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OPERATING INSTRUCTIONS

1. DIL E ith 7 gt p rr I Ue UG li i JE RH j EXA L 18 149118118 18 28 28 28128128128 LIUC LAE Ll peg e e 1286 Note Dimensions are subject to change for special non standard applications 16 HOLE BAO 103 1 AUS 47 lt gt 14 R744 CO Pressure Temperature Chart PRESSURE SATURATED VAPOR TEMPERATURE TABLE Refrigerant R744 Thermodynamic Properties Saturated Conditions in SI ABSOLUTE PRESSURE Temperature C 14 EE DC 531 2 578 8 603 8 683 6 711 9 41 71 801 8 M 866 3 970 1 1006 7 1082 8 1163 1 1204 8 1247 7 1336 7 1430 3 1478 8 1528 6 1579 6 1631 8 1740 0 1796 1853 3 1972 0 2361 4 P Bar 5 312 5 546 5 788 6 038 5 296 6 562 6 836 7 119 7 41 7 71 8 018 8 336 8 663 9 346 9 701 10 067 10 442 10 828 11 224 11 631 12 048 12 477 12 916 13 367 13 829 14 303 14 788 15 286 15 796 16 318 16 852 17 4 17 96 18 533 19 12 19 72 20 334 20 961 21 603 22 259 22 929 23 614 24 313 Bar Carbon dioxide Temperature PC 12 11 10 9 8 7 6 CO NID Or RB OG PO o Oo O N IN INININ NIN IN IN IDN 2faf a af o ao lal gt CO O CO N OD 1 A oN gt l oloo NIAo A oN gt o 31 06 C CO2 PONG PRESSURE P Bar 2502 8 25028 25 758 26504 26 504 27 265 28 042 28 835 29 644 30 47 31 313 3
2. Technical Data Electrical Data Pipe Connection Pipe Connection Max Max Starting item Noi Com IT Displacement with Number of Oil Charge Weight DL DL Motor Connection Operating Power Current s Compressor NES 4450 min 1 m3 Hour Cylinders dm3 0 Kg Discharge Line Suction Line Volt Current Consumption Locked Rotor Amp 3 kW 3 Amp 3 mm Inch J04 469 2MSL 07K y 16 K H Y 4 5 2 5 1 1 25 6 14 8 o o wo wo J04 490 2KSL 1K f 16 EN 7 2 6 1 3 5 1 8 39 0 22 5 gt gt J04 491 2HSL 3K S d y 16 K 3 3 10 7 6 0 3 44 2 25 5 8 S J04 492 2FLS 4K S E 16 S i SN UND 15 4 8 6 4 6 68 1 39 3 lt l y 3 o o 304 493 2DSL 5K d 22 x E 20 1 11 3 6 4 107 7 62 2 e e 4 4 J04 494 2CSL 6K 8 d 22 1 3 3 24 8 13 9 7 8 107 7 62 2 Ka eo N N J04 495 4DSL 10K 18 45 4 2 0 94 5 22 EN 28 1 4 8 g 39 3 22 0 12 7 168 97 Explanations O e O 9 BSE60K Oil Standard applications BSE85K Oil Booster applications and applications with high discharge gas temperatures Tolerance or 10 based on mean value of voltage range Other voltages and electrical supplies on request For the selection of contacts cables and fuse the max Working current max power consumption must be considered See also 4 Data for compressors with voltage 380V 420V 220 240V are based on average voltage of 400V 230V Conversion factors 380V 220V 0 95 420V 240V 1 05 Ancillaries Compr
3. 60 Hz gt Trans synchronous operation gt motor reserve limited with R744 constant torque requirement For a constant torque above 50 Hz gt VSD with auxiliary transformer higher output voltage gt Motor layout 230 V 3 50 Hz 9 2 5 Electronic Screening Use screen cables Ensure large area contact to the housing of the compressor The frequency inverter must be fitted with suitable EMC filters connect both ends of motor cable to the ground BAO 103 1 AUS 19 lt a gt 9 2 6 Compressor Contactor Acompressor contactor should always be used to ensure the correct function of the safety circuit Insure contactors are sized rated for each application 9 2 7 Ramp up time to Minimum Speed A Ramp up time of between 1 3 seconds to minimum speed enables a soft start and at the same time adequate lubrication is achieved 9 2 8 Abnormal Vibrations The pulsation frequency in the discharge line and the excitation frequency at the compressor feet and in the piping system depend on the compressor speed This can result in resonance effects in pipelines and other plant components Therefore the entire plant must be carefully checked for abnormal vibration during commissioning and repeatedly during the operation at each frequency Frequencies at which resonance occur must be blocked out in the frequency inverter programming In certain cases there can be a mismatch in the compressor frequency inverter selection where t
4. The hot gas injection point is in the Suction Line after the Suction ReheatBPHE and before the Suction Drier Accumulator B 93 8 93 8 5 Solenoid Valve Set point Solenoid D On 15 C Off 10 C 93 8 Hot Gas Injection Circuit Suction Line p1 3 8 9 20 Ancillaries Emergency Cooling BITZER CO Hybrid racks come with an Emergency Cooling BPHE fitted The purpose of the emergency cooling BPHE is to provide cooling to the CO refrigerant within the Liquid Receiver in the event of a power outage The BPHE is connected to the CO Liquid Receiver and includes a Tx Valve R134a TUAE mechanical expansion valve R134a is standard other refrigerants valves available on request the liquid line and suction line on the R134a require connecting to a dedicated condensing unit Emergency Cooling Condensing Unit Optional available in 3 Phase or Single phase Compressor versions each with a twin fan air cooled condenser vertical air discharge Figure 19 The Optional Integral Air Cooled condensing Unit For Emergency Cooling of CO Refrigerant within the Liquid Receiver in emergency conditions BPHE Emergency CO2 Cooling Condenser R744 Evaporator R 1343 Metal Clad amp Insulated OPTIONAL STAND BY EMERGENCY COOLING AIR COOLED CONDENSING UNIT INTEGRAL OR REMOTE SINGLE OR 3 PHASE BITZER COMPRESSOR LIQUID RECEIVER Metal Clad amp Insulated Ex An additional HP switch is fitted to control the conde
5. Although there is a slight decrease in COP with the additional increase in suction superheat the decrease is less than if one were to use an external heater additional parasitic load to maintain crankcase temperature 9 16 Suction Superheating ATTENTION The set points listed below are advisory as each system varies depending on design conditions Operation should be checked to ensure that the crankcase temperature operates between 20 C amp 30 C 9 17 Suction Superheating BPHE Additional Suction Return vapour Superheating is achieved by passing CO High Pressure Liquid in counter flow to CO Suction Return Vapour This style of superheating is less complicated and does not require as many control solenoids as the mass flow of CO liquid and vapour is balanced The Suction Re heat BPHE is engineered to application 9 18 Ancillaries Suction Drier Suction Accumulator BITZER CO Hybrid racks are equipped with a single core Suction Drier Suction Accumulator Vessel This is located at the back of the unit within a metal cradle at the rear right hand end of the rack frame assembly 1 The Suction Drier Suction Accumulator vessel is Colorbond metal clad and insulated 2 There is a removable metal insulated cover at the suction inlet end of the vessel Drier Shell End Plate Access See Figure 17 3 The insulated Individual Suctions lines along the top of the vessel are seamless stainless steel sized to each specific compressor 4 P
6. Apply a thin film of clean refrigeration oil to the O ring of the new filter and insert the new filter into the separator so that it is centred and that the O ring seats flush on the sealing surface b Re attach the new sealing washer and filter nut c Tighten the filter nut until it will not turn d Tighten the filter nut an additional 1 2 to 3 4 turn 12 Thoroughly remove the old gasket or O ring from the groove Careful not to scratch the steel surface 13 For 930R select the correct O ring and fit in the groove discard extra O ring 14 Replace the flange O ring or gasket in the groove dry and then apply oil with 360 coverage of the O ring 15 Pre charge the Oil separator with BSE60K oil see nameplate for quantity 16 Re attach the top cover plate to flange by first finger tightening nuts on bolts with lock washers in between nut and flange face Start with any given bolt and gradually tighten crisscross pattern firmly up to 27 to 29 8 N m of torque for 922R 9227R 67 7 to 74 5 N m of torque for 928R 94 9 to 101 6 N m of torque for 930R Tighten mounting bolts in an opposing pattern to ensure even pulling down of the top cover assembly 17 Leak test check the oil separator flange junction 18 Evacuate the oil separator and interconnecting lines 19 Return the oil separator to operation slowly open the isolating valves 20 Monitor the oil levels and pressure drop frequently 21 Continue t
7. Requirements of prevention should be carefully considered and limited Substantial Work should not be started until the risk has been reduced for work 6 to 7 in progress urgent action is required Considerable resources may have to be allocated Intolerable If unlimited resources cannot reduce risk work will be prohibited 8 to 9 Is risk adequately controlled using the above control measures Y N State further action required If No state further action required Note This risk assessment is only valid when all control measures are in place before the work or activity commences If the nature of the work changes or there is a dangerous occurrence 58 BAO 103 1 AUS 18 Risk Asssessment Documentation Work Activity Charging Decanting Refrigerant Site Location On site location Those at Risk YIN Comments enter names or general groups Contractors Y Installation Personnel and Assistants Other Workers Y Sub contractors site maintenance personnel General Public N Comments When charging a system when decanting a system it is also very easy to overfill a recovery cyclinder An overfilled refrigerant recovery cylinder represents a serious explosion hazard It is essential that proper charging and recovery procedures be observed to prevent serious incidents involving injury or accidental emission of refrigerant HAZARDS 1 Explosion 2 Asphyxiation 3 Refrigerant
8. outdoors by the contractor installer in the vicinity of the relevant main pressure relief valves No additional pipework should be fitted on the outlet of the EVS as in the event of CO been released dry ice will form at the point of expansion The purpose of the EVS is to relief pressure in the suction header and or the CO liquid receiver before the pressure builds up and the PRV s are activated These solenoids are a high refrigerant leak risk Excessive venting may require solenoids to be serviced or replaced 9 24 Ancillaries Pressure Switches All compressors come fitted with mechanical Low Pressure LP and High Pressure HP safety switches Recommended Settings Only LP Cut Im 1200kPa Cut out 560kPa HP Cut Im 3200kPa Cut out 3950kPa Figure 21 Additional System Pressure Switches High Pressure Control KP6 High Pressure High Pressure Control KP6 Control KP6 HP Safety HP Safety Emergency HP Bleed System Cooling Unit Low Pressure Control KP5 LP Safety System 2 Low Pressure Control KP6 LPM Bleed The additional system pressure switches are located at the right hand end of the unit frame Each pressure control has a dedicated isolation service valve for service purposes The High Pressure safety Control is for Rack Safety The High Pressure Emergency Cooling Unit control is to operate the Emergency Condensing Unit The High Pressure safety Control HP Bleed is for the HP Bleed Sole
9. refrigerant level Liquid Receiver Check for oil leaks Check operation of EEV s operation and superheat setting Check operation of suction superheat BPHE control Log system s operating parameters Check electrical cables for tightness Leak test plant Record all monthly maintenance checks Quarterly Check system operating condition Check operation of emergency cooling unit where applicable Check cleanliness of the Emergency Cooling Unit Condenser Coil Check operation of Remote Air Cooled De Superheating Unit where applicable Check cleanliness of Coil Check fan Motors Check for abnormal noise and or vibration Check compressor oils for cleanliness and levels Check CO refrigerant level liquid receiver Check for oil leaks Check operation of EEV s operation and superheat setting Check operation of suction superheat BPHE control Log system s operating parameters Check all pipe clamps for tightness Check electrical cables for tightness Leak test plant Record all monthly maintenance checks Record all quarterly maintenance checks BAO 103 1 AUS lt a gt 12 Service and Maintenance Program Continued Annually e As per monthly check with the additional check listed below e Change compressor oil Clean each compressors oil filter and magnetic plug e Replace main oil strainer replace oil Filter with new approved model BITZER COS Oil Separators If Temprite Oil separator emp
10. Assessment Documentation Risk Evaluation of Identified Hazards Probability of Occurence Possible 2 Frequent 3 Hazard Severity Mimor 4 Serious Hospital 2 Major 3 days or more 12 3 aa Identified Hazards base scores on existing or planned control measures 1 2 3 1 2 3 1 Electric shock incorrect wiring SE SE NEEE ENE eel EES SE 2 Electric shock from earth leakage a 3 4 Moderate Scores Thought should be given to reducing risk but the cost and time 1 to 5 Requirements of prevention should be carefully considered and limited Substantial Work should not be started until the risk has been reduced for work 6 to 7 in progress urgent action is required Considerable resources may have to be allocated Intolerable If unlimited resources cannot reduce risk work will be prohibited 8 to 9 Is risk adequately controlled using the above control measures Y N If No state further action required State further action required Note This risk assessment is only valid when all control measures are in place before the work or activity commences If the nature of the work changes or there is a dangerous occurrence 62 BAO 103 1 AUS 18 Risk Asssessment Documentation Work Activity Electrical fault finding testing within the packaged unit During commissioning service and maintenance Site Location On site location Those at Risk YIN Comments enter na
11. CO R134a in Counter flow NOTE Figure 7 BPHE with Dual R134a Suction Outlets Connection F1 R134a Dual Outlets 2 to Liquid Separation Vessel Connection F2 CO Inlet Superheated Vapour from Liquid Receiver Vessel Connection F3 R134a Inlet From Liquid Separation Vessel Connection F4 CO Outlet Sub Cooled Liquid to Liquid Receiver Vessel Liquid pool BAO 103 1 AUS 25 lt gt 9 9 Ancillaries BPHE OPTIONAL HOT WATER HEAT RECLAIM UNIT BITZER CO Hybrid Racks are available with OPTIONAL HOT WATER BPHE This consists of a Dual Wall Stainless Steel Brazed Plate Heat Exchanger engineered to application The Dual Wall BPHE is intended for potable water applications NOTE Water mark level 1 Certificate of conformity AS NZS 3498 2009 CERTIFICATE No 23131 9 10 Water Connection to the HOT WATER BPHE Heat Reclaim Unit Installation e Of water plumbing connection for a dedicated Hot Water circuit to the OPTIONAL HOT WATER BPHE e Ensure that the refrigeration contractor s has successfully pressure tested leak tested the HOT WATER BPHE prior to installation of plumbing water circuit e The HOT WATER BPHE 1 1 4 MBSP water connections are to be connected counter flow to the refrigeration fittings by a registered licensed Plumber We recommend that additional BSP sockets valves be installed within the water circuit for periodic water circuit cleaning purposes e The maximum allowable connection load
