Rivacold CO2NNEXT Assembly Instructions Manual Download Page 3

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NNEXT

rev.01

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Index

1.4.1.

Definitions .........................................................................................................

1.4.2.

Personal protection equipment and rules of conduct............................

1.4.3.

Graphical conventions ..................................................................................

1.6.1.

General conditions .........................................................................................

1.6.2.

Operations that invalidate the Warranty ...................................................

1.7.1.

Request for assistance ...................................................................................

2.2.1.

Passive safety devices ...................................................................................

2.2.2.

Active safety devices .....................................................................................

2.2.3.

Protection systems ..........................................................................................

2.2.4.

Notifications .....................................................................................................

3.1.1.

Name .................................................................................................................

3.1.2.

Frame and components layout ...................................................................

3.1.3.

Technical data ................................................................................................

3.1.4.

Noise ..................................................................................................................

4.3.1.

Lifting .................................................................................................................

4.4.1.

Power and control electrical panel and electrical connection ...........

4.4.2.

Refrigerating connection ..............................................................................

4.4.3.

System drain .....................................................................................................

4.4.4.

Refrigerant load ..............................................................................................

4.4.1.

Oil load ..............................................................................................................

5.1.1.

Interventions and relative periodicity .........................................................

5.3.1.

Disassembly ......................................................................................................

5.3.2.

Dismantling and disposal...............................................................................

Summary of Contents for CO2NNEXT

Page 1: ...rev01 08 2018 IT EN DE FR ES ISTRUZIONI PER L ASSEMBLAGGIO ASSEMBLY INSTRUCTIONS MONTAGEANLEITUNG INSTRUCTIONS POUR L ASSEMBLAGE INSTRUCCIONES PARA EL ENSAMBLADO CO2NNEXT ...

Page 2: ... s r l 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 preservation of the machine The company Rivacold s r l cannot be held responsible or liable for damages caused by incorrect use of the documentation In order to avoid incorrect manoeuvre...

Page 3: ... 1 Passive safety devices 2 2 2 Active safety devices 2 2 3 Protection systems 2 2 4 Notifications 3 1 1 Name 3 1 2 Frame and components layout 3 1 3 Technical data 3 1 4 Noise 4 3 1 Lifting 4 4 1 Power and control electrical panel and electrical connection 4 4 2 Refrigerating connection 4 4 3 System drain 4 4 4 Refrigerant load 4 4 1 Oil load 5 1 1 Interventions and relative periodicity 5 3 1 Dis...

Page 4: ...CO2NNEXT rev 01 EN 62 293 ...

Page 5: ...intenance of the partly completed machine to which the instructions refer The Manufacturer declares that the information contained in these instructions is consistent with the technical and safety specifications of the partly completed machine to which the instructions refer The drawings diagrams and technical data shown are updated at the date of publication of this document and are valid only fo...

Page 6: ...d commissioning of the partly completed machine x description of the mode of storage of the partly completed machine x Description of the partly completed machine uninstallation Chapter 5 Maintenance and demolition x Description of the verification and control procedures of the parts and components of the partly completed machine in particular of the parts most subject to wear x description of the...

Page 7: ...hich the presence of an exposed person is a risk to the health and safety of the person USER Any person entrepreneur company who adequately uses the partly completed machine or who entrusts its related use or operations to instructed persons EXPOSED PERSON Any person wholly or partially present in a dangerous zone or near such areas MECHANICAL MAINTENANCE TECHNICIAN Qualified technician allowed to...

Page 8: ...companied by indications that complete them providing additional information highlighting tasks that require essential attention and also particularly significant hazards to consider in this regard the following notation is used DANGER It indicates situations or operations that must be performed or information to which particular attention must be paid to prevent causing injuries to persons WARNIN...

Page 9: ... the country of use x installation of the partly completed machine under conditions other than those specified in Chapter 4 Transport and Installation x installation not compliant with the specifications provided in Chapter 4 Transport and Installation x full or partial failure to comply with the instructions provided in this instruction manual x non or incorrect maintenance x use of spare parts w...

Page 10: ...NI EN 378 2 2017 Refrigeration systems and heat pumps Safety and environmental requirements Part 2 design construction testing marking and documentation IEC EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General rules Table 3 Main harmonized standards used to design the partly completed machine Compliance with the relevant paragraphs of the afore mentioned harmonised s...

Page 11: ... to safeguard anomalous situations acting on both the pressure and voltage circuits Excessive pressure inside the refrigeration circuit The safeguard against excess pressure inside the refrigerating circuit during discharge which beside compromising system operation can also be dangerous to the personnel has two intervention steps x When the pressure reaches values exceeding the acceptable conditi...

