BEST PRACTICE

Best Practice
industrial refrigeration part
BEST PRACTICE
Industrial refrigeration sections
This document is the property of Carrefour and may not be copied or modified
without prior permission.
Contents
1 GENERAL ............................................................................................................... 7
1.1 BEST PRACTICE, INDUSTRIAL REFRIGERATION SECTIONS ..................... 7
1.2 DOCUMENTS TO BE APPLIED ....................................................................... 7
1.3 FOREWORD ..................................................................................................... 7
1.4 DEFINITION OF THE SERVICES TO BE PROVIDED ................................... 10
1.5 TECHNICAL DOCUMENTS ............................................................................ 10
1.5.1 TECHNICAL DOCUMENTS ..................................................................... 10
1.5.2 OVERALL POWERS AND FLOW-RATES ............................................... 11
1.6 LEGISLATIONS .............................................................................................. 11
2 CALCULATION BASES......................................................................................... 11
2.1 BASIC OUTDOOR CONDITIONS................................................................... 11
2.2 BASIC INDOOR CONDITIONS ...................................................................... 11
2.3 PERFORMANCE OBLIGATION ..................................................................... 11
2.4 THERMAL REQUIREMENTS ......................................................................... 12
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2.4.1 COLD ROOMS ......................................................................................... 12

2.4.2 REFRIGERATED SALES FIXTURES ...................................................... 13
3 REFRIGERATION OUTPUT ................................................................................. 15
3.1 CHARACTERISTICS AND GENERAL PRINCIPLE ........................................ 15
3.2 CENTRALIZED LOCATION ............................................................................ 16
3.3.1 REFRIGERATION MACHINES AND ACCESSORIES ............................. 17
3.3.2 REFRIGERATED DISPLAY CABINETS .................................................. 20
3.4 OPERATING RATES AND POWERS............................................................. 30
3.4.1 BOOSTER CONFIGURATION AND RATES............................................ 30
3.4.2 LABORATORY OR WORKROOM ........................................................... 32
3.4.3 EXCHANGER FOR FLASHGAS SUPER-HEATING ................................ 33
3.4.4 EXCHANGER FOR LIQUID SUBCOOLING............................................. 34
3.4.5 DE-SUPERHEATER, FREEZER INSTALLATION ................................... 35
3.4.6 GAS COOLER RATES AND CONFIGURATION ..................................... 36
3.5 DESCRIPTION OF THE EQUIPMENT ........................................................... 43
3.5.1 REFRIGERATION, BOOSTER................................................................. 43
3.6 GAS COOLER ................................................................................................ 51
3.7 FREEZER DE-SUPERHEATER ..................................................................... 53
4 INDUSTRIAL REFRIGERATION SECTION REFRIGERATED UNITS ................. 54
4.1 CHILLER AND FREEZER FIXTURES ............................................................ 54
5 R744 REFRIGERATION INSULATION AND PIPING ........................................... 63
5.1 TECHNICAL SPECIFICATIONS AND GENERAL POINTS, PIPING .............. 63
5.3 DESCRIPTION OF REFRIGERATION PIPING/FITTINGS AND INSULATION
.............................................................................................................................. 72
5.3.1 SUCTION AND DISCHARGE LINE.......................................................... 72
6 SAFETY................................................................................................................. 73
6.1 PLANT ROOM CO2 DETECTION ................................................................... 73
6.1.1 EQUIPMENT DESCRIPTION ................................................................... 73
6.2 CO2 DETECTION FOR COLD ROOMS, FREEZER ROOMS, SALES AREA,
AND ADJOINING ROOMS ................................................................................... 74
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6.3 FREEZER ROOM TRAPPED PERSON ALARM ............................................ 75

6.4 SECTION SAFETY AND CUT-OFF VALVES ................................................. 76
6.5 COMPRESSORS ............................................................................................ 77
6.6 PLANT ROOM AIR EXTRACT VENTILATION ............................................... 78
6.7 EMERGENCY COOLING (OPTION) .............................................................. 80
6.8 EMERGENCY STOP AS PER EN 378 ........................................................... 82
6.9 PLANT ROOM ................................................................................................ 82
7 HEAT RECOVERY ................................................................................................ 83
7.1 DEFINITION OF TERMS ................................................................................ 83
7.2 DECISION BASIS FOR DHW HEAT RECOVERY.......................................... 83
7.3 GENERAL ....................................................................................................... 85
7.4 DOMESTIC HOT WATER ............................................................................... 86
7.5 HEATING HOT WATER .................................................................................. 87
7.6 EQUIPMENT DESCRIPTION ......................................................................... 88
7.6.1 DOMESTIC HOT WATER ........................................................................ 88
7.7 REGULATING DESCRIPTION ....................................................................... 90
7.7.1 HEAT RECOVERY, DOMESTIC HOT WATER........................................ 90
8 REGULATION DESCRIPTION .............................................................................. 92
8.1 REFRIGERATION OUTPUT CO2 BOOSTER ................................................. 92
8.1.1 NORMAL AUTOMATIC OPERATION ...................................................... 92
8.1.2 MANUAL OR DEGRADED OPERATION ................................................. 92
8.1.3 REGULATION OF THE TRANSCRITICAL HIGH PRESSURE ................ 93
8.1.4 GAS COOLER REGULATION.................................................................. 94
8.2 REFRIGERATION UNITS ............................................................................... 95
8.2.1 REGULATION OF CHILLER AND FREEZER REFRIGERATION UNITS 95
8.3 LIGHTING CONTROL ..................................................................................... 97
8.3.1 NIGHT BLIND CONTROL: ....................................................................... 98
8.3.2 NIGHT OFFSET: ...................................................................................... 98
8.3.3 DEFROSTING REGULATION: ................................................................. 98
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8.3.4 EVAPORATION PRESSURE REGULATION ........................................... 98

8.3.5 DEW-POINT REGULATION ..................................................................... 98
8.3.6 CHILLER AND FREEZER ROOM DOOR CONTACTS ............................ 99
8.3.7 FREEZER ROOM AIR CURTAIN ............................................................. 99
8.3.8 FREEZER ROOM FAN STOPPING ......................................................... 99
8.3.9 TEMPERATURE DISPLAY ...................................................................... 99
9 CENTRAL ELECTRICAL DISTRIBUTION CABINETS AND REFRIGERATION
UNITS ..................................................................................................................... 100
9.1 GENERAL AND EQUIPMENT ..................................................................... 100
9.1.1 CHILLER AND FREEZER REFRIGERATED UNIT POWER OUTPUTS
........................................................................................................................ 105
9.1.2 EQUIPMENT ......................................................................................... 106
10. REMOTE MONITORING ................................................................................. 111
10.1 GENERAL .................................................................................................. 111
10.2 DIAGRAM OF REMOTE DATA MONITORING ......................................... 112
11. TREATMENT OF ALARMS ............................................................................. 113
11.1 TECHNICAL ALARMS ............................................................................... 113
11.2 MANAGEMENT OF ALARMS .................................................................... 114
11.3 ACTION PROCEDURE RESPONSE TO ALARMS ................................ 115
11.4 EMS SYSTEM INTERFACES .................................................................... 116
12. INSTALLATION ACCEPTANCE CONDITIONS .............................................. 116
12.1 PRIOR INSPECTION ................................................................................. 116
12.2 MOISTURE VACUUM EVACUATION LEAK-TIGHTNESS TEST* ...... 117
12.3 COMMISSIONING ..................................................................................... 118
12.3.1 GENERAL ........................................................................................... 118
12.3.2 PRIOR TO COMMISSIONING ............................................................ 118
12.3.3 PREPARATION FOR COMMISSIONING............................................ 118
12.3.4 COMMISSIONING ............................................................................... 118
12.3.5 COMMISSIONING HEAT RECOVERY FOR SANITARY HOT WATER
........................................................................................................................ 119
12.3.6 FULL TRAINING FOR STORE STAFF ............................................... 119
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12.3.7 DRAFTING THE COMMISSIONING REPORT ................................... 120

12.3.8 AFTER COMMISSIONING .................................................................. 120
12.3.9 PROVISION OF FINAL DOCUMENTS ............................................... 120
12.3.10 CHECKING REMOTE TRANSMISSION OF ALARMS ..................... 120
12.3.11 MARKING .......................................................................................... 121
12.4 DOCUMENTATION* .................................................................................. 121
12.4.1 AS BUILT FILE .................................................................................... 121
12.4.2 MISCELLANEOUS DOCUMENTS ...................................................... 123
12.5 MARKING DESIGN.................................................................................... 123
12.5.1 GENERAL ............................................................................................ 123
12.5.2 DESCRIPTION OF ELECTRICAL CONTROL CABINETS ................... 124
12.5.3 DESCRIPTION OF REFRIGERATION INSTALLATION ...................... 124
12.5.3.1 Conduits ........................................................................................... 124
12.5.3.2 Installation/Refrigerant agent ............................................................ 125
12.5.3.3 Compressor ....................................................................................... 125
12.5.3.4 All components requiring electrical connection .................................. 125
12.5.3.5 Refrigeration chiller/freezer cabinets ................................................. 126
12.5.3.6 Adhesive label for defrosts ................................................................ 126
12.5.4 SANITARY INSTALLATION DESCRIPTION ........................................ 126
12.5.5 HEATING DESCRIPTION .................................................................... 126
13. WARRANTY ..................................................................................................... 127
14. SERVICES NOT INCLUDED IN THE WORK PACKAGE / SCOPE OF
SERVICES ............................................................................................................. 127
14.1 SCOPE OF SERVICES .............................................................................. 127
14.1.1 WORKS INCLUDED IN THE FOOD PRODUCTS REFRIGERATION
WORK PACKAGE ........................................................................................... 127
14.1.2 WORKS EXCLUDED FROM THE FOOD PRODUCTS
REFRIGERATION WORK PACKAGE............................................................. 129
14.2 STRUCTURAL WORK PACKAGE.............................................................. 129
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14.2.2 WORKS REQUIRED BY THE FOOD PRODUCTS REFRIGERATION

WORK PACKAGE ........................................................................................... 129
14.3 WATER-TIGHTNESS ROOF COVERING WORK PACKAGE ................. 129
WORK PACKAGE ........................................................................................... 129
WORK PACKAGE ........................................................................................... 129
14.4 PARTITIONS PAINTING FALSE CEILINGS WORK PACKAGE .......... 129
WORK PACKAGE ........................................................................................... 130
14.5 PLUMBING SANITARY FACILITIES WORK PACKAGE ......................... 130
WORK PACKAGE ........................................................................................... 130
14.6 ELECTRICITY HIGH-VOLTAGE .............................................................. 130
WORK PACKAGE ........................................................................................... 130
14.7 MISCELLANEOUS...................................................................................... 130
14.7.1 CONDUCT SUPERVISION MAINTENANCE UNTIL ACCEPTANCE
........................................................................................................................ 130
14.7.2 TRAINING OPERATIONAL STAFF AND PROVIDING AS BUILT FILE130
14.7.3 REFRIGERANT FLUIDS ...................................................................... 131
14.7.4 PRESSURISED EQUIPMENT.............................................................. 131
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1 GENERAL
1.1 BEST PRACTICE, INDUSTRIAL REFRIGERATION SECTIONS
By working on the basis of a standard within a circle of companies involved at a national and
international level, we can develop standardization. Using this system, we obtain installations
using current techniques produced in different places and by different people, all of them
using identical working processes and techniques.
Carrefours Best Practice is an internal standard used internationally. Putting these
concepts into practice will, in the long term, lead to unified engineering with installations of
high quality. Cost reduction will be the result of rationalizing resources. The contents of best
practice documents are for information only and do not constitute a set of specifications.
The manual takes account of external temperatures of +34 C. If this value is different,
appropriate measures must be examined separately.
1.2 DOCUMENTS TO BE APPLIED

- Standards List document
- Detail drawing no. 2597S2
- Outline diagram 2597S1
- Fitting instructions, industrial refrigeration section
- Document: "Confirmation that the installation has been finished and is ready for
acceptance"
- Night blind (optional)
- Heat recovery, domestic hot water and heating option
- SHEET industrial refrigeration section
- Best Practice for refrigerated units
- Best Practice for cold rooms
- Commercial refrigeration index
- Framework contract for provision of comprehensive maintenance services for CO 2
refrigeration installations.
- Full service contract for CO2 refrigeration installations
- CO2 installation maintenance operations sheets
1.3 FOREWORD
Installations under the contract shall be carried out in accordance with the instructions and
dimensions given in this best practice document drawn up by Carrefour as both project
owner and project manager, and with the instructions common to all work packages; they
shall comply with the set of plans in the dossier.
As a general rule, the contract is assumed to include all work or rulings stipulated by the
instigators of the project and works inspectors in ensuring the compliance of the work in
accordance with the regulations in force for the work covered by the order.
All deliveries and work must correspond with statutory requirements and with the
requirements of the professional associations.
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In all cases, calculations must be based on the contents of the best practice documents
appended and must include all those elements and capacities guaranteeing a suitable
implementation and perfect operation of the installations.
If the contractor has an alternative opinion in terms of the conditions, design, capacities,
controls, or materials, or if they obtain different results, they shall state this in an ancillary
document, stating their reasons explicitly.
In the absence of written reservations or objections, it is assumed that the best practice
document bases also correspond to the opinion of the contractor (refrigeration engineer).
The contractor has an obligation to inform the project owner, at the latest at the contract
award meetings, in order to agree any possible special conditions.
In all cases, the agent shall assume entire responsibility for the installations as well as for
their faultless operation.
The tender shall include all the associated structures and services necessary for full and
perfect completion of the work. The company must supply complete installations and parts in
full working order; all work must be carried out in accordance with Best Professional Practice.
If there are several possible interpretations of this text, the contractor has an obligation to
inform the project owner of this in writing for them to clarify the situation. If they fail to do so,
the project owners interpretation shall take precedence.
If the contractor should wish to use materials or variants other than those indicated, they
must make their request in a separate written document.
The project owner reserves the right to split the contract award between several suppliers.
The contractor will not be able to claim any compensation in the event of partial or total
abandonment of certain positions during execution.
The contractor shall remove all transport and packing materials from the site at their own
expense. Unloading and fitting expenses (e.g. lifting plant) justified by the construction will be
billed to the contractor.
All prices shall be free at fitting location, with installation and adjustment, including
associated works, even if these have not been expressly mentioned in the best practice
documents or otherwise, but constitute part of the work required for faultless fitting.
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Any modifications to the order by increasing or eliminating certain work may only be carried
out with the agreement of the project owner. No claims will be accepted without written
confirmation from the project owner or by a corrective order.
All additions or modifications to the original delivery volume will take place under the same
conditions as for the principal mandate, as set down in the contractor contract.
In principle, under a cost plus basis, working time is not remunerated, other than under a
formal order from the project owner. Reports must be presented for signing within two days
of the order. No cost plus reports will be accepted if not duly signed.
The warranty starts to run as soon as all defects noted during acceptance have been
eliminated.
Any defects noted during the warranty period must be repaired at the contractors expense
(including indirect damage). If the latter is able to prove that they are not responsible for the
damage, they will be released from their obligations.
The project owner or their consulting engineers shall carry out new checks prior to expiry of
the warranty. Any defects shall be rectified within the times laid down in writing, and the
project owner shall be informed of the repair.
All documents necessary for execution of the work, such as assembly and connection
diagrams, installation diagrams, etc., must be submitted by the contractor. A detailed
diagram shall be produced for each installation and all devices shall be marked according to
their type; no legends or additional sheets will be accepted. The refrigeration diagram shall
be submitted to the project owner prior to the start of assembly.
Services provided by the project owner or their consulting engineers:
- checking execution outline diagrams
- technical spot checking of work
- acceptance of the installations
Acceptance conditions:
After the official commissioning, it will be necessary to establish an electronic temperature
control strip for each refrigerated object (e.g. Hamster or Escort). For meat and fruit & veg
cold rooms, the measurements will be made with the help of thermoscriptes. The
measurement points will be agreed in advance with the project owner or their engineers. The
minimum measurement duration shall be 24 hours. A check strip for the ambient temperature
and relative humidity of the air in the store shall also be presented in addition to the
temperature measurement. Each check strip shall be attached to an A4 format sheet; the
position, date, and duration of the measurement shall also be indicated on this.
At the latest 2 months after the unit has been officially brought into service, and following
establishment of the control strips, the unit will undergo acceptance with the project owner or
their consulting refrigeration engineers and the project owners maintenance department.
The contractor shall inform the consulting engineers 3 weeks before the planned date.
Acceptance includes:
- inspection of the equipment/supplies
- temperature checks
- checks of functions and powers
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Ten hours shall be set aside for acceptance of the refrigeration installations by the project
owner or their engineers. If at that time any untoward issues are observed in the installation
or in certain parts, the acceptance process will be interrupted and adjourned. Any additional
costs incurred by this delay will be deducted from the contractors invoice.
The refrigeration installer is responsible for the faultless operation of the refrigeration
installations and is liable for any damage caused to merchandise by malfunctions due to their
own fault, from commissioning up to reception.
Sales staff shall receive all necessary instructions for correct handling of the installations no
later than the acceptance date.
By signing, the contractor accepts the best practice documents, which form an integral part
of the order. The contractor likewise certifies that they have been informed of the nature and
volume of the work and deliveries, as well as about local conditions.
Within the operating documents, the exact locations of the probes must be shown on each of
the diagrams for the refrigerated units (p4, p1, etc.). Using these documents, maintenance
personnel must very quickly be able to locate the probes in the event of a breakdown.
1.4 DEFINITION OF THE SERVICES TO BE PROVIDED

The work in this work package involves:
Chiller and freezer refrigeration production
Refrigeration distribution as far as the cold rooms and sales area refrigerated fixtures.
Refrigeration pipework from the cold-room and laboratory evaporators
Connecting up the sales area refrigerated fixtures
Ventilation of the refrigeration plant room
Cooling of the refrigeration plant room
Connecting up the drains from the cold rooms, laboratories, and refrigerated display cabinets
The electrical and regulating installations for the various food refrigeration systems
Reports for the BMS, including connection bus
Generally, the contractor will be required to supply all necessary work and supplies and to
produce installations capable of meeting the requirements as expressed and detailed in this
Best Practice document, under all conditions of safety and regularity, or in the graphical
documents attached as an annexe.
1.5 TECHNICAL DOCUMENTS

1.5.1 TECHNICAL DOCUMENTS
This best practice document is completed by a series of engineering diagrams and drawings:
See list provided in Section 1.2
All graphical documents submitted to the contractor for execution of the work must be
considered as a proposal that they should examine before submitting their bid.
Hence under his duty to advise, the contractor will be required to point out to the project
manager those provisions that do not seem to him consistent with the conservation of the
installations or their intended use, or any failure to respect best professional practice.
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After on-site reconnaissance by the service provide and unless the client requests a
modification, it is specified that the contractor's bid will remain a fixed sum, regardless of any
changes to circuit routing that might prove necessary when finalizing the execution plans.
1.5.2 OVERALL POWERS AND FLOW-RATES
The powers and flow-rates figuring in the tender documents are given for information only;
this work package will be required to adapt the powers to the store configuration in
accordance with the clients requests.
1.6 LEGISLATIONS
In general, national and local regulations, standards, and laws must be respected.
Exceptions specific to each country, identified in relation to this best practice document, must
be communicated immediately to the project owner. It is requested that counter-proposals be
presented to the project owner.
The best practice document is subordinate to the laws and regulations specific to each
country.
The contractor is responsible for satisfying all the laws specific to each country, regulations
and standards in force.
Best Practice has been prepared on the basis of various standards. The separate
fundamental standards folder gives an overview of the various standards, but the list is not
definitive.
2 CALCULATION BASES
2.1 BASIC OUTDOOR CONDITIONS
Target values
Summer temperature
Chiller refrigerant
Freezer refrigerant
+34 C
Actual values
depending on
country
+ ___ C
R744 (CO2)
R744 (CO2)
The manual takes account of outdoor temperatures up to a maximum of +34 C. If this value
is exceeded, appropriate measures must be examined separately.
2.2 BASIC INDOOR CONDITIONS

Sales area
Target values
Actual values
depending on country
Summer temperature
+25 C/60%HR
+ ___ C / HR __ % (NC)
Winter temperature
+25 C/60%HR
+ ___ C / HR __ % (NC)
Cold rooms: see refrigeration report sheets
2.3 PERFORMANCE OBLIGATION

The description of the work and the objective to be attained for each work package are given
in the best practice technical request documents for each work package. For requests
specific to the project, minimum performance levels shall be proposed by the serviceprovider and validated by the project owner.
In the event of technical inconsistency or insufficiency, or simply to complement the services
described, contractors will be required to propose in their bid techniques and products of
their choosing, if necessary replacing the planned stipulations, in order to arrive at the
description given and the objective to be attained.
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2.4 THERMAL REQUIREMENTS

