Refrigerant Detection System Installation Manual - …

1 Rev Jan 2005 Refrigerant Detection System Installation Manual Preliminary copy CPC (UK) Ltd. Unit 7&8 Heathrow Causeway Est. Ariel Way, Hounslow, Tel: 0208 630 2270 Middlesex. TW4 6JW Fax: 0208 630 2271 Refigerant Detection System Installation Manual Rev Jan 2005 2 of 28 INDEX 1 BRIEF DESCRIPTION OF PARTS IRLDS Analyser Panel Coldroom Refrigerant Leak Alarm Panel Type 1 Type 2 Filters In-line End-of-line Manifolds Two Way Three Way Four Way Sampling Tube Other Fittings Vent line Straight connector Filter bracket Beacons Lampshade collector 2 CHOOSING PANEL POSITIONS IRLDS Analyser Panel Location Coldroom Refrigerant Leak Alarm Panel Location Refigerant Detection System Installation Manual Rev Jan 2005 3 of 28 3 CHOOSING END-OF-LINE POSITIONS 4 READING THE Installation SCHEDULE 5 INSTALLING SAMPLING TUBE Main tube run Manifolding Packs and Coldrooms 6 STANDARD WIRING & NETWORK DIAGRAMS Tesco New Store Tesco Refit with Einstein front end Tesco Refit with Woodley front end Tesco Europe store Waitrose store Refigerant Detection System Installation

2 Manual Rev Jan 2005 4 of 28 SECTION 1 : BRIEF DESCRIPTION OF PARTS IRLDS Analyser Panel Part Number : 885400-006 8 channel Freon Analyser 885400-111 8 channel Ammonia Analyser 885400-004 16 channel Freon Analyser 885400-110 16 channel Ammonia Analyser The Analyser panel is the main part of the Refrigerant Detection System . The panel is available with either 8 or 16 channels and can be fitted with an infrared bench for either standard CFC, HCFC or HFC refrigerants or an infrared bench for ammonia. Each panel is fitted with a pump to draw air samples back from each sampling location to the infrared bench and a waterbowl with a float switch to protect the panel in case of accidental ingress of water into the sampling tube.

3 Coldroom Refrigerant Leak Alarm Panel Type 1 Part Number : 000-070 8 output channels 000-080 16 output channels The Coldroom Refrigerant Leak Alarm panel type 1 is designed for use on either a stand alone Refrigerant Detection System or a System connected to a third party BMS or refrigeration alarm panel. It is available with either 8 or 16 outputs and will provide 24 Vdc through individual channels as switched by the analyser panel. Type 2 Part Number : 000-010 7 output channels 000-020 15 output channels The Coldroom Refrigerant Leak Alarm panel type 2 is designed for use specifically with a Refrigerant Detection System connected to a CPC Einstein refrigeration alarm panel. It is available with either 7 or 15 ouputs and will provide 24 Vdc through individual channels as switched by the Einstein panel.

4 Refigerant Detection System Installation Manual Rev Jan 2005 6 of 28 Filters Inline Filter Part Number : 272-0621 The Inline Filter is fitted with a fine filtration element and is used to prevent the ingress of dust particles, etc. into the analyser panel. The inline filters are fitted underneath the analyser panel and a separate filter is used for every sampling channel that is occupied on the analyser panel. End of Line Filter Part Number : 44-5100 The End of Line Filter is fitted with a slightly coarser filtration element than the inline filter and is used to prevent the ingress of dust and dirt particles into the sampling tube. End of line filters are fitted at each open end of tube local to the sampling locations that are to be monitored. Manifolds 2 Way Manifold Part Number : 44-5102 The 2 Way Manifold is a Y-piece that is used to split the sampling tube for a single channel into 2 ends to provide a local spread of sampling close to the required sampling location (ie.)

5 To enable a single sampling channel to be used to measure from both the left hand and right hand side of a multi-compressor pack without using a second sampling channel). 3 Way Manifold Part Number : 44-5103 The 3 Way manifold is used to provide further localised spread of sampling than the 2 Way manifold above. Refigerant Detection System Installation Manual Rev Jan 2005 7 of 28 4 Way Manifold Part Number : 44-5104 The 4 Way manifold is used when further localised spread of sampling is required than 2 or 3 points. As the air flow is reduced down each single point of the 4 way manifold (approximately one quarter of the air flow through the main sampling tube) we do not recommend splitting the sampling channel into any more than 4 points. Sampling Tube Part Number : 44-5201 Dark Blue 44-5202 Red 44-5203 Yellow 44-5204 Dark Green 44-5205 Dark Brown 44-5206 Black 44-5207 Natural (Clear) 44-5208 Orange 44-5209 Pink 44-5210 Grey 44-5211 Light Brown 44-5212 Violet 44-5213 Light Green 44-5214 Gold 44-5215 Beige 44-5216 Light Blue The sampling tube is used to carry the air samples from the sampling locations back to the analyser panel.