Page 12: ...repeated Electronic control malfunction In the event of malfunction of the electronic control acting on the compressors electronic valves and on the 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...

Page 13: ... the minimum level Depending on the version of the partly completed machine there may be a second indicator to identify the maximum level The oil level check must be carried out when the system is fully operational for a few 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 machine and or in the enclosed documentation...

Page 14: ...signs and indications of the plates applied to the machine and operate exclusively according to the instructions provided in this instruction manual ATTENTION All operations to be performed on the machine must be performed by qualified trained informed or properly equipped personnel Residual risk of intoxication To avoid impacts or damage that could cause leaks of gases dangerous to human health i...

Page 15: ...TS IN MOTION It signals the danger due to the presence of mobile parts close to the zone ofthe partly completed machine where it is located It reports the danger of electrical voltage It reports the danger of hot surfaces It reports the obligation to read the assembly manual instructions Indicates it is forbidden to touch the zone where it is positioned Pressurised nitrogen Remove the voltage from...

Page 16: ...NNEXT rev 01 EN 74 293 Position of the pictograms on the partly completed machine 1 On all the air exchangers present in the machine 2 On each surface subject to high temperatures 3 On each energised part ...

Page 17: ...eric agents It is a good precautionary measure to have powder extinguishers in the vicinity of the partly completed machine To prevent the possibility of fire keep the partly completed machine clean of plastic pieces oil solvents paper and rags Use of the partly completed machine for different operations could cause harm to persons or damage to the machine itself and are therefore considered impro...

Page 18: ...g make sure all machine parts are intact otherwise contact your dealer x Before using the partly completed machine make sure all guards or other protections are fitted and that all safety devices are present and working x Carefully read the labels on the partly completed machine do not cover them and replace them immediately if damaged x Do not place containers of liquids on the partly completed m...

Page 19: ... safety valve can cause damage to property and or to persons DANGER Tampering with or unauthorised replacement of one or several parts of the partly completed machine and the use of accessories tools and consumables other than those indicated by the Manufacturer may result in an accident DANGER The R744 CO2 refrigerant is colourless and odourless Its presence in the environment can cause asphyxiat...

Page 20: ...e is also a desuperheater intercooler incorporated in the gas cooler battery All models also have a casing heating element that prevents the accumulation of liquid in the lower area of the compressor during downturn periods The unit is always enclosed in a self supporting housing made of steel varnished with epoxy powder and is equipped with electrical equipment with a main disconnecting switch th...

Page 21: ... operating logics refer to the dedicated documentation and manuals Regardless of the configuration the partly completed machine is always supplied without the air evaporators so it is not able to perform the function for which it is created without the evaporating unit As a consequence it is a partly completed machine as defined by Machinery Directive 2006 42 CE In order to define the refrigeratio...

Page 22: ... is accompanied by the related declaration of incorporation of the manufacturer and the corresponding instructions for assembly which enable its simple integration in the final machine which must then be CE marked pursuant to the directives applicable to it by the integrating entity On the right front panel of the partly completed machine is the electrical panel on which the main switch and the di...

Page 23: ...the year in which the partly completed machine was produced Figures 5 6 7 8 progressive number NOTE Additional plates may be available for partly completed machine versions in which it is necessary to specify positive and or negative refrigeration powers different models of compressors pressures and operating temperatures 1 Partly completed machine code 9 Compressor 2 Power supply voltage 10 Horse...

Page 24: ...rows I Expansion type with thermostat valve L Supply voltage 1 230 1 50 neutral 2 400 3 50 neutral M Optional NOTE For further information refer to UT 3 1 2 Frame and components layout The following shows the locations of the components and main connections of a type model 1 Frame 8 Inverter 2 Electrical panel 9 Flash gas valve 3 Received liquid tank 10 HPV or backpressure valve 4 Solenoid valves ...

Page 25: ...Intermediate receiver volume x Type of oil used x PED category x Empty weight x Overall dimensions of the machine and packaging x Calculation conditions and set nominal values 3 1 4 Noise The noise level is shown in the attached documentation based on the model of the partly completed machine The value of the maximum and average noise level in the 24h is provided at a distance of 10m and depending...

Page 26: ...ed over 1000 m above sea level unless otherwise specified The partly completed machine has been engineered and manufactured to work in environments where no potentially explosive atmosphere is present 4 2 Power Supplies and Utilities The power supplies and utilities responsibility of the purchaser necessary for operation of the partly completed machine consist exclusively of power supply Unless ot...

Page 27: ... must always remain at a safety distance Lifting for handling and subsequent positioning of the machine must be performed using straps that must be inserted into the appropriate lifting pockets of the structure as shown in the figure Follow the previous recommendations for correct handling operations x never use two lifting means simultaneously x never stand beneath the suspended loads x if steel ...

