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Hillphoenix Refrigeration Systems

One Condensing Unit

Section 4: T

ranspor

t and Installation

ATTENTION: Any removal of coils from solenoid valves must take place when the equipment is
switched off. Only perform ignition after repositioning the coil on the solenoid valve.

ATTENTION: To avoid irreparable damage, do not start the compressors in vacuum conditions or
without refrigerant charged.

The service valves to which the vacuum pump must be connected include the following:

• RSD supply

• RSLIQ liquid

• RSS suction

For LT/MT machines, as shown in the figure below, a magnet must be used to open the YVO solenoid valve, with

the machine powered off.

• Remove the connector (1)

• Remove the coil (2)

• Insert the magnet (3)

Furthermore, the high pressure valve (HPV) downline of the gas cooler must be forced open, along with the

flash gas bypass valve for MT versions, by removing the valves’ stator coils and inserting and rotating a magnet

(OPTIONAL P/N: EEVMAG0000).

Refer to the VACUUM PROCEDURE MANUAL MODE instructions in

Preparation for Startup

later in this section.

Before terminating the evacuation procedure, the circuit must be loaded with 3.5 ounces of oil.

The oil in the compressor is PAG (polyglycols) 100 made by FUCHS RENISO PAG 100.

ATTENTION: Do not load any oil other than that specified by the manufacturer. For further

information, contact a Hillphoenix Field Support Engineer.

Summary of Contents for CO2One

Page 1: ...CO2 One CO2 Condensing Unit Manual DECEMBER 2021 ...

Page 2: ...rred to in this manual that are not provided by Hillphoenix is in no way intended to be authoritative or in any way ensured to be accurate INFORMATION CONTAINED WITHIN THIS MANUAL IS PROVIDED AS IS WITH ALL FAULTS WITH NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EITHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE QUAL...

Page 3: ...TION Indicates the threat of potential injury if all instructions are not followed carefully DANGER DANGER Indicates an immediate threat of serious injury or death if all instructions are not followed carefully Experienced installers and technicians not only assure that customers enjoy optimum and technicians not only assure that customers enjoy optimum system performance but that potential proble...

Page 4: ... the presence of mobile parts near the area of the partly completed machinery where it is positioned Signals the danger of electrical voltage Signals the danger of hot surfaces Signals that it is mandatory to read the manual assembly instructions Warns against touching the parts in near the area where it is affixed System or component pressurized System contains refrigerant under high pressure Do ...

Page 5: ...llphoenix Refrigeration Systems CO2One Condensing Unit 1 On all the air exchangers present in the equipment 2 On each surface subject to high temperatures 3 On each energized part Position of the Pictograms ...

Page 6: ...f Hillphoenix The installation and maintenance technicians are explicitly prohibited from disseminating the information contained and from using this manual for purposes other than for those strictly related to efficient maintenance of the equipment Hillphoenix cannot be held responsible or liable for damages caused by incorrect use of the documentation In order to avoid actions that could cause d...

Page 7: ...ed when the system or product is shipped Any claim for missing items must be made to Hillphoenix within 48 hours of receipt of the equipment Technical Support Technical Support For technical support issues regarding this unit contact the Hillphoenix Refrigeration Technical Support at 770 285 3061 Ordering Equipment Parts Contact Hillphoenix OEM Genuine Parts at 833 3PARTS1 833 372 7871 if any addi...

Page 8: ...VII ...

Page 9: ...nt in the following cases Use contrary to that described in Proper and Improper Use of the Equipment in Section 2 Safety Introduction Use contrary to local codes and ordinances Installation under conditions other than those specified in Section 4 Transport and Installation Iinstallation not compliant with the specifications provided in Section 4 Transport and Installation Full or partial failure t...

Page 10: ...per Use of the Equipment 7 Incorporation Statement 8 General Warnings and Rules of Conduct 8 Section 3 Description of the Equipment 10 Identification Plate 13 Section 4 Transport and Installation 16 Environmental Requirements 16 Power Supplies and Utilities 16 Transport and Handling 17 Installation 19 Preparation for Startup 34 Storage 46 Uninstalling 46 Section 5 Maintenance 47 Maintenance and Cl...

Page 11: ...Information These assembly instructions contain confidential proprietary information All rights reserved These instructions may not be reproduced or photocopied in whole or in part without the prior written consent of the manufacturer Only the purchaser to whom the instructions have been provided may use this documentation with the equipment and only for the purposes of installation and maintenanc...

