Panasonic OCU-CR1001VF Installation Instructions Manual
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Panasonic OCU-CR1001VF Installation Instructions Manual

Panasonic OCU-CR1001VF Installation Instructions Manual

Outdoor type refrigeration unit
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Installation Instructions
Thank you very much for purchasing
Panasonic products this time.
Please read this instruction booklet
and correctly comply with the
explanations.
In particular, please read "Cautions for
Safety" (Pages 2 to 6) for ensuring
safe operations.
Please retain this instruction booklet in
a safe place.
Caution labels are attached to the product.
This illustration represents OCU-CR1001VF
Outdoor Type Refrigeration Unit
(Non-fluorocarbon Refrigeraton Unit with
CO
Refrigerant)
2
Model No.
OCU-CR1001VF

Table of Contents

2-6
7
8
9-10
11
13
14
15-16
17
18
19
20
21
22-23
24
25-29
30-32
33-34
35-36
37-38
39
40-41
42-49
50-51

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Summary of Contents for Panasonic OCU-CR1001VF

  • Page 1: Table Of Contents

    25-29 Control Functions 30-32 Adjustment during Operation 33-34 Oil Level Control Method 35-36 About Alarms 37-38 Maintenance and Inspection Actions at the time of Failure 40-41 Failure Diagnosis 42-49 This illustration represents OCU-CR1001VF Warranty Condition of the Refrigeration Unit 50-51...

  • Page 2: Cautions For Safety

    Cautions for Safety Be sure to comply with the following For the purpose of avoiding harm to people and damage to properties, items to be complied with are explained here. Explanations are classified by degree of harm or damage caused by incorrect use. Warning Indicates possibility of death or serious injury.
  • Page 3 Cautions for Safety Be sure to comply with the following Electrical Work Always use a dedicated circuit and install a ground Grounding Work fault interrupter. Lack of grounding work may lead to electrical shock caused by current leak. Incorrect electrical work may lead to Securely carry out grounding work by current leak and fire or electrical shock.
  • Page 4 Cautions for Safety Be sure to comply with the following Repairs Disassembly or repairs should be performed by When abnormal operation was detected, or before a specialty operator. starting disassembly or repair, turn off the power switch and shut off the ground fault interrupter. Incorrect disassembly or repair may lead to abnormal operation and causes injury, fire Continued operation with abnormal...
  • Page 5 Cautions for Safety Be sure to comply with the following Caution Installation Work Do not install in a place with possible leak of Produce a refrigeration cycle within the limits of flammable gas. an operation standard (refer to “Scope of Application”).
  • Page 6 Cautions for Safety Be sure to comply with the following Cautions for Use When the refrigerant bursts out, shut off the power Do not use flammable spray near the refrigeration and fully close the service valve. unit. Do not place flammable materials nearby. Blowout of refrigerant from the refrigeration Flammable material may catch fire from cycle by opening the service valve would...

  • Page 7: Name Of Each Part And Optional Accessories

    Prevention of dust penetration Suction filter S-008T φ 15.88 D-155T Filter Dryer OCU-CR1001VF (Type: CO-085-S) (Outer diameter welding) Fin guard for gas cooler SPK-GA4014 Guard made from wire Note: The filter dryer (one is shipped with each refrigeration unit) is a standard component. When replacing the filter...

  • Page 8: Scope Of Application

    Scope of Application This refrigeration unit operates with a rotary compressor. Use the refrigeration unit within the range shown below. Item Standard Value Remarks Refrigerant R744 The charge supply amount shall be adequate. Evaporating temperature -45°C to -5°C Temperature conversion of inlet pressure Suction pressure 0.73MPa to 2.95MPa Unit inlet pressure...

