Panasonic OCU-CR1001VF User manual

Table of Contents
Cautions for Safety 2-6
Name of Each Part and Optional Accessories 7
Scope of Application 8
For Effectively Using the Refrigeration Unit 9-10
Selection of Installation Location 11
Carry-in/Installation 13
Installation Example 14
Refrigerant Piping Work 15-16
Piping Example 17
Refrigerant Circuit Diagram 18
Refrigerant Charging 19
Cautions for Electrical Wiring Work 20
Electrical Wiring Work 21
Electrical Circuit Diagram 22-23
What Needs to be Checked before Operation 24
Setting and Indication of the Control PCB 25-29
Control Functions 30-32
Adjustment during Operation 33-34
Oil Level Control Method 35-36
About Alarms 37-38
Maintenance and Inspection 39
Actions at the time of Failure 40-41
Failure Diagnosis 42-49
Warranty Condition of the Refrigeration Unit 50-51
Installation Instructions
Outdoor Type Refrigeration Unit
(Non-fluorocarbon Refrigeraton Unit with
CO2Refrigerant)
Model No.
OCU-CR1001VF
Thank you very much for purchasing
Panasonic products this time.
Please read this instruction booklet
and correctly comply with the
explanations.
In particular, please read "Cautions for
Safety" (Pages 2 to 6) for ensuring
safe operations.
Please retain this instruction booklet in
a safe place.
Caution labels are attached to the product.
This illustration represents OCU-CR1001VF

2
Cautions for Safety
For the purpose of avoiding harm to people and damage to properties, items to be complied with are
explained here.
Explanations are classified by degree of harm or damage caused by incorrect use.
Warning Indicates possibility of death or serious injury.
Caution Indicates possibility of minor injury or damage to properties.
Items to be observed are explained by the following pictograms.
Indicates what you should not do.
Indicates what you must do.
Warning
Installation Work
Request a specialty operator to perform
installation by conforming to the installation
instructions.
Incorrect installation work may lead to
malfunction such as abnormal vibration,
and generates refrigerant gas leak,
electrical shock, or fire.
Do not use other than the designated refrigerant
(for charging, adding or recharging)
Non-designated refrigerant may cause
equipment failure or burst, or injury.
Securely complete refrigerant piping before
carrying out airtight testing.
Refrigerant gas leak may cause
suffocation.
Installation should be made securely on a place
that can fully support the mass of the refrigeration
unit.
Insufficient foundation may cause falling or
dropping, and lead to refrigerant gas leak,
injury, electrical shock, or fire,
zRefrigeration unit should be secured on
a concrete base with a mass
approximately 3 times that of the unit
and fastened with anchor bolts.
Install the safety cover.
Touching the refrigeration unit by hand of
the people other than the designated
operators may cause injury.
zInstall a safety cover or protective fence.
Perform airtight test before charging refrigerant.
Refrigerant gas leak may cause insufficient
oxygen and lead to a death accident.
zCarry out airtight test and confirm no
leak of refrigerant.
Piping, equipment components and tools should
be exclusively for R744 (CO2refrigerant).
Use of components for HFC refrigerant
cay cause serious accidents such as
equipment failure and rupture of the
refrigerant cycle.
Be sure to comply with the following