Page 12: ...ption of the verification and control procedures of the parts and components of the equipment in particular of the parts most subject to wear Description of the procedures for the designated personnel to clean the equipment Instructions for disassembling demolishing and disposing of the equipment Section 6 Troubleshooting List of possible malfunctions of the equipment and related solutions Section...

Page 13: ... Any area inside or near the equipment that presents a risk to the health and safety of an exposed person USER Any person entrepreneur company who adequately uses the equipment or who entrusts its use to persons instructed on its proper operation EXPOSED PERSON Any person wholly or partially present in a dangerous zone or near such areas MECHANICAL MAINTENANCE WORKER A qualified technician allowed...

Page 14: ...es the cross references used in these instructions are expressed in the following form Paragraph Table with the number and in general the specification of the section with the number and name of that section when it is not specified it is implied that the paragraph or the table belong to the current section Technical and specialized terms the first time they appear in the text Bold text Bold text ...

Page 15: ...sor Edition 1 Issue Date 2017 09 29 CAN CSA C22 2 No 60335 2 89 17 First Edition Issue Date 2017 09 29 These standards are designed to reduce or eliminate risk of malfunction damage or injury to the greatest extent possible The components used have been carefully chosen from those available on the market the equipment is comprised of materials that involve no risks to the health and safety of pers...

Page 16: ...ssure switch and or to inhibit its operation Protection Systems The system is equipped with protections to safeguard against anomalous situations affecting either the pressure or voltage circuits Notifications The unit is equipped in addition to the signals and instruments installed on the electrical panel with indicator lights on the inside To access them it may be necessary to remove one or more...

Page 17: ...g out any work on the equipment make sure that the hot surfaces have cooled down wear protective gloves to avoid burns Proper and Improper Use of the Equipment The equipment discussed in these assembly instructions has been designed and constructed exclusively for refrigeration The equipment is configured to use only R744 CO2 refrigerant gas The equipment is designed to use only the refrigerant sp...

Page 18: ...ust be adequately trained to avoid risk of damage or injury and must work in a comfortable environment with the best possible safety and hygiene conditions Prior to using the equipment ensure that any hazardous safety conditions have been rectified and that no personnel are present in the danger area near the unit After removing the packaging make sure all equipment parts are intact otherwise cont...

Page 19: ...r accessory equipment If this is not possible it is necessary to take precautions to ensure safe working conditions in the area of the equipment DANGER The leaking of refrigerant gas after the safety valve is engaged may result in damage to property and or injury to persons DANGER Tampering with or unauthorized replacement of one or several parts of the equipment and the use of accessories tools a...

Page 20: ...cation and any alarms by signaling them on the electronic control terminal Depending on the model for the condensing unit units can be provided with a single fan motor or with a double fan All models are equipped with the following refrigerator accessories Compressor s driven by inverter Control valves Intermediate receiver Dehydrating filter and liquid indicator On board gas cooler Electrical pan...

Page 21: ...ompact design allows installation even in small spaces The structure is made of bent sheet metal with epoxy paint and suitable feet dampen the vibrations Depending on the version the equipment can be soundproofed The equipment depending on the model has two different voltages 230 1 60 Hz and 460 3 60Hz For refrigeration electrical management and operating logics refer to the appropriate documentat...

Page 22: ...compartment door and electrical enclosure 2 Main switch disconnect 3 LH gas cooler compartment door 4 Gas cooler fans 1 Electrical panel 2 Display 3 Master power switch rod 4 Compressor compartment For the description of the display see Preparation for Startup in Section 4 Transport and Installation 2 1 3 4 3 2 1 4 ...

Page 23: ...se rated frequency Refrigerant R744 M O P maximum rating of overcurrent protective device High design pressure M C A minimum circuit ampacity Mid design pressure Total input current Low design pressure Motor compressor ratings RLA LRA IP degree Fan motor rating FLA Climatic class Branch circuit selection current BCSC Example of Serial Registration number identification Digits 1 and 2 production si...

Page 24: ...n motor diameter 450 mm F Refrigerant type R744 G Progressive U version UL H No of gas cooler capacitor rows I Expansion type with thermostat valve L Supply voltage 5 230 1 60 6 460 3 60 neutral M Optional Name Frame and Component Layout 1 Frame 2 Electrical panel 3 Received liquid tank 4 Solenoid valves 5 MV LV compressors 6 Liquid line output 7 Suction line return 8 Inverter 9 Flash gas valve 10...