2.4.1 COLD ROOMS
2.4.1.1 POWER
Calculation basis for determining cold room powers:
Depending on the country's legislation
Product type
Stored
product
temperature
Air relative
humidity
Temperature
of products
when added
Specific heat
capacity of
products
Daily addition
rate
Guide power
per m
PRE-PACKED
MEAT
1/+1 C
RH 80%
7 C
3.349 kJ/kg*K
50 kg/m
0.20 kW/m
PRE-PACKED
POULTRY
1/+1 C
RH 80%
7 C
3.349 kJ/kg*K
50 kg/m
0.20 kW/m
CARCASSES
1/+1 C
RH 90%
3 C
3.141 kJ/kg*K
100 kg/m
0.20 kW/m
PRE-PACKED
DELI MEATS
+1/+3 C
RH 80%
7 C
3.349 kJ/kg*K
60 kg/m
0.20 kW/m
PREPARED
DISHES
+1/+3 C
RH 85%
3 C
3.141 kJ/kg*K
75 kg/m
0.20 kW/m
TROLLEYS
PREPARED
DISHES
1/+1 C
RH 80%
3 C
3.559 kJ/kg*K
75 kg/m
0.20 kW/m
FRESH CAKES &

PASTRIES
0/+2 C
RH 80%
7 C
2.931 kJ/kg*K
50 kg/m
0.20 kW/m
FISH ON ICE
1/+1 C
RH 90%
4 C
3.349 kJ/kg*K
75 kg/m2
0.20 kW/m
FRUITS &
VEGETABLES
+6/+8 C
RH 90%
16 C
3.768 kJ/kg*K
100 kg/m
0.25 kW/m
PACKAGED
DAIRY/EGGS
+3/+5 C
RH 80%
4 C
2.722 kJ/kg*K
100 kg/m
0.20 kW/m
CHEESE
+3/+5 C
RH 85%
6 C
2.931 kJ/kg*K
70 kg/m
0.20 kW/m
FISH
1/+1 C
RH 75%
2 C
3.768 kJ/kg*K
100 kg/m
0.20 kW/m
FOOD WASTE
+3/+5 C
RH 75%
10 C
3.349 kJ/kg*K
80 kg/m
0.20 kW/m
FROZEN
PRODUCTS
25 C
RH 90%
18 C
1.759 kJ/kg*K
90 kg/m
0.22 kW/m
ICE-CREAMS
25 C
RH 90%
-18 C
1.885 kJ/kg*K
90 kg/m
0.22 kW/m
Given the frequency of deliveries, the refrigeration power shall be calculated with a loading
factor of 25% of the total volume of the cold room.
The values must be verified according to the country and specifically for each project
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Laboratory type
CUTTING
CUTTING / PACKING
PACKING / CUTTING /
MARKING
Air
temperature
+8/+10 C
+8/+10 C
+8/+10 C
Air relative
humidity
RH 70%
RH 70%
RH 70%
Installed power
Occupation
0.06 kW/m
0.12 kW/m
0.30 kW/m
0.1 person/m
0.125 person/m
0.167 person/m
OPERATING TIMES:
Dairy cold rooms 12 hr
Fruit & veg cold rooms 14 hr
Meat cold rooms 14 hr
Fish cold room 14 hr
Miscellaneous cold rooms 14 hr
Freezer rooms 16 hr
Insulation assumptions shall correspond to existing thermally-insulating barriers for existing
cold rooms, and 6 W/m (walls, ceiling, floor) for new cold rooms.
The air renewal assumptions are specific to the volumes of the cold rooms.
2.4.1.2 THERMAL REQUIREMENTS
Where there are no consulting engineers, calculation of the thermal requirements for cold
rooms, laboratories, and other areas is the responsibility of the refrigeration work package.
The total installed power, resulting from the thermal, furnishing, cold room and laboratory
requirements, shall be used to determine the type of refrigeration unit.
Chiller installation:
Freezer installation:
+ 5%
reserve
Refrigeration power in negative

refrigeration units
reserve
100% Refrigeration power in
positive refrigeration units

negative refrigeration units
Equivalent refrigeration
power in negative
refrigeration units
Refrigeration power in positive

refrigeration units
reserve
+ 5%
reserve
2.4.2 REFRIGERATED SALES FIXTURES

2.4.2.1 POWER
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The refrigeration power and operating rate (evaporation temperature) are provided by the
unit manufacturer.
The contractor is responsible for the power calculations.
The powers declared shall comply with the EN23953-2:2005 +A1:2012 standard or be in
accordance with local legislation.
Reminder: cold rooms and refrigerated sales fixtures are intended to keep products for sale
at the correct temperature.
2.4.2.2 AMBIENT SURROUNDINGS CLASS
The store is heated in winter and cooled in summer, but not in spring or autumn, or airconditioned for part or all of the year in hot regions.
The power of the refrigerated sales fixtures shall be calculated in Class 3.
Dry temperature +25 C
Relative humidity 60%
Depending on country references
2.4.2.3 THERMAL REQUIREMENT
Where there are no consulting engineers, calculation of the thermal requirement for
refrigerated display cabinets and other elements is the responsibility of the refrigeration work
package.
Nevertheless, the refrigeration work package service provider must check all the powers.
The total installed power, resulting from the thermal, furnishing, cold room and laboratory
requirements, shall be used to determine the type of refrigeration unit.
+ 5%
reserve

refrigeration units
reserve

Equivalent refrigeration
power in negative
refrigeration units
+ 5%
reserve

refrigeration units
reserve
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3 REFRIGERATION OUTPUT
3.1 CHARACTERISTICS AND GENERAL PRINCIPLE
Chiller and freezer refrigeration production shall be accomplished by one or more booster
units or independent direct-expansion chiller installations, comprising an oil separator, oil
regulation system, subcooler, two liquid separators, a liquid receiver, regulating valves, the
machine electrical cabinet, all safety, control, and regulating devices (see outline diagram). It
is incumbent on the installer to respect the appropriate standards, stipulations, and orders
(e.g. OESP, EN 378: 2008).
Refrigeration production for all chiller and freezer units, cold rooms, laboratories, and freezer
rooms shall be provided using R744 refrigerant.
The distribution of the cooling/freezing units between the different installation units must be
such that refrigerated units with similar evaporation temperatures (e.g. higher) can be
connected to the same refrigeration installation. This allows the refrigeration installation to be
sized using a higher evaporation temperature.
Gas cooler/
condenser
Positive
compressors
Liquid subcooling
Negative
compressors
Positive units
Expansion
valves
Gas cooler
Liquid tank
High pressure regulator

valve
Medium pressure
regulator valve
Negative units
Sales area
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3.2 CENTRALIZED LOCATION

Depending on the configuration of the plant rooms (dimensions) or the store situation,
several types of refrigeration plant are possible:
One-piece indoor unit with air gas cooler on roof. Large plant rooms with easy
access. Priority variant, the best choice
Example for indoor installation in the form of a complete refrigeration unit
Conventional central refrigeration unit using multiplex and separated circuit piping
and air gas cooler on roof. Confined spaces, town-centre stores, etc.
Possible example of a separate factory pre-wired central refrigeration unit with outdoor gas cooler
Outdoor one-piece air condensation unit (gas cooler). Located in yard, outside, or on
roof.
Combined booster installation comprising all components such as gas cooler, gas desuperheater, etc. Ready to install outdoors. It is necessary to ensure compliance with
local orders concerning noise protection and access to the various services.
Example of an outdoor installation in the form of a complete refrigeration unit
Whatever type of unit is installed, outdoor or indoor, one-piece or split production, all of them
shall be fitted in a similar way and shall group together all of the refrigeration and hydraulic
equipment in accordance with the outline diagram enclosed and the data sheets.
The weight of the central units must be communicated to the project manager in order to
check the building structure.
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3.3 GENERAL AND TECHNICAL PRESCRIPTIONS

3.3.1 REFRIGERATION MACHINES AND ACCESSORIES
Power-optimized, uninterrupted operation of the refrigeration installation must be ensured.
As nothing is specified in terms of the types of compressor, these will be required to be of
sound construction, in common use, and with a certain reputation on the market. Gas units
and spare parts must be available in case of need within reasonable lead-times.
Provision must be made for central refrigeration unit fanout factors (relationship between the
refrigeration power of the refrigeration units and the refrigeration power provided by the
compressors) as follows. Within this factor, the reserve power shall be included as per
Sections 2.4.1 and 2.4.2

90% expansion
factor
Necessary power to
compressors at
maximum output
85% expansion
factor
+ 5%
reserve

refrigeration units
reserve
Necessary power to compressors at

maximum output
Equivalent refrigeration power

in negative refrigeration units

refrigeration units
reserve
+ 5%
reserve
Fanout factor for chiller installation depending on country _________%

Fanout factor for freezer installation depending on country
_________%
The refrigeration installations must be designed in such a way as to avoid refrigerant or oil
reaching the compressors directly and damaging them. If necessary, elements such as e.g. a
liquid separator or a suction superheat exchanger will have to be used.
The compressor suppliers prescriptions must be adhered to. This concerns particularly the
commissioning procedure, operating levels, and the type of oil recommended by the
manufacturer. If necessary, provision must be made for casing heaters, oil coolers, or other
necessary elements.
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The compressors must be fixed to the chassis in such a way that they do not generate
excessive vibration, and by the same token do not cause breakage of the piping (risk of
leaks) to the multiplex.
If several compressors are working in parallel on one system, each compressor must be
separately fitted onto the multiplex system in such a way that it can be changed without
interrupting operation of the system as a whole.
The refrigeration installer is responsible for complying with the prescriptions of the electricity
company for starting and running the compressors. The necessary measurements shall be
included in the price.
Compressors, gas units, and gas coolers shall be fitted on vibration dampers. Machine bases
shall be isolated accordingly. The drawings of the bases, together with any vibration
dampers, shall be prepared and supplied by the contractor.
Example of anti-vibration elements (Mafund pads)

All control and signalling instruments and devices shall be labelled.
The lubrication of the compressors using R744 must be performed in such a way as to
ensure adequate oil viscosity. If necessary, air-cooled oil coolers must be used. Furthermore,
compressor oil temperatures must be individually monitored and compressors taken out of
circuit if the limit values are exceeded.
The R744 compressors must each have a low- and high-pressure safety valve. This may be
fitted within or external to the compressor.
All armatures and suction adjustment devices must be insulated.
The filtration medium must be compatible with the refrigeration oil. Activated alumina may not
be used as a filtration medium when polyester-based refrigeration oil with special additives is
used.
The filters on the suction pipes of refrigeration installations running on R744 may include
pores with a maximum size of 60 m.
For seals with CO2, which under normal circumstances need to be replaced during the
installations lifetime (e.g. filter housing seal), these must be provided for in one material (e.g.
Ethylene-Propylene EPDM). Rubber (e.g. NBR, FKM) or fluoridated polymer (FP, proprietary
name Viton) seals must not be used. In the event that this is not possible, the non-compliant
seals must be changed when the circuit is decompressed.
Dryers must use only molecular sieve cores and be sized in such a way as to minimize the
moisture level in the installation as far as possible.
Cores using activated alumina are prohibited.
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The liquid receiver must be sized so as to always have correct high and low levels under all
conditions (heat recovery / summer / winter).
Provision must be made for at least 4 main safety valves, to be sized according to the
standards:
1. HP valve (compressors)
2. MP valve (liquid receiver)
3. Chiller BP valve (evaporators)
4. Freezer BP valve (evaporators)
Gas cooler/
condenser
Positive
compressors
High pressure
regulator valve
Liquid
sub-cooling
Negative
compressors
Positive units
Expansion
valves
Gas cooler
Liquid tank
Medium pressure
regulator valve
Negative units
Sales area
The sizing of the safety valves along with the technical data must allow for all potential
hazards (expansion, external fire, circuit partitioning).
In order to guarantee operation of the installation even in the event of a failure in the
electronic pressure regulators, provision should be made for mechanical back-up regulators.
Refrigerant alarm:
The level in the receiver must be monitored.
If the liquid level in the receiver is indicated using a magnetic level indicator, the level
indicated must show the actual level and must be able to be isolated from the receiver. The
indicators lower connecting pipe must be connected to the lowest possible point on the
receiver to avoid siphon effects.
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The level monitoring must include 3 alarm contacts as follows:

High level alarm: Priority 1 signalling, closure of HP valve
Low level alarm: Priority 2 signalling, max. delay time 20 min.
Very low level alarm: Priority 1 signalling, max. delay time 5 min.
Equipment used for the chiller and freezer circuits must be compatible with CO2 and have an
operating pressure of:
Position
Chiller high pressure, minimum
Chiller high pressure, minimum
Chiller medium pressure, minimum
Chiller low pressure, minimum
Freezer high pressure, minimum
Freezer low pressure, minimum
Set-point
110 bar
dry gas cooler
110 bar water-cooled
gas cooler
42 bar
42 bar
42 bar
24 bar
Actual, depending
on country
____ bar
____ bar
____ bar
____ bar
____ bar
____ bar
Care must be taken to ensure that the CO2 safety release valves do not present a hazard to
personnel.
Safety instruction information such as handling CO2 and handling cylinders of CO2 shall
be legibly and prominently posted adjacent to the refrigeration installations.
Safety valve opening pressures must be 2 bar higher than the pressure of the main valves.
3.3.2 REFRIGERATED DISPLAY CABINETS

The cutting points as per drawing 2597S2 form part of the technical conditions
Direct-evaporation chiller and freezer units using R744 must be regulated in such a way as to
minimize the pressure increase in the suction pipe during a failure in the installation.
Ventilations, expansion valves, and electric defrost heating must stop automatically when a
fault appears and start up again once the fault has been corrected.
If display cabinets are not in defrost mode, the evaporator fans and refrigeration power
regulation shall run continuously, corresponding to a Continuous setting.
Delivery free to site, positioning, and assembly of the refrigerated fixture elements form an
integral part of the services to be provided by the supplier. Removal and refitting of the
glazing and the provision of frames is the responsibility of the Works Management.
Chiller and freezer display cabinets must be protected in exposed locations (passages etc.)
using sturdy stainless pillars. Delivery and installation shall be carried out by the refrigeration
contractor. The dimensions of a stainless protective pillar shall be L thickness, 400
60.3 2 mm. This protective element is open at the bottom and top, fitted with a welded
stainless cap as per attached drawing.
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The pillars shall be fitted to a depth of 100 mm into holes provided for this purpose. Fixing
shall be performed using a 2-component adhesive as per the drawing. Hence the visible
height of the protective pillars in the store will be 300 mm.
Depth of hole
Example of protection for refrigerated units
Example of linear protection
Each chiller or freezer display module shall be fitted with a display giving temperature,
defrost, and alarm information. Provision shall also be made for a switch to disable the
refrigeration block in each unit.
The display must correspond to the actual temperature in the chiller and freezer cabinets.
All refrigerated sales units shall be fitted with a label indicating:
The number of defrost operations and timetable.
The regulated temperature for the unit.
This units reference on the temperature recording system.
This label shall be positioned on the units front panel adjacent to the display
thermometer, as per current legislation.
For the type of defrosting for chiller and freezer cabinets, the following instructions shall be
adhered to: Electric defrosting for chiller cabinets is not accepted. If the number of defrosting
operations set during commissioning and the optimization phase are no longer enough, the
causes must be found and eliminated. Six months after the refrigeration installation is
commissioned, the number of defrost operations may be adapted specifically to each store. If
units with glazed doors have to be fitted with electric heating elements, prior agreement from
the project owner is necessary.
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Type of display
cabinet
Chiller cabinets
Freezer cabinets

Type of defrost
fan-assisted
electric
Number of defrosts, depending on

temperature within unit
Once, up to a max. of twice a day
Once a week, up to a max. of once a day
Defrosting operations must take place as far as possible outside store opening hours and
shall be kept to a strict minimum.
During the defrost cycles, the temperature of the frozen products @ 1 cm below the surface
shall not exceed the following values:
- Ice-cream 18 C
- Frozen products 15 C
Heating of frame and glazing:
For chiller cabinets, no provision is to be made for heating the frame and glazing. For freezer
cabinets, no provision is to be made for heating the glazing (Antifog surface treatment).
Frame heating for freezer cabinets shall be controlled in accordance with the heat capacity of
the store.
Satellite distribution boards for chiller and freezer cabinets:
A satellite dis. board must be positioned adjacent to each refrigerated unit. The electrical
supply and safety functions shall originate from the main refrigeration distribution board in the
plant room. In the satellite dis. board, protective devices shall be installed for the power
devices and regulation for the refrigeration unit.
Example of a refrigerated unit satellite dis. panel
The refrigeration contractor is responsible for the electrical supply and the connection
between the main distribution board and the satellite boards. The refrigeration contractor is
likewise responsible for connecting the satellite boards to the regulators and to the power
devices in the unit. The lighting shall be connected up by an electrician.
If the satellites are to be placed below the refrigerated units, they shall be raised up off the
floor.
Example of a satellite placed on the floor
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The armatures of chiller and freezer cabinets shall be arranged as shown below:
- Stop-valves on each cabinet module.
- All armatures must be readily accessible.
All passages of piping and electrical routing shall be sealed by the refrigeration contractor.
All holes for connecting up refrigerated units (refrigeration/drains/electricity) shall be drawn
by the refrigeration contractor on the co-ordination plan for the store, as well as being
marked in situ. Clearly, there must also be co-ordination with the other trades present, as
well as compliance with the specific features of the building (e.g. pre-stressing, etc.)
Only 3 holes must be made for each cabinet module (1 each for
refrigeration/drains/electricity). It is vital that the number of holes be optimized, in order to
minimize the number.
The installation of the water discharge (including trap) between the connection on the
refrigerated unit and the floor connection shall be carried out by the refrigeration engineer.
The drain (min. diameter 40 mm) must be installed with an adequate fall.
Example of a water drain beneath the refrigerated unit
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3.3.3 COLD ROOMS AND FREEZER ROOMS

The supply boundaries as per sheet 2597S5 form an integral part of these technical
definitions.
The evaporators used must be proof-tested (except for evaporators for restoration). Spare
parts must be available in case of need within reasonable lead-times.
Cold rooms and freezer rooms with direct evaporation using R744 must be regulated in such
a way as to minimize the pressure increase in the suction pipe during a failure in the
installation. Ventilations, expansion valves, and electric defrost heating must stop
automatically when a fault appears and start up again once the fault has been corrected.
Cold room and freezer room evaporators must be installed using corrosion-resistant fixings.
Refrigerated areas holding merchandise containing vinegar or salt, or where the atmosphere
is corrosive, shall be fitted with evaporators with anti-corrosion protection. For example:
Description
Fruit & veg cold rooms
(e.g. Kba V6.04)
Dairy product cold rooms
(e.g. Kba V6.04)
Fish cold rooms
(e.g. Kba V6.02)
piping
Copper
Copper
Stainless
fins
Bladegold
(Alu-Goldlack)
Bladegold
(Alu-Goldlack)
Gold (Goldlack)
panels
Alu
Alu
Stainless
Thermostats, sensors, and thermometers shall be mounted on a common panel, adjacent to

the evaporator, on the wall at a minimum height of 220 cm. If the height of the room does not
allow this measurement to be complied with, the sensor panel shall be mounted as high as
possible.
Electrical cables must not be run directly into devices (e.g. alarm button) through the
wall/insulation.
Example of configuration for temperature sensor and thermometer panel
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Freezer rooms with rendered ceilings (conventional construction) shall be fitted with a
suitable protective plate between the ceiling and the evaporator, adjoining the end wall of the
room and overhanging the evaporator by a minimum of 70 cm.
The drains (including trap) between the evaporator and the connection point outside the cold
room / freezer (pre-installed) shall be installed by the refrigeration engineer. The drain (min.
diameter 50 mm) must be installed with an adequate fall (cold rooms min. 5 and freezer
rooms min. 10).
In every cold room with evaporators using R744, the concentration of CO2 in the air must be
monitored using infra-red detectors. When the limit value is exceeded, an alarm must be set
off inside and outside at the entrance to the room, using a flashing illuminated warning
device clearly indicating the danger. See also Section 6.2.
Evaporators fitted with electric defrosting, fitted in both cold and freezer rooms, must be fitted
with an insulating batt in order to compartmentalize the evaporator from the room ceiling.
Cold room and freezer evaporators must be fitted with a minimum of 2 fans.
All evaporators to be used in cold rooms and freezers shall be fitted with low-consumption
fans (electronically-commutated [EC] motors).
Drain heating shall be accomplished using a self-regulating system.
Cold room and freezer evaporators shall be selected with fin spacing of at least:
Description
General cold room
Fruit & veg cold room
Dairy product cold room
Meat cold room
Bakery cold room
Store freezer room
Bakery freezer room
Evaporator fin spacing

4.5 mm
7 mm
4.5 mm
4.5 mm
12 mm
7 mm
12 mm
The evaporator shall be fitted with a readily-accessible point for measuring the pressure.
The evaporator position shall be suitable for the room conditions. It is important to guard
against air short-circuits, and to avoid blowing directly into a freezer or cold room. These
situations are to be avoided whenever possible.
The evaporator positions marked in red are only possible if no other solution is possible.
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Evaporator
vaporateur
Evaporator
Evaporator
Evaporator
Evaporator
Fit two-port evaporators.