12. Contractors should ensure that all persons are properly trained in handling refrigerants and have current dated handling licence Ensure adequate levels of ventilation Check emergency exits Procedures documents etc Communications afn ala When charging liquid refrigerant disconnect the hoses slowly in case liquid remains in the hose frost on hose may indicate that liquid is still present 2 Keep an accurate record of the amount of refrigerant added decanted or transferred 1 Comply with site rules permits may be required 2 Familiarise yourself with plant site emergency plan Emergency action procedures In case of leak 1 Isolate leak if possible If isolation is not possible evacuate area and follow the site emergency plan Treatment to injuries should be in accordance with the product data sheet Access Access should be restricted to the area where work is taking place Environmental afao w Disposal of waste refrigerants covered by various Environmental Protection Acts refer to local observe the Safety Standards and other National Safety Regulations BAO 103 1 AUS 59 18 Risk Assessment Documentation Risk Evaluation of Identified Hazards Possible 2 Frequent 3 HazardSeverity Mimor 14 Serious Hospital 2 Major 3 days or more 3 Probability of Occurence x Hazard Severity Risk Rating RR Probability Severity Identified Hazards base scores on existing or pla
13. Schematic pu uoy WOJY pamala se adUaNbas JossaJduo rm EEN 109 XQ NOSSINAMOO t 1 otr So tra ON Bue 3Hd8PePpooli N39 2U VW3HOS Teen EE Estepa z nne eG uoo ay ba rem a IU wen Sususpuc paroon av barco ut W3lvM LOH A EE EE EE ee penpumg beuma img Zen ema ig oma mar ambry EEN goe poa szogszgzede ufjeep s zsy az rn az ausen am at M 9944 eege Ardana men mro awm itt PRL UNS niat IO trenes BRL mmi pn canst IL Tad eijensny YAZLIG Jo Auedojg enee Mmm m uar amem Jaar remi rail egy wos pamata se a2uanbas JHdg papoo j Y sjossaA nn AAA dn dh dn 1 D S bn po lt quan sapo g sajdno ouueu1 loo ms Ve US Me qe Pas Da Des us p lt 9qou LH Sieg g sajdno oa yL 1x3 woyog S13110 SNM anon xis Agua doi s131NI INN NOLLONS XIS pusaba7 Ajquiassy awe eau wasis 3ujooo use s ag beren UARTUSSVSUTEHIUSH Die anjen JAY PEH pinbr uonns 3Hdg 1223 uonns iomiesau 10387edas 10 sa0ssa1duio 13 Schematic depicting 3 Compressor CO Rack with recommended Thermocouple Probe locations NOTES BAO 103 1 AUS lt a 9 Ancillaries Compressors At the heart of the BITZER CO Hybrid Rack is the BITZER Octagon CO compressor the solid drive gear design and valve plate construction have been specifically adapted to th
14. Superheater e The Liquid Line upstream of the Liquid line By Pass and Drier Shell e The liquid Receiver Pressure Relief Valves Notes e The 3 way valves do not require Non Return Valves Check valves in the current configurations For 3 Way Valve Brazing Soldering instructions See Figure 28 38 BAO 103 1 AUS lt a gt 10 Commissioning Pressure test The entire system should be pressure and strength tested prior to the evacuation process the pressure test should be carried out with Dry Nitrogen in accordance to relevant Australian New Zealand standards Prior and during all pressure test s label system with appropriate warnings and inform site safety officer of proceedings DANGER Under No circumstances is Oxygen or other industrial gases to be introduced Do not add HFC refrigerant as a leak indicator WARNING All work to be carried out to the relevant Standards by licensed accredited personal Ensure that the test pressure does not exceed 2500kPa on the low side and 4000kPa on the high side Test Inspect all components connections for leaks Employ the soapy water method of leak detection to system joints junctions while system is at test pressure We also recommend the use of quality electronic CO Leak detectors to insure system integrity Warning Electronic CO leak detectors can may register CO presence in the expanded polyurethane foam insulation within the Headers BPHE Enclosures Pressure Vess
15. a lowest vacuum This process reduces condensation build up within the vacuum Gump Mill Once the first evacuation is successfully completed Record findings within commissioning report Insure that the vacuum testing instruments are disconnected or isolated Vacuum gauges must not be exposed to excessive pressures Break the 1st vacuum with Dry nitrogen 20ppm moisture content to a positive pressure We recommend to charge through a drier shell with a drier core s fitted To further insure systems internal moisture content is reduced Install all system drier filter cores between the first and the second evacuation Keep any exposure of the system to atmosphere to a minimum Install BITZER approved BSE60K refrigeration oil to each compressor and Oil Separator Reservoir between the first and the second evacuation Activate the crankcase heaters Commence 2nd evacuation process And reinstate the vacuum testing instruments Once the 2nd vacuum is achieved Record findings within commissioning report Insure that the vacuum testing instruments are again disconnected or isolated Break the 2nd vacuum with refrigeration grade R744 CO vapour only to a positive pressure We recommend charging the vapour R744 CO through a drier shell with a drier core s fitted Commence 3rd evacuation process And reinstate the vacuum testing instruments Once the 3rd final vacuum is achieved Record findings within commissioning report The system
16. concentrations of CO cause increased respiration and headache n high concentrations may cause asphyxiation Symptoms may include loss of mobility consciousness e Victim may not be aware of asphyxiation e Remove victim to uncontaminated area wearing self contained breathing apparatus Keep victim warm and rested Call a doctor Apply artificial respiration if breathing stopped e Skin eye contact n case of frostbite spray with water for at least 15 minutes Apply a sterile dressing Immediately flush eyes thoroughly with water for at least 15 minutes Obtain medical assistance e Ingestion is not considered a potential route of exposure 5 FIRE FIGHTING MEASURES e Specific hazards Exposure to fire may cause containers to rupture explode Non flammable Hazardous combustion products Non suitable extinguishing media All known extinguishants can be used e Specific methods If possible Stop flow of product Move away from the container and cool with water from a protected position 50 BAO 103 1 AUS 17 BITZER BSE 60K OIL Material Safety Data Sheet MATERIAL SAFETY DATA SHEET According to 91 155 EC Printing date 23 03 2006 Reviewed on 23 03 2006 Identification of substance Product details Trade name BSE60K OIL e Application of the substance the preparation Lubricant e Manufacturer Supplier FUCHS EUROPE SCHMIERSTOFFE GMBH EXPORT DIVISION Friesenheimer Str 15 D 68169 Mannheim Tel 49 0 621 3701 0 S
17. discharge vapour once leaving the oil separator can be directed to the Optional dual wall Hot Water BPHE or directly to the integral or remote Air Cooled De Superheater The BITZER Air cooled De Superheater reduces the discharge gas temperature to an acceptable level where the vapour can be permitted to enter the discharge inlet service valve on the Liquid Receiver vessel The superheated Discharge vapour is internally circuited to a sparge manifold within the Liquid receiver vessel The sparge manifold dissipates distributes the discharge vapour evenly within the liquid pool The superheated bubbles rise to the Liquid receiver vessel roof The superheated vapour leaves the Liquid receiver via a gravity assisted process into a CO Flooded R134a BPHE cascade Condenser Evaporator located directly above The system matched CO Flooded R134a BPHE cascade Condenser Evaporator removes the CO THR total heat of rejection and condenses the CO back into liquid state Condensing is achieved by the counter flow of R134a liquid refrigerant from the high stage of the Cascade system The liquid CO then drains back into the insulated horizontal Liquid Receiver where the whole process continues A flooded plate Heat exchanger delivers R134a refrigerant from a seperator vessel suspended above the PHX using thermosiphon processes A minimum level in the R134a vessel ensures the PHX is in a flooded state BAO 103 1 AUS 9 lt a gt e The liquid
18. is 260 Nm Torque with a maximum Bending Moment of 87 Nm to the 1 1 4 MBSP Water fitting Ensure that all interconnecting plumbing water pipes are structurally secured before and after the BPHE 26 BAO 103 1 AUS 9 11 Cleaning of the HOT WATER BPHE Thanks to the normally high degree of turbulence in the BPHE there is a self cleaning effect in the channels However in some applications the fouling tendency can be very high EG when using extremely hard water at high temperatures In such cases it is always possible to clean the exchanger by circulating an approved cleaning liquid CIP Cleaning In Place Use a tank with weak acid solution 5 0 phosphoric acid or if the exchanger is frequently cleaned a 5 0 solution of oxalic acid For optimum cleaning the cleaning solution flow rate should be minimum 1 5 times the normal flow rate preferably in a back flush mode After use do not forget to rinse the exchanger carefully with clean water A solution of 1 296 sodium hydroxide NaOH or sodium bicarbonate NaHCO before the last rinse ensures that all acid is neutralized Check PH test sample of water leaving the BPHE after the cleaning process is complete Clean the BPHE water circuit at regular intervals 9 12 Ancillaries R134a Liquid Separation Vessel BITZER CO Hybrid GEN 72 Racks are supplied with an R134a rated horizontal Liquid Separation vessel The Liquid Separation vessel comes with 50mm insulation and is encapsulated in a metal
19. is now ready for R744 CO refrigerant charging System must be charged from a vacuum with vapour R744 only For locations of Evacuation Connections refer List below and Figure 1A BITZER CO Hybrid GEN 7 Rack Schematic mec om 40 The Liquid line 3 8 MSAE Post valve upstream of the 2 Core liquid line Drier The Suction Line 23 8 MSAE Post valve upstream of the Suction Drier Accumulator vessel The 21 4 MSAE Post valves at the Suction header One per Suction Inlet The 1 4 MSAE service port on the Rotolock valve Discharge entering the Liquid Receivers Vessels internal sparge manifold The 21 4 MSAE service port on the Rotolock valve Liquid leaving the Liquid Receiver vessel The Compressor service valve 01 4 MSAE connections DL and SL Valves BAO 103 1 AUS lt a gt 10 2 Commissioning Oil Oil type BITZER BSE 60K POE SR ATTENTION The POE oils used in the BITZER CO Hybrid rack is hydroscopic when exposed to the atmosphere it absorbs moisture Excessive moisture in the CO can lead to a build up of organic acids as the free moisture reacts with both the POE and the CO e Do not reuse drained oil that has been exposed to the atmosphere e The minimization of system internals exposure to atmosphere e The use of 100 molecule sieve driers for moisture removal only e Check operation of crankcase heaters during evacuation 10 3 Commissioning Controls Special attention must be taken in the control strategies
20. level within the suspended storage vessel R134a Liquid Separation vessel is controlled by an SHP level sensor this would drive either an AKV or stepper style valve that feeds liquid refrigerant into the vessel A single point level switch is also included for safety backup To insure that the vessels level does not over fill In addition a capillary circuit is connected from the R134a BPHE Liguid inlet tube to one of the Suction Outlet Lines exiting the liguid separation vessel This is to insure that oil returns from the flooded evaporator circuit and that oil retention within both the BPHE and the Liguid Separation vessel is minimised NOTES The Air Cooled De Superheater is recommended on BITZER Flooded CO GEN 7 rack The Air Cooled De Superheater provides improved efficiency The Air Cooled de Superheater should be set to maintain a CO outlet temperature of less than 60 KTD above the R134a Evaporation temperature 10 BAO 103 1 AUS lt a Figure 1A The GEN 7 Liquid Receiver BPHE CO Flooded R134a R134a Separation Vessel amp Remote De Superheater GEN 7 d 1 4 9 Bufalo Air Cocied De Superhester j EE EL eeesoJ eg 1 4 Lud HENARES PAU ELE SEN SE AH Discharge Lira em Vessels amp Flooded BPHE Sequence as viewed from Rear Liquid Line Loes Line reuiation Z rem Weil meg BAO 103 1 AUS 11 Figure 1B BITZER CO Hybrid Rack GEN
21. liquid line Drier Core replacement 4 Please note that the driers cores are supplied loose within the accessories carton and should be installed as part of the commissioning See commissioning section 5 The 93 8 Post valve can also be employed for reclaim of residual CO refrigerant from the Drier Shell cavity prior to Drier core changes and evacuate same area before opening the system Figure 16 Liquid Line Drier circuit amp Suction Re Heat BPHE Engineered to Application Schematic Liquid line By Pass Solenoid Valve Set points Solenoid On 5 C Off 8 C 3 Way Ball Valve Liquid Line Drier By Pass circuit 3 8 Service Valve Recommended for System Evacuation and System Charging Hari iza Lona ees Ba ics Ier imire mI ATTENTION Only fit 10076 molecular sieve driers when replacing liquid drier cores excessive moisture content in the CO will lead to a build up of organic acid BAO 103 1 AUS 31 lt a gt 9 15 Ancillaries Suction Superheaters Due to the high solubility of CO amp POE oil it is essential that the compressor crankcase is kept above 20 C Low crankcase temperatures will allow the high density CO to dilute into the oil leading to compressor failure The BITZER CO Hybrid racks use several methods depending on generation to superheat the return CO suction vapour superheating the suction vapour raises the compressor discharge temperature which in turn raises the oil temperature
22. reset The level control is divided into 3 zones The green LED indicates that the oil level is within the normal limit green zone 50 70 sight glass height and only the green LED is on On reaching the yellow zone the OW3 is switching on the yellow LED after a 10 second delay The time delay of 10sec is necessary to avoid flickering of the LED s during compressor start up as the oil level can vary greatly and thereby switching the LED on off frequently When in the yellow zone only the yellow LED is on 50 30 sight glass height The yellow zone can be interpreted as a warning zone and indicate that the oil separator is not operating correctly or that the compressor is throwing out excessive oil into the system Should the oil level reach the red zone 30 sight glass height the OW3 will generate a critical alarm after a delay of 20sec The alarm relay will switch to ALARM and the red LED will illuminate pE ATTENTION The external compressor control circuit wiring should automatically shut down The compressor s failure to do so may result in compressor damage and void warranty Figure 5 OW3 Electrical Wiring Connect CAB301 cable to relay connection maximum 3A 240V according to Figure 7 e Blue open in Alarm Black Common Brown closed in Alarm e Do not switch compressor directly use the compressor power relay instead Connect CAB302 cable to 24VAC 50 60Hz 0 7A see Figure 7 Ensure the cables are paralle
23. should be carried out by qualified persons and in accordance with AS3000 or equivalent standard in the country of installation Refer to AS3000 for electrical installation and for service maintenance of electrical equipment 9 2 1 Electrical Connections BITZER Australia recommends that all electrical connections must be checked tightened amp tested prior to connection to mains power Power supplies must be checked to insure that they conform to the compressor s nameplate data All Control circuits must be checked prior to system connection to mains power 18 BAO 103 1 AUS 9 2 2 Electrical Operational Precautions BITZER Australia recommends that insure trouble free operation the following electrical precautions should be observed Voltage fluctuations in excess of 1096 must be rectified Compressor overload relays motor protection device are selected according to compressor motor demand specification and must not be changed in size or function Insure that all connected power supply is consistent with equipment nameplate rating All safety controls settings must be set according to recommendations Minimum Ensure that all safety controls are wired into circuit as title indicated within schematic Under no circumstances should electrical safety controls be removed bridged or bypassed 9 2 3 Electrical Connections Frequency Inverters BITZER Australia recommends that that the lead CO compressor should operate
