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.
Cautions for safety

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– 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 falling 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.
Cautions for safety

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Components
Electrical
compartme
nt
EC1 high
pressure
control valve
EC3 intermediate
pressure control
valve
LP/HP
pressure
transducers
HP safety
switch
Compressor
Suction line service
valveLiquid line service
valve
Sight
glass Filter
Drier Liquid line shut off
valve
Gas
cooler
Fan motor

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Scope of application
Product
CO2Y Series
GMCC Toshiba
CO2Y
50MT
CO2Y
30MT
CO2Y
67MT
CO2Y
100MT
CO2Y
75LT
CO2Y
167LT
Refrigerant
system
Refrigerant R744
Oil type PAG
PZ100S PAG oil VG100
Evaporating
temperature -20°C to +5°C -32°C to -20°C
Suction
superheating 20K or below
Discharge gas
temperature +120°C or below
Inverter operation 40–100
RPS 25–90 RPS
Nominal Revolution 70 RPS
Ambient
Temperature -15°C–42°C (the ambient temperature can be -30°C if EC fan is installed)
Relative Humidity 10%–90%
Optional:
Water system
(applicable for
liquid-cooled
condenser)
Inlet liquid
temperature -8°C to 38°C (nominal +7°C / +12°C
Liquid mass flow Variable according to capacity.
Pressure loss in the
liquid side for the
BPHX
30 kPa or below
Vibration Velocity 20 mm/s and below
On/off cycle period 5 min or longer for on/off cycles

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Dimensions
CO2Y MT series air cooled CO2Y LT series air cooled
CO2Y 30MT CO2Y
50MT
CO2Y
67MT
CO2Y
100MT CO2Y 75LT CO2Y 167LT
Fig 1 Fig 2 Fig 3 Fig 4
Dimension
s
Length (mm) 1190 1190 1190* 1190* 1190 1190*
Width (mm)
390 390 390 390 790 790
Height (mm)
1028 1028 1028 1500* 1028 1500*
Weight (kg)
125* 130 160* 185* 185* 210*
Fig 1 Fig 2
Fig 3 Fig 4
*prel.

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Handling of the unit
- 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.
Carry-in Operation

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Selection of installation location
The CO2Y is
intended for
outdoor
installation
500 mm
500 mm
1200 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 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.
250 mm

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Selection of installation location
NO air from a second unit shall be
directed towards the gas cooler of
another one!
2000 mm
In the case of face-to-face
installation, keep a minimum of
2000mm distance between the
units.

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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).
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.
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 piping work
Selection of refrigerant piping can be done by using the Green & Cool pipe
selection tool. (http://www.greenandcool.com)
PRODUCT Suction line Liquid line
MT30 9,52 mm (3/8”) 9,52 mm (3/8”)
MT50 9,52 mm (3/8”) 9,52 mm (3/8”)
MT67 12,7 mm (1/2”) 9,52 mm (3/8”)

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Refrigerant piping work
Evaporator higher than unit.
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
97/23/EC
and EN12735-1.
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 pipings, 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
unfavourable effects from the environment.
P-trap
Reverse-trap
Suction line
Evaporator lower than unit.
P-trap
5 m max
height
difference
Suction line

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– 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.
Commissioning

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– 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 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.
Operating

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Refrigerant circuit diagram
Compressor Gas cooler
EC1 High pressure valve
Filter drier
Sight glass
Receiver
EC3 Intermediate pressure
valve
HP safety switch
Non return valve
Condensing unit
Installer

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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.
Electrical connections
CO2Y MT series air cooled CO2Y LT series air cooled
CO2Y 30MT CO2Y 50MT CO2Y
67MT CO2Y 100MT CO2Y 75LT CO2Y 167LT
Power
supply 230V/Single phase/50HZ 400V/3ph/50 HZ
230V/Single
phase/50HZ
400V/3ph/50
HZ
Fuse 16A+N+G 16A+N+G 16A+N+G 3 x 10A+N+G 16A+N+G 3 x 16A+N+G
– The machine is designed in accordance with EN60204-1.
– 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 EN60204-1.
General information
Caution

EC3 J17
Suction line
temp
Outside temp
EC1 J21
230V
Gas cooler
out temp
Suction
pressure
Disch temp
Gas cooler
pressure
Receiver
pressure
Please refer to the electrical wiring diagram supplied with the CO2Y for more detailed
information.
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Control connections