In long, narrow cold rooms Air directed towards the
doors
In wide cold rooms Air directed towards the walls
Evaporator
Evaporator
Do not position the evaporator above the

door and do not direct the air flow
towards the door.
Cold room
or
freezer room
Cold room
or
freezer room
Evaporator
Evaporator
Evaporator
Freezer room
Evaporator
Fit either 2 evaporators or a two-port

evaporator.
Evaporator
Cold room
Evaporator
Evaporator
Cold room
or
freezer room
Evaporator
Evaporator
Do not position the freezer evaporator blowing towards

the cold-room door. Do not position the cold-room
evaporator blowing towards the freezer door; in this
case, position the evaporator blowing towards the coldroom door.
Each cold room shall be fitted with a display giving temperature, defrost, and alarm
information. The display must indicate the actual cold-room temperature.
Each cold room shall be fitted with a prominent label indicating defrost times and intervals.
For the type of defrosting for cold rooms and freezers, the following instructions shall be
adhered to. If the number of defrosting operations set during commissioning and the
optimization phase are no longer enough, the causes must be found and eliminated. Six
months after the refrigeration installation is commissioned, the number of defrost operations
may be adapted specifically to each store.
Description
Cold room temperature > +2 C
Cold room temperature < +2 C
Freezer room
Type of defrost
fan-assisted
electric
electric
Max. number of defrosts

per day
maximum 3 times
maximum 3 times
maximum 3 times
Defrosting operations must take place as far as possible outside store opening hours and
shall be kept to a strict minimum.
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After defrosting, re-starting of freezer room evaporator fans must be delayed. When users
have to enter the freezer room, a switch shall be provided for them to stop the refrigeration
and ventilation for around 3 minutes.
The safety devices for the door frame heating and the equalizing valve must be fitted in the
satellite where the refrigeration unit regulating control is located.
Example of pressure equalizing valve with heating
Satellite distribution boards for cold rooms and freezer rooms.

A satellite distribution board must be fitted adjacent to each refrigeration cell (not over the
door mechanism). The electrical supply and safety functions shall originate from the main
refrigeration distribution board in the plant room. In the satellite dis. board, protective devices
shall be installed for the load devices and regulating the cold room refrigeration unit.
The refrigeration contractor is responsible for the electrical supply and the connection
between the main distribution board and the satellite boards. The refrigeration contractor is
likewise responsible for connecting the satellite boards to the regulators and to the power
devices in the cold room.
The safety functions for the following load devices must be provided separately (not by the
satellite):
Refrigerated room lighting (responsibility of the PO; connection to a maintained supply must
be examined for each new configuration)
- Personnel alarm for freezer rooms (powered from POs UPS or self-contained battery)
- Floor heating for freezer rooms (from refrigeration satellite dis. board)
- Air curtains for freezer rooms (from refrigeration satellite dis. board)
Example of freezer room floor heating
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Example of air curtain
Adjacent to the door of the freezer room or near the satellite dis. board, a label must be fitted
with a message drawing users attention to the fact that the frame heating must also be
turned off when the freezer room is turned off.
Points where refrigeration and drain piping pass, as well as cables, must be sealed by the
insulation contractor.
The personnel alarm emergency button must be positioned near the door. It shall be
positioned as per the standards, but at a max. of 30 cm above floor level, in a recess
provided for this purpose. This recess shall be produced by the insulation contractor. The
personnel alarm must be repeated outside the building. The personnel alarm facilities must
be made secure by the use of a UPS. Surface wiring to the personnel alarm button.
Example of alarm button for trapped persons
Cold room lighting shall be controlled using a movement detector, fitted by the electrician.
The electrician is responsible for the positioning of these detectors.
Cold / freezer room cool-down must be accomplished in a staged manner, in accordance
with the indications and instructions from the floor supplier. The refrigeration engineer shall
seek information and it is imperative that they ensure the pre-determined cooling curve is
adhered to. During the cool-down phase, the ambient temperatures must be recorded and
presented to the project owner on request.
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Ambient temperature (C)
Example of a temperature/time curve:
commissioning
Cool-down in days
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3.4 OPERATING RATES AND POWERS

3.4.1 BOOSTER CONFIGURATION AND RATES
Depend on the climatic conditions in the country. To be verified and adapted if
necessary.
The following data are to be adhered to when sizing a booster or a chiller multiplex.
Fundamentally, the manufacturers data take precedence.
Rates
Chiller evaporation
temperature
Freezer evaporation
temperature
Freezer installation
condensation temperature
Return pressure in summer
(with atomizer)

(w/o atomizer)
Return pressure in winter

Mean pressure
Max. outdoor temperature (wet
bulb) for sizing with atomizer*
Max. outdoor temperature
w/o atomizer*
Gas cooler output temperature

(with atomizer)*
(w/o atomizer)*
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Minimum values
Target values
Maximum
values
max. 2 K lower than

9 C
9 C
the refrigeration
units evap. temp.
max. 2 K lower than
33 C
33 C
the refrigeration
units evap. temp.
Corresponds to the evaporation temperature of the
chiller installation
min. 80 bar
min. gas
max. 85 bar
cooler output
temperature
( C) factor
of 2.55
min. 90 bar
min. gas
max. 100 bar
cooler output
temperature
( C) factor
of 2.55
min. 45 bar
45 bar
max. 50 bar
min. 34 bar
35 bar
max. 38 bar
min. +30 C
+31 C
max. +33 C
min. +32 C
+34 C
2K higher than incoming air temp.

(wet bulb)
2K higher than incoming air temp.
Version 1.1
Actual
values
dependin
g on
country
C
C
C
bar
bar
bar
bar
+ C
max. +37 C,
otherwise
warning to
FCAG
max. +35 C
+ C
max. +39 C
+ C
+ C
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Suction temperature at chiller

compressors (min. 10K superheating between evaporator
output and compressor output)
min. 0 C
+5 C
In booster
installations, the
temperature is
influenced by the
freezer installation
9 C
Suction temperature at freezer

compressors (min. 10K superheating between evaporator
output and compressor output)
Liquid temperature at subcooler output
Useful super-heating
Compressor speed
min. 7 C
min. 6 K
1,450 rpm
8K
1,450 rpm
Chiller simultaneity factor

Freezer simultaneity factor
min. 90%
min. 95%
95%
95%
max. +10 C
+ ____ C
max. 10 C
____ C
min. 4 K sub-cooling required
____ K
max. 8 K
max. 2,900
rpm
max. 110%
max. 110%
____ K
_____
rpm
____ %
____ %
* See gas cooler sizing Section 3.4.6

Chiller:
The refrigeration power to be taken into account in sizing central refrigeration units shall be
the total power with a frequency controller setting of 100%.
Voltages to be verified for each country
Chiller compressor no. 1 with speed control for proportional adjustment according to the
evaporation pressure, with sinewave filter (if necessary) and cooling provided. Compressor 1
must be sized such that the part-charge and summer and winter operation rates function
without significant fluctuation of the compressor.
The refrigeration power of the chiller stage shall comprise the power of the chiller units and
that of the freezer stage return (for boosters only). The minimum and maximum number of
compressors per multiplex is to be respected.
Each installation shall require a minimum of 4 compressors and a maximum of 6. Above a
refrigeration power of 200 kW, provision must be made for at least 2 installations. Above a
refrigeration power of 400 kW, provision must be made for at least 3 installations.
Care must be taken that in winter periods with partial charge, the size of the compressors
makes it possible to ensure correct operation of the installation. The multiplex must be sized
in such a way as to be able to handle a minimum partial charge power equivalent to 10% of
the maximum charge refrigeration capacity.
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Freezer:
The refrigeration power to be taken into account in sizing central refrigeration units shall be
the total power with a frequency controller setting of 100%.
Voltages to be verified for each country
Freezer compressor no. 1 with speed control for proportional adjustment according to the
evaporation pressure, with sinewave filter (if necessary) and cooling provided. Compressor 1
must be sized such that the part-charge and summer and winter operation rates function
without significant fluctuation of the compressor.
The refrigeration power of the freezer stage shall comprises the power of the freezer units.
Each installation shall require a minimum of 3 compressors and a maximum of 5. Above a
refrigeration power of 50 kW, provision must be made for at least 2 installations. Above a
refrigeration power of 100 kW, provision must be made for at least 3 installations.
When 2 chiller installations have to be installed, check if it is necessary to double-up the
freezer installation from the point of view of redundancy.
3.4.2 LABORATORY OR WORKROOM
Dependent on the climatic conditions in the country. To be verified and adapted if
necessary.
Corridors are not to be cooled.
For cooling of the LABORATORY or WORKROOM, the following variants should be
examined on the basis of the power:
Connection to the booster (with no separate compressor/installation) up to a maximum
of 20 kW
Connection to the refrigeration installation booster, but with a separate, independent
compressor with higher evaporation temperature (see table below)
Completely separate CO2 refrigeration installation with several compressors and higher
evaporation pressure (see table below)
Rates
Minimum values
Target values
Maximum
values
Evaporation temperature
max. 2 K lower than

the refrigeration
units evap. temp.
2 C
2 C
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C
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3.4.3 EXCHANGER FOR FLASHGAS SUPER-HEATING

In the absence of any specification in terms of plate exchanger manufacturers, only
recognized makes of exchanger are to be used. Spare parts must be available in case of
need within reasonable lead-times.
These plate exchangers must be connected up in accordance with the manufacturers data.
They must generally be connected up so as to obtain opposite flow directions between the
exchanger primary and secondary.
The gas temperature at compressor inlets must be able to generate a minimum of 10 K
super-heating in all the operating levels for the installation.
General observations R-744
Target
values
Maximum operating pressure (OP) at least

Maximum operating temperature (OT) at least
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min. 42 bar
+120 C
R-744 primary side (biphase)
Target
values
Pressure
Input temperature
Output temperature
Input vapour content
Output vapour content
Max. pressure drop
35 bar
0 C
0 C
45 %
42 %
max. 50 kPa
R-744 secondary side (flashgas)
Target
values
Input vapour content
Output vapour content
Suction output temperature
Max. pressure drop
8 C
98 %
100 %
min. > 3 C
max. 30 kPa
Version 1.1
Actual
values
depending
on country
____ bar
____ C
Actual
values
depending
on country
____ bar
____ C
____ C
____ %
____ %
_____ kPa
Actual
values
depending
on country
____ C
____ %
____ %
____ C
_____ kPa
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3.4.4 EXCHANGER FOR LIQUID SUBCOOLING

In the absence of any specification in terms of plate exchanger manufacturers, only
recognized makes of exchanger are to be used. Spare parts must be available in case of
need within reasonable lead-times.
These plate exchangers must be connected up in accordance with the manufacturers data.
They must generally be connected up so as to obtain opposite flow directions between the
exchanger primary and secondary.
Liquid subcooling of 4 K must be guaranteed at the evaporator inputs.
Target
values

R-744 subcooling primary side
Target
values
Saturation pressure
Input temperature
Output temperature
Max. pressure drop
0 C
0 C
min. < 4 C
max. 20 kPa
R-744 (evaporation) secondary side
Target
values
8 C
0 C
0 C
min. > 3 C
8K
Liquid inlet saturation pressure
Liquid inlet temperature
Suction output temperature
Super-heating
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min. 42 bar
+120 C
Version 1.1
Actual
values
depending
on country
bar
C
Actual
values
depending
on country
____ C
____ C
____ C
_____ kPa
Actual
values
depending
on country
____ C
____ C
____ C
____ C
____ K
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3.4.5 DE-SUPERHEATER, FREEZER INSTALLATION

necessary.
In the absence of any specification in terms of de-superheater manufacturers, only
recognized makes of de-superheater are to be used. Spare parts must be available in case
of need within reasonable lead-times.
The permitted sound level for the sizing of these elements must correspond to the order on
noise protection. The constraints due to the layout and geography of the premises must also
be taken into account in selecting the device.
In order to reduce the effect of pulsations in the de-superheater, it is wise to fit a muffler at
the refrigerating unit.
If there is a significant risk of the refrigerants liquefying due to low outdoor temperatures, an
automatic bypass will have to be installed.
The speed of the de-superheaters EC fan shall be modulated using a variable-frequency
controller.
Target values
Materials (heat exchanger)
Stainless or
copper
Alu
Galvanized
steel, composite
paint
min. 42 bar
+120 C
min. 2.1mm
max. 1.0 bar
max. 50 dB(A)
Materials (fins)
Materials (housing)

Fin spacing
Pressure drop
Sound level @ 5 m
R-744 de-superheater
Target values
Hot gas inlet temperature

Hot gas output temperature
Outdoor air temperature
Max. refrigerant pressure drop
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+80 C
max. +45 C
+34 C
max. 40 kPa
Version 1.1
Actual
values
depending
on country
____ bar
____ C
____ mm
____ bar
____ dB(A)
Actual
values
depending
on country
____ C
____ C
____ C
_____ kPa
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3.4.6 GAS COOLER RATES AND CONFIGURATION

necessary.
The power to be taken into account in selecting the gas coolers and piping is the power of
the central refrigeration unit at its 100 % operating level.
In the absence of any specification in terms of gas cooler manufacturers, only recognized
makes of gas cooler are to be used. Spare parts must be available in case of need within
reasonable lead-times.
The permitted sound level for the sizing of these elements must correspond to the Order on
noise protection. The constraints due to the layout and geography of the premises also need
to be taken into account in selecting the device.
If several gas coolers are connected in parallel on the same installation, the return feeds
shall be connected separately to the liquid receiver.
For high-power installations with / or high outdoor temperature conditions, the use of
atomized water must be verified.
The decision to use a gas cooler with atomized water cooling shall be made in each country,
according to its mean annual outdoor temperature.
Gas coolers using atomizing shall ideally be executed with a V-shaped heat exchanger.
Execution without water atomizing
Execution with water atomizing
Water
Example of gas cooler without atomizing
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Example of gas cooler with atomizing
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Cumulative frequency [hrs/yr]
Decision matrix for using an atomizing system

1. Obtain graph of local cumulative temperature frequency
The diagram represents the cumulative number of hours against the outdoor temperature
( C) in a diagram.
Key
LT
DT
MT
Atomisation temperature
Design temperature
Mean temperature
Regional
Outside temperature Ta [C]
Diagram: Frequency, cumulative probability against outdoor temperature (calculation

example)
2. Defining the design temperature (DT)
The sizing of the installation, such as for example the compressors, gas cooler, etc. must
be calculated at the design temperature. Design Temperature is defined as the
temperature limit that the outdoor temperature does not exceed for more than 10 hours
per year.
3. Determining the median temperature (MT)
The median temperature is the temperature limit where half the annual operating hours
are above/below it. Alternatively, the average annual temperature may also be taken.
Overall
Atomisation
Not recommended
Weight
Recommended
-Value [-]
< 31
31 33
> 33
coefficient against outdoor temperature Ta (calculation example)
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4. Determining the mean temperature value

Starting from the mean temperature, the MT can be read off the diagram. The diagram is
valid globally.
5. Determining the design temperature coefficient
In a similar manner to point 4, starting from the design temperature, the DT can be read
off the diagram.
-Value [-]
-value as a function of outdoor temperature
Diagram: coefficient with respect to outdoor temperature

6. Determining the difference between MT and DT
The difference between the two coefficients is then derived: = MT DT
7. The decision whether to use atomizing or not is based on the difference .
If is greater than 33, atomizing should be used. If is between 3133, atomizing
needs to be examined in terms of profitability. Below 31, atomizing need not be used.
8. Determining the atomizing temperature limit
If atomizing has to be installed, the start/stop atomizing temperature limit can be read off
the cumulative temperature frequency graph. An atomizing system in which the gas cooler
fins come into direct contact with the water must not be used for more than 200 hours a
year.
CAUTION:
The matrix takes only the basic design temperature into account. However, when sizing the
gas coolers, it is necessary to take into account the maximum possible outdoor temperature,
and if necessary, depending on the region, look into other kinds of cooling or other
refrigeration systems (see Section 2.1).
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The refrigeration contractor shall be responsible for delivery and installation of the water
atomizing system, including the atomizer piping and valves.
When a water atomizing system is used for cooling the gas cooler, provision must be made
for a water-softener in the systems water supply.
Water atomizing
Target values
Hardness of mains water supply

Hardness of softened water (proposal)
Peak hourly consumption
Peak daily consumption
Pressure drop
Atomizer operating time
min. 30fH
max. 0.5fH
min. 0.6m/hr
min. 4.0m/hr
max. 1.0 bar
max. 200 hr a year
Actual values
depending on
country
In sizing the alternating water-softener, the gas cooler manufacturers data are to be taken
into account and shall take precedence with respect to the values quoted in this document.
The following rate data shall be determining for sizing the gas cooler. But in general the
manufacturers data shall be taken into account.
Account must be taken of the manufacturers objectives / installation directions.
The following data are to be used for sizing the gas cooler. The manufacturers data take
precedence.
Target values
Materials (tube array)
Stainless or
copper
Alu, Epoxy
Alu
Galvanized steel,
composite paint
min. 120 bar
+150 C
< 3.5%
____ bar
____ C
____ %
min. 2
min. 2.1mm
min. 3 K
max. 1.0 bar
max. 50 dB(A)
No. ____
____ mm
____ K
____ bar
____ dB(A)
Fin material with water atomizing

Fin material w/o water atomizing
Materials (housing)
Maximum operating pressure (OP)
Maximum operating temperature (OT)
Coefficient of performance (COP)
COP = power consumed PKL / Gas cooler power Qe
= 3.5%
Number of fans per unit
Fin spacing
Subcooling in winter
Pressure drop
Sound level @ 5 m
Actual
values
depending
on country
to be verified and adapted according to the location of the site and the countrys
legislation
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Rate (with atomizing)
Minimum
values
Target values
Maximum
values

(wet bulb) for sizing
min. +30 C
+31 C
max. +33 C
Actual
values
depending
on country
+ C
min. 80 bar
max. 85 bar
bar
Gas cooler input temperature

summer
+100 C
Gas cooler
output
temperature
( C) factor of
2.55
+110 C
<0}max.
+ C
2K lower than the incoming air

temperature (wet bulb)
+45 C
+55 C
<0}max.
+ C
+55 C
+ C
min. +10 C
min. +14 C
min. +15 C
+ C
min. +5 C
min. +5 C
min. +10 C
+ C
Rate (w/o water atomizing)
Minimum
values
Target values
Maximum
values

for sizing
min. +32 C
+34 C
max. +37 C
Actual
values
depending
on country
+ C
min. 88 bar
max. 100 bar
bar
Gas cooler input temperature in

summer
+110 C
Gas cooler
output
temperature
( C) factor of
2.55
+120 C
max. +130 C
+ C
2K greater than the incoming air

temperature
+45 C
+55 C
max. +39 C
+ C
+55 C
+ C
min. +10 C
min. +14 C
min. +15 C
+ C
min. +5 C
min. +5 C
min. +10 C
+ C
Gas cooler input temperature

winter
Condensation temperature
winter
Incoming air temperature
winter
Gas cooler input temperature in

winter
Condensation temperature in
winter
Incoming air temperature in
winter
One factory-wired operating switch shall be installed per fan. All of the wiring shall be brought
together on a terminal block inside an enclosure. The refrigeration contractor shall be
responsible for ensuring that the element is delivered as requested.
For horizontally-operating gas coolers, the distance between the lower edge of the gas
cooler and the ground must be a minimum of 1 metre.
Gas cooler refrigerant content is to be kept to a minimum.
A water supply and a power socket must be provided adjacent to the gas cooler for
maintenance purposes. The refrigeration contractor is responsible for ensuring these
elements are installed.
The spacing between the fins of the gas cooler register is to be adapted in accordance with
the environment. The spacing must be 2.1 mm minimum.
Directive for locating gas coolers. Account must be taken of the manufacturers objectives /
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installation directions.
Clear horizontal location
(1 gas cooler)
Clear horizontal location

(several gas coolers)
Height of legs = 1 m min.

Height of leg
Height of leg
Length
Width
Height of legs = 1.2 m min.

Length
Width
Max. distance 100 mm
Area for location =

0.8 device length width number of units
Area for location =

2 (device length + width) leg height
Max. distance between units 100 mm

Height of legs = 1.2 m min. (to be adapted in
accordance with the location)
Height of legs = 1 m min. (to be adapted in

accordance with the location)
1 horizontal gas cooler alongside a wall
1 horizontal gas cooler alongside 2 walls
Minimum distance
Length
Width
Minimum distance
Adapt the height of the legs so that the aspiration

area is 0.81.0 the exchange area
Height of legs = 1 m min.