6 The tubing is supplied in 16 separate colours to make each channel easily identifiable (last 2 digits of part number indicate standard channel number). The tubing is made from plastic and is 6mm outside diameter for easy use with the push fit connections on the filters and manifolds. Refigerant Detection System Installation Manual Rev Jan 2005 9 of 28 Other Fittings Vent Line Fitting Part number : 44-5100-3 The vent line fitting is used for terminating sampling tube into a steel vent pipe. The pipe will need to be drilled and tapped to receive the threaded end of the fitting and the 6mm push fit collar at the other end will receive the sampling tube. Full details for terminating sampling tube into vent pipes including copper materials are explained further on. Straight Connector Part number : 44-5101 The straight connector is used for joining 6mm tube to 6mm tube. It can be used for joining plastic tube with copper tube when required or simply to repair damaged tube.

7 Filter Bracket Part number : 44-5111 The filter bracket is used to neatly clip the end of line filters firmly at the required sampling location. The bracket is screwed to the framework, wall, ceiling, etc. and a spring clip holds the filter in place. Warning Beacon Part number : 44-309-5922 Red 44-312-5376 Blue The warning beacons are used together with the coldroom Refrigerant leak alarm panels to provide local warning to personnel of Refrigerant leaks. Refigerant Detection System Installation Manual Rev Jan 2005 10 of 28 Lampshade Collector Part number : 45-1000 The Lampshade Collectors are used when the gas being monitored is lighter than air such as ammonia. The collector allows the end of line filter to be fitted at a lower level if the ceiling is high making Installation and maintenance easier without fear of missing gas leaks. Refigerant Detection System Installation Manual Rev Jan 2005 12 of 28 SECTION 2 : CHOOSING PANEL POSITIONS IRLDS Analyser Panel Location The main points to think about when choosing the analyser position are as follows:- 1) Keep the majority of sampling tubes to the minimum length 2) Easy access for power and communications wiring 3) Accessibility for viewing and acknowledging alarms 4) Possibility of damage 5) Operational noise Although the sampling tubes can be run in excess of 150 metres for a single channel it is advisable to keep lengths to a minimum to ensure low pressure drops, good air flow and minimum sampling and cycle times during sequential sampling.

8 As there are up to 16 sampling tubes connected to an analyser panel it is best to position the panel central to the majority of the sampling locations being monitored. The analyser panel will require mains power to operate and thought must be given to accessibility for electrical services and communications network wiring to the panel position. The panel will need to be manually reset in case of alarm and thought must be given to accessibility to the panel for site personnel. In some cases the panel may be mounted so that site personnel can view alarms prior to entering a room containing harmful gases. Analyser panels employed to monitor for ammonia and explosive gases should be mounted in areas with no possibility of the gas being leaked into. The panel should be mounted with the display at eye level so that personnel do not have to bend low or climb ladders when viewing data or alarms. Thought should also be given to the possibility of damage to the panel if mounted in busy corridors, etc.

9 If the panel must be mounted in busy areas it is advisable to place protection such as a key clamp to prevent accidental damage. The final consideration should be given to the operational noise of the panel; it is not advisable to mount the panel in quiet office areas where the background noise of the pump in the panel may cause disturbance to site personnel. Refigerant Detection System Installation Manual Rev Jan 2005 14 of 28 Coldroom Refrigerant Leak Alarm Panel Location The coldroom Refrigerant leak alarm panel, as it s name suggests, was predominately designed to initiate warning beacons over the door to individual walk in freezers and coldrooms in the event of a Refrigerant leak being detected in that particular coldroom. It is therefore advisable to mount the panel in close proximity to the coldroom areas in order to minimise the cable lengths to the individual beacons for ease of Installation . As with the analyser panel, thought should be given for access to the panel for power and communications network wiring.

10 The panel is fitted with a buzzer and has a mute button on the door; therefore the panel should be mounted within easy reach for site personnel to press the mute button when required. Refigerant Detection System Installation Manual Rev Jan 2005 15 of 28 SECTION 3 : CHOOSING END OF LINE POSITIONS The main points to think about when choosing end of line sampling positions are as follows:- 1) Most likely points of leakage 2) Areas containing highest gas volumes 3) Protection of personnel 4) Density of gas being monitored 5) Air flow around sampling location and possible collection point Obviously, the main areas for placing gas Detection are the points with the highest possibility of leakage. Mechanical parts such as valves and compressors and parts undergoing compression and expansion through pressure or heat have a greater tendency to leak. Areas containing the largest gas volumes in a System should also be given high consideration as these have the potential to leak the highest volume.