Rivacold CO2NNEXT Assembly Instructions Manual
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Rivacold CO2NNEXT Assembly Instructions Manual

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ISTRUZIONI PER L'ASSEMBLAGGIO
INSTRUCTIONS POUR L'ASSEMBLAGE
INSTRUCCIONES PARA EL ENSAMBLADO
rev01 - 08/2018
ASSEMBLY INSTRUCTIONS
MONTAGEANLEITUNG
CO
NNEXT
2
IT
EN
DE
FR
ES

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Summary of Contents for Rivacold CO2NNEXT

  • Page 1 ISTRUZIONI PER L’ASSEMBLAGGIO ASSEMBLY INSTRUCTIONS MONTAGEANLEITUNG INSTRUCTIONS POUR L’ASSEMBLAGE INSTRUCCIONES PARA EL ENSAMBLADO NNEXT rev01 - 08/2018...
  • Page 2 Company Rivacold s.r.l. - All rights reserved These assembly instructions are entrusted to users of CO2Nnext, for the instruction of the technicians involved in installation and maintenance. The instructions, drawings, tables and anything else contained in this instruction manual are of a reserved technical nature and cannot be reproduced and/or disclosed, either completely or partially, without the specific written authorisation of Rivacold s.r.l.

  • Page 3: Table Of Contents

    NNEXT rev.01 Index 1.4.1. Definitions ......................1.4.2. Personal protection equipment and rules of conduct......1.4.3. Graphical conventions .................. 1.6.1. General conditions ..................1.6.2. Operations that invalidate the Warranty ........... 1.7.1. Request for assistance ................... 2.2.1. Passive safety devices ................... 2.2.2. Active safety devices ..................
  • Page 4 NNEXT rev.01 62 / 293...
  • Page 5 NNEXT (identified, in this document, with the term partly-completed machine) produced by the company Rivacold s.r.l.; for this reason, they will need to be part of the technical dossier of the final machine onto which this partly-completed machine will be incorporated.

  • Page 6: Definitions

    NNEXT rev.01 CHAPTER CONTENT Chapter 1 General Description of the assembly instructions, of their structure and of the information conventions used; definition of the terms used; definition of the relationship between the Manufacturer and the Purchaser/User (in terms of warranty and assistance conditions). Chapter 2 Presentation of general indications on the partly-completed machine, on Introduction on safety...

  • Page 7: Personal Protection Equipment And Rules Of Conduct

    NNEXT rev.01 1.4. Conventions and definitions The assembly instructions for the partly-completed machine were divided into chapters to enable, for each life phase of the partly-completely machine (transportation, installation, maintenance and decommissioning) readily available information necessary for the user of the partly-completed machine. The entire documentation relating to the partly-completed machine was prepared by developing the topics indicated by the Machinery Directive (2006/42/EC), by the PED Directive (2014/68 EU) and by the current safety regulations.

  • Page 8: Graphical Conventions

    NNEXT rev.01 1.4.3. Graphical conventions The graphic layout of these Assembly Instructions is such as to allow easy recognition of the contents; in this context, for example, the instructions are associated with lists, as indicated below: This symbol identifies a generic bulleted list or list in points consisting of simple actions •...

  • Page 9: General Conditions

    1.6. Warranty 1.6.1. General conditions The Manufacturer, Rivacold s.r.l., guarantees the partly-completed machine and the equipment produced by the Manufacturer itself as being free from material and processing defects for a period that is agreed upon when the contract for the sale of the same machine is concluded.
  • Page 10 NNEXT rev.01 Introduction on safety 2.1. Design criteria In designing the partly-completed machine principles and concepts have been applied according to the paragraphs on the harmonised standards indicated in Table 3. STANDA NAME EC Directive no. 2006/42 Machine Safety Directive Machinery safety - Fundamental concepts, main...

  • Page 11: Passive Safety Devices

    NNEXT rev.01 2.2. Devices and Solutions for protection 2.2.1. Passive safety devices For the partly-completed machine the devices and constructive solutions described below were adopted: fixed guards close to the moving parts; external fairing with fixed access doors (if present); safety signs corresponding to the guards of the partly-completed machine.
  • Page 12 NNEXT rev.01 Refrigerant pressure defect The causes that can cause lowering of the intake pressure beyond the values permitted in the project are: defect in the quality of refrigerant loaded; poor regulation of the thermostatic valves; gas leaks that reduce the load. This entails a drastic reduction in the thermodynamic efficiency of the system and can cause compressor failure.