Length
Width
Adapt the height of the legs so that the aspiration

area is 0.81.0 the exchange area (device
length width)
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Open vertical location

(1 gas cooler)
1 vertical gas cooler

alongside 2 walls
Height
Minimum distance
Length
Minimum distance
Direction of prevailing wind
Avoid installing the device so it blows into the

wind
Min. distance to wall for 1 row = device

height 0.8
2 rows = device height 0.6
Distance to side wall for 1 row = device
height 0.5
min. 800 mm
V gas cooler, open location
Gas cooler influence
Minimum distance
Length
Do not position devices in series
Min. distance between devices for 1 row = device

length 0.5
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3.5 DESCRIPTION OF THE EQUIPMENT

According to the French OESP [Pressurized Equipment Order] standard and the
EN 378: 2008 standard for Europe, or as per local legislation. In terms of the pressure
resistance of all the components, the contractor shall bear full responsibility for respecting
the law and the standards.
3.5.1 REFRIGERATION, BOOSTER
Pipework may be run in copper or stainless steel. This also includes the compressor
connections. Pipework, insulation, and fitting must be carried out as per the technical data in
Section 5.1.
For chiller refrigeration, a minimum of 4 compressors must be used and a maximum of 6.
Care must also be taken that in winter periods with partial charge, the size of the
compressors makes it possible to ensure correct operation of the installation. Above 200 kW,
provision must be made for 2 multiplexes (see Section 3.4.1)
The installation must be sized in such a way as to be able to handle a minimum partial
charge power equivalent to 10% of the maximum charge refrigeration capacity.
Freezer refrigeration shall comprise a minimum of 3 compressors and a maximum of 5 per
booster. Above 50 kW, provision must be made for 2 multiplexes (see Section 3.4.1)
When 2 chiller installations have to be installed, check if it is necessary to double-up the
freezer installation from the point of view of redundancy.
Compressors shall be mainly semi-hermetic reciprocating types made by BITZER, BOCK, or
DORIN, specially designed for optimum efficiency using R744.
Electric motors shall be sized so as to be able to operate overspeed at a frequency of 70 Hz
or higher (depending on voltage/frequency in the country)
Chassis shall be fitted with anti-vibration pads.
EACH COMPRESSOR SHALL BE FITTED WITH:
Suction valve
Return valve
Hot gas temperature transducer
Low pressure switch (manual mode pressure switch)
Safety valves and HP + LP pressure switches as per OESP
High pressure and low pressure pressure discharge device (compressor)
1 Electronic safety HP pressure limiter (pressure switch)
1 Electronic HP pressure limiter (pressure switch)
Connecting pipework compressor inlet to insulated liquid separator
Connecting pipework compressor outlet to insulated hot gas header
Case heater
Oil distribution system with ball valves and filter
Oil level or oil pressure (depending on type) control system
Oil cooling (as per suppliers indications)
An oil circuit isolation valve
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1 BOOSTER SHALL BE FITTED WITH:

Chiller hot gas piping:
Freezer hot gas piping:
Gas cooler return piping:
Flashgas piping:
Liquid piping:
Chiller suction piping with flashgas:
Chiller suction piping w/o flashgas:
Freezer suction piping:
Stainless, insulated as per Section 5.2

Copper, insulated as per Section 5.2
Copper, insulated as per Section 5.2
Chiller suction header in stainless, insulated, including connections for suction piping, 1
angle valve and 1 drain cock
Chiller hot gas header in stainless, insulated, including connections for hot gas piping, 1
Freezer suction header in stainless, insulated, including connections for suction piping, 1
Freezer hot gas header in stainless, insulated, including connections for hot gas piping,
1 angle valve and 1 drain cock
1
2
1
1
1
1
Insulated chiller suction filter

Schrader valves
Manual full-bore stop valve in main suction pipe, insulated
Gas filler valve
Safety valve
Main safety valve fitted external to chiller units, opening pressure 42 bar, sized as per
relevant standards. Safety valve output discharge pipe, sized as per relevant standards.
1
2
1
1
1
Insulated freezer suction filter

Schrader valves
Manual full-bore stop valve in main suction pipe, insulated
Gas filler valve
Main safety valve fitted external to freezer units, opening pressure 24 bar, sized as per
relevant standards. Safety valve output discharge pipe, sized as per relevant standards.
LIQUID SEPARATOR
Liquid tank
Level sensor
CO2 gas air
cooler, 0C
Safety valve
Changeover valve
Dryer
Lamp with humidity indication
Liquid filler valve
Safety valve
Ball valve
CO2
compressors,
+30C
Measuring valve
Safety valve
Emergency generator for
maintaining CO2 pressure
CO2 supercooler,
0C
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Liquid separators shall be of vertical or horizontal type, fitted with:

Complete refrigerant receiver, insulated as per Section 5.2, including the necessary
safety and stop valves (no Rotalock valves), including connections and fixings, capacity
sized as per the technical standards.
Authorization, control, and verification of the liquid receivers, if necessary as per the
OESP standard.
2 Refrigerant level detectors, including two alarms for low refrigerant level (pre-alarm and
alarm)
1 Refrigerant level detector, including high refrigerant level alarm
2 Intermediate-pressure main safety valves, opening pressure: 42 bar, sized as per
relevant standards. Externally-fitted safety valves: fitting of external valves and piping
from the booster. Safety valve output discharge pipes, sized as per relevant standards.
1
1
1
1
1
3
2
2
1
-
Replacement valve for main safety valves.

Dryer with interchangeable core, insulated
Sight-glass with humidity indicator
Liquid filler valve
Safety valves
Full-bore ball valves (dryer bypass)
Measurement valves
Liquid pipe safety valve
Isolation valve on gas cooler liquid return
The volume of the liquid separator must be correctly sized in order to ensure correct
operation at summer, winter, and heat-recovery rates
Liquid pipework shall be insulated, e.g. as per Section 5.2 or equivalent, between the
dryer output and the exchanger input.
PRESSURE MAINTENANCE WITH COOLING OFF (BACKUP)
Independent refrigeration unit allowing the CO2 to be liquefied when the main
refrigeration plant is stopped. This shall include the condenser, evaporator, solenoid
valve, dryer, sight-glass with humidity indicator, thermostatic expansion valve, the
regulation system, fixings, and minor hardware for fitting. Also included shall be the
refrigeration connections, fitting, and commissioning
Under normal circumstances, the pressure maintenance with cooling off (backup) is
powered from the refrigeration electrical distribution board, but in the event of an
electricity outage, the supply must be provided from the buildings standby generator. If
this is not possible, the refrigeration engineer shall be required to supply and fit a UPS to
ensure operation in the event of an electricity outage. The pressure maintenance with
cooling off (backup) must be tested automatically once a week.
3
1
3
Chiller high-pressure safety valve, opening pressure: 110 bar, sized as per relevant
standards. Externally-fitted safety valves: fitting of external valves and piping from the
booster. Safety valve output discharge pipes, sized as per relevant standards.
Freezer high-pressure safety valve, opening pressure: 42 bar, sized as per relevant
standards. Externally-fitted safety valves: fitting of external valves and piping from the
booster. Safety valve output discharge pipes, sized as per relevant standards.
Full-bore ball valves (gas cooler bypass)
Freezer manual hot gas stop valve
Full-bore ball valves (freezer de-superheater bypass)
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LIQUID SEPARATOR
Suction pipe liquid separator
Manual stop valve
Magnetic valve
Oil return lamp
CO2
compressors, -9C
CO2 positive and

negative units, -9C
Oil compressors
Liquid separators shall be fitted in the chiller and freezer central refrigeration unit suction line.
These accumulators will make it possible to avoid liquid reaching the booster.
1
1
1
1
-
Insulated chiller suction liquid separator

Oil return sight-glass
Manual stop valve
Solenoid valve
Oil return piping to the multiplex
1
1
1
1
-
Insulated freezer suction liquid separator

Oil return sight-glass
Manual stop valve
Solenoid valve
Oil return piping to the multiplex
OIL CIRCUIT LINE

Gas air cooler
Liquid tank
Per compressor
Positive compressors
Oil filter
Negative compressors
Indicator light on oil return pipe
Oil separator
Oil level regulation
Manual stop valve
Safety valve
Magnetic valve
Measuring valve
Flowrate regulator valve
Differential pressure valve
Oil tank
Manual valve before each

regulator
Positive units
Per compressor
Negative units
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Insulated HP oil separator, with oil return piping, drain cock
1
1
2
1
4
1
1
1
1
1
-
Oil reservoir sized according to the power and minimum oil volume for each compressor
Safety valve
Pressure measurement connection and stop valves
Solenoid valve
Manual stop valves
Oil filter
Sight-glass on oil return pipe
Regulating valve
Discharge valve
Degassing pipe between oil reservoir and liquid receiver
Oil piping
Tapping points with isolating valves for supplying the various regulating and checking
devices (pressure gauge/switch/detector, etc.)
Manual isolating valves ahead of each compressors oil level regulator
GENERAL:
Air oil cooler, including fixing, regulation, and connecting piping (depending on
compressor type).
-
Oil pressure or level checker (depending on compressor type).
Filling with ..kg R-744 refrigerant, quality at least 4.5, guaranteed maximum humidity
100 ppm.
High-pressure filling hose, operating valve, safety relief valve, safety cable, pressure
gauge, dryer, connections.
Filling with refrigeration oil
Safety valves on pipes, if necessary in addition

Service valves on pipes or for pressure measurements, if necessary in addition.
Sturdily-built lacquered steel frame to take the above-mentioned machines and the
electrical cabinets for the machines.
The machine shall be assembled in such a way that each compressor can be removed
easily by separating each element (all pipes must be removable).
A discharge control system must be present for installations where the refrigerant
capacity exceeds 300 kg. This is to verify that the safety valves have indeed operated
and discharged gas. For example, a U-tube of oil with sight-glasses or a pressure
controller with an alarm.
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CONTROL AND SAFETY PANEL

Chiller low pressure suction
System
Chiller suction
Manometer, positive
suction pressure
Manometer, negative
suction pressure
Manometer,
intermediate pressure
High pressure
manometer
Positive low pressure
manometer
Manometer, negative
low pressure
Manometer,
intermediate pressure
Freezer low pressure suction
Intermediate pressure
System
Freezer suction
System
Intermediate pressure
Chiller high pressure
Freezer high pressure
System
Chiller high pressure
System
Freezer high pressure
Positive safety pressure switch

Negative safety pressure switch
Intermediate pressure switch
Safety valve
Pressure limiter, high pressure
alarm
High pressure switch
This panel shall include all the control and regulating organs such as:
1 High-pressure gauge (adjustable), stop valve, and connection for measuring pressure
1 Intermediate pressure gauge (adjustable), stop valve, and connection for measuring
pressure
1 Chiller suction pressure gauge (adjustable), stop valve, and connection for measuring
pressure
1 Freezer suction pressure gauge (adjustable), stop valve, and connection for measuring
pressure
1 Pre-alarm high-pressure safety pressure switch
1 Main high-pressure safety pressure switch
1
1
1
1
-
Intermediate pressure switch

Freezer installation high pressure switch
Chiller overall low-pressure safety pressure switch
Freezer overall low-pressure safety pressure switch
Pressure transducers (high pressure, intermediate pressure, low pressure)
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EXCHANGER FOR FLASHGAS SUPERHEATING

CO2 gas air
cooler, +36C
Electronic high pressure regulator valve

High pressure regulator valve
Electronic flash gas regulator valve
Mechanical flash gas regulator valve
Manual stop valve
Measuring valve
Temperature sensor
High pressure regulation
Intermediate pressure regulator
Fine mesh filter
Superheater
CO2 composite
refrigeration, -2C
Medium pressure
regulator valve
Tank, CO2
0C
Tank, CO2
0C
The heat exchanger is fitted to the booster

4
Pressure measurement connection and operating valves
HIGH-PRESSURE AND INTERMEDIATE-PRESSURE REGULATING VALVES PER

BOOSTER
1
1
1
Electronic high-pressure regulating valve, c/w drive

Mechanical high-pressure regulating valve
Fine-mesh filters ahead of the high-pressure regulating valve
1
1
Electronic flashgas regulating valve, c/w drive

Mechanical flashgas regulating valve
4
4
4
Full-bore manual stop valves (high-pressure regulating valves)

Full-bore manual stop valves (flashgas regulating valves)
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EXCHANGER FOR LIQUID SUBCOOLING
Tank, CO2
0C
Stop valve
Electronic expansion valve
CO2
compressor,
-2C
Pressure sensor
Temperature sensor
Regulation
Measuring valve
CO2 positive and

negative units, -2C
Supercooler
Safety valve
The heat exchanger is fitted to the booster

1
1
3
1
1
1
1
1
1
Full-bore stop valve (liquid phase)

Full-bore stop valve (extracted gas)
Pressure measurement connection and service valves
Danfoss AKV 10 electronic expansion valve
Pressure transducer
Regulation, e.g. refrigeration unit regulator
Sector and discharge valve
Temperature transducer including fitting and positioning
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3.6 GAS COOLER

Condensation/de-superheating of the R744 shall be accomplished using a spiral-type air gas
cooler. As per the technical specifications
1
-
CO2 gas cooler for sub-critical and trans-critical operation with block optimized for subcritical operation
Vibration dampers, capable of withstanding the contact pressure and weather-resistant
Craning, positioning the element
Including EC fans + regulator for external 010 V signal
Where the air flow is vertical , at least 1 m of aspiration must be ensured.
Factory-fitted operating switches (1 per fan), fitted adjacent to each fan and wired back
to a terminal block
The permitted sound level for the gas cooler for the execution phase must be in line with the
Noise Protection Order. The constraints due to the location, including the outdoor
temperature, must likewise be taken into account and must be adapted according to the
project.
Reminder:
The gas cooler must be selected for the booster power as per the rates in Section 3.4.6 and
for the outdoor air temperature, depending on the climate in the country.
When an atomizer system is used with a gas cooler, it is wise to make provision for a device
for demineralizing the water.
Example of a water treatment installation for atomizing
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1
WATER DEMINERALIZATION INSTALLATION AS PER DESCRIPTION
Outside temperature
Ta = +34C
Salt reservoir
Flexible pipes
Magnetic valve, water
vapour and drainage
Drainage valve
Stop valve
Non-return valve
Pressure reducer
Interface,
refrig. contr.
Sanitary
interface
Gas air cooler
Mains water
Automatic
draining
Water softener
Salt tank, filled, connected up, commissioned

2 Hoses
Supply of demineralizing salt, 50 kg min.
Discharge piping
Overflow pipes
Electronic regulation, including measuring and positioning elements
Water hardness test kit
Maintenance log
Supply piping to gas cooler for atomization
5 Stop valve
1 Non-return valve
1 Pressure reducer (if necessary)
1 Drain cock
2 Solenoid valves for atomization and draining
complete water atomization system, including nozzles and installing pipework
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3.7 FREEZER DE-SUPERHEATER
Negative CO2
compressors, +80C
Positive CO2
compressors, +45C
De-superheater
Service valve
Temperature sensor
Regulator
The de-superheater shall make it possible to cool the freezer CO2 return down to a
temperature 10 degrees above ambient temperature. No account shall be taken of the desuperheater in sizing the compressors and gas cooler. As per the technical specifications
1 Air-cooled de-superheater for cooling the hot gas in the freezer installation
Vibration dampers, capable of withstanding the contact pressure and weather-resistant
Craning, positioning the element
Including EC fans + regulator for external 010 V signal
2 Measurement valves
Provision must be made for bypass valves for bypassing the de-superheater in the event
of low outdoor temperatures
An example of a gas de-superheater for outdoor installation
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4 INDUSTRIAL REFRIGERATION SECTION REFRIGERATED UNITS

4.1 CHILLER AND FREEZER FIXTURES
The fixture manufacturer supplies the electronic expansion unit and regulators, displays, and
transducers with the units.
Each unit must be standalone, and hence there is one regulator per unit.
The refrigeration work package contractor must provide (see interface sheet 2597S2):
Connection to the alarm switch.
Electrical connections, including the communication bus.
Refrigerant connections.
Condensate connections (to connections pre-installed by structural work package).
Connection of the voltage-free contact from the store's BMS to an input of the
refrigeration installation's regulator system in the plant room (from the cable in the plant
room that is not part of the food refrigeration work package).
Technical equipment to be supplied by the refrigeration work package:
2 Identified, sealed stop valve with built-in safety valve for each product section (maximum
of 4 refrigerated units)
2 Service valves for decompression
Connecting up display cabinet piping
Mounting hardware
Industrial refrigeration connections
Technical equipment to be provided by the display cabinet supplier:
1 Special R-744 evaporator
1 Electronic R-744 expansion valve, Danfoss AKV 10
1 Temperature probe for expansion valve overheat
Regulator temperature probes, intake and outflow (min. 2 per unit)
1 Pressure transducer (1 for a maximum of 4 refrigerated units)
1 Temperature defrost probe (1 per unit)
1 Regulator displays, make and type to be indicated by the refrigeration contractor
Condensate drain with trap per connection
Electrical control boxes and protective boxes for the defrosting components, plus a fire
safety thermostat.
Machinery standards require the manufacturer to include an electrical cut-off system for
each unit.
NB:
The location and mounting of the probes is the sole responsibility of the manufacturer, who is
also in the best position to know where best to fit them.
If chiller fixtures are supplied with frame heaters, these shall not be connected up.
The supplier of the refrigerated units must provide:
An electrical terminal strip onto which ventilation, lighting, heater cables and defrost
elements are connected.
For electrical defrosting, the contactors for the defrost heating elements shall be as
per reference.
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Example of a dis. board fitted with terminal blocks on a refrigerated unit
4.2 LABORATORIES AND COLD ROOMS

For cold rooms, preparation cold rooms, and walk-in freezers, a CO2 detector shall be
installed in any refrigerated spaces where the gas concentration might be exceeded. See
Section 6.2.
In the event of an excessive gas level being detected, an audible and visual alarm shall
clearly indicate that it is forbidden to enter and the need to leave the room, in accordance
with current legislation.
Each cold room shall be fitted with one or more evaporators (see Section 3.3.3), each of
which shall be equipped as follows:
1 Special evaporator for R-744 with EC motor as per description
1 Evaporator mounting element
1 Temperature probe for expansion valve superheat
1 Pressure transducer (where necessary)
2 Sealed, identified stop valves
1 Temperature transducer (regulation and alarm)
1 Temperature transducer (defrosting) in the case of electric defrosting
1 Self-regulating drain heater unit (when ambient temperature <+2 C)
1 Analogue thermometer
1 Digital thermometer with position indicator
1 Dis. board for temperature transducers and thermometer
1 Drain trap per cold room
Each freezer room shall be fitted with one or more evaporators (see attached file), each of
which shall be equipped as follows:
1 Special evaporator for R-744 with EC motor as per description
1 Evaporator mounting element
1 Temperature probe for expansion valve superheat
1 Pressure transducer
2 Sealed, identified stop valves
1 Temperature transducer (regulation and alarm)
1 Temperature transducer (defrosting)
1 Self-regulating drain heater unit
drain insulation as per Section 5.2 (in freezer rooms)
1 Trapped person alarm as per Section 6.3 (in freezer rooms)
1 Analogue thermometer
1 Digital thermometer with position indicator
1 Dis. board for temperature transducers and thermometer
1 Magnetic door contact
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1
Drain trap per freezer room
Example of an evaporator in a cold room
Example of a temperature transducer and thermometer panel in cold rooms and freezers
Example of a satellite unit
Example of a magnetic door contact
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4.2.1 REFRIGERATION AND CONDENSATE DRAIN CONNECTIONS

Suction pipework insulated as per Section 5.2.
Liquid pipework insulated as per Section 5.2.
Condensate and defrost water drain in 50 mm PE-HP, including trap, for cold
rooms.
Condensate and defrost water drain in PE-HP (provided this meets local
requirements) or V4A stainless-steel or copper, 50 mm , with trace heating and
insulation on the pipework, including trap, for freezer rooms.
All PVC drains visible to customers must be installed in white.
As far as possible, all refrigeration circuits shall be run above the ceiling of cold rooms,
where the cold rooms are accessible from above, or otherwise (if not accessible) within the
cold rooms.
4.2.2 ELECTRICAL CONNECTIONS

On the front of each cold room shall be fitted an electrical display unit (satellite) comprising:
A regulator
A contactor for the fans
A circuit-breaker for the supply to the regulator and fans
A circuit-breaker for the defrosting heating elements
A defrost contactor (freezer rooms)
An alarm relay
A differential circuit-breaker (30 mA) for the trace heating (freezer rooms)
A connecting terminal block using modular terminals (with spare capacity).
The refrigeration work package contractor shall be responsible for connecting up the
decompression valve and supplying and connecting up the trapped person system
Freezer room floor heating (if necessary)
Freezer room cold air curtain (if necessary)
Freezer room door frame heating
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4.3 ICE MACHINE

The ice generator is located either in the room above the cold room, with the ice delivered in
wheeled bins to the fishmongery section, or above the fishmongery section itself.
Example of installation within the cold room and above it.
Example of an ice machine above the fishmongery section/ counter

