Refrigerant Detection System Installation Manual
Contents
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6. 1 03 Jan 2005 Refrigerant Detection System Installation Manual Preliminary copy CPC UK Ltd Unit 7 amp 8 Heathrow Causeway Est Ariel Way Hounslow Tel 0208 630 2270 Middlesex TW4 6JW Fax 0208 630 2271 UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi INDEX 1 BRIEF DESCRIPTION OF PARTS 1 1 IRLDS Analyser Panel 1 2 Coldroom Refrigerant Leak Alarm Panel 1 2 1 1 1 2 2 2 1 3 Filters 1 3 1 In line 1 3 2 End of line 1 4 Manifolds 1 4 1 Two Way 1 4 2 Three Way 1 4 3 Four Way 1 5 Sampling Tube 1 6 Other Fittings 1 6 1 Vent line 1 6 2 Straight connector 1 6 3 Filter bracket 1 6 4 Beacons 1 6 5 Lampshade collector 2 CHOOSING PANEL POSITIONS 2 1 IRLDS Analyser Panel Location 2 2 Coldroom Refrigerant Leak Alarm Panel Location 2 of 28 UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi 3 CHOOSING END OF LINE POSITIONS 4 READING THE INSTALLATION SCHEDULE 5 INSTALLING SAMPLING TUBE 5 1 Main tube run 5 2 Manifolding 5 3 Packs and Coldrooms 6 STANDARD WIRING amp NETWORK DIAGRAMS 6 1 Tesco New Store 6 2 Tesco Refit with Einstein front end 6 3 Tesco Refit with Woodley front end 6 4 Tesco Europe store 6 5 Waitrose store 3 of 28 UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi SECTION 1 BRIEF DESCRIPTION OF PARTS 11 IRLDS Analyser Panel Part Numb
7. 226 606 14 uoop g 1122 0 98 OZO X04 0722 0298 020 9 YML X3SFTIGGIN MOTSNNOH AVM TAYY 1 153 36 8 Z SLINN LLLIG vv ON ld 9114 0001 1 1019 1 146 0215 IS CS 0016 3 3 ON 19 UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi SECTION 2 CHOOSING PANEL POSITIONS 2 1 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 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 posit
8. 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 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 7 of 28 PS35505 8 FO 9 sud L SuOISIA 3 20 00008 Odd big eqn SPIOHUDA _ 016 Ld ADM 1290 2 2 1 39314 0 98 OZO 0 22 0298 020 9 YML MOTSNNOH AVM TAYY 1 153 8 4 SLINN Id 016 ld pIOJHUuDA ADM 26 ld eqn 0 0 9 ZOLG vr ld ADM Z 0016 ON ld 39114 u Jo pu3 UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi 1 6 Other Fittings 1 6 1 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 thre
9. 1 etc 7 Comments this is for any special relevant information that may be required to assist the installation engineer Care should be taken to follow the details on the installation schedule as closely as possible as in many instances sampling tubes are measured and cut to exact lengths Any changes made at site may result in tubes being too short resulting in connectors and additional tube needing to be supplied 16 of 28 L JO 002 0 2 452 cz 4 15 4 44 0202 _ 4 2 qn Suelsiq 10 2 ueuo 1 S AS 2 qd 0 0 93 1 gt 19e U0D el 18514 K Si u Bud 2 1 2 lnp u5S L HUN UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi SECTION 5 INSTALLING SAMPLING 5 1 Main Tube Run The main considerations when installing the 6mm sampling tube are to keep it tidy inconspicuous and not to squash or kink it The tube can be ran on cable tray pipework steel beams or in trunking or conduit and appropriate fixings should be used such as cable tie wraps insulation tape pipe clips or purling clips The ma
10. 1 03 Jan 2005 pi SECTION 4 INSTALLATION SCHEDULE Most CPC detection systems will be supplied together with an installation schedule The unit number at the top left hand side of the schedule differentiates between analyser panels in the event of more than one panel being used on a single site Other information at the top of the sheet includes the CPC customer name contract quote number the date that the schedule was written and the site name where the equipment is being installed The table on the schedule has 7 labelled columns giving information as follows 1 Channel Reference this indicates the channel number that the sampling point will be connected to on the analyser panel 2 Location this indicates the area or zone to be monitored from 3 No of points this indicates whether a 2 way 3 way or 4 way manifold is required point indicates that no manifold is required 4 Distance Run this indicates the length in metres of the main tube run between the analyser panel and the sampling location 5 Distance Legs this indicates the length in metres of each single leg between the manifold and the end of line filter Generally this is less than 5 metres 6 Tube Colour this indicates which colour tube is assigned to each particular sampling location The last 2 digits of the part number printed on each tube indicate the channel number that the tube is generally used for ie dark blue tube is channel
11. 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 Working areas with personnel operating within may need consideration in order to prevent the possibility of toxic fumes causing any harm The positioning of the end of line filters within the sampling location is important as an incorrectly placed filter may cause delay in sensing a leak or may cause the analyser panel to draw back unwanted substances The density of the gas being monitored is an important factor in choosing filter positions heavier than air gases will obviously fall towards the floor whilst lighter than air gases will rise towards the ceiling Extract fans and louvres will tend to draw the air from a room and consideration should be given to which way the air may be flowing across the particular point being monitored to ensure that the leaking gas is pulled towards the filter rather than away from it A final consideration should be given to the possibility of liquids and other unwanted substances being drawn into the sampling lines end of line filters should not be placed directly into areas with the possibility of liquid falling onto them and filters should be fitted at least 50mm above floor level to prevent them falling into puddles etc 15 of 28 UK Refigerant Detection System Installation Manual Rev