  • Page 13: Notifications

    NNEXT rev.01 2.2.4. Notifications The partly-completed machine is equipped, in addition to the luminous signals and the instruments installed on the panel of the electrical panel, with indicator lights on the inside. To access it, it may be necessary to remove one or more covering panels that close the structure. For further information on the light signals and on the instruments of the electrical panel, refer to the wiring diagram and to the relative documentation attached to this manual.
  • Page 14 NNEXT rev.01 2.3. Residual risks To avoid any dangerous condition for persons or damage to the partly-completed machine caused by residual risks, i.e. those risks that persist despite all provisions implemented, or potential risks which were not obvious, the manufacturer recommends that maintenance personnel and all personnel in charge of operating the partly-completed machine strictly follow the warnings indicated in the following pages.
  • Page 15 NNEXT rev.01 2.4. Safety Plates The warning plates shown in Table 4 are present on the partly-completed machine. PLATE DESCRIPTION It indicates the prohibition to remove the devices and the safety protections installed; it is typically also accompanied explanatory text: DO NOT REMOVE THE PROTECTIVE DEVICES.
  • Page 16 NNEXT rev.01 Position of the pictograms on the partly-completed machine On all the air exchangers present in the machine On each surface subject to high temperatures On each energised part 74 / 293...
  • Page 17 NNEXT rev.01 2.5. Proper and improper use of the partly-completed machine The partly-completed machine which is the subject of these assembly instructions has been designed and constructed exclusively for refrigeration. The partly-completed machine is configured to use only R744 (CO2) refrigerant gas.
  • Page 18 NNEXT rev.01 2.7. General Warnings and Rules of Conduct In order to avoid any risk to persons or damage to the machine, it is advisable to strictly follow the warnings and general rules of conduct reported here. DANGER WARNING: the Manufacturer disclaims any liability for any damage to property and/or persons arising from improper operations carried out by unqualified, untrained or unauthorized personnel.
  • Page 19 NNEXT rev.01 The area where the maintenance operations are carried out must always be clean, dry and with the appropriate equipment always available and efficient. If it is necessary to perform interventions in the vicinity of electrical components, operate with dry hands and use dielectric gloves.
  • Page 20 NNEXT rev.01 Description of the partly-completed machine The partly-completed machine models that are the subject of this document are faired condensing units for use in commercial refrigeration. The faired condensing units are systems for positive and negative refrigeration where the heat can be disposed of into the environment. The faired condensing units are compact, low noise systems, suitable for working outdoors.
  • Page 21 NNEXT rev.01 The partly-completed machine can communicate with the supervisory systems through Modbus RTU communication via RS485, and can also be provided with a system of remote communication with the owner. The compact design allows installation even in small spaces. The structure is made of bent sheet metal with epoxy paint and suitable feet dampen the vibrations.
  • Page 22 NNEXT rev.01 Regardless of the configuration, the partly-completed machine is always supplied without the air evaporators so it is not able to perform the function for which it is created without the evaporating unit. As a consequence, it is a partly-completed machine, as defined by Machinery Directive 2006/42/CE. In order to define the refrigeration cycle envisaged, the purchaser has to insert it in a complete refrigeration circuit.
  • Page 23 NNEXT rev.01 3.1. Identification plate For identification of the partly-completed machine a specific CE identification plate has been affixed; the identification data shown on this plate must be reported to the Manufacturer's offices for each request for intervention or for the ordering of spare parts. The identification plate contains the following data: Partly-completed machine code Compressor Power supply voltage...

  • Page 24: Name

    NNEXT rev.01 3.1.1. Name Series: CO2NNext with BLDC motor Size of compressor(s) Type of application: M = medium temperature (TN) L = low temperature Number of fans: 1 = an electronic fan-motor 2 = two electronic fan-motors Fan-motors diameter: 450 mm Refrigerant type R744 Progressive no.

  • Page 25: Technical Data

    NNEXT rev.01 3.1.3. Technical data In the documentation attached to this document, including a specific electric and refrigeration scheme, it is possible to find the following detailed technical information concerning the specific machine: R744 (CO2) as the only usable refrigerant; Machine code;...

  • Page 26: Lifting

    NNEXT rev.01 Transport and Installation DANGER: The operations indicated below must be carried out by qualified operators. The Manufacturer declines all responsibility for operations carried out without respecting the safety regulations, by unqualified operators and without compliance with the specifications of this manual. ATTENTION! The user, having purchased the equipment, before use, becomes the person in charge of the component subject to Directive 2014/68/EU (PED) and must arrange for the legal checks to be performed according to the national legislation in force (Ministerial Decree 329 dated 1/12/2004...
  • Page 27 NNEXT rev.01 4.3.1. Lifting DANGER: the lifting operations must be performed under the direct supervision of a qualified mechanical maintenance operator. ATTENTION: during all these operations, exercise the necessary caution to avoid collisions and tipping over, handling the partly-completed machine in a manner that maintains conditions of balance. DANGER: Make sure there are no unauthorised personnel near the area where the lifting, handling, and unloading operations are taking place.
  • Page 28 NNEXT rev.01 4.4. Installation ATTENTION: The partly-completed machine that is the object of this manual is part of a refrigeration system consisting of the condensing unit and components of a refrigeration system such as evaporator(s), pipes, safety components, etc. The total volume of the evaporators associated with the partly-completed machine must NOT exceed 9 litres.