The ice shall be directed via a guide channel into the ice bucket or bin.
Possible products and the quantity of ice required are indicated by Carrefour (countryspecific).
Optional, depending on country requirements:
Defrosting of the ice may be accomplished as per the following variants:
Natural melting depending on the ambient temperature (country-specific)
Hot water it is obligatory for this to be obtained from the refrigeration installation heat
recovery facility.
Ventilation with hot air over the fish counter, blowing hot air onto the ice. It is obligatory
that this hot air is heated using heat recovery
Separate area where the ice is melted using heating supplied from heat recovery.
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The minimum quantity of ice can be calculated using the diagram available below.
Quantity of ice required
Filling height 0.10m

Quantit de glace
(kg)

Frozen surface
Ice machine
Target value
Housing/body material
Ice machine material
Ice discharge pipe material
Stainless steel
Stainless steel
Plastic or
stainless steel
as per Carrefour
instructions
as per minimum
daily quantity
diagram or
Carrefour
instructions
Type of ice
Daily ice output
Actual value,
depending on
country
4.3.1 EQUIPMENT, SUPPLIES

-
1
1
1
Ice-maker as per project owners specifications, completely in stainless steel, fully

independent production unit (separate refrigeration installation just for the ice machine)
For ice machine installation within the cold room, appropriate measures must be taken to
avoid the ice-makers freezing up.
Electronic regulator, including external key-operated control panel, including 10 m of
cable, electrical power and control devices complete and ready to be connected, all
wired up with a manual switch
Thermostatic expansion valve c/w necessary temperature transducers
Solenoid valve including coil
Evaporation pressure regulator
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4
2
1
1
2
-
Schrader connections
Ice machine stop valves
Refrigeration unit with liquid receiver, including all necessary safety devices (pressure
switches)
Outdoor air condenser with fan speed control (condenser installed outside the building)
Condenser stop valves
connecting pipework (suction and liquid / hot gas and condensate pipes) insulated as
per Section 5.2.
Ice machine and refrigeration unit alarm contact to main refrigeration plant electrical
cabinet under this contract.
Filled salt bin, size as per project owners information (including 1 spare fill)
1
-
Salt-water metering pump, flow rate according to ice machine requirements

Salt-water metering pump control, together with an alarm signal from it for the main
refrigeration plant electrical cabinet under this contract.
Ice guide channel in stainless steel or transparent plastic, as per project owner data
Vibration-damping supports
Sturdy stainless steel wall brackets or ceiling hangers for ice machine.
In the event of the ice machines being installed on the roof of the cold room, a retaining
tray shall be installed under the machine, including water outlet/drain pipe
Truck presence detector kit (automatic stop) and bin-full stop
Stainless steel or plastic channel, insulated using e.g. 19 mm Armaflex outside the cold
room
e.g. using Aeroflex insulation (passing through the cold-room wall), including fitting and
sealing
Vibration-damping supports
Small hardware and mounting hardware
1
2
Insulated plastic wheeled truck for transporting the ice, with inspection grille and drain
cock, capacity for approx. 400 litres of ice.
Example of a truck for transporting ice

As a variant, the contact to enable ice production may be accomplished by a voltage-free
contact from the BMS system rather than from the machines own regulation.
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4.4 COOLING THE PLANT ROOM

Where the temperature in the plant room may exceed +30 C, provision must be made for
cooling, to be supplied by the refrigeration work package. Set-point temperature +30 C.
The plant room cooling shall operated via a split air-conditioning installation (inverter). The
outdoor unit shall be housed in a weather- and corrosion-resistant housing.
Electrically, the installation must be completely pre-wired. Powering shall be from the main
refrigeration electrical distribution board.
The installation must satisfy standards, prescriptions, and statutory stipulations (particularly
EN 378).
Outdoor unit technical data
Target value
Refrigerant
R410A,
if possible CO2 or
other natural liquid
min. 613 kW
+5 C
+46 C
+35 C
50 dB(A)
Refrigeration power
Condensation temperature
SPL @ 5 m
1
1
1
1
-
Actual value,
depending on
country
____ kW
+ ____ C
+ ____ C
+ ____ C
____ dB(A)
Air-cooled outdoor compressor/condenser unit

Possibility of external 010 V start command
Liquid shut-off valve in outdoor unit
Suction shut-off valve in outdoor unit
Winter regulation
Liquid pipework insulated as per Section 5.2
Suction pipework insulated as per Section 5.2
Anti-vibration elements
Small hardware and mounting hardware such as unions, weldable materials, clamps,
bolts, etc.
Refrigeration connections
Commissioning
Plant room temperature monitoring (hot and cold) by a regulator on the commercial
refrigeration installation, with connection to the remote monitoring system
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Indoor unit technical data
Refrigerant
Refrigeration power
SPL @ 5 m
1
-

Target value
R410A, if possible
CO2 or other
natural liquid
min. 613 kW
variable
+5 C
+27 C
50 dB(A)
Actual value,
depending on
country
____ kW
+ ____ C
+ ____ C
Indoor unit
Small hardware and mounting hardware such as unions, weldable materials, clamps,
bolts, etc.
Refrigeration connections
Commissioning and start-up
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5 R744 REFRIGERATION INSULATION AND PIPING

5.1 TECHNICAL SPECIFICATIONS AND GENERAL POINTS, PIPING
General
According to the French OESP [Pressurized Equipment Order] standard and the
EN 378: 2008 standard for Europe, or as per local legislation. In terms of the pressure
The headers shall be determined in accordance with the distance and the refrigeration
powers assigned to each circuit, taking the temperature schemes and programmed unit
shutdowns such as butchery work area, delivery airlock, etc. into account in assigning the
refrigeration units.
Piping, pipe runs
Refrigeration piping may be carried out in Cu-DHP copper (semi-annealed copper,
refrigeration quality, material no. EN CW024A), corrosion-resistant stainless steel (1.4301,
1.4306, 1.4307, 1.4401, 1.4404, 1.4435) or in K65. The indications given in EN 378 and
usual best professional practice must be observed and adhered to.
If other materials are employed, this must be clarified in advance with the project owner.
Copper refrigeration pipes must be brazed using special hard solder ensuring sufficient
pressure resistance and under gas protection (forming gas) or using a flow-rate indicator.
Proofs of adequate pressure strength and the wall thickness calculations for pipes and
unions as per the Pressurized Devices Order are to be presented on request. The maximum
permitted operating pressure for refrigerant pipes and valves etc. must, if necessary, be
determined according to best professional practice, or if necessary in accordance with valid
regulations. The combination of pressure and temperature shall always be determinant for
the maximum permitted operating pressure in valves etc. and piping. For hot gas, the
maximum temperature shall always be taken as at least +140 C. In the case of minimum
temperature, account must be taken of the fact that extremely low temperatures can arise
during refrigerant filling.
If the system is subject to other pressures, the protection and the possible pressure ranges
of the components shall be adapted.
In all cases, piping shall be degreased and delivered to the site with protective end caps.
Overhead runs of suction and liquid pipes (fitted on brackets) shall be carried out in stainless
steel or refrigeration-quality copper pipe, with sufficient fall to ensure natural oil return.
Pipework shall be fixed in such a way as to avoid friction, vibration, or other mechanical
stresses.
Flexible hoses shall only be used if they satisfy the mechanical requirements in terms of
safety. They must in particular withstand pressure peaks, vibration, permeability, and
explosive decompression.
In the case of vertical (and horizontal) suction and pressurized piping, special care shall be
taken to ensure faultless transport of the oil under all operating conditions that arise.
Risers shall allow efficient oil return, without excessive pressure loss, with trap and backflow
preventer.
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All refrigeration pipes are to be fitted to the concrete floor slab. Fixing hardware such as
stirrups, pipe collars, etc. shall be supplied and fitted by the refrigeration engineer. All
refrigeration piping is to be fitted in such a way as to be free of oscillations and structureborne noise (insulation level 98%).
All piping is to be fitted with a sufficient number of flow direction arrows. The arrows must
indicate the type of liquid and the physical state (in the case of refrigerant pipes). See
Section 12.5
Calculation and operating points:
In direct expansion installations, the pressure loss in the suction pipe, measured between the
evaporator output of the most distant refrigerated unit and the compressor suction connector
must not exceed the values below:
1.5 bar and 2 K
Freezer installation: 0.9 bar and 2 K
In the case of execution using buried pipework, the contractor shall be responsible for the
plastic sleeves, soldering/brazing/welding points shall be grouped together in the inspection
chambers; in cases where there are no inspection points, the locating plans and the
application of marker points on the tiling (to look into on site during the works) must allow
reliable, fast, easy location for repair work in the event of leaks.
All pipework that will be subsequently inaccessible shall have been pressure and vacuum
tested. The contractor will be required to provide certification of its sealing.
Upward-flow areas (see industrial refrigeration section of fitting instructions document):
In the case of short areas of upwards flow on suction pipes, elbows and counter-elbows shall
be installed. In the case of longer areas of upwards flow, double risers shall be fitted.
In the case of short areas of upwards flow on hot gas pipes, elbows and counter-elbows shall
be installed. In the case of long areas of upwards flow on hot gas pipes, elbows and counterelbows shall be installed approx. every 46 m.
In the case of long areas of upwards flow on gas cooler return pipes or liquid pipes,
allowance shall be made for hammer because of the height difference. If the refrigeration
installation is located lower than the refrigerated units, the risk of flashgas shall be taken into
account.
All soldered/welded/brazed joints concealed by insulation must be marked using adhesive
tape.
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Outgoing feeds (see industrial refrigeration part of fitting instructions document):

It is obligatory that suction pipe outlets shall be mounted upwards. The outgoing feed must
be at least 45 with respect to the main pipe (oil).
Outgoing liquid feeds should be introduced using a tee with the branch downwards (the main
pipe is fed in at the bottom). If this is not possible, outgoing feeds must at least be made in a
downwards direction.
Safety relief valves
All sections of lines must be fitted with section pressure discharge valves, if they can be
closed in operation and may contain a certain amount of liquid, or if the gas temperature may
be lower than the ambient temperature.
The segment pressure discharge valve opening pressures must as far as possible be set
2 bar higher than the opening pressures of the main safety valves.
Miscellaneous
As far as possible, all joints must be soldered, welded or brazed. Screw or compression
fittings shall only be used where soldering, welding or brazing are not possible, or where
removable joins are necessary for repairing or maintaining the installation. Flange fittings are
prohibited.
Provision shall be made exclusively for shut-off valves with protective shroud.
Under no circumstances must installations containing R744 refrigerant include elastomer
hoses or any other form of piping in plastic.
The chiller and freezer refrigeration has been determined for a compressor operating rate as
per Section 3.4.1 and as per the terms of reference for the country.
WARNING
All soldering, brazing or welding operations are FORBIDDEN in the vicinity of cold rooms
with open doors and/or unwrapped produce. In the event of contamination of fresh produce
(particularly meat) by heavy metals, this work package shall be held responsible for the loss
of merchandise and shall assume the financial and commercial consequences. In the event
of loss of merchandise, the project owner will submit to the food refrigeration work package
contractor an invoice, accompanied by the certificate from the Public Health authorities or the
removal note from a knackery, or other regulations in force under local legislation.
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The R744 and Polyolester oil together form an aggressive solution. Hence special attention
shall be paid to cleaning tubing: elimination of:
Oils and grease
Carbon and oxidation deposits, rust, etc.
Metal shavings, filings, burrs
Consequently, it is imperative that tubing is cut using a pipe cutter; using a hacksaw is
forbidden. Deburring, together with re-rounding of the tube if necessary, are obligatory in
order to avoid creating additional resistance losses. Surfaces to be brazed shall be cleaned
using steel wool or emery cloth; any other abrasives are prohibited.
Brazing
Brazing or silver-soldering must be carried out in a controlled inert gas atmosphere (Nitrogen
R, forming gas) to avoid any internal oxidation that might generate carbon deposits or slag.
Surface mounting
Surface-mounted pipework shall be in stainless or refrigeration-quality copper tubing.
Connections such as tees, elbows, etc. may be produced on site by tapping-in, bending, etc.
or by the use of standard fittings.
Embedded installation
Embedded installation shall be carried out using annealed tubing; cold-drawn tubing may be
used, but only on runs shorter than one length of pipe, with elbows produced by bending.
In embedded installation, unions and even butt-joining pipe lengths is forbidden.
The pipes shall be fitted in ducts or within insulating sleeves. This work package is
responsible for these sleeves.
The contractor shall take care that piping is not crushed, pinched, or deformed during the
embedding operations, whether this work is performed by themselves or by the structural
contractor.
In the event of damage, the contractor is liable for replacing the part concerned; the circuit
must then be pressurized in order to verify the sealing.
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5.2 TECHNICAL SPECIFICATIONS AND GENERAL POINTS, INSULATION

Insulation is achieved using close-cell synthetic rubber foam, impermeable to water vapour.
All pipework inside the building must be insulated. Provision shall be made for the minimum
insulation thicknesses as per the table below. Insulation thickness must be specially adapted
to each project and to specific local conditions, but it is obligatory that the prescribed
minimum thicknesses be adhered to. The insulation material must have Microban
antimicrobial protection and must meet the DIN EN 13501 European fire class certifications
(min. B/BL-s3, d0 for pipework and at least B/BL-s3, d0 for insulating panels) or local
stipulations.
Valves and other such devices in suction and liquid pipes must be insulated.
Insulating materials for refrigeration components: e.g. artificial synthetic rubber (e.g. EPDM)
Water permeability ()
Hot gas piping up to and with

heat recovery
Hot gas piping from heat recovery
Target
min. 5,000
min. 5,000
Gas cooler flow and return lines
min. 5,000
Liquid pipes
min. 10,000
Chiller suction piping w/o

flashgas
Chiller suction piping with
flashgas
Freezer suction piping
min. 10,000
Liquid receiver/separator
min. 10,000
Freezer room drain
min. 10,000
Ice machine channels
min. 10,000
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min. 10,000
min. 10,000
Version 1.1
Thermal
transmission
(W/m*K)
for 0 C
Target
Actual
min.
0.032
min.
0.032
min.
0.032
min.
0.033
min.
0.033
min.
0.033
min.
0.033
min.
0.033
min.
0.033
min.
0.033
Minimum insulation
thickness
Target
min.
25 mm
min.
20 mm
min.
20 mm
min.
20 mm
min.
20 mm
min.
20 mm
min.
32 mm
min.
32 mm
min.
20 mm
min.
20 mm
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Insulating materials for DHW components: e.g. PIR-Alu polyisocyanate duromer insulating
materials
Tank insulation using soft foam and quick-fit technique.
Water permeability
()
Target
Actual
Heat recovery, domestic hot

water (tank)
DHW heat recovery, water
side
Thermal
transmission
(W/m*K) for 0 C
Target
Actual
min.
0.035
min.
0.035
Minimum insulation
thickness
Target
min.
100 mm
30 mm
Actual
Insulating materials for heating components: e.g. PIR-Alu polyisocyanate duromer insulating
material
Tank insulation using soft foam and quick-fit technique.
Water permeability
()
Target
Heat recovery, heating hot
water (tank)
DHW heat recovery, water
side
Actual
Thermal
transmission
(W/m*K) for 0 C
Target
Actual
min.
0.035
min.
0.035
Minimum insulation
thickness
Target
min.
100 mm
30 mm
Actual
Halogen-free insulation may be used as long as it meets the prescribed values.

These tables give the minimum values to be complied with when installing, on pain of
rejection at acceptance, with an obligation to replace the insulation.
Piping to be insulated shall first be cleaned and if necessary degreased; the latter is
obligatory in the case of bonded fitting. The surfaces must be protected against corrosion.
All straight sections of piping shall be insulated before being fitted to their supports.
The internal diameter of the insulation tube shall be equal to or barely larger than the
external diameter of the pipe being insulated.
Collars and supports shall be fitted before the piping is run.
After the installation has been sealing tested, the insulation shall be fitted at the position of
welded/brazed/soldered joints, unions, and valves and their accessories, using split sleeves
or appropriately-cut pieces of insulation, in such a way as to be an exact fit around the parts
to be insulated.
The adhesive used shall be that recommended by the insulation manufacturer, and shall be
applied transversely and longitudinally so as to maintain the continuity of the insulation.
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Example of insulation on a refrigeration pipe
Example of insulation on a domestic hot water pipe
Example of insulation on a heating pipe

All suction and liquid pipes must be fitted with decoupled and thermally-insulated pipe
clamps in such a way as to avoid the formation of condensation or ice.
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Insulating materials for clamps/shells: e.g. PUR/PIR (elastomer) body (e.g. EPDM)
Water permeability
()
Liquid pipes
Chiller suction piping
w/o flashgas
Chiller suction piping
with flashgas
Freezer suction piping
Target
min.
7,000
min.
7,000
min.
7,000
min.
7,000
Actual
Thermal
transmission
(W/m*K) for 0 C
Target
Actual
min.
0.033
min.
0.033
min.
0.033
min.
0.033
Minimum insulation
thickness
Target
min.
20 mm
min.
20 mm
min.
20 mm
min.
32 mm
Actual
Hot gas, gas cooler flow/return, and heating and DHW piping are to be installed with
traditional pipe clamps fitted with noise-reducing material. After installation, these shall be
insulated using insulation as per Section 5.2.
Clamps with shells shall be fitted externally with a layer of aluminium which contributes to
stability as a vapour block for PUR/PIR sections. Tube fixing shall be provided by means of a
rigid foam compartment.
Fitting of PVC half-shells will be rejected and the installer will have to replace them with
insulated supports at their own expense.
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It is obligatory for adjoining sleeves to be bonded together. The collars used shall be of
standard type, with no resilient material.
Valves and accessories to which access is required for verifying, maintenance, or other
reasons, shall be fitted with removable insulating shrouds with quick-release catches.
Operating hand-wheels and handles must remain accessible.
Other refrigeration valves shall be insulated using a product identical to that used for
insulating the pipe.
Exterior coverings
All insulation, piping and accessories, shall be protected by PVC cladding (UV- and volatile
compound resistant). This cladding must be guaranteed.
In all cases, sheet aluminium-type cladding must include 8 mm holes every 50 cm, to drain
off water ingress and/or condensation. Not necessary for suction pipes.
All plaster cladding is strictly PROHIBITED.
Prior to using any other insulation or cladding not described but equivalent or more suitable
for certain uses, this must be proposed to the project owner or their consulting engineers in
order to obtain their approval in writing.
Example of fixings for refrigeration pipes, liquid part
Example of gas cooler pipe fixings before and after insulation
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Example of DHW pipe fixings before and after insulation
Example of heating pipe fixings before and after insulation
5.3 DESCRIPTION OF REFRIGERATION PIPING/FITTINGS AND INSULATION

The weight of the systems must be taken into account when calculating the supports. It must
also be communicated to the project manager for checking the building structure.
5.3.1 SUCTION AND DISCHARGE LINE
Complete circuit comprising piping, insulation, fittings, and cutting to length up to and with
connection of the refrigerated positions, as per the technical specifications, commissioning
as per the Pressurized Devices Order and the EN 378: 2008 standard or according to current
local legislation. In terms of the pressure resistance of all the components, the contractor
shall bear full responsibility for respecting the law and the standards.
The price must include all minor hardware and tool for a complete circuit, ready to operate
correctly.
5.3.2 HP, MP RETURN AND LIQUID RETURN LINES

Complete circuit comprising piping, insulation, fittings, and cutting to length from the
refrigeration unit and with connection to the gas cooler or liquid separator respectively, as per
the technical specifications, commissioning as per the Pressurized Devices Order and the
EN 378: 2008 standard or according to local legislation in force. In terms of the pressure
Within the central technical unit and inside the building, hot gas and gas cooler return piping
must be insulated.
5.3.3 BOOSTER REFRIGERATION CONNECTIONS

All the suction, return, liquid flow and return headers shall be fabricated from stainless steel
or refrigeration-grade copper, with cross-sections large enough to minimize pressure loss.
Max. speed in suction header 2.5 m/s.
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6 SAFETY
6.1 PLANT ROOM CO2 DETECTION
A CO2 detector shall be installed in the plant room, 40 cm above the floor, and shall operate:
- the extract fan which must discharge the air outside the building
- the flashing emergency warning signs inside and outside the plant room, marked:
- CO2 alarm leave the room
- CO2 alarm do not enter room
A remote alarm shall be connected into the remote refrigeration monitoring system and as
per local legislation.
The electrical ventilation control shall be incorporated into the refrigeration control cabinet.
The plant room ventilation is run by:
a) The refrigerant gas alarm
b) Manually, using a switch located on the front panel of the refrigeration control cabinet
c) Manually, using a switch located outside the refrigeration plant room, adjacent to the
entrance door.
Proposed limit values to be monitored as per EN 378. See in relation to local legislation
Main alarm
Target
Actual
CO2 concentration in the air
Min. 1.9 % vol. (19,000 ppm)
______ %vol. (_______
ppm)
Emergency illuminated visual Automatic triggering
and audible warning signals
Plant room ventilation
Automatic triggering
Generating a technical alarm Priority 1
Alarm transmission
to the refrigeration contractor
automatically
Alarm reset
Example of gas detection sensor device with Do not enter room warning
6.1.1 EQUIPMENT DESCRIPTION