12. 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 1 4 Manifolds 1 4 1 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 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 1 4 2 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 6 of 28 UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi 1 4 3 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 1 5 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
13. 4 way manifold will be fitted The single exit of the manifold will be fitted to the end of the main sampling tube run leaving the multiple exits for the sampling legs Each sampling leg from the same manifold should be of equal length and should not exceed 5 metres in length in order to keep identical air flows through each leg and pressure drops to a minimum 18 of 28 1222 098 OZO 58 50 09610 so SUOISIADY 20 00008 242 ON 01 Jash DUY 5013 AG 9313 WALSAS 40 553 1 5 3 OL SON3 38NL 3dVl OL YOLOVYLNOD 8 583114 INNNI ONY OL 5 381 SENL IN3A33d 01 08350 38 Ol SNYNL SNIGVY SNO1 SYSLSW WZ lt 38 OL ONIGNL LHON 91 39139 SL g109 N3339 LHON L 13101A LHON OL N33389 MOTT3A q33 UNOS 3871 G or OD 55151 001550009 098 0409050705070 9 06 09 0 024 0 00106 0222 0298 020 9 5 015 AVM TAYY 1 163 AVMASNVD 8 P 4 SLINN 4 S49 4 9 S 2 g 84 84914
14. aded 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 1 6 2 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 1 6 3 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 1 6 4 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 9 of 28 Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi 1 6 5 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 10 of 28 Emm arma 05012 211 0 00008 Odd big 9 6 216 Ld
15. anel 4 of 28 10 00008 249 oN big s j upq 20 4914 0235 29 Jaesk DUY syo 309110 S 020 000 ON ld 540 3ndino Z 010 000 ON ld 2 woy TaNVd 3134 1NV2J39l8433J 1222 0698 OZO 0 00 0698 020 9 YML X3SFTIGGIN MOISNNOH AVM TAYY 31V1S3 8 4 SLINN 540 309310 91 080 000 ON 14 540 199100 8 040 000 ld d l u d q 1 dl 9 839 334 WOONdI0D 91 011 00 598 91 00 00 588 8 LLL 00rS88 4 8 900 00 688 I8upg JA s puv g g 4 d q UK Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi 1 3 Filters 1 3 1 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 1 3 2 End of Line Filter Part Number 44 5100 The End of Line Filter is fitted
16. er 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 1 2 Coldroom Refrigerant Leak Alarm Panel 1 2 1 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 24Vdc through individual channels as switched by the analyser panel 1 2 2 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 15 ouputs and will provide 24Vdc through individual channels as switched by the Einstein p
17. in tube runs should be fixed approximately every 1 5 metres to prevent them sagging or working loose however care should be taken not to over tighten any fixings which may result in crushed or damaged sampling tubes Tight bends should also be avoided as this will probably cause the tubing to kink and give flow fault alarms when the analyser panel is switched on large radius curves should be used when the tube run needs to change direction Main tube runs should be taped at each end until the final filters are fitted to prevent dirt getting into them Thought should be given to ensure that the tube is not installed in areas that may cause long term damage to it or be a nuisance to maintenance contractors Tubes run along hot pipes or close to moving parts run the risk of being melted or worn and tubes fixed to mechanical parts such as compressors may impede maintenance work 5 2 Manifolding The main sampling tube run will connect the analyser panel to the required sampling location If the sampling location does not require a localised spread of sampling then a single end of line filter will be fitted at the sampling location end of the tube The sampling tube should have a neat cross sectional cut at the end to ensure a good connection when fitting the push fit end of line filter Where a further spread of sampling is required such as a large multi compressor pack having several points fitted underneath the compressors either a 2 way 3way or
18. ion 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 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 12 of 28 2 SUOISIAAY 70 00008 2409 big J s ouv BununoNW lt 01 1222 0 98 OZO 3 0 22 0298 020 9 YML X3S31q0IN 015 AVM TAYY 1 163 35 8 4 SLINN Supip o Supip 5 oSupip 5 06 061 Refigerant Detection System Installation Man
19. ual Rev 1 03 Jan 2005 pi 2 2 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 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 14 of 28 Refigerant Detection System Installation Manual Rev 1 03 Jan 2005 pi 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
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