Page 25: ...in the various sections of the circuit Intermediate receiver volume Type of oil used Empty weight Overall dimensions of the unit and packaging Calculation conditions and set nominal values Noise Levels The noise level is shown in the attached documentation based on the model of the equipment The value of the maximum and average noise level over 24Hz is provided at a distance of 32 8 feet The prese...

Page 26: ...rrect operation of the system following the instructions provided in this section and if necessary consulting the manufacturer before installation Ambient Conditions The system does not have any specific restrictions regarding ambient temperature The ambient temperature may vary between 14 F and 104 F The relative humidity must not exceed 50 with an ambient temperature of 104 F higher relative hum...

Page 27: ...ctly balanced and that there are no parts that are incorrectly installed or at risk of damage The structure of the equipment must be intact and completely assembled Ensure that the area intended for handling is clear and that there are no obstacles that could create a dangerous situation Do not move or stand under suspended loads Always place the unit on bearing surfaces suitable for supporting it...

Page 28: ...the following figure Follow these additional recommendations for correct handling Never use two lifting means simultaneously Never stand beneath the suspended loads If steel ropes are used fit always the loop on the end on the lifting hook If steel ropes are used pay attention not to create narrow bends i e with a bending radius lower than the loops on the end of the rope Use ropes of suitable len...

Page 29: ...on local codes and ordinances must be complied with DANGER The installation surface must permanently support the weight of the equipment persons and equipment necessary for safe maintenance Overloads should be considered in compliance with the conditions of the installation site and with local codes and ordinances DANGER Perform the required installation steps using appropriate work tools and payi...

Page 30: ...chine display can be done with power on and the RH compartment door open ATTENTION DO NOT open the fan panel with power on ATTENTION DO NOT access the electrical enclosure with power on ATTENTION DO NOT work on the inverter or the electronic components with power on ATTENTION Check the power supply phases to obtain correct rotation direction of the compressors Incorrect rotation can irreparably da...

Page 31: ...romechanical circuit breaker must be placed in the immediate vicinity of the equipment so that it can be clearly visible and reachable by the technician while performing maintenance The gauge of the power supply cable must be adequate for the power rating of the equipment For further information on the total amp draw of the equipment refer to the wiring diagram attached to this manual The power su...

Page 32: ...ring the equipment or in general for powering motors i e fans and solenoid valves and those dedicated to the transmission of signals such as network cables or 0 10V Failure to comply with this provision could jeopardize proper functionality of the system due to major disruption of the power supply Supervision Network ATTENTION Where possible it is recommended to keep the equipment s supervision ne...

Page 33: ...ments Liquid line The lines line components and thermostat valves must be rated for a pressure at least equal to the pressure rating of the liquid line of the condensing unit to avoid problems when running at high ambient temperatures Suction line the lines line components and evaporators may be rated for pressures lower than the pressure rating of the condensing unit s suction line ATTENTION The ...

Page 34: ...ratings and safety criteria must conform to all local codes and ordinances The unit must be connected to the following components to complete the entire system Medium temperature evaporators Low temperature evaporators if equipped The connections are as follows Liquid MT suction LT suction if equipped Near each connection is shown the relative label 1 with the type indicated while the information ...

Page 35: ...iquid line must be insulated with a suitable thickness and not less than 5 inch for medium temperature units and 74 inch for low temperature units The intake line from positive if equipped and or negative if equipped users must be created in a way that guarantees correct oil return to the equipment and that reduces pressure drops It is advisable not to exceed 7 2 Psi The intake lines must be insul...

Page 36: ...o not install the equipment and instead contact Hillphoenix Technical Support ATTENTION Prepare the connections by making a clean cut using appropriate tools Excessive pressure inside the refrigeration circuit Excess pressure inside the refrigerating circuit during discharge can compromise system operation and can be dangerous to personnel The safeguard against this pressure involves two phases Wh...

Page 37: ...emove the covering panels Malfunctions and alarms The presence of alarms is signaled by a red light on the electronic control terminal located on the unit door The light can be flashing or fixed in the first case the light indicates the presence of active and unseen alarms and the second indicates that an alarm has been viewed A red light on the electronic control display in the panel area general...

