Green&Cool Mistral Installation and operation manual

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Operating & Maintenance Instructions
Models: Mistral, Mistral CLU & CDU, Crystal, Crystal CLU & CDU, Sirocco, Sirocco CLU & CDU

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The machine identification plate is located at the front of the control cabinet.
Use the machine ID when corresponding with the manufacturer and service
provider.
This product meets the basic requirements of EU directives regarding health,
safety and the environment and is approved for sale within the EEA without further requirements.

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Figure 1: Note that the unit is delivered with a protective charge.
Figure 2: Note the warning!

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Table of Contents
1Introduction..................................................................................................................................................... 6
1.1 Important information............................................................................................................................ 6
1.2 Carbon dioxide ...................................................................................................................................... 7
2Delivery........................................................................................................................................................... 8
3Damaged goods............................................................................................................................................... 8
3.1 Missing goods........................................................................................................................................ 8
3.2 Claim settlement.................................................................................................................................... 8
3.3 Storage................................................................................................................................................... 9
4Safety ............................................................................................................................................................ 10
4.1 Handling.............................................................................................................................................. 11
4.2 Dimensions and weights...................................................................................................................... 12
5Installation..................................................................................................................................................... 13
5.1 Location............................................................................................................................................... 13
5.2 Connecting wiring & piping................................................................................................................ 14
5.2.1 Units connected to fluid systems..................................................................................................... 15
5.2.2 Pipe system ..................................................................................................................................... 15
5.3 Installing rupture discs and pressure relief valves ............................................................................... 17
5.3.1 Rupture disc .................................................................................................................................... 19
5.4 Commissioning.................................................................................................................................... 20
5.4.1 Pre start inspection.......................................................................................................................... 20
5.4.2 Maintenance instructions................................................................................................................. 20
5.4.3 Pressure testing................................................................................................................................ 21
5.4.4 Dehydrating circuits........................................................................................................................ 21
5.4.5 Oils.................................................................................................................................................. 21
5.4.6 Fan control ...................................................................................................................................... 22
5.4.7 Presetting control systems............................................................................................................... 22
5.4.8 Start-Up........................................................................................................................................... 22
5.5 Filling with oil & refrigerant ............................................................................................................... 22
5.5.1 Evacuation and filling oil................................................................................................................ 22
5.5.2 Filling refrigerant ............................................................................................................................ 23
5.6 Follow-up inspection........................................................................................................................... 24
5.6.1 Checks immediately after start-up................................................................................................... 24
5.6.2 Actions after start-up....................................................................................................................... 25
5.6.3 First service checks: 500 hours ....................................................................................................... 25
6System description, CO2refrigeration plant and components....................................................................... 26
7Green Co2ntrol control system...................................................................................................................... 27
8Shutdown ...................................................................................................................................................... 27
8.1 Preparations for shutdown................................................................................................................... 28
8.2 Restart.................................................................................................................................................. 28
9Basic maintenance of CO2 plant.................................................................................................................... 29

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9.1 Regular checks..................................................................................................................................... 29
9.2 Cleaning............................................................................................................................................... 29
9.3 Scheduled plant maintenance .............................................................................................................. 30
9.4 Spare parts ........................................................................................................................................... 30
9.5 Maintenance checks............................................................................................................................. 30
9.6 Checking the oil level.......................................................................................................................... 31
9.7 Checking compressor oil pressure....................................................................................................... 31
9.8 Replacing filter dryers (DH)................................................................................................................ 32
9.9 Oil separator ........................................................................................................................................ 32
9.10 Replacing oil separator filters (OS)..................................................................................................... 33
10 Troubleshooting....................................................................................................................................... 34
Appendix 1a.......................................................................................................................................................... 36

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1Introduction
Thank you for choosing a Green & Cool product. We hope that it will meet your
expectations for a long time to come.
The CO2used in the installations occurs as a by-product in the production of
industrial gases. This means that the refrigerant used in the unit has no
additional environment impact.
1.1 Important information
This manual contains descriptions of procedures such as installation, operation
and maintenance. It is important to read it carefully before installing the
refrigeration unit. Therefore, keep the instructions in a safe place throughout the
service life of the unit. Contact Green & Cool for additional copies.
In order for supplier liability for defects to apply, the enclosed installation and
commissioning instructions must be strictly adhered to and a commissioning
protocol submitted to the supplier immediately after commissioning, together
with parameter lists and design documentation for expansion valve nozzle
dimensions. Regular scheduled service items must also be completed. This is to
ensure as far as possible that the plant is not subjected to operating conditions
outside its normal operating range or design requirements based on the tender
enquiry documentation. Examples of such conditions are hydraulic shock, oil
pressures, oil temperatures, evaporation temperatures and condensation
temperatures that are outside the operational range of the plant.
The symbol indicates information that must be followed to avoid
serious injury or property damage.
The symbol means that the paragraph contains information that merits
careful consideration.
Green & Cool disclaims any liability for damage or injury arising from incorrect
handling of the equipment supplied.