24. system control valves amp electronic controls are not factory set due to the flexible applications of this unit All controls must be correctly commissioned by a qualified amp trained technician 1 BAO 103 1 AUS lt a gt 2 Safety Instructions All work on compressors and refrigeration systems shall be carried out only by refrigeration personnel who have been trained and instructed in all work The qualification and expert knowledge of the refrigeration personnel corresponds to respectively valid guidelines We recommend hanging a large sheet of paper on the rack and labelling this sheet indicating the systems condition during commissioning process e g System in pressure leak test System Under 1st Evacuation with all inline valves fully open System under electrical controls circuits test etc This assists with completing the commissioning worksheet and informs site personal and site Safety Officer of the progress of the commissioning All plumbing work on the Optional Hot Water BPHE shall be carried out only by licensed accredited plumbing personnel who has been trained and instructed in all work The qualification and expert knowledge of the plumbing personnel corresponds to respectively valid guidelines See 9 10 The BITZER CO Hybrid Rack is constructed according to the state of the art and valid regulations Particular emphasis has been placed on the users safety Retain these Operating Instructions during the entire li
25. the system 3 8 MSAE Liquid line charging Service Valve This insures refrigerant charging through the systems dual core liquid line drier 2 We recommend an additional 10096 molecular sieve driers shell be installed in the charging line to further insure that the system is charged with Dry R744 3 This system must be vapour charged with R744 until the system pressure is above 500kPa 4 Only when the entire system is at 500kPa or greater can you then begin to Liquid Charge R744 CO into the Liquid Line Charging Service Valve 3 8 MSAE And the Liquid Receiver once an overall all system pressure of above 500 kPa has been reached 5 Continue charging liquid into the receiver until a level is clearly visible in the second sight glass Once this level has been reached turn on one sub system at a time do not turn to many sub systems at once as this can lead to a rapid rise in pressure Add additional refrigerant as required Vapour can be charged into the liquid receiver wet gas return or dry suction Liquid can be charged in to the liquid receiver or liquid line Ensure that the system is sufficiently charged with R744 CO IN WARNING CHARGING LIQUID CO INTO THE SYSTEM AT PRESSURES BELOW 500kPa CAN LEAD TO THE FORMATION OF CO IN A SOLID FORM DRY ICE OND BAO 103 1 AUS 41 yN WARNING Do not overcharge system with refrigerant mi ATTENTION Avoid high cycling rates on compressors m ATTENTION Switch off compr
26. used to control the BITZER CO Hybrid rack and the high stage rack the very minimum we require the following The use of electrical interlocks to prevent the BITZER Hybrid CO rack operating without the high stage rack operating e Evaporator and fans should be staged off in the event of the suction pressure reaching 2200kPa Evaporators and fans should be staged back on after a power outage 10 4 Commissioning Starting Up and Charging IN WARNING The following should only be carried out by suitably qualified refrigeration technician Ensure that all gauges are accurate and hoses are in good condition and have sufficient pressure rating A Risk Assessment and SOP should be completed before this work is carried Appropriate PPE must be worn The high stage system and emergency cooling unit must be commissioned with all safety and control circuits proven All safeties and control circuits on the BITZER CO Hybrid Rack should be set and tested Energise the crankcase heaters and ensure that the oil temperature is between 35 C to 40 and that there is sufficient oil in the compressors and the oil separator gt The BITZER Hybrid CO unit should be charged with refrigeration grade R744 CO with a moisture content of 10 parts per million or less Extreme care must be taken when charging the system with R744 From a vacuum Only Vapour Charge R744 Refrigerant into The Refrigeration System 1 Connect the refrigerant charging line into
27. with a frequency inverter in order to reduce compressor cycling It is also advantages as higher system efficiency can be achieved especially under partial load 9 2 4 Selection Criteria Frequency Inverters The frequency inverter must be able to continuously supply the maximum operating current to the compressor motor additionally a 10 reserve should be planned for Selections should be made in accordance with KT 420 1 Application Manual The torque of reciprocating compressors is not constant with the angle of rotation the higher the number of cylinders the more constant the torque thus a greater starting torque is required for a smaller number of cylinders The maximum current must be within the transient overload rating of the frequency inverter If this is not the case then a larger type of frequency inverter must be selected Several values of rated current constant and quadratic torque ratings are provided by frequency inverter manufacturers select a frequency invertor based on a constant torque rating The frequency inverter must be capable of briefly delivering over torque during the starting phase in order to overcome the break away torque and too accelerate the drive This results in increased current demand for starting the compressor which must be provided for by the frequency inverter in the ramp up time gt Variable speed drive VSD gt Standard speed range gt HC Series 30 Hz 50 Hz gt SLSeries 30 Hz
28. x spare Temprite coalescent Oil Cartridge sized to application when Temprite Oil Separator selected 1 x S56 119 Hansen Level Probe SHP12 0 5 Volt R134a GEN 7 1 x S56 166 Hansen SPSF Single Point Level Switch R134a GEN 7 Component Check list for 3 Compressor CO Rack e 1 x BITZER CO Three Compressor Parallel Rack 3 x BITZER Compressor instructions comes with spare service valve gaskets for compressors 1 x Wooden packing crate 3 x Crankcase heaters Supplied loose 9 x One litre cans of BSE60K BITZER Compressor Refrigeration Oil Item No 106 033 6 x Embelton NR3 Equipment Mounting feet each 500kg rated Item No P37 053 e 3 x Traxon Oil level control electrical leads 1 x Suction Drier felt element F48 e 2 x Liquid line Drier Cores 48 DM 100 Molecular sieve Item No S03 033 e 1 x Henry Optical level Switch E 9224A N C 24V AC DC Item No K06 003 to suit Liquid Receiver bottom Sight Glass 5 x Henry Frost Shield Perspex viewing elements to suit Liquid Receiver top and middle Sight Glasses e 1 x spare Temprite coalescent Oil Cartridge sized to application when Temprite Oil Separator selected 1 x S56 119 Hansen Level Probe SHP12 0 5 Volt R134a GEN 7 1 x S56 166 Hansen SPSF Single Point Level Switch R134a GEN 7 Component Check list for 4 Compressor CO Rack e 1 x BITZER CO Four Compressor Parallel Rack 4 x BITZER Compressor instructions comes with spare service valve gask
29. 2 173 3305 3305 33944 33944 34 857 35 787 36 735 37 702 38 688 3969 3 39 693 40 716 41 76 42823 42823 43 906 450 4501 46134 46 134 47 279 48 446 49 634 50 844 52 077 53332 53332 54 611 5591 4 55914 57 242 58 594 59 973 61 378 62812 62812 64 274 65 766 67 289 68 846 70 437 72 065 73 733 73 834 Kpa Bar 48 BAO 103 1 AUS lt a The R744 CO operating window displays the fact where R744 CO refrigerant must be initially charged as vapour only to reduce the risk of the refrigerant forming internally as DRY ICE 15 R744 CO Operating Window Pressure bar e 10 1 80 70 60 50 40 20 0 OF 10 20 30 40 50 70 80 90 100 Temperature De g C BAO 103 1 AUS 49 lt a gt 16 R744 CO Material Safety Data Sheet Safety Data Sheet Version 1 Product R744 MSDS Nr 300 00 2008BOC A Date 13 12 2005 BOC UNITED KINGDOM 1 IDENTIFICATION OF THE SUBSTANCE PREPARATION AND OF THE COMPANY e Product name R744 e Chemical formula CO e Company identification see heading and or footer 2 COMPOSITION INFORMATION ON INGREDIENTS e Substance Preparation Substance e Components Impurities Contains Carbon dioxide EINECS No 204 696 9 CAS Nr 124 38 9 e EC Nr from EINECS 204 696 9 3 HAZARDS IDENTIFICATION Hazards identification Liquified gas n high concentrations may cause asphyxiation 4 FIRST AID MEASURES e Low
30. 3 1 AUS lt a gt Carbon dioxide is colourless odourless gas or cryogenic liquid The AS1677 Refrigeration standard classifies R744 CO as a A1 group refrigerant 3 SAFETY CARBON DIOXIDE R744 At low concentrations the gas is odourless higher concentrations it has a sharp acidic odour Carbon dioxide is a powerful cerebral dilator It is also an asphyxiate and an irritant The effects and there concentrations of CO refrigerant are listed below in Table 1 Table 1 Physiological Effects of CO PPM EFFECTS ON HEALTH 350 Normal value in atmosphere 1 000 Recommended not to be exceeded for human comfort Threshold Limit Value TLV Time Weighted Average TWA mone Concentration to which one may be repeatedly exposed for 8 hours per day without adverse effects 20 000 Can affect the respiration function and case exitation followed by depression of the central nervous system plus 3 a 509 increase in breathing rate 30 000 1009 increase in breathing rate after Short Term Exposure Limit STEL 15 minutes TWA exposure should not i exceed at any time of day 40 000 a 50 000 Immediately Dangerous to Life or Health IDLH maximum level 100 000 Lowest lethal concentration Few minutes exposure produces unconsciousness 200 000 Death accidents have been reported 300 000 Quickly results in unconsciousness and convulsions ZW CAUTION B Contact with CO cold gas or liquid can cause freezing to exposed tissue Note Do not attempt to re
31. 7 3725 1360 tel 64 9 415 030 fax 61 2 9673 4698 fax 61 3 9310 2520 fax 61 8 8268 4555 fax 61 8 9359 2077 fax 61 7 3274 3621 BAO 103 1 AUS 66
32. 7 Schematic Compressors Oil Separator Reservoir Suction Reheat BPHE Suction Liquid Header amp Relief Valve manifold Front Frame Assembly es a S Je SIX SUCTION LINE INLETS Top Entry Liquid Line Vessels BPHE s Emergency Cooling System Rear frame Assembly SIX LIQUID LINE OUTLETS Bottom Exit sell sel eel cel cell se FAA HEADER Ab 1 D L Ka Discharge Une ma Vessels amp Flooded BPHE Sequence as viewed from Rear SS Intellectual Property of BITZER Australia o gt BITZER chemate GEN 78 Rach System RTM 2014 Becvoni Espanaion Paine varva 1 ici Onchang Une its Ot parao Oei to Meat aci BPE ta ty SCHEMATIC GEN 78 Flooded BPHE Drawing No arg oy A 3 COMPRESSOR DX CO RACK 2014 U23 XXX Compressor Sequence as viewed from front tenda EARN NOTES Schematic depicting 3 Compressor CO GEN 7 Rack Schematic depicting system complete with Temprite Oil Separator Reservoir and Pressure Differential Indicator Schematic depicting system complete with Hot Water BPHE Remote Air Cooled De Superheater depicted with dotted lines Integral Air Cooled De Superheater Option not shown Remote or integral Air Cooled Condensing Unit for Emergency Cooling BPHE Option not shown BAO 103 1 AUS 12 Figure 1C Thermocouple probe Locations BITZER CO Hybrid Rack
33. C 55 mm s DIN 51 562 Stability and reactivity Thermal decomposition conditions to be avoided No decomposition if used according to specifications Dangerous reactions No dangerous reactions known Dangerous products of decomposition No dangerous decomposition products known Toxicological information Acute toxicity Primary irritant effect on the skin No irritant effect known on the eye No irritant effect known Sensitization No sensitizing effect known Additional toxicological information When used and handled according to specifications the product does not have any harmful effects according to our actual information Ecological information e Behaviour in environmental systems e Mobility and bioaccumulation potential No data available Eco toxic effects Remark Harmful to fish e Behaviour in sewage processing plants e The product sinks in the sewage water on account of its high specific gravity eventually it is able to pass the conventional collector for light density material General notes German Water Endangering Class 1 Self assessment slightly hazardous for water Do not allow to reach ground water water bodies or sewage system Harmful to aquatic organisms Disposal considerations e Product e Recommendation Must not be disposed of together with household garbage Do not allow product to reach sewage system When storing used mineral oil products ensure that t
34. Class 1 Self assessment slightly hazardous for water Other information All ingredients are listed in the European Inventories These data are based on our present knowledge However they shall not constitute a guarantee for any specific product features and shall not establish a legally valid contractual relationship This data sheet is a safety data sheet according to 91 155 EU For products which are not subject to classification according to EU lists this data sheet is made on a voluntary base e Relevant R phrases 50 53 Very toxic to aquatic organisms may cause long term adverse effects in the aquatic environment Department issuing data specification sheet FUCHS EUROPE SCHMIERSTOFFE GMBH Export Division Product Safety Department Contact Product Safety Department Tel 49 0 621 3701 333 Mrs Manuwald e Validity With this latest edition of this MSDS all former editions are invalid 54 BAO 103 1 AUS 18 Risk Assessment Documentation Work Activity Transport lifting Site Location Onsite location Those at Risk Y N Comments enter names of general groups Contractor Y Installation personnel and Assistants Other workers Y General Public N Comments The package is supplied shrink wrapped on an export treated wooden skid and requires installing in its final position No one under the age of 18 will undertake lifting or slinging operations unless directly and closely supervi
35. FILTER KIT CLEAN UP 922R 923R B36 080 OIL FILTER KIT STD 924R 925R B36 081 OIL FILTER KIT CLEAN UP 924R 925R B36 082 OIL FILTER KIT STD 926R 927R B36 083 OIL FILTER KIT CLEAN UP 926R 927R B36 084 OIL FILTER KIT STD 928R B36 085 OIL FILTER KIT CLEAN UP 928R B36 086 OIL FILTER KIT STD 930R B36 087 OIL FILTER KIT CLEAN UP 930R B36 088 PRESSURE DIFFERENTIAL INDICATOR 2243 Temprite Oil Separator Reservoirs are manufactured to AS2971 with a Design Pressure 45 bar Description Temprite Oil Separator Reservoirs recommended BSE60K vessel oil charge BITZER Item Description Oil Charge No P Litres B36 070 2 27 B36 071 2 27 B36 072 3 22 B36 073 322 836 074 67 836 075 6 7 B36 076 7 55 836 077 2125 NOTE BITZER COS and Temprite Coalescent Oil Separator Reservoirs complete with accessories are available from BITZER Price Book BAO 103 1 AUS 23 lt a gt 9 4 Ancillaries TRAX Oil Compressor oil level control The OW3 Trax Oil uses a Hall Sensor to measure oil level A magnetic float changes its position according to the oil level The Hall Sensor converts these magnetic field changes into an equivalent signal which is used by the electronic controller to show with LED s the actual oil level If the oil level drops into the red zone the OW3 generates an alarm signal and the alarm contact SPDT changes into the alarm state The later can be used to shut down the compressor If the oil level comes back to normal the alarm will