  • Page 9: For Effectively Using The Refrigeration Unit

    For Effectively Using the Refrigeration Unit Cautions for Installation Work This refrigeration unit has been designed exclusively for R744 (CO refrigerant). Refrigeration oil and each component including the compressor have been exclusively designed for the refrigeration unit. Please use sufficient caution for maintaining the reliability of the product. (1) Since CO refrigeration cycle becomes high pressure during operation, use the piping material and other components particularly designed for CO...
  • Page 10 (5) Rotary compressor consists of high precision components. Use caution during piping work to avoid contaminaion of dust, metal powder, or oxide scale, etc. Initial Oil Quantity Oil are pre-charged in compressor and oil separator. Model No. Compressor Oil separator OCU-CR1001VF 1.8 L 5.0 L...

  • Page 11: Selection Of Installation Location

    Selection of Installation Location General Cautions Each unit of the equipment should be placed by selecting the most convenient location such as easy to install, operate or maintain. (1) Each unit should be placed to make the piping and wiring length as short as possible and easy to install. (2) Controller should be located within the reach of the user's hand for convenient daily operations (RUN, STOP, reset warning, etc.).
  • Page 12 Carry-in/Installation Carry-in Operation Hoist Operation (1) Carry the refrigeration unit gently by keeping the When hoisting the refrigeration unit, use caution for the vertical position as much as possible. following points. (2) Absolutely avoid a lay-down position of the (1) When hoisting the refrigeration unit, follow the refrigeration unit.

  • Page 13: Carry-In/Installation

    Carry-in/Installation External Dimensions (Piping hole dimension) Liquid line (Unit outlet) Suction line (Unit inlet) Details of piping hole on the bottom of the refrigeration unit Suction line (Unit inlet) (Φ19.05 outer diameter connection) Liquid line (Unit outlet) (Φ15.88 outer diameter Monitor display connection) (Pressure,...

  • Page 14: Installation Example

    Installation Example When there's an obstacle in the upward Standard installation direction The gas cooler is designed to take air from 3 directions, When there's an obstacle in the including the front, left and right side, and blow out from upward direction, the installation the top.

  • Page 15: Refrigerant Piping Work

    (Outer diameter welding) φ 19.05 φ 15.88 OCU-CR1001VF (1) Piping material should be seamless phosphorous-deoxidized copper pipes (refrigeration grade.) (2) The specified piping installation pressure is 8 MPa for both suction line and liquid line. (3) When cutting pipes, use a pipe cutter and always apply deburring.
  • Page 16 Refrigerant Piping Work Cautions for Heat Insulation Work (1) Apply heat insulation on the suction line and liquid line for avoiding thermal effect from outside. (2) Do not wrap together the suction line and liquid line with heat insulation material. Liquid line Refer to the right illustration.

  • Page 17: Piping Example

    Piping Example When the evaporator is located higher Height difference 5 m or below (1) The suction line should ideally slope gently towards the unit. Expansion valve Recommendation slope is 1/200~1/250. (2) Refrigerant pipe should be covered with heat insulation material on both suction line and liquid line.

  • Page 18: Refrigerant Circuit Diagram

    Refrigerant Circuit Diagram Unit  outlet temperature sensor Split cycle outlet Unit outlet temperature  sensor  Split cycle heat exchanger (Liquid line) Filter dryer Unit  outlet pressure sensor MOV7  Electronic expansion MOV5 MOV6 valve for liquid return Flash Electronic expansion  Electronic expansion chamber valve for pressure valve for gas return reduction  High pressure  service valve Ambient  temperature sensor Intermediate  pressure sensor Gas cooler outlet Gas cooler temperature sensor separator Inter cooler Oil return 2nd stage Oil cooler discharge service valve Oil service valve Check valve...

  • Page 19: Refrigerant Charging

    Refrigerant Charging Evacuation [Perform after completing electrical wiring.] To avoid inclusion of air or moisture in the refrigerant circuit, be sure to execute vacuum drying of the entire circuit before charging refrigerant by using a vacuum pump. Execute evacuation after securely carrying out airtight test by using the following sequence.