Page 28: ...ntry of installation DANGER Perform the required interventions using appropriate work tools and paying the utmost attention to elements that could cause accidents and in compliance with the legislation in force in the country of installation DANGER There must be no access to rooms at a lower level and or to wells close to the installation site of the partly completed machine this is to avoid any g...

Page 29: ...he partly completed machine the permissible tolerance is 10 of the rated voltage In case of presence on the machine of user devices that generate earth fault currents with high continuous and or high frequency components inverter UPS etc use a class differential thermal breaker suitable for use with such non linear circuits ATTENTION The differential thermal magnetic circuit breaker must be placed...

Page 30: ...for powering motors fans solenoid valves etc and those dedicated to the transmission of signals such as network cables 0 10V etc Failure to comply with this provision could jeopardise correct functionality of the system due to serious capacitive couplings that disturb the communication of very low power Supervision network ATTENTION Where possible it is recommended to keep the partly completed mac...

Page 31: ...ntennas transformers contactors neon lights etc x Strictly respect the polarity of the and wires Use the same colour for polarity for example white wire for and black for The sheath must always only be connected to the dedicated terminal usually called GND and near the and terminals The two terminals must be connected to the GND terminal that of the incoming cable and that of the outgoing cable x ...

Page 32: ...d to this manual The dimensions of the outlet pipes intake line and liquid line shown in the refrigeration diagram are calculated for a MAXIMUM TUBING LENGTH of 30 m This maximum length valid for each individual section of both intake and liquid has been defined in order to obtain a pressure drop that does not compromise correct functioning of the evaporator Furthermore the following functional re...

Page 33: ... of the country of installation The size of the output on the machine is valid for a linear conveyance with a maximum length of 10m The conveyance is necessary where it is necessary to send the gas leaving the safety valves outside of a possible machines room The connections are performed in such a way that welding or brazing can be carried out according to the type of material of the pipe being u...

Page 34: ...Information on the type of connection possible can be found on the refrigerator diagram 1 Pre cut 4 Connection with ODS brazing 2 Closure cap 5 Connection with head head welding 3 Connection points RS service valve 1 Closure cap a Position Passage open 2 SAE fitting b Position Passage closed 3 Closure screw two positions ...

Page 35: ...nevertheless be at least 24 hours In addition to reaching a vacuum level of at least 0 3 mbar it must remain constant over time The IND1 indicator of liquid passage must be green to indicate the absence of humidity ATTENTION Before proceeding with the drain phase check that all the valves on the machine and on the system are open ATTENTION The drain phase can take place when the machine is not ele...

Page 36: ...d x positive intake RS1 x negative intake RS1 if present Furthermore as shown in the following figures when the machine is switched off opening magnets must be inserted in the solenoid valves YVEq LT and YVEq P if present x remove the connector 1 x remove the coil 2 x insert the magnet 3 NOTE Refer to the procedure DRAIN PROCEDURE MANUAL MODE par 4 4 1 ...

Page 37: ...hat the valves HPV and VFL are manually opened by electronic control to guarantee opening of the entire refrigeration circuit During refrigerant pre load it is necessary to insert CO2 in the gaseous state at a pressure value well above the triple point 5 185 bar a to avoid the formation of dry ice inside the system A gaseous pre filling of 10 bars is recommended throughout the circuit The load poi...

Page 38: ...ny is found the system must be stopped and the emptying and loading phases repeated DANGER For refrigerant filling recovery and verification operations wear gloves for protection against low temperatures The filling operations must be performed only by specialized technicians DANGER The R744 CO2 refrigerant is colourless and odourless Its presence in the environment can cause asphyxiation All oper...

Page 39: ...alve RS2 x once loading is complete close the RS1 and continue with the drain phase to the value previously described x remove the vacuum pump and related pipes from the service valve x reopen the previously closed valves x reactivate the machine in the ON position x reactivate the utilities x wait for the system to stabilise and for no alarms to be present ATTENTION DO NOT load more than 250 g of...

Page 40: ...ves are closed and that they all are fitted with caps Check utilities thermostatic valves Make sure that all the electronic thermostatic valves of the utilities are correctly programmed ATTENTION The positive and negative utilities must have a minimum overheating of 5K and a correct MOP value on the expansion valve control to avoid increasing the intake pressure in the event of system shutdown 35 ...

Page 41: ... CO2 in state of ON Green Control Hecu CO2 powered x Bring the application software that manages the compressors to ON Inside the electrical panel there are two electronic boards one for the management of the high pressure part of the partly completed machine heat recovery gas cooler back pressure valve gas flash valve etc and one for the management of BLDC rotary compressors Normally the display ...