3
Cautions for Safety
Electrical Work
Always use a dedicated circuit and install a ground
fault interrupter.
Incorrect electrical work may lead to
current leak and fire or electrical shock.
zWiring work should conform to the
installation instructions.
Grounding Work
Lack of grounding work may lead to
electrical shock caused by current leak.
zSecurely carry out grounding work by
qualified technicians.
Securely place the cover on the electrical box and
enclosure panel.
Incomplete attachment may lead to
penetration of water and living creatures,
thereby causing current leak and
fire/electrical shock.
zConfirm that covers are securely
installed.
Electrical wiring should use the specified cable
and to be properly secured.
When the specified cable is not used, or
connection or securing is incomplete,
electrical resistance becomes larger and
may cause abnormal heating or fire.
zUse the specified cable and properly
secure it on an appropriate location.
Cautions for Use
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.
zDo not change the set values of the
safety device. If they are changed
unintentionally, shut off the power switch
and ground fault interrupter and consult
with the distributor.
Do not insert a finger, stick or foreign object into
the ventilation opening and fan guard of the
enclosure panel.
Such object may hit the fast rotating fan
and result in injury.
When water or other material gets into the
electrical box, turn off the power switch and shut
off the ground fault interrupter.
Continued use may cause short-circuit,
leading to fire or electrical shock.
zDo not splash water on electrical
components or wash them with water.
When the ground fault interrupter activates, report
to the specialty company.
Forced recovery of power may cause
current leak, leading to fire or electrical
shock.
For the purpose of controlling concentration of
refrigerant gas, install a leak detector and
mechanical ventilation equipment in the
refrigerant-handling facility (inside the room).
Refrigerant gas leak may cause suffocation.
Be sure to comply with the following

Cautions for Safety
Repairs
Disassembly or repairs should be performed by
a specialty operator.
Incorrect disassembly or repair may lead to
abnormal operation and causes injury, fire
or electrical shock.
zRequest a specialty operator to perform
disassembly or repair work.
Do not absolutely perform modification.
When abnormal operation was detected, or before
starting disassembly or repair, turn off the power
switch and shut off the ground fault interrupter.
Continued operation with abnormal
condition, or disassembly/repair without
shutting off the power would lead to current
leak or short-circuit and may cause fire or
electrical shock.
Stop the compressor before disconnecting the
refrigerant piping.
Disconnecting the piping while the
compressor is in operation would cause
abnormally high pressure with air intake,
and may lead to a burst or injury.
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.
zConsult with the distributor.
Moving or Change of Installation Location
Request a specialty operator for moving or
changing the location.
Incorrect installation or moving work may
lead to malfunction such as abnormal
vibration, and generates refrigerant gas
leak, electrical shock, or fire.
4
Use the piping, equipment components and tools
specifically designed for R744 (CO2refrigerant).
Using other materials for HFC refrigerant
may cause equipment failure and serious
accident such as rapture of the refrigeration
cycle components.
Be sure to comply with the following

5
Cautions for Safety
Caution
Installation Work
Do not install in a place with possible leak of
flammable gas.
Leaked flammable gas around the
refrigeration unit may catch fire from a
spark of a switch and lead to fire.
Produce a refrigeration cycle within the limits of
an operation standard (refer to “Scope of
Application”).
Non-standard refrigeration cycle may
generate abnormal high pressure and
abnormal heat generation, thereby causing
burst, smoke generation, fire and current
leak.
Apply heat insulation on the suction line and liquid
line.
Lack of heat insulation generates water
from condensation and mold and moss,
thus causing slipping on the floor.
Apply a drain work according to the need.
Without consideration of drain water
processing, moisture from rainwater and
defrosted water generates mold and moss,
and may cause slipping on the floor.
Request a specialty operator for moving
the refrigeration unit.
Incorrect moving may cause falling or
dropping of the refrigeration unit, and
cause injury.
zRefrigeration unit is a heavy item.
Always consult with a specialty operator.
Install in a place without air stagnation.
Leak of refrigerant gas may cause
insufficient oxygen and harm human health.
zInstall in a place with good ventilation.
Electrical Work
Always install a ground fault interrupter with the
specified capacity.
Incorrect capacity does not operate safety
stop function and may lead to fire or
electrical shock.
Do not include electrical wiring in the heat
insulation material.
Condensation of piping may cause current
leak and fire caused by overheating.
Be sure to comply with the following