  • Page 20: Cautions For Electrical Wiring Work

    30 m 50 m current current 3.5 or OCU-CR1001VF 50 A 100 mA thicker Notes: 1. The values in the table above indicate at wire ambient temperature 40°C or below, wire type 600 V vinyl insulated wire 3 wires or less.

  • Page 21: Electrical Wiring Work

    Electrical Wiring Work Wiring Block Diagram Example Power source 3-phase 200 V Operation control (operation signal, back-up solenoid valve) Operation control Controller (optional) Cooler Refrigeration unit Indoor Outdoor Wiring Guide Opening Wiring guide opening is located on the left side of the refrigeration unit. (A square hole is provided in the unit base for electrical wiring.) By using a cable bundling tie attached to the bottom section of the electrical box, bundle the power cable, grounding wire,...

  • Page 22: Electrical Circuit Diagram

    Electrical Circuit Diagram Standard electrical Electrical circuit diagram ( wiring diagram) Connect a back-up solenoid valve and display case operation signal input according to the standard electrical wiring diagram.
  • Page 23 Installation of a ground fault interrupter and grounding wiring work is required. Left section of left side of Left side of Front of refrigeration unit refrigeration unit refrigeration unit...

  • Page 24: What Needs To Be Checked Before Operation

    What Needs to be Checked before Operation Confirmation before Operation (1) Please recheck if any incorrect wiring or loose wiring exists. (2) Fully open each stage discharge service valve and suction service valve around the compressor. (3) Check that the power supply voltage is within ± 10% of the rated voltage (normally 200V to 210V) (4) Check that insulation resistance is 1MΩ...

  • Page 25: Setting And Indication Of The Control Pcb

    Setting and Indication of the Control PCB This refrigeration unit is equipped with the function of setting a variety of compressor operation modes by the switch on the control PCB. Operating condition of the compressor can be checked by the LED on the control PCB. In particular, when any anomalies occur in the refrigeration unit, an alarm LED (red) lights up or blinks, and the cause of anomaly is displayed digitally by an alarm code.
  • Page 26 Setting and Indication of the Control PCB Low Pressure Setting Set the refrigeration operation to OFF and then supply power. With this condition, execute initial setting. (1) Low pressure setting procedure • Turn ON the DIP switch SW13－8. • Align the rotary switch (knob) with the position corresponding to each setting ( “ON” or “OFF” of “Pressure Setting” ). •...
  • Page 27 Setting and Indication of the Control PCB Switch Setting (1) Auto/Forced selection switch (Slide switch, SW14) SW14 Function Remarks Auto (自動) Auto operation Normal operation setting Forced operation Not in use Forced (強制) (2) Control/Check selection switch (Slide switch, SW15) SW15 Function Remarks...
  • Page 28 Setting and Indication of the Control PCB Indication (1) Individual LED 1) Power (電源); 3 places (Yellow) Lights up when power is supplied to the PCB. (Main unit, electronic expansion valve, relay) 2) Hi (Yellow) Lights up when the low pressure is equal to the Control "ON value" or higher. 3) Lo (Yellow) Lights up when the low pressure is equal to the Control "OFF value"...
  • Page 29 Setting and Indication of the Control PCB Setting/Display Listing Digital display and operation list Rotary switch Mode Display/Setup Remarks switch Switch (Knob) position SW13-8 SW13-7 Press ▲: Red LED blinking cancelled Low pressure: The display alternates Lo.0.00 to 9.98 (MPa) During pressing ▼: Indicates Operation between Low pressure...