Page 42: ...Values x Evaporation x Parallel Aspiration x Condensing x BLDC compressor speed LV and Parallel 3 Unit Status x Compressor Status x Gas cooler fan status x HPV valve status 4 Signal of active alarm and or manual operation 5 Access to additional information pages ...

Page 43: ...CO2NNEXT rev 01 EN 101 293 INFORMATION PAGES Press the display key Information on the variables of the intake side Information on the LV compressor ...

Page 44: ...CO2NNEXT rev 01 EN 102 293 Parallel compressor information Information on the Gas Cooler ...

Page 45: ...formation on the HPV valve UNIT ON OFF Press the display key Press the key The cursor will move onto the first figure of the password Enter the password 0000 The 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 46: ...ly during the vacuum phase and with the unit OFF UNIT ON OFF Press the display key Press the key The cursor will move onto the first figure of the password Enter the password 0000 The 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 47: ...ss the key Move down with the 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 move to the mask in the figure At that point press one of the arrow keys to switch from NO to YES Then select YES with the ENTER key ...

Page 48: ...e figure Make sure that the values are equal to 100 of opening for the valve and in position O Open for the equalisation valves present NOTE In the TN machines the Bbd02 mask is as follows Confirm by pressing the key Move down with the key Check and retain the default values ...

Page 49: ... in the figure Pressing the key The percentage value is 100 Confirm by pressing the key Only perform this operation in the TN units At this point if the wiring has been carried out correctly the HPV and VFL valves if present will move to the maximum opening until the Time out time is reached or until the initial situation is restored placing DIS in mask Bb01 If there is a cell control MPX Pro or U...

Page 50: ...e password 0000 The press the key Move down with the key until E Evaporator appears then press the key Move down with the key until d Driver EVD appears then press the key Press the key Select YES Press again to confirm the selection Select the value to be inserted 100 600 step Press again to confirm the selection Press the key until returning to the main page ...

Page 51: ...ll ventilated o ambient temperature between 10 C and 40 C o relative air humidity between 30 and 80 ATTENTION Do not remove the packages possibly present for certain partly completed machine components or take appropriate precautions to protect the parts exposed 4 7 Disassembling If it is necessary to uninstall the partly completed machine proceed in the reverse order with respect to the installat...

Page 52: ...tive Equipment PPE DANGER During the maintenance and demolition of the partly completed machine it is necessary to follow the warnings listed below DANGER Before carrying out any type of intervention it is necessary to check with a specific gas detector the absence of CO2 leaks R744 x It is necessary to warn using appropriate signs of the intervention on the partly completed machine to prevent any...

Page 53: ...cal panels and in the terminals of each electrical utility Monthly Check for refrigerant and oil leaks Visually check the entire refrigerant circuit for refrigerant leaks including inside the partly completed machine These leaks are also evident from traces of lubricating oil Intervene promptly and investigate further in case of uncertainty Monthly Check efficiency of the earthing Check the earthi...

Page 54: ...e partly completed machine replacing the gas only after having carried out the drain procedure again It may also be necessary to replace the filter on liquid FL1 which is installed by brazing Replacement is possible by closing 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 oper...

Page 55: ...ossible through the use of shut off valves if any or through the use of valves in the system DANGER Before replacing the valve check that in the intervention area the system is neither pressurised or at a high temperature ATTENTION No maintenance is required for the safety valves Removal of the cap or tampering with the seal is considered unauthorised modification to the factory settings which wil...

Page 56: ...eted its life cycle before proceeding with final dismantling it is necessary to carry out a series of operations aimed at minimising the environmental impact related to disposal of the components of the partly completed machine as required by current regulations on the disposal of waste These operations are 1 Separate and store the polluting parts a separate the parts that could cause pollution b ...

Page 57: ...ompressor x Replace compressor C Inverter alarm intervention x Low voltage to the compressor unbalanced phases on three phase motors x Identify the cause and eliminate it x Check its characteristics and replace it if necessary x Alarms presence x Check compressor rotation x Check compressor working conditions x Check the alarm type to identify and eliminate the cause x Replace compressor D Compres...

Page 58: ...inimum set point x Clean entire mechanism and filter if provided for the HPV valve x Replace the HPV valve H High pressure liquid receiver x VFL gas flash valve not working properly x Check valve check alarms and reset x Check the correct operation of the VFL valve x Clean the entire mechanism and filter if required of the VFL valve x Replace the VFL valve x Parallel compressor if present x Check ...

Page 59: ...CO2NNEXT rev 01 EN 117 293 7 Annexes The specific characteristics of the partly completed machine are reported in x Declaration of Incorporation x datasheet x refrigeration diagram x wiring diagram ...

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