Complete detection with detectors and illuminated warning signs with wording as per
Section 6.1
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6.2 CO2 DETECTION FOR COLD ROOMS, FREEZER ROOMS, SALES AREA,
AND ADJOINING ROOMS
A CO2 detector shall be installed in each cold room, preparation cold room, and freezer room
at 40 cm above the floor and shall operate flashing illuminated emergency signs inside and
outside the spaces marked:
- CO2 alarm - / leave the room
- CO2 alarm - do not enter room
A remote alarm shall be connected into the remote refrigeration surveillance system and as
per local legislation.
Main alarm
Target
Actual
CO2 concentration in the air
Min. 1.9 % vol. (19,000 ppm) ______ %vol. (_______
ppm)
Emergency illuminated visual Automatic triggering
and audible warning signals
Room ventilation
Automatic triggering
Generating a technical alarm priority 1
Alarm transmission
to the refrigeration contractor
automatically
Alarm reset
Example of gas detection sensor device with Do not enter room warning

Complete detection with detectors and illuminated warning signs with wording as per
Section 6.2
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6.3 FREEZER ROOM TRAPPED PERSON ALARM

A trapped person alarm shall be installed in every freezer room.
As per local legislation
When the alarm is set off, a signal parallel to the siren is sent directly to the remote
management system. The trapped person alarm can only be stopped from inside the freezer
room. Out of opening hours, the trapped person alarm is signalled directly via the remote
management system and a voltage-free contact that is relayed to the project owners own
security company (if there is one).
If operated, the trapped person alarm shuts down the refrigeration and ventilation in the
freezer room.
Example of a freezer room trapped person alarm

a) Unit with warning sounder outside the room and b) Button inside the room

One Trapped person alarm per freezer room as per Section 6.3 with:
1 Alarm device including safety button and shut-off switch
1 robust protective surround for safety button
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6.4 SECTION SAFETY AND CUT-OFF VALVES

Each pressure range must be protected by main discharge valves (MDV). The actual safety
valve operating pressures shall be set in such a way that they react before the section
discharge valves (SDV) (lower pressure setting). In normal operation, only the main
discharge valves (MDV) must react. In normal cases, the main discharge valves must be
sized and set with the following set-point pressure settings:
Sales area
The section safety valves (SDV) are called upon to protect line sections in which an increase
in pressure may occur due to a blockage and a heat contribution. Depending on how they
are arranged, these SDVs are either active or inactive during normal operation. Inactive
SDVs become active only by blocking the refrigerated unit.
Equipment for refrigeration units with safety valves
CO2
compressors
CO2 supercooler
CO2
compressors
CO2 supercooler
Three-way valve
Stop valve
NEW: Equipment for refrigeration units without safety valves
CO2
compressors
CO2 supercooler
Safety valve
Manual overpressure valve
Electronic expansion valve
Refrigeration unit
Stop valve with integral discharge flap-valve
CAUTION!
Closure valves can be activated only by trained
authorised personnel After closure, the pressure
should immediately be reduced to under 6 bar.
Example of a connection to the refrigeration unit from below
In refrigeration units, it is possible to use shut-off valves instead of safety valves, but this
requires that the shut-off valves be sealed and labelled to indicate that the pressure in the
closed sector must be reduced below 6 bar.
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6.5 COMPRESSORS
Depending on flow rate, compressors shall be fitted with a pressure switch or/and a pressure
switch discharge device. A compressor pressure discharge device is usually set higher than
the maximum permitted pressure for the installation and should not be used for protecting the
installation or other components, unless it is set to the maximum permitted pressure. The
statutory base is based on EN 378-2: 2008 +A1: 2009. Table 3 summarizes the requirement
concerning pressure switches.
Terminology and definitions:
Designation as per EN 378
PSL
Pressure switch (falling pressure)
PSH
Pressure switch (rising pressure)
PZL
Pressure limiter (falling pressure)
PZH
Pressure limiter (rising pressure)
PZLL
Safety pressure limiter (falling pressure)
PZHH
Safety pressure limiter (rising pressure)
Previous names
Low pressure switch
High pressure switch
Safety low pressure switch
Safety high pressure switch
Safety low pressure switch
Safety high pressure switch
Arrangement of pressure switches per compressor:
Compressor swept volume V' < 90 m/h
Charge < 100 kg
1 approved pressure
switch (PSH)
Charge 100 kg
(electrical in series): 1
approved pressure limiter
(PZH)
1 Approved safety
pressure limiter (PZHH)
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Compressor swept volume V' < 90 m/h
Either variant 1 or variant 2

Variant 2: 1 pressure
Variant 1: pressure
discharge device (PS
discharge device with PS
compressor) (electrical in
depending on installation
series): 1 approved
1 approved pressure
pressure limiter (PZH) 1
limiter (PZH)
safety pressure limiter
(PZHH)
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6.6 PLANT ROOM AIR EXTRACT VENTILATION

The refrigeration engineer shall be responsible for fitting emergency ventilation in the central
refrigeration plant room. The emergency ventilation shall not be used for cooling the machine
room.
Outline diagram of central refrigeration plant room ventilation installation:
Firestop
flapvalve
Corridors
Corridors
Firestop
flapvalve
From warehouse or
outside
Voltage-free switch
Light switch
Refrigeration plant room
*) Execute both speed when the air flow is substantial

**) Only when sucking from outdoors
Example of an air extract ventilation device, including the switch fitted outside
The mechanical ventilation is only started up as a safety facility in the event of malfunction.
The installation of this ventilation must comply with the relevant standards and directives.
The extract fan is started either when the refrigerant detector is triggered or by manual
operation of the switch. It discharges the extracted air directly to outside the refrigeration
plant room. Fan starts immediately refrigeration plant room motorized air extract and air
intake flaps open fire dampers already open.
The expelled air must be discharged outdoors.
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The incoming air shall be drawn from outdoors or via a fire damper.
Care shall be taken in positioning the air inlets and extracts to ensure that transverse
ventilation occurs across the plant room.
The refrigeration engineer shall scale the extract flow on the basis of the EN 378 standard,
which gives the air flow calculation as follows:
-3
Air flow = 14 10 (refrigerant content of largest installation)
3600 =
Example for a 200 kg load:

14 10-3 200 3600 = 1,723
rounded up to 1,800
In all cases, the minimum air flow must not be less than 1,000
If, when the size of the plant room is taken into account, the air renewal is less than 15 per
hour, the ventilation shall be sized on the basis of air renewal. This means that a greater air
flow will be necessary.
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6.7 EMERGENCY COOLING (OPTION)

Emergency cooling is quoted as an option only, if the project owner wishes it.
For the planning and operation of the emergency cooling, the following objectives shall be
determining:
The emergency cooling may only be used in an emergency. If it is observed to operate for
lengthy periods without obvious cause, the cost of the water consumed will be billed to the
refrigeration engineer. In the event of problems with the refrigeration installation that
necessitate emergency cooling, the faults must be eliminated within a reasonable time and
the emergency cooling stopped.
Provision for emergency cooling is only made where a plate heat exchanger has been
installed for heating hot water heat recovery.
The procedure for starting and stopping it must be described in great detail and prominently
displayed in the location. The various elements must be labelled accordingly.
Emergency cooling for refrigeration installations with heating hot water heat recovery:
The heating hot water heat exchanger is also used for the refrigeration installations
emergency cooling, e.g. in the event of a malfunction in the gas cooler.
The emergency cooling shall always be started up manually. To this end, provision shall be
made in the electrical control cabinet for a switch for starting the emergency cooling. Starting
the emergency cooling shuts down the heat recovery. When the emergency cooling is
started, the refrigeration circuit 3-way regulation valve allows the refrigerant to pass through
the heat exchanger. On the water side, the 2-way valve regulates and if this is not available,
a water valve (option) controlled by the temperature in the discharge pipe adjusts the output
temperature to the fixed value set to +40 C. Operation of the emergency cooling must be
notified and recorded as a Prio. 1 breakdown.
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Sizing of the emergency cooling heat exchanger using mains water:

Rate
Target
De-superheating power
100% at the emergency

cooling high pressure
100% of compressor
80 bar
+110 C
< +45 C
max. +15 C
max. +40 C
max. 40 kPa
max. 25 kPa
Flow rate
High pressure
Incoming refrigerant temperature
Outgoing refrigerant temperature
Incoming water temperature
Outgoing water temperature
Pressure drop, refrigeration side
Pressure drop, water side
Actual value,
depending on country
____ kW
____ bar
+ ____ C
+ ____ C
+ ____ C
+ ____ C
_____ kPa
_____ kPa
Heating water heat

recovery
Sanitary hot water

heat recovery or
CO2 composite
refrigeration,
+110C
CO2 gas air cooler,

+45C
Flowrate
regulator
valve
Optional
Heating water
heat recovery
Emergency
water cooler
To be connected only when

emergency water cooling is
required
Connection to
emergency
water cooler, 3 4 bar
Example of emergency cooling and connection
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6.8 EMERGENCY STOP AS PER EN 378

For stopping the refrigeration installation, provision must be made a remote stop outside the
plant room, adjacent to the door. The refrigeration engineer shall also make provision for a
switch for this purpose in an appropriate location within the plant room. The switches must
meet the emergency switch requirements as per EN ISO 13850 and EN 60204-1
a) Emergency stop switch inside plant room

b) Emergency stop switch outside, together with plant room air
extract ventilation switch
6.9 PLANT ROOM

The EN 378-3: 2008 standard shall form an integral part of the refrigeration plant stipulations.
Local requirements are to be complied with.
The plant room must have a sufficient number of outward-opening doors to ensure persons
within the space can be rescued in the event of an emergency. The doors must have
automatic closure devices and be able to be opened from inside (panic bars). Emergency
exits and escape routes, if not immediately recognizable as such, must be indicated,
preferably using pictograms.
The refrigeration engineer must fit the following indicator signs outside the plant room.
Example No smoking
Example No entry to
unauthorized persons
Condensed instructions for use as per EN 378
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7 HEAT RECOVERY
7.1 DEFINITION OF TERMS
HR
DHW
CW
HHW
HE
HW
= Heat recovery
= Domestic hot water
= Cold water
= Heating hot water
= Heat exchanger
= Hot water
7.2 DECISION BASIS FOR DHW HEAT RECOVERY

1.
Identify the consumers in detail and measure the additional pipe runs needed for
connection to the industrial refrigeration system.
Standard
Additional,
plus-value
Connection to heat
recovery circuit i.a.w.
schematic diagram
Daily water requirements

[litres/day]
Additional pipe lengths (m) = l1 + l2 + + ln

Principle for determining the length of additional pipe runs
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2.
Determine the consumers hot water requirements
Additional pipe lengths [m]
Hot water preparation with

heat recovery is sustainable
but not financially viable
Transition zone (detailed

analysis necessary)
Hot water preparation with heat

recovery is sustainable and
financially viable
Daily water requirements [litres/day]
Graph for determining the gain from DHW heat recovery of a given consumer
3.
On the basis of the graph, it is possible to determine whether or not the consumer
should be connected to the DHW heat recovery system.
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7.3 GENERAL
Heat recovery for DHW shall always have a higher priority than for heating hot water.
Heating hot water recovery is described in a separate document Best Practice for heating
hot water recovery.
Special country or local stipulations shall be taken into account.
The refrigeration engineer remains responsible for installing, controlling, and regulating the
recovery system, as well as for its faultless operation. If the set values are wrong or
inappropriate handling of the hot water recovery system is noted, all related expenses
together with the cost of the energy lost will be billed to the refrigeration engineer.
Flow rate calculation:
Example of a flow rate calculation for a plate heat exchanger with a de-superheating power
of 50 kW:
Sizing circulating pumps:

Rate
Primary liquid
Type of construction
Materials
Minimum max. operating
pressure (OP)
Minimum max. operating
temperature (OT)
Flow rate
Head
Electrical connection
Coefficient of performance
(COP)
Target value
Actual value, depending

on country
Drinking water
Inline pump
Grey cast-iron for the intermediate circuit and stainless steel
for the load circuit
10 bar
____ bar
+110 C
+ ____ C
as per separate formula

as per system pressure loss
calculation
1/230V
< 3.5%
____ m/h
____ m WATER
____ V
____ %
Electrical power
Gas cooler power
Local specifications shall take priority over the above information.
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7.4 DOMESTIC HOT WATER

Domestic hot water recovery shall be produced by a heat exchanger, including the
intermediate circuit. Account shall be taken of the fact that the hot water must be softened in
order to avoid scaling in the boiler. The de-superheating capacity shall be determined by the
water consumption.
CO2 compressors,
+110C
Sanitary hot water

recovery
Heat recovery
fault
Heating water heat
recovery or CO2 gas
cooler, +45C
Monitoring
Commercial refrigeration
Sanitari
Sanitary hot water recovery
Safety and regulator sensor
Emergency stop regulator
Cold charge circuit connection
Recovery between circulation
Pressure monitor
Sanitary hot water boiler
Safety thermostat
Circulating pump
Safety valve
Cold water supply
Temperature regulator
Three-way regulator valve
NO magnetic valve
Hot water supply
Temperature sensor
Progressive valve
NC magnetic valve
Circulation
230 V protective anode
Ball valve
Regulator
Hot charge circuit connection
Fuses for electric heating

Thermal safety
Fehler! Textmarke nicht definiert.

The boiler capacity shall be sized on the basis of the water flow required.
The ideal conditions for the boiler below shall also be taken into account:
1. Maximum height, taking into account the height of the space available
2. Diameter (max. = 0.5 of the boilers height from the ground)
3. If necessary, couple a 2nd boiler in series.
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Sizing exchanger 1 (refrigerant):

Rate
Primary liquid
Secondary liquid
Materials
Maximum operating pressure

(OP) at least
Maximum operating
temperature (OT) at least
Superheat capacity
Target value

on country
Refrigerant R-744 CO2
Heating water
stainless steel
Tube bundle, coaxial, or
____
plate heat exchanger
120 bar
____ bar
+140 C
+ ____ C
as per separate formula;

____ kW
30% of gas cooler power
100% of compressor
80 bar
____ bar
+110 C
+ ____ C
Flow rate
High pressure
Incoming refrigerant
temperature
Outgoing refrigerant
temperature
Incoming water temperature
Outgoing water temperature
Pressure drop, refrigeration
side
Pressure drop, water side
Calculate, < +40 C
+ ____ C
+25 C
+58 C
max. 40 kPa
+ ____ C
+ ____ C
_____ kPa
max. 25 kPa
_____ kPa
Sizing boiler internal damper (intermediate circuit):

Rate
Target value
Primary liquid
Secondary liquid
Materials
Maximum operating pressure
(OP) at least
Maximum operating
temperature (OT) at least
Superheat capacity
Incoming heating water
temperature
Outgoing heating water
temperature
Domestic hot water boiler
incoming temperature
Domestic hot water boiler
output temperature
Pressure drop, heating water

on country
Heating water
Drinking water
Stainless steel
Tube bundle
____
10 bar
10 bar
+100 C
+100 C
Same as exchanger 1
Same as exchanger 1
+ ____ C
Same as exchanger 1
+ ____ C
+15 C
+ ____ C
+55 C
+ ____ C
max. 25 kPa
_____ kPa
7.5 HEATING HOT WATER

Heating hot water recovery is described in a separate document Best Practice for heating
hot water recovery.
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7.6 EQUIPMENT DESCRIPTION

7.6.1 DOMESTIC HOT WATER
7.6.1.1 DHW HEAT RECOVERY WITH HEAT EXCHANGER AND INTERMEDIATE

CIRCUIT
Sanitary hot water

recovery
Heat
recovery
fault
Heating water heat

recovery or CO2 gas
cooler, +45C
CO2 compressors,
+110C
Monitoring
Sanitary
Pressure monitor
Safety thermostat
Circulating pump
Safety valve
Cold water supply
NO magnetic valve
Hot water supply
Temperature sensor
Progressive valve
NC magnetic valve
Circulation
Ball valve
Regulator

Thermal safety

The refrigeration engineer must supply and install the following components:
The heat exchanger, including insulation, shall be fitted to the booster
Exchanger 1, insulated as per Section 5.2
Load circuit pump, make Grundfos (w/o speed regulation) or equivalent, insulated using
manufacturers insulating shell
3-way regulating valve, make Siemens VVG 41 (with SQX 62 actuator) or equivalent, insulated
using manufacturers insulating shell
Ballorex / STA adjusting valves in the load circuit as per outline diagram
Regulating / safety probes, including thermowells
Sufficient measuring fittings for the system
Load circuit connecting piping to hot water cylinder, insulated as per Section 5.2
Pressure monitoring for emergency changeover (automatic bypass)
Air bleed valves / drain cocks
6 bar safety valves for the load circuit
Expansion vessel for load circuit, including pressure gauge and filling connector
Refrigerant bypass valves for bypassing the exchange
Refrigerant bypass valves for emergency changeover (bypass)
> 2 no. normally open solenoid valves
> 1 no. normally closed solenoid valve
Load circuit water analysis after 1 year in operation
Load circuit water analysis after 2 year in operation
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Boiler equipment:
1 Boiler insulated using soft PU foam and PVC sheath, including cutting out holes ready
for the quick-fit connections (insulation as per Section 5.2), in gas-welded stainlesssteel, and full insulation. Certified as per the stipulations specific to the country.
1 Introducing and positioning the boiler (water connection by the sanitation work package)
1 Cold water connection, min 1", at bottom
1 Hot water connection, min. 1", at top
1 Circulation connection, min. 1", located in centre (if necessary)
1 Boiler internal coil, sized on the basis of the necessary capacity, located at the bottom,
as per outline diagram
1 6 bar safety valves (security valve) including discharge to drain
min. 4 probes, including thermowells (regulation)
1 Safety thermostat to shut down heat recovery in the event of overheating
min. 3 thermometers, including thermowells
1 230 V protective anode, if necessary
1 Additional electrical heating (sized according to the size of the boiler, to heat the water
within the boiler up to +60 C within 12 hr); the heater unit will be verified by the heating
installation, country-specific
1 Thermal discharge safety device, including discharge to drain
Service/inspection opening
The sanitary plumbing installer will provide the following elements:
Main cold- and hot-water supply connections
Hot water circulating pump connection, including pump (if necessary)
Delivery, fitting, regulating, and commissioning hot water circulating pump
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7.7 REGULATING DESCRIPTION

7.7.1 HEAT RECOVERY, DOMESTIC HOT WATER
Sanitary hot water

recovery
Heat
recovery
fault
Heating water heat

recovery or CO2 gas
cooler, +45C
CO2 compressors,
+110C
Monitoring
Sanitary
Pressure monitor
Safety thermostat
Circulating pump
Safety valve
Cold water supply
NO magnetic valve
Hot water supply
Temperature sensor
Progressive valve
NC magnetic valve
Circulation
Ball valve
Regulator

Thermal safety

Control / regulation:
The domestic hot water supply shall be heated using the heat from the refrigeration circuit
de-superheater via a booster refrigeration installation. Provision shall be made for heat
recovery to be installed on the refrigeration installation having the greatest amount of heat.
The high pressure for operating the recovery is not offset. The boiler probe (no. 2) starts the
recovery process. This probe controls the refrigeration circuit 3-way bypass valve and the
load circuit pump starts up. The exchanger output water temperature is adjusted to the
desired value using a 3-way regulating valve, and the boiler is heated. If the desired
exchanger output water temperature value is not reached, this is offset or reduced (time
delay) in such a way that there is always a minimum flow to the boiler and that the latter can
be heated to a lower temperature level. If the temperature in the boiler indicated by the probe
(no. 1) is already higher than the hot gas input temperature, the recovery process will be
stopped (time delay). If the desired temperature is reached at the probe (no. 4), the recovery
process is stopped.
All the set values and time delays must be freely adjustable. It shall be possible to visualize
and record the whole of the heat recovery process through the remote monitoring system.
Heater unit:
If the desired boiler temperature is not reached and if a defined target value is not achieved
at the probe (no. 1), the heater unit (heating) is started and the water is heated to the desired
temperature. It must be possible to adjust the start and stop temperatures for the heater and
heat recovery units independently of each other, and starting of the heater unit is to be
notified as a Prio. 2 breakdown message. The regulation, including the starting command, for
the heater unit is controlled by the refrigeration system.
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Safety:
The boiler must be protected against overheating on the one hand and over-pressure on the
other. In the event of too high a temperature in the boiler, the heat recovery must be stopped
via the probe (no. 1) or a safety thermostat and only started again when the water
temperature reaches the predefined value.
If excess pressure builds up in the boiler (e.g. because of a leak), the pressure monitoring
shall stop the heat recovery system and the hot gas shall be bypassed directly to the gas
cooler. The boiler must likewise be protected against over-pressure by a safety release
valve. Excess temperature and over-pressure are both to be notified to remote management
as Prio. 1 breakdowns.
Setting parameters:
The setting parameters are given as an indication only. They are to be optimized and
adapted specifically for the purpose.
Regulation setting parameters
Stage 1 input (probe no. 2)