  • Page 30: Control Functions

    Control Functions Low Pressure Control Method Compressor capacity is controlled by changing the inverter frequency based on the difference between the low pressure and set value by adjusting the low pressure to the set value (ON value to OFF value). However, compressor operation continues even if the low pressure becomes below OFF value and finally stops when the low pressure reaches below the Lim value.
  • Page 31 Control Functions Protective Functions (1) Reverse phase, loss of phase, abnormal high pressure, abnormal intermediate pressure, abnormal unit outlet pressure Stops the compressor. (2) Discharge gas temperature anomaly 1) Normal operation Compressor operation stops when the discharge gas temperature exceeds 118°C, and resumes when the discharge gas temperature becomes 75°C.
  • Page 32 Control Functions Gas Cooler Fan Control Controls the fan motor rotation speed to achieve the target gas cooler outlet temperature in accordance with the following operation modes. The fan operation mode at the time of shipment is set to "Auto“. <Fan operation mode>...

  • Page 33: Adjustment During Operation

    Adjustment during Operation Preventing Short Cycle Operations Short cycle operation (frequent start/stop operation) causes excessive oil carry-over during starting and causes insufficient lubrication. (1) Adjust operation cycle to avoid short cycle operation. Note: Adjust ON-OFF cycle to be 10 minutes or longer. (2) The main cause of short cycle operation is inappropriate pressure setting on the control PCB, suction filter clogging, and unbalance of cooling capacity and load.
  • Page 34 Adjustment during Operation Adjusting Refrigerant Quantity of the Refrigeration Unit During determination of refrigerant quantity, temperature setting of all Unit coolers/Display cases needs to be set to the lowest temperature without activation of the thermostat for making the refrigeration unit operating continuously. (1) Method of determining refrigerant quantity Check the operation condition of the refrigeration unit by the following method, and adjust the refrigerant quantity to the appropriate value according to Table 3 (Determination criteria of refrigerant quantity).

  • Page 35: Oil Level Control Method

    Oil Level Control Method Oil Level Control and Oil Addition Assessment Criteria When the connection piping is long, oil in the refrigeration unit tends to attach to the in inner surface of the piping, resulting in insufficient oil in the compressor. When the piping length exceeds 50 m, add oil according to the table below. Connected pipe length Additional oil quantity (per refrigeration unit)
  • Page 36 Oil Level Control Method Replenishing Method For the detailed method of adding oil, refer to the Engineering Service Manual "Oil Replenishing Procedure" section. (1) Turn operation switch S1 to "OFF" to stop the operation of the refrigeration unit. (2) Confirm that the access ports of the compressor 1st stage discharge service valve and oil service valve are closed (back seated position), and connect the service piping (SPK-TU126) with an attached (closed) joint valve to each access port.

  • Page 37: About Alarms

    About Alarms Installation of an Alarm System This refrigeration unit has a variety of protection devices for securing safety. When a ground fault interrupter or other protection device is activated without the alarm system and temperature management system, the cooling operation is stopped for many hours thereby damaging the food items. To enable prompt actions at such time, an alarm system and temperature management system should be considered at the time of plan development.
  • Page 38 About Alarms Explanations of Anomaly Alarm When the ground fault interrupter is activated, check insulation of the equipment and circuit, eliminate the cause, and then supply power again. Alarm indication Compressor Operation/Stop External Communi- Anomaly item Reset method alarm cation during anomaly Red LED Alarm code...

  • Page 39: Maintenance And Inspection

    Maintenance and Inspection Maintenance and inspection should be contacted with a specialty company. Request for Maintenance and Inspection (To a specialty company for installation work) The structural components of refrigeration unit do not last permanently but include those wearing out in a certain period of time.

  • Page 40: Actions At The Time Of Failure

    Actions at the time of Failure When a component failure or malfunction is found, request the specialty company to repair. Actions at the time of Failure When the refrigeration unit or any refrigerant circuit component fails to operate by some reason, shut off the power for a repair.
  • Page 41 Actions at the time of Failure Replacing the Compressor Before replacing the compressor, refer to the Engineering Service Manual "Compressor Replacement Procedure" Caution (1) Be sure to shut off the ground fault interrupter. Note: Operation switch OFF does not shut off the crankcase heater. (2) Replace the compressor with attaching the oil level switch.