Page 38: ...diagram 1 Cut the cap 2 Prepare for brazing 3 Braze the line RS service valve 1 1 Closure cap Closure cap 2 2 SAE fitting SAE fitting 3 3 Closure screw Two positions Closure screw Two positions a Position Passage open b Position Passage closed Service valves RSD Gas cooler delivery service valve RSLIQ Liquid line service valve RSS User suction service valve RS1 Second stage receiver compressor lin...

Page 39: ...rly it is essential to correctly draw a vacuum on the system to ensure values of air and especially of humidity below the permissible values Charging the new refrigerant requires the use of polyester based oils with characteristics of high hygroscopicity necessitating greater attention when drawing a vacuum The duration of the evacuation phase is variable as it depends on several factors but must ...

Page 40: ...ed to open the YVO solenoid valve with the machine powered off Remove the connector 1 Remove the coil 2 Insert the magnet 3 Furthermore the high pressure valve HPV downline of the gas cooler must be forced open along with the flash gas bypass valve for MT versions by removing the valves stator coils and inserting and rotating a magnet OPTIONAL P N EEVMAG0000 Refer to the VACUUM PROCEDURE MANUAL MO...

Page 41: ...e charged with carbon dioxide CO2 R744 Purity 99 99 H2O 10 ppm O2 10 ppm N2 50 ppm or higher R744 refrigerant CO2 is designated as safety class A1 per AHRI ASHRAE standards non flammable non toxic ODP 0 and GWP 1 High CO2 concentrations are dangerous This refrigerant is odorless and colorless ATTENTION The CO2 refrigerant is heavier than air The use of CO2 detectors and a ventilation system is rec...

Page 42: ...Energize the high pressure and flash gas valves HPV and VFL if previously removed ATTENTION Energize the YVO valve solenoid coil if equipped Charging can then continue with liquid on RSLIQ valve and or vapor on RSS Add evaporative load gradually ATTENTION Cases and unit coolers must already be configured properly for use with CO2 ATTENTION During charging the compressors will run and may set off a...

Page 43: ...ervice valve Reopen the previously closed valves Restart the equipment by placing it in the ON mode in the electronic control display Switch on the power Wait for the system to stabilize and for no alarms to be present ATTENTION DO NOT charge more than 8 8 ounces of oil at a time If more oil is needed repeat the above procedure Oil Fill The oil in the compressor is PAG polyglycols 100 made by FUCH...

Page 44: ...hours and for a few days after starting If it is necessary to top up always use only the type of oil indicated on the plate of the unit and or in the enclosed documentation Humidity reporting On the liquid passage indicator it is possible to observe a colored element that indicates if the refrigerant is dry or contains moisture Based on the color it is possible to determine the status In the prese...

Page 45: ...ve control to avoid increasing the intake pressure in the event of system shutdown 35 bar 30 F and 507 5 PSI is recommended Pre heating of the compressor casing if equipped Crankcase heating for compressors is active during the evacuation procedure if the latter is done as instructed below Furthermore crankcase heating is active if the compressor is off and the external temperature is low Insuffic...

Page 46: ...ction In the event of malfunction of the electronic control acting on the compressors electronic valves and gas cooler there may be limited functionality or system shutdown depending on the type of fault The high pressure safety related to the pressure switches independent of the electronic control continues to be active Probe reading failure or breakage of the probes related to electronic control...

Page 47: ...y the cursor DOWN Switch to the lower value in a list or decrease the value of a variable highlighted by the cursor ENTER Enter the selected sub menus or confirm the set values BUTTONS ASSOCIATED Red Flashing Active alarms not seen Fixed Alarms seen Yellow Control Hecu CO2 in state of ON Green Control Hecu CO2 powered Turn the controller ON Turn on the application software that manages the compres...

Page 48: ...oller of the high pressure part pRack application Therefore to turn the software of the second controller ON it is necessary to disconnect the telephone cable connected to the display and to attach the second telephone cable located nearby This procedure provides accessibility to the second controller Turn the pRack CO2 application ON Follow these steps for this application MAIN PAGE 1 Time and Da...

Page 49: ...39 Section 4 Transport and Installation INFORMATION PAGES Press the key Information on the variables of the intake side Information on the compressor ...

Page 50: ...40 Hillphoenix Refrigeration Systems CO2One Condensing Unit Section 4 Transport and Installation Information on the parallel compressor LT Information on the gas cooler ...