36. HORT CYCLING SETTING Min COMPRESSOR OIL LEVELS A SSS eS OIL SEPARATOR RESERVOIR LEVEL TEMPRITE PRESSURE DIFFERENTIAL INDICATOR READING Lite J TRAX OIL LEVEL CONTROL CHECK AAA AAA LIQUID RECEIVER LIQUID LEVEL A A A LIQUID LEVEL OPTICAL LEVEL SENSOR TEST E EST LP TRANSDUCER CHECK NorX HP TRANSDUCER CHECK sox T T HIGH STAGE SYSTEM 134a E AA EU HIGH STAGE SYSTEM R134a CHECK FOR OPERATION COMMISSIONING yox V GKG Y SK HIGH STAGE SYSTEM R134a SUCTION SUPERHEAT RIGHT HAND SUCTION LINE rc SSS SSS 22383 HIGH STAGE SYSTEM R134a SUCTION SUPERHEAT LEFT HAND SUCTION LINE loc h HIGH STAGE SYSTEM R134a AKV OR EEV SETTING oC Il LIQUID SEPARATION VESSEL R134a LEVEL LIQUID SEPARATION VESSEL R134a SHP LEVEL PROBE a E PD LIQUID TEMP R134a ENTERING BPHE loc 1 LIQUID TEMP R134a EXITING RIGHT HAND SIDE OF BPHE Eo SS Se a LIQUID TEMP R134a EXITING LEFT HAND SIDE OF BPHE eo hf REMOTE EMERGENCY BACKUP CONDENSING UNIT BITZER COND UNIT MODEL NO BITZER COND UNIT SERIAL NO pr ERSTE DENEN S COMPRESSOR RUN AMPS RWB SUCTION PRESSURE e E S O 1 SUCTION TEMP Lc 0g Y DISCHARGE PRESSURE PA O ET DISCHARGE TEMP Lc po HP CONTROL SETTING Kpa COMPRESSOR OIL LEVEL BAO 103 1 AUS 43 lt a gt 12 Service and Maintenance Program BITZER Australia recommends that the following service and maintenance checks should be carried out as a minimum requirement HA ATTEN
37. Location of PRV s on Rack Solenoids shown without Coils fitted High Pressure High Pressure High Pressure OPTIONAL High Pressure Low Pressure i High Pressure Liquid i 1 GEES a Solenoid Vent q Discharge line High Pressure Liquid line Liquid line Line Liquid Receiver Before and Discharge After Drier After Drier HP Bleed EE Relief Valve After Oil Sep circuit Relief Valve Relief Valve Relief Valve No 2 40 bar Relief Valve Relief Valve 40 bar 25bar No 1 40 bar 40 bar 40 bar Low Pressure Solenoid Vent Line LP Bleed 3 Way Ball Valve To switch from Liquid Receiver Relief valves No 1 or No 2 NOT SHOWN Low Pressure Transducer Connection 91 4 MSAE High Pressure Transducer Connection 91 4 MSAE BAO 103 1 AUS 35 lt a gt 9 22 Ancillaries Transducer Points BITZER CO Hybrid come with suction and discharge transducer post valves Figure 20 Please note that the actual transducers are not part of the rack scope of supply Transducers by others The suction transducer post valve is connected the main suction header the discharge transducer post valve is connected to the CO liquid receiver 9 23 Ancillaries Emergency Vent Solenoid EVS LP Bleed and HP Bleed The BITZER CO racks come fitted with additional HP switches to control emergency vent solenoids Figure 21 Emergency Vent Solenoids are included within the part of the scope of supply of the rack and should be relocated
38. THE HEART OF FRESHNESS OPERATING INSTRUCTIONS BITZER AUSTRALIA LEA AAA DL E E A E RE A AR A SS NN R A BITZER CO HYBRID GEN 7 PARALLEL COMPRESSOR PLANT Content 1 General 2 Safety Instructions 3 Safety Carbon Dioxide R744 CO 4 Inspection and Unit designation 5 Product Accessories Check list 6 Installation T Application 8 Operation 9 Ancillaries Product Components 10 Commissioning data 11 Commissioning Sheet 12 Service and Maintenance 13 Pictures and Drawings 14 CO Pressure Temperature Chart 15 CO Operating Window 16 CO MSDS Sheets 17 BITZER OIL BSE 60K MSDS Sheets 18 Risk Assessments 1 General This document is designed to outline the installation requirements commissioning amp operating instructions for the successful operation of the BITZER Sub Critical CO Hybrid Gen 7 Parallel Compressor Rack BITZER Designed and Engineered Sub Critical CO Applications only DX Direct Expansion CO Evaporators Systems only Not suitable for Flooded Evaporator Liquid Recirculation Cooling Hybrid Gen 7 system of mixed origins R744 CO Low stage and R134a High stage Parallel Compressors available in 2 3 8 4 Compressor line ups employing the latest BITZER CO sub critical SL series compressors Rack Industry title Racked Compressor Systems Parallel compressor units for multiple refrigeration compressor units NOTE The safety switches controls
39. TION Failure to comply with the schedule listed below and to maintain accurate service and maintenance records may result in premature failure and poor operation of the BITZER CO Hybrid rack and will affect any warranty claims First 100 Hours of operation Change compressor oil Clean compressor oil filter and magnetic plug Replace main oil strainer replace oil Filter with new approved model BITZER COS Oil Separators If Temprite Oil separator employed check pressure differential indicator and replace Temprite cartridge with spare Take oil sample for analysis Check Clean internal filters within the Traxon Oil level Controls Check evaporators frost patterns Check high stage rack system Log system s operating parameters Both CO and High stage Plant Check operation of emergency cooling unit Check for abnormal noise and vibration Check compressor crankcase temperatures Check all refrigeration unit pipe clamps Stauff Clamps for tightness Check Air Cooled De Superheater Check electrical cables for tightness Check Electrical Switchboard s for hot spots Laser Thermal Sensor Check Compressors current draw Check the system refrigerant charge Leak test plant Record all 100 hour maintenance checks Monthly Check system operating conditions Check operation of emergency cooling unit Check for abnormal noise and or vibration Check compressor oils for bubbles cleanliness and levels Check CO
40. a a three way ball valve then on to the 2 core 10096 molecular sieve drier shell There is also a drier shell by pass circuit to simplify drier core changeover while the system remains in operation The by pass is operated by the liquid line three way ball valve and straight thru ball valve We have also provided an 23 8 post valve for liquid charging fast evacuation or reclaiming refrigerant from the drier cavity prior to drier core replacement The Liquid refrigerant exiting the liquid line then enters the four six or eight circuit liquid header manifold The sub cooled liquid then enters field piping to the LT evaporators via electronic expansion valves located at fixtures and returns to the rack as superheated vapour via the four six or eight circuit Suction Return header manifold The suction vapour then flows within the suction line to the CO suction vapour BPHE gaining superheat The suction return vapour then enters the suction filter accumulator vessel before reaching the compressors The low pressure suction vapour then enters the compressor s where it becomes compressed to a high superheated pressure then discharged into a common header before it enters the Oil Separator Reservoir The Oil is separated filtered and returned back to the compressor s via an oil manifold Individual oil levels within each compressor are maintained with oil level controls fitted to the crankcase of each compressor The high pressure
41. alled 60W VAC VDC L 3A leads _to alarms etc Figure 4B Temprite Pressure differential Indicator PDI BITZER Item No B36 088 This PDI indicator includes electrical leads that can be wired to your Micro processor refrigeration control system To indicate when the differential across the oil separator is too high requiring a filter change The Alarm differential pressure is 0 83 Bar The Yellow Green transition is 0 69 Bar The Yellow Red transition is 0 89 Bar PDI Pressure Differential Indicator Electrical data 60W VAC VDC 3 0 Amp leads to your Alarm BAO 103 1 AUS 21 lt a gt 9 3 2 Ancillaries BITZER Temprite Coalescent Oil Separation System Figure 4C Temprite Clean up Filter Temprite Filter Change Instructions 1 Isolate Oil separator from System 2 Recover or recycle any remaining refrigerant from the oil separator 3 Be sure that the Oil Separator is de pressurized 4 Carefully unbolt the flange bolts and nuts Put aside with washers to be reused 5 Carefully remove the top plate 6 Remove the filter retaining nut and sealing washer 7 Remove the old filter and O ring from the bottom of the filter 8 Make sure that the filter sealing surface inside the separator is smooth and clean of dirt 9 Wipe clean oil separator internals so that it is free from any dirt scale or contaminates 10 Dispose old oil properly 11 Install a new Temprite replacement filter cartridge a
42. allel BPHE Cascade Condensers comes with Metal Cladding and 75mm Insulation Engineered to application and clients specifications BPHE s CO Condenser side and R134a Evaporator side 1 x Suction Re Heat BPHE comes with metal cladding and insulation Engineered to application 1 x Emergency Cooling BPHE Cascade Condenser Evaporator R744 R134a comes with R134a TX Valve To maintain refrigerant CO temperature pressure within the Liquid Receiver during i e catastrophic system failure power failure The emergency unit is designed to hold R744 in the system only 1 x Horizontal liquid Receiver c w Level Indicator Sight glasses engineered to application 1 x BITZER Dual Suction Liquid header assembly comes with Insulated enclosure suction ball valves Service valves Liquid ball valves 1 x Liquid line 2 Core Drier assembly comes with Insulated enclosure liquid line by pass circuit for continuous run during drier replacement and one 03 8 MSAE post service valve for system charging or refrigerant reclaim prior to drier core replacement Compressor pressure controls 1 x LP and 1 x HP per compressor System Pressure Controls 5 comprising of 1 x LP and 4 x HP controls BITZER Pressure Relief Manifold consisting of 1 x LP Pressure Relief Valve 2500kPa 6 x HP Pressure Relief Valves 4000kPa 1 x LP Bleed Solenoid 1 x HP Bleed Solenoid associated Service valves 1 x LP transducer port comes with service valve and 1 x HP transd
43. be lifted from the base The BITZER CO Rack should remain within its wooden crate until located on designated area within plant room 3 The BITZER CO Rack must remain perpendicular upright and level during installation 4 A single BITZER CO Rack unit will have a Net Weight between 1250kg up to 2100kg depending on number of compressors compressor models BPHE s and options applied 5 The BITZER CO Rack must be set on a flat level foundation 6 The BITZER CO Rack is intended for indoor use In a designated plant room area to Australian New Zealand building codes T The designated plant room floor area must allow for the rack weight and size Including the refrigerant weight electrical wiring equipment and conform to current building codes 8 Clearances A safe working space surrounding 360 to be provided including free access to above and must conform to current building codes A safe working distance must also apply to any adjacent switchboards or mains boards Free working space is required for service of the BITZER CO Hybrid Rack 10 When the BITZER CO Hybrid Rack in located in its designated location Unpack the wooden crate plastic wrapping Install the Embelton mounting feet to both the floor and the unit frame Adjust mounting feet until the rack is level Embelton NR3 adjustable mounting foot Capacity 500Kg each Item No P37 053 4 SH 11 The Embelton mounting feet slightly raise the BITZER DX CO Hyb
44. d level Alarm sensor be tested during Commissioning and periodically when general maintenance occurs 4 The Horizontal Liquid Receiver B30 242 GEN 7 for Systems 40kW to 70kW nominal capacity 110Kg Pump Down capacity CO 2 Csst 80 Full 5 The Horizontal Liquid Receiver B30 262 GEN 7 for Systems below 40kW nominal capacity 55Kg Pump Down capacity CO 2 Csst 80 Full 6 TheLiquid Receiver Vessel is located on the base of the unit frame directly below the BPHE Cascade CO Condenser R134a Fully Flooded Evaporator BITZER CO Hybrid GEN 7 Racks are supplied with a CO rated horizontal liquid receiver the receiver comes with 50mm insulation and is encapsulated in a metal enclosure All vessels are manufactured to AS1210 Figure 12 shows technical details for the different type of the receivers Figure 12 B30 242 Horizontal Liquid Receiver CO Colorbond Metal Clad and insulated CO DISCHARGE LIQUID CO co co ee INLET VALVE CO VESSEL INLET FROM ae EMERGENCY EMERGENCY CO LIQUID FOR LEVEL ROTOLOCK RELIEF VALVE THE BPHE TUE BPHE COOLING COOLING INLET OUTLET VALVE INDICATION TO INTERNAL SOCKET CONDENSER CONDENSER OUTLET TO EM FROM EM ROTOLOCK SPARGE COOLINGE COOLING BPHE MANIFOLD NAMEPLATE NOTE Frost shield viewing elements and E 9224 Liquid Level Sensor not shown within Figure 12 1 The three Frost Shield Perspex viewing elements are supplied within the accessories carton Gently insert one Frost S
45. e requirements of CO which leads to a further increase in operational efficiency BITZER SL Series sub critical CO Compressor Maximum Permissible Pressure standstill Suction side SL Models 30 Bar HC Models 25 Bar Discharge side SL Models 53 Bar HC Models 43 Bar Minimum Suction Gas Superheat 20K lower suction gas superheat is possible provided that the minimum oil and discharge gas temperatures are maintained Minimum Oil Temperature 20 C for continuous operation oil temp should not fall below 30 C Minimum Discharge Temperature 40 C for continuous operation discharge temp should not fall below 50 C Operation of Discharge Temperatures Discharge temperatures below 35K above sct indicate low suction superheat conditions check evaporator operation Operating Envelope BITZER CO Sub Critical Compressors enerationll 55 50 45 40 35 30 25 20 15 10 t C Note SL Series Latest Generation HC Series Previous Generation still current 1st Generation 14 BAO 103 1 AUS 9 Ancillaries Compressors BITZER CO Sub Critical Compressors Figure 2 The BITZER CO Hybrid SL Series Compressors Figure 3 BITZER Compressor Program Survey Program Survey OCTAGON CO Series 50 A F rdervolumina mei Displacements 50 Hz 40 Volumes balay s BAO 103 1 AUS 15 lt a gt Table 3 BITZER Compressor Technical data
46. els Insulation Site piping During the pressure testing process we recommend covering relief valves Bleed vents with balloons to visually check for any leaks When the pressure test s are completed record findings When the pressure test s are completed reduce the system pressure to a safe holding pressure recommended 500 kPa BAO 103 1 AUS 39 lt a gt 10 1 Commissioning Evacuation and Dehydration The BITZER CO Hybrid rack requires a minimum evacuation of 500 microns we therefore recommend the following The Initial Step is to record commencement time and temperature of each evacuation Then record results and time taken Recommended safety precaution Remove compressor circuit breakers fuses prior to the evacuation process to insure that compressors cannot accidently run during this phase of commissioning Option Purge the entire system with Dry Nitrogen to extract any access moisture captured during installation Evacuation Employ the Triple Evacuation Process Evacuate with two Stage vacuum pump s sized to application Use multiple pumps where necessary Provide new approved vacuum pump oil to the vacuum pump s prior to evacuation Employ 23 8 hoses minimum size to both high and low sides of system Ensure that all circuits of the CO system are all evacuated Insure that the Compressors and the Oil Separator Reservoir are drained of oil prior to evacuation Label all Compressors and the Oil Separator Reservo