  • Page 29: Power And Control Electrical Panel And Electrical Connection

    NNEXT rev.01 4.4.1. Power and control electrical panel and electrical connection DANGER: The electrical connection operations must be carried out by qualified personnel who meet the necessary technical requirements established by the country in which the machine is installed. ATTENTION: The Manufacturer declines all responsibility deriving from non-observance of the indications below.
  • Page 30 NNEXT rev.01 Wiring of the various components of the system The first electrical operations to be performed on the machine, even before powering it, are those of wiring the various devices that compose it: supervision network (where present); other optional components. ATTENTION: The sizing and laying of the cables that connect the machine to all its external components must be carried out in compliance with the laws in force in the country in which it is installed.
  • Page 31 NNEXT rev.01 Avoid passing the serial cable near power cables; provide separate conduits for power and communication cables; furthermore, it is advisable to keep the cable away from devices that generate magnetic or electromagnetic fields, such as radio antennas, transformers, contactors, neon lights, etc.;...

  • Page 32: Refrigerating Connection

    NNEXT rev.01 4.4.2. Refrigerating connection ATTENTION: The pipes must be sized according to the type and extension of the system in full compliance with the safety restrictions imposed by the laws of the country of installation. The Manufacturer is not responsible for the incorrect selection and execution of the system pipes. ATTENTION: The pipes may have different dimensions from that of the partly-completed machine connection.
  • Page 33 NNEXT rev.01 The following images show a number of explanatory notes for the installation of the described sections in order to guarantee a correct oil return by creating siphons and slopes. a. Evaporator positioned at a lower level with respect to the central point b.
  • Page 34 NNEXT rev.01 Connections with the possibility of welding or brazing or with the possibility only of brazing Information on the type of connection possible can be found on the refrigerator diagram. Pre-cut Connection with ODS brazing Closure cap Connection with head-head welding Connection points RS service valve Closure cap...

  • Page 35: System Drain

    NNEXT rev.01 4.4.3. System drain For the refrigerating machine and the compressors to work properly, it is essential to correctly vacuum the system to ensure a value of air and above all of humidity below the permissible values. Introduction of the new gases required the use of polyester-based oils with characteristics of high hygroscopicity, necessitating greater attention in creating of the vacuum.
  • Page 36 NNEXT rev.01 The service valves to which the vacuum pump must be connected are the following: RS2 or RS2.P delivery (if present); RS3 liquid; positive intake RS1; negative intake RS1 (if present). Furthermore, as shown in the following figures, when the machine is switched off, opening magnets must be inserted in the solenoid valves YVEq.LT and YVEq.P if present.

  • Page 37: Refrigerant Load

    NNEXT rev.01 4.4.4. Refrigerant load After the drain operation, the system must be loaded with carbon dioxide –CO2 – R744 Purity ≥ 99.99%) H2O ≤ 10 ppm, O2 ≤ 10 ppm, N2 ≤ 50 ppm or higher. R744 refrigerant (CO2) is classified as safety class A1 according to EN 378-1 (non-flammable, non-toxic). ODP = 0 and GWP = 1.
  • Page 38 NNEXT rev.01 Loading ends when the level of liquid inside the receivers exceeds at least half the indicator light of the visual indicator (1) present on them and there is no presence of bubbles on the IND1 indicator in stationary conditions.

