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CERTUS
AUTOMATIC EVACUATING AND
HYDROCARBONS CHARGING EQUIPMENT
INSTRUCTIONS FOR USE AND
INSTALLATION
Translated from original code: 8.023.0.005_rev13
GALILEO TP PROCESS EQUIPMENT S.r.l.
Via del Pantano 73 - 50018 Scandicci (Firenze) Italia
Tel. (+39) 055 7221358 – Fax (+39) 055 7222225
Website
www.galileotp.com
– mail
info@galileotp.com
Code: 8.023.1.005_rev.13
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Summary of Contents for GALILEO TP CERTUS C11
- Page 1 AUTOMATIC EVACUATING AND HYDROCARBONS CHARGING EQUIPMENT INSTRUCTIONS FOR USE AND INSTALLATION Translated from original code: 8.023.0.005_rev13 GALILEO TP PROCESS EQUIPMENT S.r.l. Via del Pantano 73 - 50018 Scandicci (Firenze) Italia Tel. (+39) 055 7221358 – Fax (+39) 055 7222225 Website www.galileotp.com –...
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Page 2: Table Of Contents
HARZARDOUS AND RESIDUL RISK ......................16 HAZARDS INTERACTIONS AMONG MACHINE AUTOMATIC ..............16 INSTALLATION .............................17 GENERAL INFORMATIONS ........................17 SAFETY PRECONDITIONS TO USE INFLAMMABLE FLUIDS CHARGING EQUIPMENT WITH GAS CONTROL SYSTEMS AND VENTILATION SYSTEMS NOT PROVIDED BY GALILEO TP P ROCESS QUIPMENT 3.2.1 SUCTION ............................18... - Page 3 4.2.3 DOSAGE TESTING ..........................26 ALARMS AND TROUBLE SHOOTING .......................27 GENERALITY .............................28 5.1.1 GENERAL NOTES ..........................28 5.1.2 SENSOR CONTROL PROCEDURES ....................28 5.1.3 SOLENOID VALVES CHECKING PROCEDURES ................29 ALARMS AND TROUBLE SHOOTING TABLE.....................30 ERRORS TABLE ............................33 MAINTENANCE GUIDE ..........................34 DICHIARAZIONE DI CONFORMITÀ (DECLARATION OF CONFORMITY) (ANNEX IIA DIR. 2006/42/CE) .................................37 DICHIARIAMO CHE LA SEGUENTE MACCHINA (WE DECLARE THE FOLLOWING MACHINE) ......37 È...
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Page 4: Introduction
NTRODUCTION 1.1 GENERAL RULES This typology of plants has been engineered and manufactured to be used on refrigerant equipment lines (refrigerators, freezers, etc.) in order to vacuum, detect possible leaks or clogs in the circuit and naturally, to charge them with the appropriate refrigerant. The plant is made to respond to requirements of productions with accurate doses. -
Page 5: Technical Characteristics
1.2 TECHNICAL CHARACTERISTICS N° of charging fillers 1 Length of the fillers 3.5 m (others on request) Programmable cycles number 200 (more on request) ¼”, 3/8” Hansen female quick coupler Pipe sealer (for smooth pipes with outer diameter 6 mm) Connection type to the refrigerating circuit PCU models 61, 71 series 250 Nitto SP CUPLA type A ¼”, 3/8”... -
Page 6: Symbols, Controls And Conventions
1.3 SYMBOLS, CONTROLS and CONVENTIONS This symbol identifies operations that - if not executed according to the instructions – might damage the equipment or injure the people working at it. Operator’s commands: The equipment is provided with touch screen monitor, so the operator can send commands by typing directly on the monitor. -
Page 7: Security And Controls
1.5 SECURITY AND CONTROLS 1.5.1 CONSTRUCTION STANDARDS The whole electrical supply and control part has been manufactured in compliance with the EN60204-1 standards, (Electrical equipment of machines). The electrical components installed inside the dangerous zones are in accordance to EN50014 standards (Electrical apparatus for potentially explosive atmospheres - General requirements), EN60079-10 (Explosive atmospheres. -
Page 8: Mechanical Safety Devices
1.5.3 MECHANICAL SAFETY DEVICES Safety devices for pressure build-up are mounted on each of the dosing cylinders and corresponding exhausts are configured to release externally. Access to the dosing systems can be obtained by opening the door on the lower side of the machine: •... - Page 9 Switch position to “I OFF” position to switch off the power to the machine • Start button on the control panel marked with "I". • START (start cycle) and EXIT (exit alarms) button positioned on the filler. Code: 8.023.1.005_rev.13...