47. emove injured person s from danger area if without risk 3 Call emergency services Access 1 The normal site rules restrict access to the panel room to authorised maintenance personnel who are all familiar with electrical safety 63 BAO 103 1 AUS 18 Risk Assessment Documentation Risk Evaluation of Identified Hazards Probability of Occurence Possible 2 Frequent 3 Hazard Severity Minor 1 Serious Hospital 2 Major 3 days or more 3 Probability of Occurence x Hazard Severity Risk Rating RR Probability Severity RR Identified Hazards base scores on existing or planned control measures 1 EA 3 EE ee 1 Electric shock from power circuitry 2 Electric shock from 110 Volt control circuit 4 3 3 Eye injury from electrick arc SS IER o mq AO f 3 4 Burn injury 1 5 Injury to third party Maintenance Personnel 1 2 7 top D f Note Moderate Scores Thought should be given to reducing risk but the cost and time 1 to 5 Requirements of prevention should be carefully considered and limited Substantial Work should not be started until the risk has been reduced for work 6 to 7 in progress urgent action is required Considerable resources may have to be allocated Intolerable If unlimited resources cannot reduce risk work will be prohibited 8 to 9 Is risk adequately controlled using the above control measures Y N Y If No state further action required State further acti
48. enclosure All vessels are manufactured to AS1210 Figure 11 shows technical details for the Liquid Separation Vessel Figure 11 B40 083 Horizontal Liquid Separation Vessel R134a Colorbond Metal Clad and insulated 355 119 LEFT HAND LIQUID R134a R134a TOP SIGHT SHP LEVEL Riza SUCTION RIGHT HAND R134a SUCTION INLET GLASS FOR LEVELI PROBE R134a OUTLET c w OUTLET c w 1 ID TUBE INDICATION 0 5 Volt BALL VALVE BALL VALVE REAR SIDE OF Ya NPT SOCKET VESSEL LEFT HAND S55 166 LIQUID R134a RIGHT HAND R134a BOTTOM R134a SUCTION SPSF SINGLE R134a VESSEL OUTLET 91 44 R134a SUCTION SIGHT GLASS RETURN INLET POINT LEVEL RELIEF VALVE ID STEEL PIPE RETURN INLET FOR EVEL FROM FLOODED PROBE R134a SOCKET BSP TO FLOODED FROM FLOODED INDICATION BPHE Y NPT SOCKET BPHE BPHE NOTE The 2 x Frost shield viewing elements The S56 119 SHP12 Liquid Level Probe and the S56 166 SPSF Single point Level Sensor are not shown within Figure 11 BAO 103 1 AUS 27 lt a gt 1 The three Frost Shield Perspex viewing elements are supplied within the accessories carton Gently insert one Frost Shield viewing element horizontally into the top sight glass and the other into the middle sight glass 2 One of the HENRY E 9224 liquid level sensors is supplied within the accessories carton Gently insert horizontally the liquid level sensor into the bottom sight glass and wire to switchboard control system 3 NOTE It is imperative that the Liqui
49. essors Crankcase Heaters Crankcase heaters are required due to the high solubility of CO in the oil Models 2KMC 05K to 2FCH 3K Self Regulating PTC heater 0 60W Models 2EHC 3K to 4CHC 9K Self Regulating PTC heater 0 120W Models 4VHC 10K to 4NHC 20K Self Regulating PTC heater 0 140W Crankcase heater is required due to high solubility of CO in the oil 16 BAO 103 1 AUS Figure 3B Dimensional Drawings Refer BITZER KP 120 4 at www bitzer com au AFSL TK ACEL 12K BAO 103 1 AUS RBS lt a gt 9 Ancillaries Compressors Suction Filter Within each Compressor BITZER compressors of the Octagon series are designed with a Suction Filter located under the Suction service valve This filter is easily removed for inspection cleaning when necessary i e during oil change SUCTION GAS FILTER SHOULD ALWAYS BE IN SL A POSITION ON BITZER CO RACKS Figure 3C Compress Suction Filter detail For futher information refer to document KB100 5 www bitzer com au 9 2 Ancillaries Electrical Connections A WARNING ELECTRICAL SHOCK HAZARD Failure to comply with these safety warnings could result in serious injury or death All installation and servicing activities should be performed only by trained personnel Wear safety goggles Shut off all power to this equipment during installation service and maintenance Lock and tag all disconnect locations until work is complete A WARNING All electrical wiring
50. essors immediately upon exceeding the application limits or in case of abnormal conditions e g wet operation Only switch compressors back on when pressure levels are stabilised or after correcting any faults HN ATTENTION Avoid rapid pressure pull down inside the crankcase when starting and during operation as this will lead to oil foaming and result in a lack of lubrication 10 5 Commissioning Checks The following should be checked and verified as part of the commissioning procedure ATTENTION BITZER Australia reserve the right to request one week s running data from newly commissioned sites as proof that the BITZER CO Hybrid rack is operating within its design envelope Failure to do so may result in voiding warranty on certain componentry Set all system pressure compressor safety controls as described in section 6 The superheat operation of the High Stage Cascade EEV must be checked and verified that the conditions described in section 6 12 do not exist Operation of suction superheater should be verified and compressor crankcase discharge temperature and suction temperature should be logged The mains power to the plant should be turned off to the BITZER CO Hybrid Rack The operation of the Emergency Cooling BPHE needs to be checked Operation of the air cooled de superheater should be checked continuous cycling of the de superheater fans should be avoided All de superheater fans should be off when the CO outlet vapour
51. ets for compressors 1 x Wooden packing crate e 4 x Crankcase heaters Supplied loose 12 x One Litre cans of BSE60K BITZER Compressor Refrigeration Oil Item No 106 033 6 x Embelton NR3 Equipment Mounting feet each 500kg Rated Item No P37 053 4 x Traxon Oil level Control electrical leads 1 x Suction Drier felt Element F48 e 2 x Liquid line Drier Cores 48 DM 100 Molecular sieve Item No S03 033 1 x Henry Optical level Switch E 9224A N C 24V AC DC Item No K06 003 to suit Liquid Receiver bottom Sight Glass 5 x Henry Frost Shield Perspex viewing elements to suit Liquid Receiver top and middle Sight Glasses e 1 x spare Temprite coalescent Oil Cartridge sized to application when Temprite Oil Separator selected 1 x 856 119 Hansen Level Probe SHP12 0 5 Volt R134a GEN 7 1 x S56 166 Hansen SPSF Single Point Level Switch R134a GEN 7 Note 1xS56 170 Hansen Level Probe SHP16 0 6 Volt R134a Gen 7 70kW and over systems 6 BAO 103 1 AUS lt a gt BITZER Sub Critical CO Hybrid racks are designed exclusively for indoor use preferably within a designated plant equipment room Refer enclosed safety data especially 3 1 and Risk assessment documentation prior to any equipment unloading from transport lifting and installation 6 Installation WARNING Careful considerations to lifting should be applied prior to removal from transporter Instructions 1 The BITZER CO Rack should only
52. fetime of the BITZER CO Hybrid Rack 2 1 Residual hazards Certain residual hazards from the BITZER CO Hybrid Rack are unavoidable All persons working on these units must therefore read these Operating Instructions carefully N 2 Safety References ATTENTION Instructions on preventing possible damage to equipment CAUTION Instructions on preventing minor hazard to persons a WARNING Instructions on preventing a possible severe hazard to persons B DANGER Instructions on preventing an immediate risk of severe hazard to persons e N w General safety references WARNING The BITZER CO Hybrid Rack is under pressure with a holding charge of nitrogen to a pressure of 1000 kPa above atmospheric pressure incorrect handling may cause injury to skin and eyes Wear safety goggles while working on compressor Do not open connections before pressure has been released E CAUTION During operation surface temperatures exceed 60 C or fall below 0 C Serious burns and frostbite are possible Switch off and allow cooling down before working on the compressor and associated pipework KI D CAUTION Compressors contain oil amp refrigerant under pressure Release pressure from both high amp low side of compressor before servicing CAUTION Tube brazing amp compressor operation can produce hot surfaces To avoid burns allow surfaces to cool down before continuing installation or servicing D 2 BAO 10
53. food storage rooms E attention BITZER CO Hybrid Racks are exclusively intended for the use in low temperature sub critical cascade applications This documentation applies to BITZER CO Parallel Hybrid Racks Series only The BITZER CO Hybrid series are a factory assembled range of highly efficient and reliable multiple compressor refrigeration racks designed with all piping ready for onsite connection including all required components excludes R134a EEV s controls transducers and safety devices The BITZER CO Hybrid Rack is designed with simplicity and serviceability in mind Figure 1 shows a system schematic outlining the design and refrigerant flow Details of specific component operation are outlined in section 6 The BITZER CO Hybrid Racks are individually fabricated to each particular specific application The BITZER CO Hybrid Racks comprise of 1 x BITZER Designed Engineered structural steel unit frame assembly 1 x BITZER Compressor mount cradle 2 4 BITZER SL Series CO compressors 2 4 Stainless Steel Suction Lines from 1 Core Suction Drier Accumulator Vessel to each compressor 1 x BITZER 1 Core Drier Shell Accumulator Metal Clad and Insulated Vessel 2 4 Steel Discharge Branches 1 x Steel Discharge manifold and steel discharge pipe to oil separator 1 x Oil Separator Reservoir sized to application Optional BITZER COS or Temprite Coalescent Oil Separator Reservoir Two in par
54. he categories for waste oil and mixing instructions are observed e Delivery of waste oil only to officially authorized collectors European waste catalogue e 13 02 08 other engine gear and lubricating oils e Uncleaned packaging s Recommendation Empty contaminated packaging s thoroughly They can be recycled after thorough and proper cleaning Small one way packaging s have to be disposed according to the local regulations EWC 15 01 99 BAO 103 1 AUS 53 lt a gt 17 BITZER BSE 60K Material Safety Data Sheet continued Transport information e Land transport ADR RID and GGVS GGVE cross border domestic ADR RID GGVS E Class e Maritime transport IMDG GGVSea IMDG GGVSea Class Marine pollutant No Airtransport ICAO TI and IATA DGR e I CAO IATA Class e Transport Additional information No dangerous good acc to dangerous goods transport directions Regulatory information Designation according to EU guidelines Observe the normal safety regulations when handling chemicals or mineral oil products The product has been classified and labelled in accordance with EC Directives until 2004 73 EC 29 ATP e Risk phrases 52 53 Harmful to aquatic organisms may cause long term adverse effects in the aquatic environment e Safety phrases Avoid release to the environment Refer to special instructions safety data sheets National regulations German Water Hazard Class Water Endangering
55. he compressor and inverter do not have adequate reserves this may result in a large number of frequency ranges where resonance occurs PLEASE CONTACT BITZER AUSTRALIA IN SUCH CASES FOR FURTHER ADVICE Further information on frequency inverters refer to Document KT420 www bitzer com au 9 3 Ancillaries BITZER COS Oil Separation System OPTION No 1 The BITZER CO Hybrid racks come with a high efficiency BITZER COS Oil separator Reservoir used in conjunction with Traxon oil level controls Figure 4 BITZER COS CO Oil Separator our LET Oil Separator Technical Data The BITZER Centrifugal oil separator provides improved oil separation very low pressure drops and greatly reduced vibration levels due to the patented centrifugal oil separator cartridgefittedwithinthetophalfofthevessel Thelowersectioncontainstheoilreservoirwith a high and low level sight glass and oil service valve The BITZER COS Oil Separator is manufactured to AS1210 The centrifugal separators are ideally suited to multiple compressor parallel systems and compressors using capacity control or systems with a wide range of required Model BITZER inlet outlet Number HERE No size Y size Y me S SR mm glass inlet ar me ring o o mm oo semm SS EE EA med eric COS2 G Safety relief valve socket 03 8 BSP Fastening bolt 21 2 BSP Oil outlet valve 23 8 rotalock NOTE Oil Separator is not Pre charged with Oil Please insure that the oil
56. hield viewing element horizontally into the top sight glass and the other into the middle sight glass 2 NOTE It is imperative that the Liquid level Alarm sensor be tested during Commissioning and periodically when general maintenance occurs 3 The Horizontal Liquid Receiver B30 242 GEN 7 for Systems 40kW to 70kW nominal capacity 110Kg Pump Down capacity CO 2 Csst 80 Full 4 The Horizontal Liquid Receiver B30 262 GEN 7 for Systems below 40kW nominal capacity 55Kg Pump Down capacity CO 2 Csst 80 Full 5 The Liquid Receiver Vessel is located on the base of the unit frame directly below the BPHE Cascade CO Condenser R134a Fully Flooded Evaporator 28 BAO 103 1 AUS lt a gt 9 13 Ancillaries Liquid Level Alarm A low level liquid alarms are generated by a liquid level sensor the switch is mounted horizontally in the bottom receiver sight glass switch locates on O ring see Figure 13 The uses an infrared light reflecting from a conical glass prism moulded into a Lucite body as a means of detecting the absence of CO liquid in the receiver When no CO liquid covers the lower half of the cone infrared light from the module reflects from the mirror like inner surface of the cone back to a light detector signalling the electronic module to switch when CO liquid covers the lower half of the glass cone the light from the module passes into the CO liquid the absence of light is detected by the module which Switches in
57. ied persons Observe National Safety Regulations Ensure adequate levels of ventilation Check emergency exits Observe the Safety Standards and National Safety Regulations Information Instruction and Training DAPON AIN SIONS Environment Procedures documents etc Refer to relevant BITZER documentation AS1667 Comply with site rules permits may be required Familiarise yourself with plant site emergency plan Emergency action procedures In case of leak Communications N 2 9N SIN SIN gt Isolate leak if possible If isolation is not possible evacuate area and follow the site emergency plan Treatment to injuries should be in accordance with the product data sheet Access should be restricted to the area where work is taking place 1 2 3 1 Access ET BAO 103 1 AUS 57 18 Risk Assessment Documentation Risk Evaluation of Identified Hazards Probability of Occurence Remote 1 Possible 2 Frequent 3 Hazard Severity Minor 1 Serious Hospital 2 Major 3 days or more 12 3 Probability of Occurence x Hazard Severity Risk Rating RR Probability Identified Hazards base scores on existing or planned control measures A A A A A EE ii 1 Risk of explosion o0 3 3 2 Risk of over pressure p E qp p n ARA 3 Environmental pollution 4 E T A 2 Moderate Scores Thought should be given to reducing risk but the cost and time 1 to 5