  • Page 42: Failure Diagnosis

    Failure Diagnosis Control PCB Alarm Code (1) When the rotary switch (knob) is at “Operation (運転)" position, the digital display on the control PCB alternately displays low pressure, high pressure, and alarm code (E ∗∗∗ < Alarm code table > Alarm Meaning Cause...
  • Page 43 Failure Diagnosis Control PCB Alarm Code Alarm Meaning Cause Correction method code ▪ Gas cooler fan motor became abnormal. (1) Check for the presence of a fan lock, fan dislocation, etc. Gas cooler fan (2) Check the connection of FC3-PCB "CN2, CN3, CN4 connectors“. E271 ▪...
  • Page 44 Failure Diagnosis Failure Diagnosis at the time of Discharge Gas Temperature Anomaly When the discharge gas temperature goes up abnormally, compressor is stopped for protecting the compression components of the compressor and discharge gas temperature anomaly alarm is generated at the same time. In such a case, check the problem position and apply appropriate actions in the sequence shown below.
  • Page 45 Failure Diagnosis Failure Diagnosis of Gas Cooler Fan (1) When the ground fault interrupter is turned OFF 1) Check the insulation resistance between the ground (G terminal) and each terminal of the power supply, inverter unit and FC3-PCB..1M Ω or below indicates an insulation failure of the inverter unit, FC3-PCB or fan motor. 2) Disconnect the FC3-PCB fan motor lead wires, and check the insulation resistance between the lead wire and ground.
  • Page 46 Failure Diagnosis Method of Checking Sensor Characteristics (1) Pressure (Low, Intermediate, High, Unit outlet) sensor While the connector is inserted to the control PCB, measure the voltage and check if the pressure is normal by using the table below. < Relationship between sensor output voltage and pressure > Pressure (MPa) 0.00 1.00...
  • Page 47 Failure Diagnosis Method of Checking Resistance Value of Electronic Expansion Valve Coil and Oil Level Switch (1) Electronic expansion valve coil: Used in Oil control electronic expansion valve (MOV1), Electronic expansion valve for pressure reduction (MOV5), Electronic expansion valve for gas return (MOV6), Electronic expansion valve for liquid return (MOV7) Measure the resistance with the connector disconnected from the control PCB, and check if the resistance value is correct by using the table below.
  • Page 48 Failure Diagnosis Failure Diagnosis of Inverter Unit Caution When performing an inspection or replacement, make sure to start working after the high voltage danger indication light (red) has been turned off. Capacitor discharge takes approx. 5 minutes. Electric component layout of inverter unit Left section of left side Left side of Front of...
  • Page 49 Failure Diagnosis Failure Diagnosis of Inverter Unit (2) When inverter anomaly (E6 ∗1 to E7∗1) is generated Possible cause is as follows. Check all of the following causes. Cause Method of Checking Method of Action 1) Check if the compressor motor current is high. Eliminate the cause of Overload condition 2) Check if any overload condition occurred even in a...

  • Page 50: Warranty Condition Of The Refrigeration Unit

    Warranty Condition of the Refrigeration Unit No-charge Warranty Period and Coverage No charge warranty period is 1 year from the date of installation of the refrigeration unit. However, the coverage of the no- charge warranty is the failed component by supplying a replacement component. Any failure caused by the following reason is considered chargeable even during the warranty period.
  • Page 51 Warranty Condition of the Refrigeration Unit Conditions not Covered by the Warranty (6) Accident caused by failure of power source Failure of the motor or electric component caused by a blown fuse in the power source, single-phase operation caused by loose terminal of wiring. Failure of the motor or electric component caused by abnormal power voltage drop (170 V or below) when starting after power failure and switching to emergency power source.
  • Page 52 Memo...
  • Page 53 < Purpose of Use > The personal information received from our customers is used only for consultation on products and services or for responding to inquiries. Panasonic Corporation and its affiliate companies may use the personal information for such purpose.

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