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Page 10: Intercepting Valve With Suction Box (Codice 2.002.2.500)
1.6 INTERCEPTING VALVE WITH SUCTION BOX (codice 2.002.2.500) “Intercepting valve with suction box kit” is a necessary device that grants the safety of the charging area of a flammable refrigerant charging machine. Through its use it is possible to limit the extension of the dangerous area relevant to the sectioning valves of the refrigerant fluid distribution line inside a closed container (in case the ventilation system is properly proportioned). -
Page 11: Definition And Classification Of The Hazardous Areas Around The Equipment
1.7 DEFINITION AND CLASSIFICATION OF THE HAZARDOUS AREAS AROUND THE EQUIPMENT 1.7.1 CLASSIFICATION METHOD OF THE HAZARDOUS AREAS AND OF THE ELECTRICAL EQUIPMENT INSPECTION The classification of the hazardous areas is made according to the standard EN 60079-10 “Explosive atmospheres. Classification of areas. Explosive gas atmospheres”. Referring to the standard EN 60079-10 it is possible, by the known released gas quantity and present ventilation, to calculate the “hypothetical volume Vz“. -
Page 12: Sources Of Release
1.7.3 SOURCES OF RELEASE The sources of releases on the equipment are composed of (see drawing 7.007.0.058): a) Flanged systems and block/shut off valves, installed in the metering systems box of the equipment. b) Filler and refrigerator group provided charged and not sealed. c) Discharging pipes (to be installed by the customer). - Page 13 The hypothetical volume application to the operative reality of the charging machine shall be evaluated for each single case in compliance with the following characteristics: • Ventilation efficiency • Efficiency and effectiveness of the diagnostic system of the machine (pressure sensor injector) •...
- Page 14 involvement of the gas detector. Actually a gas leak inside the sucked boxes is completely managed by the suction system with an increased speed of 150 m Code: 8.023.1.005_rev.13...
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Page 15: Equipment Standard Use
QUIPMENT TANDARD 2.1 QUALIFICATIONS AND OBLIGATIONS OF EQUIPMENT OPERATOR The equipment is intended for professional and specific industrial applications, hence it can only be maneuvered by qualified personnel that: • is not underage; • is physically and mentally capable to the use and maintenance of the equipment; •... -
Page 16: Prohibited Use
Attention: make sure that when starting the equipment there are no devices connected to the USB port on the front panel. 2.4 PROHIBITED USE The manufacturer declines any responsibility deriving from improper use of the equipment Attention: if the equipment is utilized with flammable refrigerant must be grant the safety condition indicated at chapter 3.2. -
Page 17: Installation
3.2 SAFETY PRECONDITIONS TO USE INFLAMMABLE FLUIDS CHARGING EQUIPMENT WITH GAS CONTROL SYSTEMS AND VENTILATION SYSTEMS NOT PROVIDED BY GALILEO TP Process Equipment S.r.l Inside the lower section of the charging machine and the box with interception pneumatic valve, there are second-degree emission sources (according to EN 60079-10 reference standard). -
Page 18: Suction
2. Check on inflammable refrigerant gas concentration inside the charging machine. This way you can manage correctly a hypothetical important concentration. 3. Take automatically off the voltage to the machine in case of anomaly detected on functions at points 1 or 2. NOTE: This document does not deal with how to manage in safety the charging area external to the charging machine. -
Page 19: Fixed Positioning Plant In Work Area
EVENT RESULT Depression OK, gas not detected Gas detected = (15 ÷ 30) % L.E.L. PRE-ALARM Gas detected > 30% L.E.L. ALARM Lack of suctioning in the dosing section (opening of pressure switch contact) ALARM Pre-alarm conditions: The suction system must double the suctioning speed inside the charging machine. Under this circumstance, the equipment can keep on working. -
Page 20: Electric Supply
3.3 ELECTRIC SUPPLY The electrical supply of the machine needs to be compliant to the following specifications: Voltage : See machine plate (standard: 3Ph+PE, 230/400 V - 50/60 Hz) Deliverable power : 1 kW Current protection : 16 A Cable type : 4G 2.5 mm minimum, 500/700 V WARNING: be sure to power off the voltage source before working with the supply cable. -
Page 21: Refrigerant Supply