6
Cautions for Safety
Cautions for Use
When the refrigerant bursts out, shut off the power
and fully close the service valve.
Blowout of refrigerant from the refrigeration
cycle by opening the service valve would
cause insufficient oxygen and harm human
health.
Do not use flammable spray near the refrigeration
unit. Do not place flammable materials nearby.
Flammable material may catch fire from
switch spark.
Before any inspection service, turn off the power
switch and shut down the ground fault interrupter.
Inspection work with power on may lead to
electrical shock, interference with the
moving mechanism, and heat generation,
thereby leading to injury and skin burn.
Do not touch electrical components by a wet hand.
Switching operation by a wet hand may
cause electrical shock and injury.
Periodically check operation of the ground fault
interrupter.
Failed interrupter does not operate safety
stop function and may lead to fire or
electrical shock.
When removing the fin guard of the gas cooler, do
not touch the fin.
Touching the fin and sliding along the fin
may cause skin cut by the fin edge.
Do not ride on the refrigeration unit.
Riding on the refrigeration unit or placing
an article on it may lead to falling or
dropping by vibration and cause injury.
Periodically check the installed base.
Damaged base after a long-time use may
cause the refrigeration unit to fall or drop
and lead to injury.
Request a specialty operator for disposing the
refrigeration unit.
Disposal with the refrigerant and oil inside
the refrigeration unit may cause fire or
explosion.
Do not operate with the service valves of each stage
around the compressor kept closed.
Operating the compressor with the
discharge service valve of each stage
closed, would generate abnormally high
pressure and may lead to rapture.
Disposal
Be sure to comply with the following

7
Name of Each Part and Optional Accessories
Name of Each Part
Optional Accessories
Note: The filter dryer (one is shipped with each refrigeration unit) is a standard component. When replacing the filter
dryer, use the same filter dryer (Model No. D-155T) shown above as the standard component.
Component Layout in the Electrical Box
Front of
refrigeration unit
Left side of
refrigeration unit
Left section of left side
of refrigeration unit
Name Model No. Applicable refrigeration unit Remarks
Suction filter S-008T
OCU-CR1001VF
Prevention of dust penetration
Filter Dryer D-155T
(Type: CO-085-S)
φ15.88
(Outer diameter welding)
Fin guard for gas cooler SPK-GA4014 Guard made from wire
Power terminal block
High voltage danger
indication light
INV-F PCB
Diode
Heatsink temperature sensor
Control terminal block
INV-M
PCB
Reactor FC3-
PCB
INV-H PCB CR2A-PCB
Operation
switch
From left 1X1, 1X2, 1X3
FM1
(Box back side)
From top F1, F2
F7
Compressor
Oil level switch
Oil separator
Low pressure
sensor
Electrical box
Low pressure
service valve
High pressure
service valve
Oil service valve
Ambient
temperature
sensor
Flash chamber
Intermediate
pressure sensor
Unit outlet
pressure sensor
Electronic expansion valve
for liquid return (MOV7)
High pressure
sensor
Electronic expansion
valve for pressure
reduction
(MOV5)
Balance pressure
solenoid valve
(EV2)
Electronic expansion
Valve for gas return
(MOV6)
Front of refrigeration unit Back of refrigeration unit

8
Scope of Application
This refrigeration unit operates with a rotary compressor.
Use the refrigeration unit within the range shown below.
Note ※: Operation may not be possible depending on the installed condition.
Counter measures in a cold weather operation
In order to prevent excessive reduction of high pressure in a cold weather location, surrounding around the refrigeration
unit should be made.
Item Standard Value Remarks
Refrigerant R744 The charge supply amount shall be adequate.
Evaporating temperature -45°Cto-5°CTemperature conversion of inlet pressure
Suction pressure 0.73MPa to 2.95MPa Unit inlet pressure
Inverter operation ※30 s-1 to 60 s-1 
Suction gas temperature 18°C or below Unit inlet (suction gas) pipe temperature
Superheat at suction 10 K or above Difference between evaporating temperature
and compressor inlet temperature
Discharge pressure 9.1MPa or below
(except transient) Compressor outlet pressure
Discharge gas temperature 97°C or below Compressor outlet temperature
Oil temperature 100°C or below
(Ambient temperature +10 K or above) 
Ambient temperature -15°Cto+43°CGas cooler intake air temperature
Applied electricity 3 phase 200 V ± 20 V Power source terminal voltage
on Refrigeration unit
Unbalance of phase voltage 2% or below 
Installation inclination angle 1° or below 
ON/OFF cycle period 10 minutes or longer
for ON/OFF cycle Oil return shall be ensured.
Installation Outdoor The foundation shall be rigid enough.