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1.2 Carbon dioxide
CO2is an extremely efficient refrigerant which EN378-1 regards as having low
toxicity and is non flammable. It is regarded as a ‘safe’ refrigerant and belongs
to the group A1/L1.
However CO2is toxic at high concentrations and since it is odourless and
colourless the use of a suitable detector is necessary when working in confined
or unventilated areas. The concentration of CO2in the lungs controls breathing
and high concentrations can lead to unconsciousness and even death.
370ppm (0.037%)
normal concentration in the atmosphere
5000ppm (0.5%)
recommended level for upper limit on CO2 detector
20,000ppm (2%)
short exposure will not entail problems
30,000ppm (3%)
discomfort, breathing difficulties, increased heart rate,
headaches, dizziness
100,000ppm (10%)
unconsciousness and death
Since CO2 can only exist in the solid and vapour phase at atmospheric pressure
(dry ice) at a temperature of -79.9C; sublimation temperature; care must be
taken to avoid cold burns by contact with the ice or vapour. Additional care
should be taken when handling liquid CO2especially when charging or
removing refrigerant from the system where suitable gloves and eye protection
should be worn.
NOTE: Carbon dioxide is heavier than air and tends to settle at floor level.
Ensure good ventilation in the plant room. The plant room must also be
equipped with CO2alarms, and personal detectors should also be worn.

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2Delivery
The equipment is inspected before it leaves the factory. The consignee is
responsible for checking that all equipment items ordered have been delivered,
that they are undamaged and match what was ordered.
Check the condition of the goods and packaging on taking delivery.
Cross-check quantities to make sure they correspond with the details on the
waybill.
Take care of the manuals and CE document delivered with the goods. This is
especially important in respect of refrigeration unit auxiliary equipment such
as evaporators and gas coolers.
3Damaged goods
Procedures for damaged goods conform to local regulations. The example below
applies to Sweden.
Take delivery of the goods but never sign the waybill without first making a
note in the consignee’s signature box. If possible take a photograph of the
damage and submit it together with the claim; also try to limit the damage as far
as possible.
If the damage was not discovered until unpacking (damage hidden by
packaging) it must be reported to the shipper within seven (7) working days of
receipt for the claim to be processed. Damaged goods may not be returned, sold
or repaired without first contacting the shipper’s claims department.
3.1 Missing goods
Make a note on the waybill before signing for delivery. Contact the shipper. If
the missing goods are not correctly delivered within 30 days (60 days outside
Sweden) they are considered lost (local regulations).
3.2 Claim settlement
The customer is responsible for preparing the claim and providing evidence of
the amount concerned, which usually entails producing the following
documentation:
Notification of damage (loss)

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Waybill or packing list
Commercial invoice between the seller and purchaser, or other
documentation that verifies the value of the goods.
Repair invoice, or an invoice for a replacement delivery or spare part.
Any other documentation, such as photographs, considered important for the
correct settlement of the damage or loss.
3.3 Storage
If the unit will be stored before installation it must be protected from moisture in
max/min temperature conditions of +50°C to –30°C.

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4Safety
Note that for protection the plant is factory filled with nitrogen at 5 bar: handle
valves and pipe fittings with care.
This plant conforms with applicable health and safety legislation.
It is important that the equipment be installed and commissioned by qualified
personnel in compliance with EN 378, EN 14276, EN 13136, EN 13313, EN
60204 and EN 60335 standards where applicable, EU directives, generally
recognized safety regulations, best technical practice, local ordinances including
such ordinances as may be introduced due to advances in technology and
attendant changes to regulations. The following must be complied with for the
plant to function in a safe manner:
Do not carry out repairs or maintenance unless you are classified by your
employer as being competent to work on CO2refrigeration systems and
have received suitable training.
Pay careful attention to instructions, decals and notices.
Never weld or solder pressurized components without fully emptying the
system.
Be aware of rotating fans in plant with integrated gas coolers or forced-
draught oil coolers; never operate the equipment without all the fan
guards installed.
Make sure no cables or other electrical components are damaged during
repairs and maintenance.
Operate manual valves with care to prevent pressure surges in the system.
Always switch off at the main switch before performing any repairs or
maintenance.
Pressure vessels are fitted with rupture discs and/or pressure relief valves.
If a rupture disc bursts it is important to ascertain the cause. It is also
extremely important that the burst disc be replaced with a new one
designed for the same pressure and temperature ranges; affix the rupture
disc data plate to the rupture disc holder to prevent any confusion.
Make sure new components have the same specifications as those
replaced during service and maintenance work.
Ensure all tools and fittings such as gauges, manifolds, flexible hoses,
bottle connectors, charging devices etc have the correct pressure rating for
the high pressure associated with CO2.