  • Page 39: Oil Load

    NNEXT rev.01 4.4.1.Oil fill The oil must be added according to the refrigerant load as indicated in the table. If the refrigerant load is LOWER than 4kg, no oil must be added. REFRIGERANT LOAD UP TO 4kg OVER 4kg R744 ADD 50g OIL OIL LOAD DO NOT...
  • Page 40 NNEXT rev.01 4.5. Preparation for start up DANGER: The following operations must out be carried only by qualified and specifically trained technicians. The Manufacturer declines all responsibility for operations carried out without respecting the safety regulations, by unqualified operators and without compliance with the specifications of this manual.
  • Page 41 NNEXT rev.01 Looking at the display on the door of the partly-completed machine electrical panel the following are evident: BUTTONS ASSOCIATED ALARM It shows the list of active alarms and access to the alarm logs PRG. It is used to enter the main menu BACK Return to the previous page To switch to the upper value in a list or to increase the value of a variable...
  • Page 42 NNEXT rev.01 MAIN PAGE Time and Date Main Values: Evaporation Parallel Aspiration Condensing BLDC compressor speed: LV and Parallel Unit Status: Compressor Status Gas cooler fan status HPV valve status Signal of active alarm and/or manual operation Access to additional information pages 100 / 293...
  • Page 43 NNEXT rev.01 INFORMATION PAGES Press the display key Information on the variables of the intake side. Information on the LV compressor. 101 / 293...
  • Page 44 NNEXT rev.01 Parallel compressor information. Information on the Gas Cooler. 102 / 293...
  • Page 45 NNEXT rev.01 Information on the fans of the Gas Cooler. Information on the HPV valve. UNIT ON/OFF Press the display key Press the key The cursor will move onto the first figure of the password. Enter the password “0000”. The press the key Select the “A.Unit Status”...
  • Page 46 NNEXT rev.01 1.1. Manual mode for the drain procedure Perform this procedure only during the vacuum phase and with the unit OFF. UNIT ON/OFF Press the display key Press the key The cursor will move onto the first figure of the password. Enter the password “0000”.
  • Page 47 NNEXT rev.01 Starting from the main screen: Press the display key Press the key The cursor will move onto the first figure of the password. Enter the password “0000”. The press the key Move down with the key until "B. Inputs/Outputs” is highlighted, then press the key Move down with the key until "b.
  • Page 48 NNEXT rev.01 Press the key to reach the mask as shown in the figure. Make sure that the values are equal to 100% of opening for the valve and in position O=Open for the equalisation valves present. NOTE: In the TN machines the Bbd02 mask is as follows: Confirm by pressing the key Move down with the key Check and retain the default values...
  • Page 49 NNEXT rev.01 N.B.: For softwares preceding the Hecu CO2 r3.0.012 version and for machines manufacturerd before OCTOBER 2018, proceed as follows: Move down with the key until "b. Manual Management” is highlighted, then press the Press the key until the cursor is positioned on "L1 – Discharge:". At that point, press one of the arrow keys to switch from DIS to EN.
  • Page 50 NNEXT rev.01 Starting from the main screen: Press the display key Press the key The cursor will move onto the first figure of the password. Enter the password “0000”. The press the key Move down with the key until “E. Evaporator” appears then press the key Move down with the key until “d.
  • Page 51 NNEXT rev.01 At this point, if the wiring has been carried out correctly, the EEV valve will move to the inserted opening until the initial situation is restored by setting NO at the "EEV Manual" parameter in mask Ead01. Wait until the system is stable and perform the necessary optimisations, referring to the machine manual, software manual of the controls.
  • Page 52 NNEXT rev.01 Maintenance and dismantling To guarantee maximum reliability on the machine and to avoid dangerous conditions, carefully follow the instructions and warnings on the following pages. Periodic maintenance and correct use are essential factors to guarantee the full efficiency and safety of the machine.
  • Page 53 NNEXT rev.01 Checking the availability of the material 60 days prior to the date determined for interventions of maintenance, perform a detailed examination of the material necessary: 1. check if the material is on the stock, 2. if necessary, ask the manufacturer's Technical Office for the missing parts at least 30 days in advance. 5.1.
  • Page 54 NNEXT rev.01 DESCRIPTION OF THE MAINTENANCE FREQUENCY Controls and safety devices checks Proceed with verification of the operation of all the safety control devices by checking Monthly the anomalies signalled by the electronic control, which detects probe faults and anomalies of the same. Refer to the dedicated manual. Check for the presence of oil on the separators (if any) Check that there are no oil alarms on the electronic control and that the level on the separators is higher than the minimum as indicated by the sensor.
  • Page 55 NNEXT rev.01 5.2. Safety valve interventions It is advisable to replace the safety valve if it has intervened as the point of intervention is no longer guaranteed and reclosing may not be perfect, thus generating loss of refrigerant. Check the safety valve (if any) every three years or according to different periods depending on the valve manufacturer.

  • Page 56: Disassembly

    NNEXT rev.01 5.3. Disassembly and demolition See the instructions provided at the beginning of Chapter 5 regarding the warnings and the Personal Protective Equipment to be used. 5.3.1. Disassembly In case it is necessary to disassemble the PARTLY-COMPLETED MACHINE, follow the procedure indicated below.
  • Page 57 NNEXT rev.01 6. Troubleshooting POSSIBLE CAUSE SOLUTI The compressor does not start and does not hum Absence of voltage. Starter relay with contacts Check the line or replace the relay. open. The thermal protector intervenes. Check the electrical connections. Loose electrical connections or incorrect Tighten the connections or re-perform the electrical connections.
  • Page 58 NNEXT rev.01 POSSIBLE CAUSE SOLUTI Compressor works continuously or for long periods System not sufficiently sized according to the Replace the system with a more powerful one. load. Excessive load to cool or insufficient insulation Reduce the load and improve insulation, if possible.
  • Page 59 NNEXT rev.01 7. Annexes The specific characteristics of the partly-completed machine are reported in: Declaration of Incorporation; datasheet; refrigeration diagram; wiring diagram. 117 / 293...

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