58. ir stating that they are drained of Oil Insure that all Solenoid valves are fully open during the evacuation process This can be achieved by energising the coils or replacing them with coil magnets during this process Important Replace any coil magnets with the appropriate Solenoid coil s once evacuation process is fully completed Insure that the Electronic Tx valves are fully open during the evacuation process Employ accurate gauges for measuring vacuum e g Digital vacuum gauge correctly calibrated certified If digital vacuum measurement is employed the process maybe recorded plotted graphed Commence the 1st evacuation During this initial process Test vacuum to check for inward leaks During initial evacuation Leave vacuum to stand for a period and record vacuum findings If pressure rises rapidly showing a possible inward leak Evacuate different sections one at a time to determine leak source Once leak is located and fully repaired pressure test leak test system prior to recommencing evacuation Option on larger plants isolate sections of the refrigeration plant and Evacuate different sections one at a time or employ several vac pumps one on each section of the system During initial evacuation open the 2 Stage vacuum pump s gas ballast valve to exhaust remove any non condensable s entering the vac pump Once the ballast exhaust shows no signs of condensation a lower vacuum is approaching close the Ballast valve to achieve
59. k area eg red and white bunting Information Instruction and 1 Isolate by removing fuses power circuits within a panel before fault finding Training 2 Prove your test instrument prior to and immediately after testing for dead 3 Test for dead power circuits with exposed conductors 4 Fault find power circuits in the dead condition 5 The 240 Volt control circuit may be kept live for fault finding purposes providing that there is no reasonable way of doing the work dead and that all control measures are followed 6 When live testing ensure that a current wiring diagram is available and followed 7T Familiarise yourself with all safety and operating controls such as pressure switches oil differential switches motor starters etc 8 Isolate or discharge power factor correction capacitors before primary circuit work if installed Control Details Supervision 1 Two person team required whilst live testing is being carried out keep other persons away from the work area Environment 1 Maintain a 1m clear space around the work area 2 Rubber mats should be placed around package ensure that eses do not pose a trip hazard Procedures documents etc 1 Follow site safety rules 2 Lock individual panel doors Communications 1 Inform the site manager when isolating panels as this may mean safety circuits are being isolated Inform second person if applicable of emergency actions Emergency action procedures 1 Switch off and isolate supply 2 R
60. l to each other and they protrude out the side and not over the LED s WARNING All electrical wiring should be carried out by qualified persons and in accordance with AS300 or equivalent standard in the country of installation 24 BAO 103 1 AUS lt a gt Figure 6 OW3 Sight Glass Level Control Zones amp Technical Data TR3 Operation The sight glass is divided into three main zones When the level reaches the yellow zone 2 tge TR3 starts filling after a time delay of 10 seconds When the level drops to the red zone 3 the control will switch the alarm relay contacts on after a time delay of 20 seconds The current oil status is indicated with the three LED s according to the following table LED Status Function Oil Level zone 1 70 50 Yellow Oil Level zone 2 50 30 injection O Red Yellow Oil Level zone 3 30 0 alarm amp injection Oil Level Zones 70 50 30 9 5 Ancillaries CO Brazed Plate Heat Exchanger BPHE Cascade Condensers Evaporators The condensing of CO vapour is achieved by the BPHE Cascade Condenser Evaporator BITZER CO Hybrid GEN 7 racks use liquid refrigerant typically R134a from the high stage of the cascade system to the R134a Liquid Separation Vessel located above the Dual R134a outlet BPHE The CO condenses through the BPHE condenser The direction of flow of the R134a is always in counter flow to the CO see Figure 7 Figure 7 BPHE Cascade Condenser Evaporator with
61. lease note that the suction felt is not fitted when the rack is supplied and should be installed as part of the commissioning The suction felt should be removed after commissioning in order to avoid excessive pressure drop through the filter Burnt out cores should be installed in the event of a compressor burn out or high moisture content A Service post valve 03 8 MSAE is connected upstream of the Suction Drier Suction Accumulator to assist with changing drier Cores and evacuation 99 Figure 17 Suction 1 Core Drier Accumulator vessel Schematic BITZER 1 Core Suction Drier Suction Accumulator Vessel Colorbond Metal Clad 938 amp Insulated SERVICE VALVE FILTER MAINTENANCE DSQ Comp No 1 Comp No 2 Comp No 3 Steel Discharge Main Manifold Oil Return Manifold Compressor Sequence viewed from front 32 BAO 103 1 AUS 9 19 Ancillaries Hot Gas Injection All BITZER CO Hybrid racks come fitted with a Hot Gas Injection solenoid HGIS the purpose of the HGIS to provide additional suction superheating if required or in the event of a continuous low superheat The HGIS consist of a solenoid with two non return valves Figure 18 The solenoid injects hot gas from the discharge line directly into the CO suction line upstream of the suction Drier Accumulator vessel In the event of the CO suction return gas vapour remaining below 15 C Figure 18 Hot Gas Injection Solenoid Schematic
62. levant licences Lifting and slinging takes place under all conditions and weather Important considerations are that the load is balanced and that tag lines are used to steady and guide the load Very windy conditions may prohibit the lift 1 Theload should be slung from correctly attached shackles the most common failure is that of an eyebolt pulled at an incorrect angle 2 The load should be lifted a few inches and checked that it is stable before the full lift is attempted 3 When lifting operations are su contracted to specialist the contractor should ensure that the crane was thoroughly examined within the last 12 months that thie accessories were thoroughly examined within the last 6 months and that both the crane dirver and banks man are certified competent 4 Observe the safety standards and other national safety regulations 5 Referto relevant BITZER documentation Lift should be supervised by suitably trained or qualified persons radios or other suitable communication devices should be used zx Observe the safety standards and other national safety regulations Persons trained in the use of first aid should be present Call emergency services Access should be restricted to the area where lift is taking place issue appropriate signage Access to the area beneath the crane radius over which a load will pass should be prohibited to prevent a load striking a person Access around the crane will be controlled to prevent the c
63. liquid burns 4 The following hazards have been identified Manual handling injury when moving cylinders or plant Control Measures existing or planned Environment Control Details PPE 1 Safety boots with a heel good grip and steel to cap 2 Overalls protective clothing 3 Safety goggles 4 Neoprene impervious gloves 5 Hard hat Equipment 1 Refrigerant recovery pump 2 Scales for recovery 3 Suitable charging transfer lines 4 Properly identified refrigerant recovery cylinders 5 Log book for recording amount charged decanted or transferred Information Instruction and 1 Wear impervious gloves to prevent refrigerant contacting the hands Training 2 Eye protection must be worn when opening any refrigeration system As a minimum goggles are required 3 Only persons experienced in handling refrigerations and with relevant licences will charge decant refrigerant They may have an apprentice or assistant helping them or observing the operation 4 Continuously and accurately weigh recovery cylinders during decanting 5 Continuously supervise charging decanting or transferring operations 6 Secure cylinders from falling over 7 Do not trap liquid refrigerant between valves 8 Use mechanical handling equipment or follow good manual handling techniques 9 Warning signs to be erected warning of hazards 10 Transfer lines to be made safe by marking with bunting to stop accidental collision Control Details Supervision
64. loyed check pressure differential indicator and replace Temprite cartridge with spare Replace liquid line drier cores Take oil sample for analysis Check Clean internal filters within the Traxon Oil level Controls Check operation of safety circuits Check high stage rack system Check all refrigeration unit pipe clamps Stauff Clamps for tightness Check operation and calibration of plant room CO refrigerant detection system Check plant room ventilation system Record all annual maintenance checks 13 Pictures amp Drawings Figure 25 BITZER GEN 74 3 Compressor CO Hybrid Low Temperature Rack Frontal isometric view showing left hand side BAO 103 1 AUS 45 lt a gt Figure 26 BITZER GEN 7 3 Compressor CO Hybrid Low Temperature Rack Back isometric view showing right hand end and rear of rack Rear view depicting The Lower vessel Liquid Receiver The Metal Clad Insulated BPHE the Upper vessel Liquid Separation Vessel and including the optional Integral Emergency Cooling Unit Figure 27 BITZER GEN 7 3 Compressor CO Hybrid Low Temperature Rack Side view showing Right hand side 46 BAO 103 1 AUS lt a gt Figure 28 BITZER GEN 7 3 or 4 Compressor CO Hybrid Low Temperature Rack Dimensional drawing ya 4 SL itti tr M T IEEE A LL UE a AAA a TT o o ai HI LAA W M LH AE Nn amp a amp A aj d Po UL D pma 4 Wig um E M r 1876
65. luble in water ethanol amp acetone Slightly acidic 3 3 CO Refrigerant Handling and Storage Use only in well ventilated areas Storage Keep in a cool dry well ventilated place Do not store above 45 C 3 4 CO Refrigerant Accidental release measures Personal precautions Shut off source of leak if safe to do so In poorly ventilated areas or confined spaces use airline respirator or approved self contained breathing apparatus Wear approved safety boots and gloves 3 5 Environmental precautions Refer to special instructions within safety data sheets Clean up actions Shut off source of leak if safe to do so Allow product to evaporate Ventilate area Table 2 shows HAZCHEM ratings for all commonly used refrigerants The HAZCHEM code provides advisory information for the emergency service personal to enable them to take appropriate action in the event of an accident It can be seen that R744 CO has the same HAZCHEM rating as all other commonly used refrigerants That is to say that in the event of a major leak of CO the emergency services would respond in the same manner as with any of the other commonly used refrigerants Table 2 HAZCHEM Rating of Refrigerants A a 3 ASHREA TLV TWA Refrigerant Description HAZCHEM Boiling Point Safety Code nenn Tum R744 CO2 Carbon Dioxide 2RE 78 5 C Asphixiate 5000 Asphixiate in high Asphixiate in high Asphixiate in high Asphixiate in high Asphi
66. mes or general groups Contractors Yy Service and Maintenance Contractors and Assistants Other Workers Y On site maintenance personnel General Public N Comments All circuits to be worked on will be treated as live until verified dead There are no exceptions to this requirement experience of employees is irrelevant HAZARDS Because of the complexity of the refrigeration package control circuits it will occasionally be necessary to cary out live testing fault finding This assessment addresses the hazards associated with such work Live testing fault finding is to be carried out by a trained competent authorised person In general each plant contains control circuitry at 240 Volts and power circuits at 415 Volts 3 Phase The following hazards have been identified 1 Electric shock from power circuitry 2 Electric shock from 240 Volt control circuitry 3 Eye injury from an electric arc 4 Burn injury 5 Injury to third party Maintenance Personnel Control Measures existing or planned Control Details PPE For Live Testing 1 Rubber soled shoes or boots 2 Rubber mats 3 Safety glasses 4 Suitable work wear overalls For work on dead systems 1 Padlock for lock off isolator Equipment 1 General hand tools insulated 2 Electrical test equipment eg Clamp amp meter multi meter test lamp etc Insulated fused and with calibration 3 Warning notices 4 Suitable means of cordoning off the wor
67. move clothing which has stuck to the skin Burns must be treated by a physician WW CAUTION Contact with eyes immediately wash out with plenty of water for several minutes Obtain medical attention W CAUTION Moisture with the air can lead to the formation of carbonic acid that can irritate the eyes All forms of CO carbon dioxide are non combustible A CAUTION Ingestion is not regarded as potential route of exposure give 200 300 millilitres half pint of water to drink Never give anything by mouth to an unconscious person Do not induce vomiting Seek immediate medical attention 3 1 CO Refrigerant detection Oxygen deprivation detectors Ensure that the plant room s other confined spaces Coolrooms are fitted with CO detection sensors systems or oxygen deprivation sensor s Also refer AS1677 Accumulation of heavier than air refrigerants and Safety provisions for personnel in refrigerated spaces Ensure that the plant room has adequate ventilation at all times BAO 103 1 AUS 3 lt a gt 3 2 CO Refrigerant physical properties Carbon dioxide CO is heavier than air and should not be allowed to accumulate in low lying areas Ensure that the current Material Safety Data Sheets for carbon dioxide CO are on site See MSD attached Melting point 56 6 C Boiling point 78 5 C Density 1 977kg m Freezing point 56 6 C Vapour Density 1 53 air is 1 Vapour pressure 15 C 5105 kPa So
68. ng operations unless directly and closely supervised by a competent person Any good Boson or Rigger s manual with a section on rigging practices Maintenance checklist of slings and lifting equipment Weights of items slung and lifted should be known before lift is undertaken Only those trained in slinging will carry out these operations Damaged slings of lifting equipment must be discarded immediately and cut or otherwise rendered unuseable O For large and unusually shaped loads or loads with not fixed lifting points are provided a professional rigger should be subcontracted in addition to crane operator 11 The safe working load must be clearly marked on all lifting equipment and tackle Check before use 12 A competent person must plan non routine lifts 13 Ropes chains or slings should be shortened in a safe manne 14 Lifting tackle will be returned to appropriate storage after use 15 Extreme care should be taken not to trap fingers when loads are being positioned ZLeLNOAASONSA Na la RON SD Control Supervision Environment Procedures documents etc Communications Access Emergency action procedures Details An experienced person who has been trained in slinging will attach the slings or direct the rigger to the appropriate lifting points No fixed lifting points are provided so a competent rigging sub contractor should be employed The crane driver will not lead the lift Forklift drivers should possess re