On the machine there is a pressure switch able to detect the presence of the compressed air. 3.5 REFRIGERANT SUPPLY According to the charging equipment configuration there can be up to 2 pipelines (labeled R.X SUPPLY) for the inlet of the refrigerant to be injected. The refrigerant inlet pipeline configuration depends on the type of refrigerant used: Non-flammable gases or without the “intercepting valve with suction box”... -
Page 22: Safety Valve Discharge
Every safety valve of the machine has its discharge channeled in the back of the machine, to a connection label “DISCHARGE”. Galileo TP supply includes a flexible pipe (3/16’’ inner diameter and 1/8’’G connections), for the connection to a discharge pipeline with the following characteristics required:... -
Page 23: Grouning Of The Metering Systems Box
3.10 GROUNING OF THE METERING SYSTEMS BOX The metering systems box and the installation ambient shall be equipotential, so that is necessary to connect the metering systems box to the ground line of the workplace. To do that, connect the ground line to the appropriate connection in the machine, located in the vacuum pump compartment and indicated by a tag with the grounding graphic symbol. -
Page 24: Use Of The Machine
ACHINE The machine uses a login system to grant a greater level of safety during the using. In facts, at system boot it is not possible to do any operation until it is not executed the user login that can be done pressing the button according to the following privilege levels: •... -
Page 25: Working Phase
4.2 WORKING PHASE 4.2.1 GENERAL RULES For entering in the working phase it is necessary to log in and pressing the button located at the main screen. As soon as you enter the work phase the stand by window is displayed. The principal function of this window is the selection of the work cycle to be carried out and to show the data of the cycle. -
Page 26: Dosage Testing
FILLING UP COMPRESSION INJECTION Injected grams FLOWING DISCHARGE NOTE : The cycle can be interrupted pushing the EXIT key on the filler for 2 seconds during the FOREVACUUM, EVACUATION and LEAK TEST phases. During the work phase, the filler must not be subjected to strong traction. It is necessary to avoid extreme stress to the connection pipes and earth cable, avoid efforts to the movements of connection of the filler and avoid deformation of the copper pipe of connection between the filler and the compressor. -
Page 27: Alarms And Trouble Shooting
LARMS ROUBLE HOOTING This chapter describes all the operations necessary to set the correct working conditions of the equipment in case of an alarm intervention during the work cycle. Anyway, contact our technical assistance for the correct execution of the operations. IMPORTANT NOTES: WARNING: Before executing any intervention regarding components (dosing system, filler etc.) and tubes containing refrigerant discharge the dosing line. -
Page 28: Generality
5.1 GENERALITY 5.1.1 GENERAL NOTES a) For trouble identification there are references to drawings collected in 8.016.0.088, in particular to the functional diagram 7.001.0.202 and to the general wiring diagrams 7.002.0.308, 7.002.0.314. b) In the description of the tests executed for the failure search the solenoid valves mentioned are those of the dosing / injection line n°1 version K1. -
Page 29: Solenoid Valves Checking Procedures
VACUUM SENSOR P90: (rif.4 dis.2.002.0.549) Display the value read by the sensor. With a vacuum value < 1 Pa the sensor should measure 1540 ± 100 bit. Measuring circuit check: a) Measure the tension present at the terminal blocks 2 and 5 of the Ex barrier. The circuit of the barrier is working correctly if the tension value is between 15,5Vcc and 24Vcc. -
Page 30: Alarms And Trouble Shooting Table
5.2 ALARMS AND TROUBLE SHOOTING TABLE During the work cycle execution there is a check over all the parameters that concern it. In case of parameters’ measures out of the values admitted, the alarm starts. The alarm is indicated acoustically and through relevant description on the display. To get out from the acoustic and light signals press either EXIT on the filler or EXIT on the control panel. - Page 31 Display: Sources: This alarm activates during the injection phase of the refrigerant in the refrigerant CLOGGED CIRCUIT: circuit. The alarm indicates the presence of anomalies on the cooling circuit as a GAS INFILTRATION IN connection or inlet pipe clogged or partially clogged. This alarm may occur only on COMPLEMENTARY machines that have two dosing systems for injection line and implies that the DOSING SYSTEM...