Page 51: ...ation on the HPV and VFL valves if applicable UNIT ON OFF Press the key Press the key The cursor will move onto the first figure of the password Enter the password 0000 and press the key Select the A Unit Status item Press the key Select the c On Off item Press the key Press the key ...

Page 52: ...ocedure Perform this procedure only during the evacuation phase and with the unit OFF UNIT ON OFF Press the key Press the key The cursor will move onto the first figure of the password Enter the password 0000 and press the key Select the A Unit Status option Press the key Select the c On Off option Press the key Press the key ...

Page 53: ... key until B Inputs Outputs is highlighted then press the key Move down with the key until b Manual Management is highlighted then press the key Move down with the key until d Vacuum appears then press the key Press the key to move to the mask as shown in the figure and press one of the arrow keys to switch from NO to YES Then select YES with the ENTER key Starting from the main screen ...

Page 54: ... valves present NOTE In the MT units the Bbd02 mask is as follows Confirm by pressing the key Move down with the key Check and retain the default values End of evacuation procedure Press the key to reach the mask as shown in the figure At that point press one of the arrow keys to switch from NO to YES Now select NO with the ENTER key If a DC coldroom controller is connected to the unit it is also ...

Page 55: ...ystem This parameter can be modified to suit the final application If the unit is combined with a dedicated evaporator the suction setpoint regulation is not fixed but rather floating when serial communications with evaporator are available Serial communications enable exchange of realtime information between the main Hecu CO2 controller and the coldroom controller The floating suction pressure se...

Page 56: ... and 80 ATTENTION Do not remove the packages possibly present for certain equipment components or take appropriate precautions to protect the parts exposed Uninstalling If it is necessary to uninstall the equipment perform the installation procedure provided in Paragraph 4 4 Installation in reverse sequence The service valves on which to operate are RSD RSLIQ and RSS Do not remove the gas from the...

Page 57: ...ng procedures described in this section it is necessary to disconnect the equipment from the electric power supply via the main disconnecting switch located on the panel that closes the electrical equipment The disconnector must be locked in the open position with a padlock ATTENTION During maintenance or dismantling procedures the operator must use all necessary Personal Protective Equipment PPE ...

Page 58: ...environmental impact materials removed as a result of maintenance must be disposed of in accordance with current regulations ATTENTION For the disposal of materials with high environmental impact if necessary use specialist waste collection facilities Checking the availability of necessary material 60 days prior to the date of scheduled maintenance perform a detailed examination of the necessary m...

Page 59: ... periods especially in spring it is necessary to perform cleaning procedures more frequently due to the presence of increased impurities in the air Monthly Check electrical cable status Check that the cables inside the equipment compartment do not show any alterations of any kind abrasion burns deterioration etc Any possible variation in cable quality requires immediate replacement of the cables M...

Page 60: ... the R4 and R5 valves upstream and downstream of the filter itself The RS3 service valve will allow the refrigerant to be removed as well as the subsequent pressure test procedures evacuation and preload up to 10 bar Quarterly Check compressor noise The control procedures must be performed in the absence of unauthorized personnel and with instruments suitable for the type of operation The instrume...

Page 61: ...ystem DANGER Before replacing the valve confirm that in the work area the system is neither pressurized nor at a high temperature ATTENTION No maintenance is required for the safety valves Removal of the cap or tampering with the seal is considered unauthorized modification to the factory settings which will void the manufacturer s warranty Inspection of the safety valves is only permitted by supe...

Page 62: ... wiring Inverter Check the power cables between the inverter and compressor and communication cables Check for the presence of alarms on the compressor Replace the compressor Inverter alarm issues C Low voltage to the compressor unbalanced phases on three phase motors Identify and eliminate the cause Check its characteristics and replace it if necessary Alarm occurence Check compressor rotation Ch...

Page 63: ...lve not working properly Check the valve check alarms and reset Confirm correct operation of the HPV valve Check the minimum set point Clean the entire mechanism and filter if provided for the HPV valve Replace the HPV valve High pressure liquid receiver H VFL gas flash valve not working properly Check the valve check alarms and reset Confirm correct operation of the VFL valve Clean the entire mec...

Page 64: ...enix Refrigeration Systems CO2One Condensing Unit Section 7 Appendices Section 7 Appendices Machine specifications are outlined in the following supporting materials Datasheet Refrigeration diagram Wiring diagram ...

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