69. nned control measures 1 Explosion 2 Asphyxiation 3 Refrigerant liquid burns 4 Manual handling injury when moving cylinders or plants Moderate Scores Thought should be given to reducing risk but the cost and time 1 to 5 Requirements of prevention should be carefully considered and limited Substantial Work should not be started until the risk has been reduced for work 6 to 7 in progress urgent action is required Considerable resources may have to be allocated Intolerable If unlimited resources cannot reduce risk work will be prohibited 8 to 9 Is risk adequately controlled using the above control measures Y N If No state further action required State further action required Note This risk assessment is only valid when all control measures are in place before the work or activity commences If the nature of the work changes or there is a dangerous occurrence 60 BAO 103 1 AUS 18 Risk Asssessment Documentation Work Activity Electrical Connections Site Location On site location Those at Risk End User Employees Other Workers General Public Comments Comments enter names or general groups Installation Service and Maintenance Personnel and Assistants The package is supplied with no wiring contractors need to wire mains power for compressor and relevant control circuits Work should only be carried by qualified persons HAZARDS The following hazard
70. noid Valve The Low Pressure safety Control is for Rack Safety The Low Pressure safety Control LP Bleed is for the LP Bleed Solenoid Valve Oo ov 36 BAO 103 1 AUS 9 25 Suction and Liquid Headers BITZER CO Hybrid Racks come fitted with six or eight stub suction and liquid headers 2 compressor racks have four stub headers fitted as standard The headers are encased with urethane insulation Figure 22 to reduce condensation Figure 24 Suction 8 Liquid headers SUCTION RETURN INLETS DUAL SUCTION LIQUID HEADER The dual Suction Liquid header is specially designed by BITZER for DX CO GEN 6 and GEN 7 systems The Suction Return Vapour Inlet connections are located on the top of the enclosure and the Liquid outlet connections are located at the bottom of the enclosure with external pipework facing upwards The dual suction headers are available in three combinations For 2 Compressor Racks only 4 x Suctions 7 8 and 4 x Liquids 27 8 For 3 or 4 Compressor Racks 6 x Suctions 7 8 and 6 x Liquids 07 8 For 3 or 4 Compressor Racks 8 x Suctions 7 8 and 8 x Liquids 07 8 NOTE Other combinations sizes can be ordered as special applications 1 The Suction return Inlets consist of 4 6 or 8 stubs of 7 8 refrigeration pipe Each complete with system ball valves with non return valve NRV bypass Suction stubs have an additional post valve fitted This arrangement allows for the pumping down and evacua
71. nsing unit for the emergency cooling BPHE HP Switch 3 Function Emergency Cooling BPHE Condensing unit Control Cut in 3800kPa Cut out 3600kPa BAO 103 1 AUS 31 lt a gt The OPTIONAL emergency Cooling Unit includes the following 1x BITZER Compressor R134a available in 3 Phase or Single Phase 1x Top mounted Air Cooled Condenser Twin Fan vertical Air Discharge e 1x Dual Pressure Control Safety e 1x Suction Accumulator Insulated e 1x Vertical Liquid Receiver e 1x Liquid line Drier 163 e 1x Sight Glass Moisture indicator e nterconnecting pipework including connection to Emergency Cooling BPHE The Emergency Cooling Air cooled Condensing has a holding charge of NITROGEN The R134a Refrigerant required for this unit is supplied by others 9 21 Ancillaries Pressure Relief Valves PRV s BITZER CO Hybrid racks come with factory fitted PRV s Figure 24 The PRV s are high quality cryogenic valves and are designed to reset after opening Relief Valve Operating Temperature Range 196 C to 185 C The PRV s must be removed from the rack by the contractor and installed outside of the plant room They must be securely fixed and NO pipework should be fitted at the outlet of the PRV as in the event of CO been released dry ice will form at the point of expansion See Warning below WARNING Failure to comply with the above can result in serious injury to personnel 34 BAO 103 1 AUS Figure 20
72. o replace filters until you maintain a pressure drop staying below 0 896 Bar 89 63kPa 13 0PSI differential across the separator The separator is clean NOTES The clean up Oil Filters are for clean up purposes only They remove dirt down to 3 0 microns The STD oil filters remove dirt down to 0 3 microns and you will have 98 596 oil separation for normal operation Oil Separator is not Pre charged with Oil Please ensure that the oil separator is charged with a correct quantity of the nominated oil prior to evacuation E ATTENTION Only use BITZER BSE 60K POE Oil als BITZER Australia Item No 106 033 Oil BSE 60K litre container 2 BITZER Australia Item No 106 038 Oil BSE 60K 10 Litre container 22 BAO 103 1 AUS D 9 3 Ancillaries BITZER Temprite Coalescent Oil Separation System Temprite AS2971 Coalescent Oil Separator Reservoirs models and Accessories BITZER Item No B36 070 922R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 071 923R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 072 924R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 073 925R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 074 926R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 075 927R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 076 928R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 077 930R OIL SEPARATOR RESERVOIR COALESCENT c w Filter kit B36 078 OIL FILTER KIT STD 922R 923R B36 079 OIL
73. of the work changes or there is a dangerous occurrence 56 BAO 103 1 AUS 18 Risk Assessment Documentation Work Activity Pressure Testing amp Evacuating Site Location Onsite location Those at Risk Contractor Other workers Comments enter names of general groups Y Installation Personnel and Assistants General Public Comments The package is delivered with a holding charge of dry nitrogen which requires releasing before additional field pipework is connected Care should be taken during pressure testing the entire system and during the commissioning of the package The following hazards have been identified 1 Risk of explosion 2 Risk of over pressure 3 Environmental pollution Control Measures existing or planned Control Details PPE Gloves Safety goggles Steel toe cap boots Equipment General tools Calibrated gauges and test equipment Only use dry nitrogen for pressure testing never use Oxygen or other industrial gases as this leads to an explosion Never add refrigerant to the test gas environmental pollution is possible Refer to relevant BITZER documentation Only use calibrated gauges and equipment use serviced regulators to control the flow of nitrogen Continuously observe the flow and pressure of nitrogen Only qualified personnel should install and commission the package Control Details Supervision Work should be carried out only by qualif
74. on of aerosols Do not eat drink or smoke when working with the product Take usual precautions when handling mineral oil products or chemical products Information about protection against explosions and fires Do not heat up Oil to temperatures close to the flash point Storage Requirements to be met by storerooms and containers No special requirements Information about storage in one common storage facility Store away from foodstuffs Further information about storage conditions Local regulations concerning handling and storage of water polluting products have to be followed Exposure controls and personal protection Additional information about design of technical systems No further data see item 7 Components with critical values that require monitoring at the workplace The product does not contain any relevant quantities of materials with critical values that have to be monitored at the workplace Additional information The lists that were valid during the compilation were used as basis Personal protective equipment General protective and hygienic measures The usual precautionary measures should be adhered to in handling the chemicals and the mineral oil products Wash hands during breaks and at the end of the work Avoid close or long term contact with the skin Use skin protection cream for preventive skin protection Do not carry cleaning cloths impregnated with the product in tro
75. on required Note This risk assessment is only valid when all control measures are in place before the work or activity commences If the nature of the work changes or there is a dangerous occurrence 64 BAO 103 1 AUS 19 20 lt a gt Our products are manufactured in compliance with applicable international standards and regulations If you have any questions about how to use our products or if you are planning special applications please contact MANUFACTURER BITZER Australia Pty Ltd Please contact us via email and visit our website 134 136 Dunheved Circuit info bitzer com au St Marys NSW 2760 www bitzeravp com au Tel 61 0 2 8801 9300 www bitzer com au Fax 61 0 2 9673 4698 SERVICE ADDRESS For local support please refer to our website www bitzeravp com au for a list of our nearest branch office 65 BAO 103 1 AUS Quality ISO 9001 SAI GLOBAL 08 2014 In the interest of continuous improvement BITZER reserves the right to change the specifications or design of any of its products without notice The BITZER Symbol Name BITZER and model numbers are registered trade marks All products manufactured are pending design and specification registration and must not be copied or duplicated in any way Please note The ISO Certification applies to New South Wales and Victoria branches only NSW Victoria SA WA QLD NZ tel 61 2 8801 9300 tel 61 3 8326 8200 tel 61 8 8345 6110 tel 61 8 6350 6297 tel 61
76. r consult doctor in case of symptoms Eventually by inhaling the overheated product After skin contact The product is not skin irritating e After eye contact Rinse opened eye for several minutes under running water e After swallowing In case of persistent symptoms consult doctor Fire fighting measures e Suitable extinguishing agents CO Extinguishing powder or water jet Fight larger fires with water jet or alcohol resistant foam Use fire fighting measures that suit the environment For safety reasons unsuitable extinguishing agents Water with a full water jet Protective equipment In case of fire fighting wear self containing breathing apparatus BAO 103 1 AUS 51 lt a gt 17 BITZER BSE 60K Material Safety Data Sheet continued Accidental release measures Person related safety precautions Particular danger of slipping on leaked spilled product Environmental protection measures Inform respective authorities in case product reaches water or sewage system Do not allow to enter drainage system surface or ground water Prevent from spreading e g by binding or oil barriers Do not allow to enter the ground soil Measures for cleaning collecting Absorb with liquid binding material sand diatomite acid binders universal binders sawdust Dispose of the material collected according to regulations Handling and storage Handling Information for safe handling Prevent formati
77. rane trapping persons es chen BAO 103 1 AUS 55 18 Risk Assessment Documentation Risk Evaluation of Identified Hazards Probability of Occurence Remote 1 Possible 2 Frequent 3 Hazard Severity Minor 1 Serious Hospital 2 Major 3 days or more 3 Probability of Occurence x Hazard Severity Risk Rating RR Probability Severity dentified Hazards base scores on existing or planned control measures 1 Collision with moving plant 2 Collision with moving machine parts 3 Collision with moving materials 4 Weather conditions 5 Insufficient lighting Dropping loads due to mechanical failure 7 Dropping load due to misapplication of lifting equipment 8 Trapped fingers or toes Cuts or abrasions Moderate Scores Thought should be given to reducing risk but the cost and time 1 to 5 Requirements of prevention should be carefully considered and limited Substantial Work should not be started until the risk has been reduced for work 6 to 7 in progress urgent action is required Considerable resources may have to be allocated Intolerable If unlimited resources cannot reduce risk work will be prohibited 8 to 9 Is risk adequately controlled using the above control measures Y N If No state further action required State further action required Note This risk assessment is only valid when all control measures are in place before the work or activity commences If the nature
78. rid Rack off the floor allowing free space for a metal condensate oil tray to be inserted at floor level Recommended 12 Ensure that fully operational tested certified CO Refrigerant detection Oxygen deprivation detectors Are installed prior to receiving any R744 CO Refrigerant to site 13 The equipment plant room should be free of dust before the BITZER CO Hybrid Rack is connected to any field piping to ensure internal cleanliness 14 Ensure that the system nitrogen holding charge is expelled from the BITZER CO Hybrid Rack prior to any attempts at connecting field piping 15 Ensure that the BITZER CO Hybrid Rack and all refrigeration field piping are not exposed to atmosphere for any long periods 16 The System field piping must be to AS1677 An inert gas Dry Nitrogen must be charged through field refrigeration pipe work during the brazing process It is recommended that the inert gas be delivered into the pipework so that air is not also introduced BAO 103 1 AUS 7 lt a gt 7 Application BITZER Sub Critical CO Hybrid Racks are designed exclusively for the use of carbon dioxide R744 as the low stage refrigerant and R134a as the high stage refrigerant in a two stage cascade system where the R744 CO systems evaporators are of direct expansion design They are designed to be applied in low temperature refrigeration applications and ideal for medium to large supermarkets industrial processes and frozen
79. s have been identified 1 Electric shock incorrect wiring 2 Electric shock from earth leakage Control Measures existing or planned Control Details PPE 1 N A Equipment 1 General hand tools insulated 2 Electrical test equipment eg Clamp amp meter multi meter test lamp etc Insulated fused and with calibration 3 Warning notices Information Instruction and 1 Electrical installation should be carried out in accordance with wiring diagram in the compressor terminal box Training 2 Observe the Safety Standards and other National Safety Regulations 3 Compressor housing must be grounded or connected to an equipotential bond 4 Refer to relevant BITZER documentation Control Details Supervision 1 Work should only be carried out by qualified persons 2 Observe National Safety Regulations Environment 1 Observe National Safety Regulations in case of emergency Procedures documents etc 1 Observe the Safety Standards and other National Safety Regulations 2 Refer to relevant BITZER documentation Communications 1 If in doubt contact your local BITZER office Emergency action procedures 1 Switch off and isolate supply 2 Remove injured person s from danger area if without risk 3 Call emergency services Access 1 The normal site rules restrict access to the panel room to authorised maintenance personnel who are all familiar with electrical safety BAO 103 1 AUS 61 lt a gt 18 Risk
80. sed by a componenet person Trapped fingers or toes PONS No HAZARDS Collision of moving crane host forklift truck or lifting other device with people or plant Collision of crane boom hook block or other moving part with people or plant Collision of suspended load with people or plant Working in windy or rainy weather or when sunshine makes observation difficult Working at night when there is insufficient lighting to observe the full travel of the load Dropping of load due to mechanical failure of load bearing component crane sling or shackle Dropping of load due to incorrect slinging method or use of equipment or overload of crane or sling Cuts and abrasions whilst handling chains or sling Control Measures existing or planned Information Instruction and Training Control Details PPE Steel toecap boots Overalls protective clothing Safety helmet Leather gloves for handling chains or slings Safety harness if appropriate Equipment Forklift Slings hooks fitted with safety catches plate clamps eyebolts and shackles Crane or hoist mobile cranes must be fitted with overload warning devices Observe local standards and guidelines relating to lifting operations and lifting equipment and safe use of cranes Insure that all lifting equipment including forklifts are properly maintained Only qualified personnel should lift or install package No one under the age of 18 will undertake lifting or slingi