- Page 32 Display: Sources: INSUFFICIENT VACUUM At the beginning of the cycle the program checks on the efficiency of the pumping TO PERFORM CYCLE system. Normally this alarm shows the vacuum pump is still. (30) PRESSURE LOSS High pressure in the injector caused by a leak in the injection valves. IN THE FILLER (31) At the beginning of the cycle the program checks on the good sealing of the filler box...
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Page 33: Errors Table
5.3 ERRORS TABLE The following table illustrates every possible error message that may appear while operating the machine. Display: Source: INDEX OF INJECTOR EXCEEDING THE LIMITS Main error, contact assistance (20) INDEX OF DOSING CYLINDER EXCEEDING THE LIMITS Main error, contact assistance (21) INDEX OF CYCLE EXCEEDING Indicates that the operator has tried to program a cycle that is... -
Page 34: Maintenance Guide
Display: Source: INSERTED TWO IDENTICAL Indicates that two identical barcodes have been inserted with BARCODES the “Bar Code Check” option enabled. (36) CYCLE INHIBITED The cycle can not be executed because in a previous station FROM GEDA the piece has failed the test (41) CYCLE INHIBITED FROM The cycle can not be executed because the piece has skipped a... - Page 35 • Replace the gaskets of the kit 2.002.1.052. • • VACUUM Substitute the oil in the pump Verify the Clean the vacuum line PUMPING GROUP (for the characteristics of the vacuum pump and sensor by oil level (see eliminating the oil oil and the substitution procedure see the relative pump...
- Page 36 EQUIPMENT MAINTENANCE FORM TYPE OF EQUIPMENT: SERIAL NUMBER: INSTALLATION DATE: TYPE OF DATE HOURS ASSISTANCE CARRIED OUT PIECES REPLACED ASSISTANCE Code: 8.023.1.005_rev.13...
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Page 37: Dichiarazione Di Conformità (Declaration Of Conformity)
DICHIARAZIONE DI CONFORMITÀ (DECLARATION OF CONFORMITY) IIA D . 2006/42/CE) NNEX Galileo TP Process Equipment S.r.l. 50018 Scandicci (Firenze) - Italy DICHIARIAMO CHE LA SEGUENTE MACCHINA (WE DECLARE THE FOLLOWING MACHINE) UNITÀ PER L'EVACUAZIONE E CARICA DI IDROCARBURI E FLUIDI FRIGORIGENI "CERTUS"... -
Page 38: È Stata Costruita Nel Rispetto Delle Seguenti Normative (Meets The Requirements Of The Following Standards)
• Atmosfere esplosive Parte 14: Progettazione, scelta e installazione degli impianti elettrici (EN 60079-14) (Explosive atmospheres. Electrical installations design, selection and erection) • Atmosfere esplosive Parte 7: Apparecchiature con modo di protezione a sicurezza aumentata "e" (EN 60079-7) (Explosive atmospheres. Equipment protection by increased safety "e") •... - Page 39 CITTÀ Scandicci PROVINCIA FI (PLACE) (PROVINCE) Scandicci Data (Date) 06/2020 Il fabbricante (The manufacturer) Code: 8.023.1.005_rev.13...
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