9
Cautions for Installation Work
This refrigeration unit has been designed exclusively for R744 (CO2refrigerant).
Refrigeration oil and each component including the compressor have been exclusively designed for
the refrigeration unit.
Please use sufficient caution for maintaining the reliability of the product.
(1) Since CO2refrigeration cycle becomes high pressure during operation, use the piping material and other components
particularly designed for CO2refrigerant with sufficient strength.
(2) As the refrigeration oil has high moisture absorption property, make the opening time as short as possible. Connection
of the piping to the refrigeration unit should be made at the last stage of piping installation work. Avoid outdoor work
on a rainy day.
(3) For piping work, use "phosphorous-deoxidized copper pipe" of refrigeration grade, clean, dehydrated and "phosphor-
copper brazing solder."
If "silver brazing solder" is to be used, do not use any flux containing chlorine.
(4) Do not use pipe joints made for HFC refrigerant, because they do not have the required strength. In addition,
absolutely do not use flared joints.
(5) For the purpose of protecting the refrigeration unit and refrigeration cycle, make sure to install the optional suction
filter and included filter dryer in the refrigeration unit.
(6) Gas leak detector used for airtight test should be foaming liquid or soap water. Do not use kitchen detergent. Kitchen
detergent may corrode metals.
For Effectively Using the Refrigeration Unit
For Economically Using the Refrigeration Unit
For the purpose of using the refrigeration unit economically, consider the following.
Cooling capacity largely vary by the method of use.
Reduction of evaporating temperature (unit inlet pressure converted to temperature) reduces cooling capacity by 2 to 4%,
and increase of discharge pressure decreases cooling capacity and increases power consumption.
In order to fully extract the unit performance, compressor suction pressure should be increased as high as possible, and
discharge pressure should be made as low as possible. For this reason, caution should be used in the following points.
(1) Make the piping resistance as small as possible.
Ref: Capacity change rate per 1°C pressure loss of suction line
(2) Select an evaporator of sufficient capacity for raising evaporating temperature as high as possible.
(3) Do not block the cold air outlet in a refrigerator, freezer, or display case with food items.
(4) Operate door opening of a refrigerator or freezer as quick as possible. (To avoid leak of cold air, reduce the time of
door opening)
(5) Periodically perform cleaning of the gas cooler to avoid clogging.
Evaporating temperature Capacity change rate per 1°C
-45°Cto-5°C2% to 4%

10
Caution for an Inverter-based Refrigeration Unit
(1) Even after turning the power OFF, voltage still remains in the charged part. Until the LED (red) of the inverter-PCB
turns off (until the capacitor discharges the potential), approximately 5 minutes are required. Do not touch the charged
part.
(2) Phase-advancing capacitor is prohibited
Do not attach a phase-advancing capacitor to an inverter compressor. It may cause inverter failure or capacitor
breakage.
(3) Inverter noise prevention
Take as much distance as possible from the wiring of a radio receiver or wired broadcasting.
Inverter noise may cause undesired noise sound.
(4) The two-stage compression mechanism prevents temperature rise of the second stage discharge gas of the
compressor.
During the operation with a small quantity of refrigerant in the refrigeration circuit, a protection device (the control
PCB) makes the compressor to stop.
Avoid refrigerant shortage operation.
(5) Rotary compressor consists of high precision components. Use caution during piping work to avoid contaminaion of
dust, metal powder, or oxide scale, etc.
For Effectively Using the Refrigeration Unit
Initial Oil Quantity
Oil are pre-charged in compressor and oil separator.
Model No. Compressor Oil separator
OCU-CR1001VF 1.8 L 5.0 L