81. sel Figure 15 The SPSF Single Point Level Probe Horizontal R134a vessel and wiring diagram r uto UQUID ABOVE PROBE ON N O POSITION UQUID BELOW PROBE OFF N C POSITION L N e FILL SOLENOSD VALVE OR LOW LEVEL ALARM E t D HIGH LEVEL ALARM OR COMPRESSOR CUTOUT The SPSF Single point Level Probe in supplied loose and requires installation into the 21 2 NPT Female Socket on the side of the Liquid Separation vessel Socket is front facing 30 BAO 103 1 AUS 9 14 A Ancillaries Filter Driers amp Moisture The solubility of water in CO vapour is considerably lower than in other refrigerants as a consequence relatively low moisture content can freeze out of the refrigerant and block control valves Excessive moisture can also lead to a build up of organic acid as the moisture reacts with both the CO and the POE oil Therefore all BITZER CO DX Hybrid racks come fitted with a generously sized liquid drier complete with 2 x 100 molecular sieve driers cores supplied loose The drier shell is installed at the rear right hand end of the rack encased in urethane insulation 1 Upstream of the Drier Shell is a service Charging Drain Post Valve 23 8 See Figure 16 Upstream of the Drier shell is a Liquid line Three Way Ball Valve See Figure 12 3 The Liquid Line can be temporarily diverted along the Liquid line By Pass line during Drier changes This means that the system can fully functional during
82. separator is charged with a correct quantity of the nominated oil prior to final evacuation ATTENTION Only use BITZER BSE 60K POE Oil 20 BAO 103 1 AUS BITZER Item No Model No Oil Quantities in Litres 2 Oil Level to Centre Line of Oil Level to Centre Line of Upper l R SOUS EUe SES Ee Lower Sight Glass Sight Glass 536 0635 cosi 1e 329 B360536 cose 29 7 44 Tolerance or 50ml 9 3 4 Ancillaries BITZER Temprite Coalescent Oil Separation System OPTION No 2 The BITZER CO Hybrid racks come with a high efficiency Temprite Coalescent Oil Separator Reservoir The Temprite Coalescent Oil Separators have an internal filter installed Temprite Coalescent Oil Filters will pickupalldirtandeffluentto 3 0 microns Typical Filter driers only catch 50 microns orlarger Replace the coalescent filter if dirt loading is above 0 896 Bar 89 63kPa 13 0 PSI differential across the separator Refer the Temprite Differential Indicator See below e The Temprite Coalescent Oil Separators are also excellent at maintaining oil cleanliness This has a direct positive effect in reducing operational costs The Temprite Coalescent Oil separator Reservoirs are not affected by velocity and are 98 5 efficient down to 2096 of total rated load Figure 4A Temprite Coalescent Oil Separator Reservoir Temprite Coalescent Oil separator Reservoir Temprite Oil Separator with Pressure differential Indicator PDI inst
83. ssor unless the terminal box cover is in place amp secured Measurement of amps amp voltage during running conditions must be taken at other points in the power supply Do not remove terminal box cover until all electrical sources have been disconnected Follow recommended safety precautions listed on the terminal box cover label before attempting any service work on the compressor During operation surface temperatures can exceed 60 C Severe burns are possible Discharge Lines are painted red from compressor service valves to the inlet of the oil separator BAO 103 1 AUS 5 lt a gt 5 Product Accessories Check List Component Check list for 2 Compressor CO Rack e 1 x BITZER CO Twin Compressor Parallel Rack 2 x BITZER Compressor instructions comes with spare service valve gaskets for compressors e 1 x Wooden packing crate 2 x Crankcase heaters Supplied loose 6 x One Litre cans of BSE60K BITZER Compressor Refrigeration Oil Item No 106 033 6 x Embelton NR3 Equipment Mounting feet each 500kg rated Item No P37 053 2 x Oil level Control electrical leads e 1 x Suction Drier felt element F48 2 x Liquid line Drier Cores 48 DM 100 Molecular sieve Item No S03 033 1 x Henry Optical level Switch E 9224A N C 24V AC DC Item No K06 003 to suit Liquid Receiver bottom Sight Glass 5 x Henry Frost Shield Perspex viewing elements to suit Liquid Receiver top and middle Sight Glasses e 1
84. temperature reaches 12 C Case defrost should be set so that no excessive loads are created Operation of low liquid level alarm should be verified Cycling frequency of compressors should be checked compressor starts should not exceed eight starts per hour min operating time two minutes 42 BAO 103 1 AUS 11 Commissioning Sheet BITZER COMMISSIONING DATA SHEET COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR DESCRIPTION NO No 3 Ge BITZER COMPRESSOR MODEL NO BITZER COMPRESSOR SERIAL NO A e ez sz COMPRESSOR PRESSURE RELIEF VALVE FITTED ra COMPRESSOR SUMP HEATER FITTED amp CHECKED dex p qp IT COMPRESSOR RUN AMPS RWB Amp SUCTION PRESSURE Km cm SUCTION TEMP C SUCTION TEMP Hot Gas Injection Solenoid oc ee SUCTION REHEAT bphe by pass Solenoid setting C DISCHARGE PRESSURE ka SSS SSS A DISCHARGE TEMP Compressor a KEK RB DISCHARGE TEMP Main Discharge Manifold Ise III DISCHARGE TEMP Entering Air Cooled De Superheater loc DISCHARGE TEMP Exiting Air Cooled De Superheater Pc a IEEE DISCHARGE TEMP Entering Liquid Receivers Internal Sparge Manifold oc LP CONTROL SETTING Compressor EE O y HP CONTROL SETTING Compressor a LP CONTROL SETTING Rack ka LP CONTROL SETTING LP Bleed Kea HP CONTROL SETTING RACK GER EE HP CONTROL SETTING LP Bleed Kpa HP CONTROL SETTING Emergency Cooling Kpa P ANTI S
85. the opposite direction Figure 13 Liquid Level Switch Wiring Details Disassembled View Sight Glass Adapter O Ring Lucite Body coi T n Relay Module E Retainer Ring Check and Test function of the low level Alarm probe during Commissioning Figure 13A Liquid Level Switch Wiring Details Supply amp Load Wiring Level Switch Leads AC Wiring Relay Output Load y Output LEVEL L2AC DC Wiring Relay Output Load y Output LEVEL DC A WARNING All electrical wiring should be carried out by qualified persons and in accordance with AS300 or equivalent standard in the country of installation Contact When liquid present 9424 N C 9424A N O Working Pressure 8273kPa BAO 103 1 AUS 29 lt a 9 14 Ancillaries R134a Level Probe SHP for Liquid Separation Vessel Figure 14 SHP level Probe Horizontal R134a vessel and wiring diagram CONTROL LOOP WIRING GROUND E DO NOT RUN WIRES WITH OR NEAR POWER EE WIRING FOR BEST ELECTRICAL NOISE 24 VOLT D C POWER SUPPL Y HANSEN P N PSU LINE VOLTAGE CONTROLLER 0 5 VOL T D C INPUT e 1 6 VOLT S SPAN CALIBRATION SCREW Z ZERO CALIBRATION SCREW PROBE HOUSING PERMANENT JOINT The SHP level probe in supplied loose and requires installation into the 03 4 NPT Female Socket located on the top of the Liquid Separation Vessel 9 15 Ancillaries R134a Level Probe SHP for Liquid Separation Ves
86. tion of the field evaporators to be carried out from the rack 2 The liquid Outlets 4 6 or 8 stubs of 27 8 refrigeration pipe Each complete with system ball valves with non return valve NRV bypass 3 The dual header design also provides additional Suction Superheating and Liquid Sub Cooling with its internal pipe network For Connection and operating instructions of the ball valves See Figure 23 Note Insure that all site pipe work is structurally self supported prior to connecting to the BITZER CO Hybrid Rack BAO 103 1 AUS 37 Figure 23 Connection 8 Operating Instructions for Ball Valves Ball Valve Brazing Instructions Ball Valve Operating Instructions Ambient Operating Media ao to 175 F 8 40 to 300 F TS 40 to 79 C 40 to 149 C e MWP 700 psig Vo 48 Bar 1 P Ar Loosen Nut Change Stem V Direction qu 4 lr MAX 700 C a d is y Le wi S wax ioc C bam wg KG L er J I Cu Cu ai Hand Tighten Tighten 1 4 Turn J EI J E Ball Valve MUST be in FULL OPEN OPEN Position CLOSED Position or FULL CLOSED POSITION Figure 24 Connection 8 Operating Instructions for 3 Way Ball Valves FACES PERPENDICULAR FACES PARALLEL TO TUBE FLOW GOES TO TUBE FLOW GOES TOWARDS SCHREADER AWAY FROM SCHREADER The three way ball valves are primarily located e The Discharge line upstream of the Hot Water BPHE When HW is BPHE fitted e The Discharge line prior to the Air Cooled De
87. ucer port comes with service valve System interconnecting refrigeration pipe work engineered to application and safe working pressure specifications e System interconnecting flexible hoses engineered to application and safe working pressure specifications All Refrigeration Ball Valves Packed Capped Valves Rotolock Valves Check Valves inline products Copper Tubing Copper Fittings Brass Fittings Flexible Lines are safe working pressure rated at greater than 2500kPA low side and greater than 4500kPA High side 8 BAO 103 1 AUS lt a 8 Operation The BITZER GEN 7 CO Hybrid Racks e The High pressure liquid CO leaves the Liquid Receiver via the insulated liquid line This liquid enters a CO liquid CO suction vapour brazed plate heat exchanger BPHE The purpose of this heat exchanger is to add additional superheat to the suction return vapour This ensures that the oil in the compressor crankcase is sufficiently warm to avoid catastrophic compressor failure An additional a hot gas injection is installed into the suction line to ensure sufficient superheat This design also provides simultaneous sub cooling to the liquid supply to the evaporators There is a liquid line by pass circuit complete with inline NC solenoid valve prior to the BPHE this solenoid when open causes the liquid refrigerant to partially by pass the BPHE reducing the amount of superheat of the return suction CO The Liquid CO leaves the BPHE vi
88. user pockets Breathing equipment Not required Protection of hands Protective gloves and protective skin cream Material of gloves The selection of the suitable gloves does not only depend on the material but also on further marks of quality and varies from manufacturer to manufacturer As the product is a preparation of several substances the resistance of the glove material cannot be calculated in advance and has therefore to be checked prior to the application Penetration time of glove material The exact break through time has to be found out by the manufacturer of the protective gloves and has to be observed Eye protection Safety glasses recommended during refilling Body protection Protective work clothing 52 BAO 103 1 AUS 17 BITZER BSE 60K Material Safety Data Sheet continued Physical and chemical properties General Information e Form Fluid e Colour Light yellow e Smell Characteristic Value Range Unit Method e Change in condition e Melting point Melting range Not determined Boiling point Boiling range Not applicable or not determined e Flash point 286 C ISO 2592 Decomposition temperature Not determined e Self in flammability Product is not self igniting Danger of explosion Product is not explosive e Density at 20 C 1 01 g cm DIN 51 757 e Solubility in Miscibility with e Water Not miscible or difficult to mix e Viscosity or Consistency Class e Kinematic at 40
89. witch Board Fax 49 0 621 3701 570 e Informing department Product safety department Tel 49 0 621 3701 333 e Emergency information Tel 49 0 621 3701 333 or 49 0 621 3701 0 Switch Board 2 Composition Data on components e Chemical characterisation Description Mixture of synthetic base oils with additives Dangerous components R phrases Triaryl phosphate 0 1 1 96 N R 50 53 e Additional information For the wording of the listed risk phrases refer to section 16 Hazards identification Hazard designation By handling of mineral oil products and chemical products no particular hazard is known when normal precautions item 7 and personal protective equipment item 8 are kept e Information pertaining to particular dangers for man and environment This product is water polluting see item 12 R 52 53 Harmful to aquatic organisms may cause long term adverse effects in the aquatic environment Classification system The classification is in line with current EC lists It is expanded however by information from technical literature and by information furnished by supplier companies The classification results from the Conventional Method of 1999 45 EC concerning specific data of compounds First aid measures e General information Change clothes and shoes contaminated or soaked by the product Never put rags contaminated by the product into cloth pockets e After inhalation Supply fresh ai
90. xiate in high Asphixiate in high R717 NH3 2RE 33 49C 25 The code can be broken down to The number 2 represents the category of gas Class 2 being nontoxic The letter R indicates that a water fog or fine mist sprays used by emergency services to contain a spill or major gas leak The letter E indicates the possibility of evacuation 4 BAO 103 1 AUS 4 lt a gt Inspection and Designation On receiving your BITZER CO Rack 1 10 11 12 13 14 15 16 17 18 19 20 21 22 Immediately upon receiving the BITZER CO Hybrid Parallel Compressor Rack please inspect the crating packaging and the BITZER Rack for possible damage during shipment The crating and packaging has been designed to provide the safest possible protection for equipment transport IMPORTANT Contact BITZER Australia immediately to notify of any damage reported Check the BITZER picking slip list bill of goods and product s provided are correct to your purchase order Check unit s nameplate s and record serial number s Accessories are packaged in separate carton s See Check list section 5 Check compressor nameplate to ensure you have the correct model amp voltage for the application Also ensure that the maximum pressure temperature ratings listed on the nameplate are not exceeded during installation or operation Before attempting to install rack be sure to review this document in its entiret
91. y Ensure that all work carried out on the unit is done by qualified refrigeration personnel who are suitably trained amp instructed Applicable safety procedures amp practices should be followed The unit is supplied under pressure approximately 1000kPa above atmospheric pressure Failure to relieve the holding charge in the correct manner may result in injury Safety glasses safety footwear safety gloves and appropriate work wear must be worn when working on the unit When receiving multiple BITZER CO racks check and insure that the correct rack is located on the nominated system platform designated area Install the supplied loose crankcase heaters to each of the compressors Do not apply any power supply to the compressor s unless all suction amp discharge shut off service valves are opened Fully back seated position Do not operate compressor s system until in line valves controls are set for operation Do not operate compressor s unless the crankcase heater s are installed Do not operate compressor s unless compressors are correctly charged with BITZER BSE60K oil Do not operate compressor s unless the Oil Separator Reservoir is correctly charged with BITZER BSE60K oil Do not operate compressor s unless system is pre charged with R744 CO Refrigerant Do not operate compressor s unless High Stage system has been commissioned and is fully functional Do not operate or provide any electrical power to the compre

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