Stage 1 stop (probe no. 4)
Stage 2 input (probe no. 2)
Stage 2 stop (probe no. 4)
Heating unit input (probe no. 1)
Heating unit stop (probe no. 1)
Safety stop
Safety input
Input circulation
Circulation stop
Monitoring intermediate circuit input
pressure
Monitoring intermediate circuit stop
pressure
Load starting temperature
minimum setting (valve set to minimum
flow)
Temperature difference for boiler
temperature
Time delay for starting temperature offset
Time delay for stopping recovery
because of low hot gas temperature
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Target value
+50 C
+52 C
+45 C
+45 C
+45 C
+50 C
+70 C
+65 C
DHW
DHW
5 bar
Actual value,
depending on
country
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
____ bar
4 bar
____ bar
+40 C
+ ____ C
5K
____ K
30 sec.
180 sec.
____ sec.
____ sec.
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8 REGULATION DESCRIPTION
The regulation of CO2 installations is inherently more sensitive with respect to variations in
refrigeration power requirements. Primarily because of the high pressures (small cushions
of gas) and the high volumetric heat capacity of CO2. It may be wise to adjust the setting
parameters to a little faster.
In practice, the objectives are generally achieved using the usual settings however, very
particular attention must be paid to the setting of the refrigeration points in order to avoid
liquid reaching the compressors.
Attention must be paid to the specific features of the different regulation system
manufacturers.
The regulation systems must have a read only function for the remote monitoring system
(no management function) with the help of all the parameters, and the Log evaluations shall
be able to be consulted remotely.
8.1 REFRIGERATION OUTPUT CO2 BOOSTER

8.1.1 NORMAL AUTOMATIC OPERATION
Regulation of the chiller and freezer central refrigeration units shall be achieved via an
electronic regulator with the ability to vary the number of compressor stages and fans in the
gas cooler by using extension modules.
The regulation system must have a consistent communication bus allowing all the adjusting
devices in the system to communicate with each other.
The following types are approved (inasmuch as the read only function and the process
diagram are possible):
- Carel, pRack series
- Danfoss, AK series
- Eckelmann, LDS series
- Wurm, Frigolink series
- Eliwell
All adjustment values must be visible via the remote monitoring system.
8.1.2 MANUAL OR DEGRADED OPERATION
Emergency manual compressor operation:
In the event of a breakdown or regulation problem, the compressor must be able to continue
running by means of manual high / low pressure switches. To achieve this, it must be
possible to operate the compressors by means of an on-site switch (or control panels) and to
switch them from automatic to manual mode. The switch position must be monitored.
Emergency manual use of the high pressure regulating valve:
In the event of a problem with the electronic high pressure regulating valve or with the high
pressure regulating system, the mechanical high pressure regulating valve, installed in
parallel, must be operated manually. When the refrigeration installation is commissioned, the
valve shall be set to a specific pressure (e.g. 80 bar) so that it is ready for use in emergency
operation. In the event of emergency operation, this operation must be monitored.
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Emergency manual use of the flashgas valve:

In the event of a problem with the electronic flashgas regulating valve or with the flashgas
regulating system, the mechanical flashgas regulating valve, installed in parallel, must be
operated manually. When the refrigeration installation is commissioned, the valve shall be
set to a specific pressure (e.g. 35 bar) so that it is ready for use in emergency operation. In
the event of emergency operation, this operation must be monitored.
Operation of the regulator in the event of breakdown/failure:
All regulators must have a backup mode that makes it possible to set an imposed fixed value
in the event of transducer failure.
Pressure P [bara]
8.1.3 REGULATION OF THE TRANSCRITICAL HIGH PRESSURE

In the transcritical zone, the temperature and pressure are not explicitly dependent on each
other. This is why it is necessary to have an additional high pressure valve that adjusts the
high pressure in accordance with the gas cooler output temperature. In the subcritical zone,
the high pressure is adjusted so that there is always subcooling of a few Kelvins. The graph
below shows the theoretical high pressure values with respect to the gas cooler output
temperature, as achieved by certain makes of regulation devices.
High pressure
setpoint
Critical point
[+31C / 74 bara]
Two-phase region
Enthalpy [kJ/Kg]
Diagram of high pressure with respect to gas cooler output temperature
Towards the high and low ends, the theoretical values are limited by a number of threshold
values: the minimum high pressure and the condensation pressure depend on the
compressor use limit and the maximum high pressure as a function of the application point
with a maximum outdoor temperature or as a function of the sizing of the installation. This
last point includes the compressor use limit, as well as the maximum pressures and
temperatures for the installation with respect to high pressures.
When setting the high and medium pressures, it is important to keep them as stable as
possible.
Instabilities may lead to the following:
Pressure peaks and triggering of the safety valves or pressure switches
The flashgas bypass stays closed too long: insufficient motor cooling and tripping of
the motor protection contactor and high suction gas temperatures
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8.1.4 GAS COOLER REGULATION

The gas cooler fan speeds shall be adjusted in accordance with the refrigerant gas output
temperature. The refrigerant gas output temperature must be 2 K higher than the outdoor
temperature. If the refrigerant gas output temperature exceeds this limit, the fan speed is
increased. At refrigerant gas output temperatures above +20 C, the fans run at maximum
speed. A minimum speed is often laid down. In this way, more stable system operation is
obtained. This increased speed is not a problem as long as the refrigerant gas output
temperature is above +5 C. The refrigerant gas output temperature must never fall below
+5 C; to achieve this, the speed offset must be disabled in the event of low outdoor
temperatures. The graph below shows gas cooler output temperature with respect to outdoor
temperature.
Fan speed [%]

With a gas cooler outlet
temperature +20C fans rotate at
100%
The gas cooler outlet temperature must

always be +5C. Below an outlet
temperature of +5C there is no
minimum setpoint for the speed of the
fans.
The gas cooler outlet temperature is
controlled by fan speed to be 2 K above
the outside temperature A minimum
speed may be predefined for stable
operation.
Gas cooler outlet temperature [C]
Example of gas cooler fan regulation

Atomizing:
The atomizer is controlled in accordance with the outdoor temperature and the gas cooler
output temperature (adjustable value). The fans and atomizer are controlled in accordance
with the power demand.
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8.2 REFRIGERATION UNITS

8.2.1 REGULATION OF CHILLER AND FREEZER REFRIGERATION UNITS
For maintenance of the unit:
Unit is shut down from the remote monitoring system and the corresponding alarm
bypassed
Faults and alarms are dealt with by addressing the regulators via the remote
monitoring system
Alarm thresholds:
Low threshold, to avoid the products freezing
High threshold, to avoid exceeding the food standards, in accordance with legislation
in force.
Unit by unit defrosting. Defrosting managed by time and/or by the end defrost probe
(maximum number of defrosts as per Section 3.3).
Confirmation of return to normal operation at end of defrosting via the interconnection bus.
Handling of defrost time too long fault. If defrost too long fault, then re-start until regulation
level is reached.
Supply, fit, and connect up the protective circuit-breakers for all units.
The supply, electrical and refrigeration connections of the various components for all units.
Injection adjustment:
The regulation of the superheating for these refrigeration units is more tricky than on ordinary
installations, as CO2 has greater enthalpy (heat capacity) and the volumes in the evaporators
are smaller. Particular attention must be paid in positioning the superheat temperature
probes and when commissioning the refrigeration units.
Chiller refrigerated fixture:
Temperature of the merchandise regulated by continuous or pulse-modulated
electronic expansion valve as per PID,
target value: merchandise temperature
Fans run constantly
No adjustment of superheating (it results from operation and is around 15 K),
minimum superheating limitation.
Cold room and freezer room:
Temperature of the merchandise regulated by electronic expansion valve in
thermostatic mode
target value: merchandise temperature
Ventilation runs only during operation
Target values: merchandise temperature and superheating
During operation: Temperature of the merchandise regulated by continuous or pulsemodulated electronic expansion valve as per PID, target value: superheating e.g.
10 K
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Provision must be made for freezer unit regulators with the following adjustable MOP values:
t0 reaches MOP1: electronic expansion valve fully closed, setting e.g. 20 C
t0 reaches MOP2: in addition, the refrigerated unit fans are stopped, setting e.g.
19 C
This function makes it possible to avoid constant opening of the safety valve because of the
heat input, which creates a pressure increase.
Also advisable is a type of control such that complete failure of the freezer multiplex safety
chain closes the electronic expansion valves on the freezer refrigeration units.
Remark:
Danfoss (AKV) pulse-modulated electronic expansion valves require special (more
powerful) solenoid coils for CO2. This is why it is vital to specify the refrigerant used
(CO2) when ordering.
When electronic expansion valves are being commissioned on refrigeration units, the
superheating must be set to a high enough value and then reduced.
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8.3 LIGHTING CONTROL

The lighting for all refrigerated fixtures is powered when the stores shelf stocking
lighting is turned on. When the night blind is opened using the zone switch, the
refrigerated unit lighting comes on.
The refrigerated unit lighting is turned off completely with the store lighting.
On:
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- When the shop is closed and the lighting turned off

Night-blind closure:
- During opening with 100% shop lighting

- Using (manual) switches with 50% shop lighting
Opening night-blind:
Power supply from Carrefour main

panel
Main 230V/50Hz distribution
External
switch for
blind
Lighting
Caution external voltage
Separate switch
for blind
Night-blind motor
(optional)
Off:
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8.3.1 NIGHT BLIND CONTROL:

Only for display cabinets with electric night blinds. See separate Night blind option
documentation
8.3.2 NIGHT OFFSET:
The night-time increase in evaporation temperature can be obviated if an offset is
established for the store heat capacity and the effective evaporation temperature necessary
at the multiplex.
On:
Off:
the night offset signal is activated when the lighting is turned off in the chiller and
freezer units.
If the lighting is turned on on the chiller and freezer units, the night set-point offset
must be disabled.
8.3.3 DEFROSTING REGULATION:

Refrigerated fixtures shall be defrosted as a first priority by means of the ambient air. The
number of defrost operations and the defrost time must be kept to a strict minimum.
Refrigeration units shall be defrosted using ambient air or electrically.
Freezer refrigeration units shall be defrosted electrically.
Provision to be made to stop the outer air curtain from the regulator when the night blind is
closed and in defrost mode for fixtures fitted with a double curtain, in accordance with
manufacturers recommendations.
Defrosting times shall be programmed:
spread at regular intervals throughout the day, for all defrost types (electric and fanassisted)
separately distributed throughout the day in order to minimize electrical consumption
peaks for all electric defrosts (this distribution shall take account of fixture defrosting)
In accordance with cold room activity, outside the times when the doors are assumed
to be opened often and/or for a long time. For example, meat carcass cold rooms
shall be defrosted outside the 46 am time slot.
A single sales display unit (adjoining units with no transparent separators) shall be defrosted
all at the same time, even if the unit is supplied by 2 (or more) separate electric expansion
valves.
8.3.4 EVAPORATION PRESSURE REGULATION
Thanks to the good heat transfer characteristics and the LOW suction pipe pressure losses,
the theoretical suction pressure value can be 12 K higher than for ordinary installations.
Suction pressures of 9 C or 35 C and lower on the compressors are common.
Evaporation temperatures must be adapted to the refrigeration installation in accordance with
the enthalpy of the store and the effective evaporation temperature required.
8.3.5 DEW-POINT REGULATION
Freezer fixture glazing and frame heating regulation must be carried out in accordance with
the enthalpy of the store. To do this, the temperature and humidity are measured at a defined
position in the store, which together determine a dew-point. The heaters are tact/adjusted in
accordance with the enthalpy.
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8.3.6 CHILLER AND FREEZER ROOM DOOR CONTACTS

Cold room and freezer room doors shall be monitored using a door contact supplied and
installed by the refrigeration engineer. If a door remains open for a given length of time (set
to e.g. 60 min), a Priority 2 alarm shall be generated. The door open position must be
signalled through the remote monitoring system. When the door contacts are fitted, account
must be taken of the door frame heating and other installations. Supplied under Refrigeration
work package
8.3.7 FREEZER ROOM AIR CURTAIN
If freezer room doors are open, there is a rapid exchange of air because of the temperature
difference. To reduce this problem, an airlock cold room must be installed whenever
possible. If for constructional reasons this is not possible, it is absolutely essential to install
an air curtain on the outside above the freezer room door. A door contact sets off the air
curtain as soon as the freezer room is opened. It remains in operation as long as the door is
open. Supply and fit by the cold room and freezer room manufacturer.
8.3.8 FREEZER ROOM FAN STOPPING
If the evaporator continues to run with freezer room doors open, the hot, moist outside air is
driven into the freezer room because of the significant exchange of air. This leads to icing on
the walls, ceiling, and equipment, which can cause the installation to break down. Moreover,
it is not pleasant for the staff to work with the refrigeration running.
In order to counter this effect, a door contact shall be installed on the outside to shut down
the refrigeration for a given time (e.g. 600 seconds, adjustable). Supplied under Refrigeration
work package.
8.3.9 TEMPERATURE DISPLAY
In accordance with the EN ISO 23953 standard, temperature display is required on each
fixture in all countries, including outside Europe.
The refrigeration engineer shall include in their bid digital display thermometers fitted to the
front of the fixtures.
The sales fixture temperature display shall correspond to a probe located in the air extract,
except for freezer cabinets with doors, where the probe will be within the interior space.
The extract probe shall be positioned in the least-favourable location in the fixture.
Under no circumstances shall the probe be positioned too close to the refrigeration heat
exchanger, which would cause a false reading if it became iced up. Ideally, it should be
positioned in the extract grille at the front of the fixture.
The Food Refrigeration work package shall check that the fixture supplier has correctly
installed the display probes in the air extract.
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9 CENTRAL ELECTRICAL DISTRIBUTION CABINETS AND

REFRIGERATION UNITS
9.1 GENERAL AND EQUIPMENT
These are the currently applicable legal requirements.
These electrical distribution cabinets shall be located in the plant room, in the
proximity of the refrigeration units, and installed on the floor using a plinth provided
for that purpose.
Electrical distribution cabinets for the retail refrigeration installation, divided in a
carefully designed manner between the various systems: gas cooler, heat recovery,
distribution of satellite units etc.
All the chiller and freezer units shall be equipped with a frequency converter on at
least one compressor (two variable switches for those equipped with 6 No.
compressors).
The electrical distribution cabinets shall include the necessary electrical equipment
for protection, control and emergency operation applying to the use of frequency
converters.
The automatic controllers shall also include the components needed for operation
and control of the frequency converters.
Electrical connections to compressors supplied by frequency converter must utilise
armoured cables of a section dependent upon the type of compressor and the
maximum amperage set by the manufacturer.
Cabinets shall be equipped with at least 2 No. doors in order to limit the spatial
impact when they are opened.
Cabinets shall be of sheet steel, totally enclosed, with a base frame (not a concrete
base), divided into sections of 80 cm maximum width. Each section to have 1 No.
single-leaf, waterproof door with an espagnolette lock and, on the inside of the doors,
a pocket for diagrams and replacement fuses. The indicator lights may be mounted
inside the cabinet, so long as they are visible and readable from outside (window).
Fuses and other control facilities shall be labelled. The distribution of connection
terminals shall be agreed beforehand with the electrician.
In the supermarket context, these same cabinets shall contain the equipment for
control, monitoring and supply of refrigeration output (central unit, gas cooler etc.)
and the refrigeration unit outputs in relation to the unit they are supplied from (chiller
storage units/main chiller unit).
Though contained within the same enclosure, a general circuit breaker shall protect
the storage unit output distributor.
Electrical power for the whole installation shall be metered using an electricity meter
with a 0/10 V output or Modbus serving all the installations. This shall be COUNTIS
E40 type by SOCOMEC.
The electrical equipment as well as regulation of the refrigeration units are definitively
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specified by a diagram contained in the file.

This diagram constitutes the minimum for equipment and regulators to be contained
in the electrical cabinets.
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The electrical diagram shall be drawn with current off, the switches being in the "cooling"
position. All electrical diagrams shall be spontaneously submitted to the Owner before
installation.
The neutral earthing schemes shall be: TN neutral, TT or unearthed neutral.
The short-circuit currents (SCC) shall be as follows:
Supermarket smaller than than 2500 m: 15KA
Supermarket larger than 2500 m: 20 Ka.
Hypermarket: 25Ka
The electrical distribution panel shall include:
2 No. sockets,
lighting system,
thermostat-controlled ventilation system as shown in the drawing below:
Natural ventilation
Separate rack sections on

the electrical distribution
panel. Mechanical
ventilation
Example of electrical cabinet ventilation
Aluminium or steel sheet cabinets, totally enclosed, with a 10 cm plinth, splash-protected

according to current Standards. The inside of doors shall have a fitting to hold diagrams.
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A transparent, Plexiglass covering shall be fitted behind the doors and suitably divided. The
control and signage devices shall be integrated into the door and be covered on the inside
face with a safety contact device. The signage devices shall be located within the cabinet
insofar as the special windows in the cabinet door enable easy reading and visibility.
Safety and control devices as well as equipment shall be durably labelled. The layout of
connection terminals shall be arranged beforehand with the competent electricity company.
Each control cabinet shall be equipped with a main switch with latch. Waterproofing of the
cable ducts shall be checked by the service provider after completion.
The control cabinets shall be constructed and installed in such a way that the doors can be
freely opened and complying with the requirements of the country concerned with regard to
the minimum space between the control cabinet and components and with regard to the
minimum escape route that shall not be obstructed.
The control cabinet shall have clear marking and inscriptions compliant with the electrical
engineer's instructions. The main circuit breaker shall be labelled with the plant room number
and the name/description of the control cabinet containing the supply fuse.
A main switch shall be provided on the front of the control cabinet for each main feed (heavy
current).
The control devices, control safety devices, operating switches, heating, defrost heating,
ventilator fans, timers, signal lights, terminals etc. shall also be durably marked with clear text
and location numbers.
The compressors must be restarted in stages after an emergency stop or any other fault.
Moreover, the multiplex control shall be equipped to limit current peaks to the compressors,
with regard to local conditions.
All operating states (e.g. heat recovery operation etc.) shall be clearly, visibly indicated.
Fault messages shall be indicated by a flashing light until the fault is resolved. An indicator
lamp shall be installed to all signage displays. All the alarm displays shall have automatic
UPS and a reset button.
Regulations applying to electrical installations and control installations must be complied
with.
All major safety-related alarms shall be operated in a closed circuit with no electrical current
(phase monitoring).
Transmission of alarm signals shall be supported by an inverter. The refrigeration contractor
shall deliver install and test it and maintain it.
Frequency switches shall be mounted on a wall, outside the electrical control cabinets. The
requirement for sine filters for the frequency controllers shall be determined by the
refrigeration contractor.
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The switch being in the STOP position shall cut out the power and control circuit for the
energy-consuming device concerned. Unless required by local law, it is not necessary to
install isolation switches on the compressors once the electrical control cabinet is located
within visual range of the energy-consuming device concerned.
Temperature fault alarms shall be indicated on the corresponding group alarm systems.
There shall be three indicator lights on the electrical cabinet doors:
Power on: white/yellow,
Fault: red,
Unit operated manually: orange.
The front of the cabinet shall also include the emergency-stop, mushroom-head button, wired
in parallel with that situated at the plant room entrance.
1 No. AUTO/STOP/MANUAL manual switch shall be provided for:
each compressor, pump, gas cooler fans;
the plant room ventilation control, linked to the R744 monitoring system.
Operating hours metering shall be provided for:
each compressor,
all gas cooler fans,
emergency mains-water cooling (if available),
gas cooler atomising (if available).
A meter to register the number of activations per day shall be provided for:
each compressor,
The following indicators are mandatory:
per compressor
operating,
overload (thermal),
coil (thermal resistor),
high pressure,
oil pressure
hot gas.
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The following indicators are mandatory:

per system
low pressure,
high pressure,
R744 alarm level,
CO2 gas leak: plant room,
CO2 gas leak: adjoining premises,
CO2 gas leak: store,
CO2 gas leak: cold stores and freezer rooms,
emergency mains-water cooling (if available),
electronic control;
plant room
high-temperature
heat recovery
positive operation for sanitary hot water,
operation for heating system hot water (if available);
temperature alarm
all refrigeration points;
group alarm
temperature alarm on voltage-free switch.
The temperature and technical fault alarms shall be separate from the general alarms.
The number of times the compressors are switched on and off should be limited to a
maximum of six an hour.
No other energy-consuming device, of any type whatsoever, may be connected to the safety
installations is not permitted.
Switches that can be easily manipulated shall be installed to the various electrical circuits.
The electrical diagram shall show the system disconnected from the power source, it being
understood that the switching contacts shall be drawn in the "refrigeration" position. All
electrical diagrams shall be presented to the Project Owner or specialist planner before being
distributed, without this having to be specifically requested.
The electrical diagrams shall be the property of Carrefour. The files shall be presented to
Carrefour in, at least, .pdf and .dwg formats. If other formats are used, the corresponding
software shall be submitted with them.
9.1.1 CHILLER AND FREEZER REFRIGERATED UNIT POWER OUTPUTS
There shall be as many refrigerated unit outputs as there are regulators (see furnishing and
cold store equipment table).
These outputs shall be of the bipolar circuit breaker type with neutral cut-out.
The selection curve shall be a function of the length, the cable section and the current drawn.
NB. These cabinets only contain outputs, distribution and regulation shall be effected at the
units and cold stores. This is with the exception of refrigeration plant room and refrigeration
unit cooling.
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9.1.2 EQUIPMENT
Example of electrical control cabinet for refrigeration blocks and booster (with removable, hinged door leaves)
Panel comprising multiplex cabling for all components on the booster or chiller
installation. A main circuit breaker for supply to the whole installation.
Power control cabinet by booster or chiller unit operation:

Control and regulation of chiller and freezer installation according to suction
pressure;
Raising the evaporation temperature of the chiller and freezer installation
according to the store temperature and humidity as well as day/night operation;
All necessary control, monitoring, display and data input modules for the chiller
and freezer installation;
1 No. chiller installation, hot gas temperature sensor;
1 No. freezer installation, hot gas temperature sensor;
1 No. hot gas temperature sensor, post heat recovery for sanitary hot water;
1 No. hot gas temperature sensor, post heat recovery for heating system hot
water (if available);
1 No overheat temperature sensor to gas cooler outlet conduit, for flash-gas;
2 No. overheat temperature sensors for inlet and outlet flash-gas
2 No. temperature sensors to liquid inlet and outlet of liquid sub-cooler;
1 No. temperature sensor for monitoring chiller suction gas prior to integration of
freezers;
1 No. temperature sensor for monitoring chiller suction gas after integration of
freezers;
1 No. temperature sensor for monitoring chiller suction gas after integration of
flash-gas;
1 No. temperature sensor for monitoring suction gas for the chiller suction
collector;
1 No. temperature sensor for monitoring suction gas for the freezer suction
collector;
6 No. reserve temperature sensors;
all modules required for temperature data input;
regulation of refrigeration units and liquid sub-cooler;
Main module with control timer, including grouping and clear signage of operation and
fault messages.
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Full regulation of gas cooler:

High pressure regulation according to external temperature or temperature of the gas
cooler outlet for optimum production under subcritical and transcritical operation,
including control of HP valve regulation;
Offsetting the high pressure setpoint in heat recovery operation (if applicable);
Regulating the high pressure emergency schedule;
Direction, continuous control and monitoring of the gas cooler fans according to the gas
cooler outlet temperature and the external temperature;
1 No. external air temperature sensor;
Setting the minimum and maximum high-pressure and outlet temperature for the gas
cooler;
Regulating atomising as well as draining down if not used (if available);
Regulation of average temperature in relation to a configurable setpoint value, including
control of the bypass valve;
Control of high-pressure (HP) valve for average, minimum and maximum pressures;
Remote monitoring of all settings and measurement values as well as the setpoint value;
Pressure recorders for: chiller installation low pressure (LP), freezer installation LP,
average pressure (AP) and HP, including manual cut-off valves;
All necessary control, monitoring, display and data entry modules;
Temperature sensor at gas cooler outlet;
All modules required for operation of valve adjustments and status monitoring;
All logical links for safe functioning of the installation in compliance with regulations
(valve closing, compressor shut off etc.);
Emergency cut out for refrigeration installations inside and outside the plant room (press
button);
Security, control and regulation of gas cooling fans according to external temperature;
Security, distribution and control (interfaces) of heat recovery, sanitary hot water and
heating as well as logical links with the outlet temperature. Additional measurement and
display of inlet and outlet water temperatures;
Switch for setpoint value changeover for heating hot water recovery and signalling the
emergency functioning on the remote monitoring system (if available);
All interfaces for heat recovery for other systems;
Monitoring the refrigerant level;
Incorporating the day/night store lighting control.
All operating and fault indicator panels for:
Display for sanitary hot water recovery, Booster 1, Level 1;
Display for sanitary hot water recovery, supplementary electric heating / post-heating in
operation;
Various displays for heating system hot water recovery (if available);
Pre-alarm display/main alarm refrigerant level low;
Pre-alarm display/main alarm refrigerant level high;
Gas cooler fault display.
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High pressure regulation fault display.

Emergency-water operation display.
Display as Priority 1, for emergency switching of sanitary hot water and heating system
heat recovery, alarm interval one minute (adjustable).
Display of all pressures, temperatures, valve position signals and turning speeds, as well
as operating status and fault messages on the remote monitoring system.
Price for complete installation and cabling of power control cabinet.

Complete cabling between power control cabinet and booster.
Cablequick cable entry plates, or equivalent, for water-tightness of control cabinet.
Complete delivery of control cabinet, cooler and freezer refrigerator units.

Main cold power supply with separate outputs to booster installations power control
cabinets.
1 No. kWh meter according to measurement design, calibrated and sealed for the main
power supply, transformer ratio (calculation factor for meter reading) on a clearly visible,
engraved plate on the meter with M-Bus connection.
All necessary control, monitoring and data entry modules.
Distribution and securing of all refrigeration units

Pressure sensors for electronic expansion valves, with a 1/4 inch shut-off valve for the
refrigeration chiller units.
Distribution and securing of plant room cooling.
Distribution and securing of all glass door freezer cabinets, freezer rooms, ice machines
and fermentation chambers.
Necessary pressure sensors for electronic expansion valves, with a 1/4 inch shut-off
valve for refrigeration freezer units.
Regulation of heating for frames of all glass door freezer cabinets and for evaporation
pressure according to the dew point.
Indication of door position for each cold room and freezer room "door open" with Alarm
Priority 2 (delivery of door contacts: refrigeration work package). Three-minute timing
(adjustable).
Direction of refrigerant gas leak monitoring in plant room.

Voltage-free switch for R744 gas alarm in plant room (230V/13A).
Voltage-free switch for Priority 1 (technical) fault signalling.
Starting up air extract ventilation in and outside the plant room.
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Direction of R744 refrigerant gas leak monitoring in the adjacent premises;

Voltage-free R744 gas alarm switch in the adjacent premises (230V/13A);
Voltage-free switch for Priority 1 (technical) fault signalling for each of the adjoining plant
room;
Direction of R744 refrigerant gas monitoring on sales floor;

Voltage-free switch for R744 gas alarm on sales floor (230V/13A);
Voltage-free switch for Priority 1 (technical) fault signalling for each detector on sales
floor.
All operating and fault indicator panels required for:

Indicating R744 gas leak in the plant room;
Ventilation and air extraction in rooms with equipment in operation;
Indicating R744 gas leak on sales floor (for each gas detector);
Indication of R744 gas leak in adjoining premises (for each of the premises);
Signalling door position for each cold room and freezer room with Alarm Priority 2 for
"door open" (delivery of door contacts: refrigeration work package). Five-minute timing
(adjustable);
Day/night operation display;
2 No. voltage-free switches to indicate Priority 1 faults (1 x temperature 1 x technical);
Voltage-free switch for CO2 alarm for each cold room and freezer room (230V/13A);
Voltage-free switch for trapped person alarm for each freezer room (230V/13A);
Treatment of the system / Electrical diagram and commissioning;

Schematic drawing / Visualisation of store;
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Example: visualisation of store
Cold room and

freezer cabinets
Example: schematic drawing
Price for complete installation and cabling of refrigeration units cabinet;

Complete cabling between the cabinet and refrigeration units;
Attendance at progress meetings for clarification of interfacing;
Cablequick cable entry plates, or equivalent, for control cabinet water-tightness.
If this is not provided for on the low voltage master distribution board, overload
protection shall be provided. It shall be ensured that the protection and the conductor are
as close together as possible.
Interface with the building management system compliant with Section 11.4.
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10. REMOTE MONITORING

10.1 GENERAL
Delivery and commissioning an alarm system COMPRISING:
A central unit made up of a central multi-gate processor (with data backup), multiplex and
modem, mounted in the electrical cabinet, inclusive of operating software and
commissioning. For monitoring purposes, a check shall be made of all de-superheat or
condensation and evaporation temperatures for the cooler and freezer system. Both
pressures and merchandise temperatures shall be checked.
The alarm must be able to operate even during a power outage. Backup is provided by
means of an uninterruptible power supply (UPS), that shall be delivered by the refrigeration
contractor.
All necessary components for the proper functioning of the remote management system shall
be delivered by the refrigeration contractor.
Installation of software and integration of the parallel alarm system connected to the Project
Owner's control centre. Delivery and installation data to the specialist contractor. During the
guarantee period, a complete remote monitoring and data storage service shall be provided
by the refrigeration contractor (including linkage and connection costs).
The contractor shall, at all times and upon request by the Project Owner, be able to transmit
installation data. Moreover, the contractor shall supply the client and the specialist planner
with all things required for access to the remote management system in read-only format.
Control and alarm system tests:
Tests of temperature, technical and person alarms and of the linkage between these
and the building's Measurement Control and Adjustment (MCR) system, in
collaboration with other trades.
Testing lighting and ventilator fan cut-out power supply in the freezer compartments,
to be conducted with the electrician.
Testing heating, ventilation and sanitary facilities connections with the contractors
concerned.
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10.2 DIAGRAM OF REMOTE DATA MONITORING
Store No.1
Store No.2
Store No.3
Store No.4
Store No.
Firewall
Danfoss
Server
Eckelmann
Server
Wum
Server
Server
Contractor 3
Contractor 4
Firewall
Contractor 1
Contractor 2
Internet connection (e.g. TCP/IP)

Fixed interface connection (e.g. RS 232)
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11. TREATMENT OF ALARMS

11.1 TECHNICAL ALARMS
The refrigeration contractor shall ensure that all necessary alarms are generated by the
remote monitoring system in order to determine action to be taken or possible causes.
Various alarm situations are listed below, showing the priority of each. This list is not
exhaustive. It is essential that the priorities are observed, save in the event that the Project
Manager demands otherwise.
Component
Compressor
Gas cooler
Systems
Sanitary hot
water recovery
Chiller and
freezer
refrigeration
units
Alarm
High pressure
Low pressure
Oil level
Oil pressure
Motor
Frequency regulator compressor fault
Motor fans
Regulation fault
Sensor fault
Gas outlet temperature too high/low
Each gas detection alarm, individually
Pre-alarm: low refrigerant level
Main alarm: low refrigerant level
Alarm: refrigerant level too high
Regulation sensor fault
Display sensor fault
Defective pressure sensor
Suction gas temperature too high/low
Hot gas temperature too high/low
Power outage fault
Safety low-pressure
Safety high-pressure
Safety average pressure
HP regulating valve fault
Flash-gas regulating valve fault
Freezer installation, gas de-superheater
dysfunction
Emergency stop button activated
Emergency cooling in operation
Refrigeration pressure maintenance unit
fault
Operation of refrigeration unit and pressure
maintenance
UPS fault
Heat recovery in operation
Safety thermostat
Heat recovery pump fault
Too hot
Too cold
Defrost time exceeded
Sensor fault
Each gas detection alarm, individually
Trapped person alarm
Priority 1
X
X
X
X
X
Priority 2
Priority 3
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Negative logic physical contacts (power on in normal operation and cut off in the event of a
fault).
Malfunctions are indicated by means of an alarm contact as group faults:
Priority 1: requiring immediate action (group technical and temperature fault);
Priority 2: requiring action within three working days (group technical and temperature
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fault);
Priority 3: not requiring immediate action, status indicators, not communicated
externally.
Transmission of alarms is mandatory from the time that an item of equipment is made
available to the operator (cold rooms and glass-door display cabinets).
11.2 MANAGEMENT OF ALARMS

The two gateway fault switches are connected to an alarm box (see diagram) installed in the
proximity of the remote monitoring control centre.
The alarm box, supplied and installed under this work package, enables:
the gateway fault switches to be kept open for between two and 10 minutes
(signalling new faults);
automatic maintenance of fault status until cancelled by use of a push button on the
front of the box (store staff taking account of the fault).
signalling non-cancelled faults with two red indicator lights;
signalling the occurrence of a new fault with a buzzer.
NB.
The refrigeration contractor performing the installation shall check with the store's remote
monitoring company that alarms are being correctly transmitted. All equipment transferred for
operation shall be fitted with alarms. In default of this, the contractor for this work package
shall be held responsible for loss of merchandise in affected equipment.
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11.3 ACTION PROCEDURE RESPONSE TO ALARMS

The company providing standby service shall be jointly specified by the refrigeration
contractor and the Project Owner. The following procedure is specified:
Daytime, during store opening hours
Night-time, outside store opening

hours
Alarm/Fault via
remote
monitoring
Alarms/
Faults
Alarms/
Faults
Fault/ Message
from store
Alarm/Fault
via remote
monitoring
Refrigeration contractor
Action by the
remote
monitoring
service
Refrigeration contractor
Direct action on
site
Action by the
remote
monitoring
service
Clearing the fault
Direct action on
site
Access procedure
Action sheet
Clearing the fault
Information to technical manager
Action sheet
Information to technical manager
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11.4 EMS SYSTEM INTERFACES

The following interfaces shall be made available to Carrefour by the refrigeration contractor
by means of an RS-232 interface:
Automatic controller, virtual watchdog;
Chiller cabinets temperature;
Freezer cabinets temperature;
HP, LP overview: chiller compressors;
HP, LP overview: freezer compressors;
Refrigerant fluid level low;
Communications faults: units and cold/freezer rooms.
12. INSTALLATION ACCEPTANCE CONDITIONS

Each country's specific regulations shall be taken into account. All additional duties arising
from other Standards shall be taken into account during commissioning and preparing for
commissioning.
12.1 PRIOR INSPECTION

The contractor responsible for refrigeration shall submit all components or the entire
refrigeration installation to the following pre-commissioning inspections:
Pressure strength testing in compliance with Standard EN-378-2: 2008, Section 6.3.3;
Testing leak tightness in compliance with the Standard EN378-2: 2008, Section
6.3.4;;
Operational inspection of pressure-limiting control and safety devices;
Compliance inspection of the total installation in accordance with Standard EN378-2:
2008, Section 6.3.5;
Markings and documentation of components in accordance with Standard EN378-2:
2008, Section 6.4;
Training of staff responsible for use in compliance with Standard EN378-2: 2008,
Section 4.2;
Performing an external visual inspection of the total installation in compliance with
Standard EN378-2: 2008 (Annex G).
All inspection results shall be recorded.
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12.2 MOISTURE VACUUM EVACUATION LEAK-TIGHTNESS TEST*

*According to current local legislation
Both R744 and Polyol Ester fluid are very moisture sensitive.
If this precaution is not taken, hydrofluoric acid may be formed, considerably reducing the
service life of the installation (especially compressors)..
This operation shall be carried out to the entire installation.
If particular site conditions obtain, pipework shall be isolated segment by segment.
This work package shall apply the same method to each segment as to the entire installation.
The various segments shall be commissioned in such a way that introduction of air into the
circuit is prevented.
These vacuum evacuations shall be carried out once all soldering and connections have
been carried out to the part concerned.
The vacuum evacuation shall be carried out:
with a vacuum pump: in two stages, with sufficient capacity to obtain a final vacuum
of 0.03 mbar (3 Pa) suitable for R744 fluid containing Polyol Ester oil;
using R744-compatible hoses (lined with nylon or polyamid) of sufficient diameter to
limit loss of pressure.
A vacuum meter, located in the proximity of or on the installation, shall be used to monitor
pressure. Under no circumstances shall vacuum pressure be measured in the proximity of
the pump (measurement error due to pressure loss in the hoses).
The vacuum shall be maintained for 24 hours (pump stopped) in the first instance. Changes
to the vacuum shall be measured each hour. The test shall only be deemed successful if the
pressure rise does not exceed 0.3 mbar.
The refrigeration plant being delivered pressurised by dehydrated nitrogen, the plant isolation
valves shall remain closed during the first vacuum evacuation.
Once the vacuum has been maintained 24 hours without a pressure rise greater than 0.3
mbar, the vacuum shall be released with dehydrated nitrogen in order to absorb residual
moisture. The unit valves shall, thus, be open. The vacuum shall be released at least once
with the nitrogen and recreated once more.
The vacuum shall, thus, be created a second and final time over the whole installation (the
circuit plus the central refrigeration unit), to the same levels as the first time.
Following these two operations and after the installation has been in operation for 72 hours,
the residual moisture, which should not exceed 40 ppm, shall be measured by the contractor
for this work package. This measurement shall be clearly shown in the oil sample analysis
required.
After commissioning the refrigeration installation, and oil test is required and shall be the
subject of a written confirmation during technical acceptance of the installations.
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12.3 COMMISSIONING
12.3.1 GENERAL
The finished installations shall be brought into operation as soon as possible.
The contractor shall the proceed with the commissioning, safety and alarm operations
described in the "Acceptance conditions" Section.
The contractor shall produce written instructions for both routine monitoring and checks of
proper functioning.
Electrical installations insulation check.
Programming and adjusting the automatic controller regulators.
All commissioning of refrigeration equipment shall be carried out by the equipment
manufacturer.
The contractor shall supply the necessary calibrated measuring instruments to take accurate
readings and these instruments shall remain its property.
The schedule of checks of performance, temperature compliance, hygrometry etc. shall be
carried out and reported upon in the acceptance report according to the terms of the
"Acceptance conditions" Section.
The following points, set out between Section 12.3.2 and Section 12.3.9, are only a partial
extract of the relevant points. Checks and commissioning shall be carried out according to
Standard EN-378 and the pressurised equipment regulations, as well as in relation to local
conditions.
12.3.2 PRIOR TO COMMISSIONING
Check the safety valves degassing device.
Check the position of the safety valves for the various sectors.
Check the markings/labelling on the safety valves (regulating pressure, rated
decompression power, flow rates and diameter of opening).
Check positioning of gas detectors.
12.3.3 PREPARATION FOR COMMISSIONING
Check operation of alarms.
Check operation of gas detection.
Check and re-tighten all terminals, protective systems, relays etc.
Create vacuum.
Air extraction to plant room operational.
Verify leak tightness of plant room.
Remote monitoring operational.
12.3.4 COMMISSIONING
Regulation and testing of emergency circuits.
Regulation and checking all safety devices.
Checking temperatures, regulation of expansion valves.
Measurement of air and hydraulic flows as well as balancing them.
Measurement of pressure loss to the most vulnerable refrigerant circuits, under
maximum load.
Measurement of electrical current drawn.
Regulation of calibration and reference points of probes and other sensors.
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Regulation of thermo relays after checking their proper functioning.

Checking alarm and regulation safety sequences.
Behaviour of various materials.
Setting up cold rooms (temperature and hygrometry).
Measurement of speed of refrigeration for food items on the premises.
Defrosting tests.
Checking safety devices and automatic controllers.
Measurement of power consumed by compressors and motors using clamp-on
ammeter.
Certification of contractual temperatures by furnishing recorded temperature curve.
Commissioning refrigeration unit and pressure maintenance, with all necessary tests
(with emergency generator).
12.3.5 COMMISSIONING HEAT RECOVERY FOR SANITARY HOT WATER
Check that all connections to the boiler are present and sealed.
Check that the system has been correctly installed and that all safety devices are in
place (safety pressure valves, pressure switches, sensors etc.)
Check boiler filled.
Check intermediate circuit filled.
Calibration of pressure gauges and thermometers
Check that intermediate circuit expansion vessel correctly commissioned (initial
pressure etc.)
Safety sequence testing
Checking the siting of probes (provide all sensors with conductive paste, aluminium
strip and insulation).
Open all valves and frames.
Switch on the intermediate pump for the circuit.
Start up the pump.
Set regulation mode to p constant.
Check the flow volume and, in all events, reduce the flow if there is a major
discrepancy.
Regulate the settings according to Section 7.7.1.
Check the 0-10 V signal to see whether the pump is operating with the signal.
Test the fault contact.
Commission the three-way valve in the charging circuit.
Calibrate the valve.
Check regulation against a constant/linear percentage.
Test starting and stopping contacts.
Test boiler load.
Commission the heat recovery system.
Check safety devices once more.
Complete the commissioning report.
12.3.6 FULL TRAINING FOR STORE STAFF
Before commissioning, the contractor responsible for the refrigeration installation is required
to provide full instruction for sales staff as well as technical personnel. For this purpose, the
attached "Instruction form" document should be completed and signed off by the relevant
departments at the end of training. The document shall be submitted at the same time as the
service documents.
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12.3.7 DRAFTING THE COMMISSIONING REPORT

In compliance with Standard EN-378, the refrigeration contractor is required to document the
settings.
To this effect, a commissioning report shall be drafted with all settings
important to the safety of the installation. Commissioning protocols shall be submitted before
technical acceptance.
12.3.8 AFTER COMMISSIONING
Refrigerant fluid and oil
The refrigeration work package contractor is required to supply the fluids necessary for
operation of the refrigeration installations: refrigerant fluid, non-freezing oil etc.
The contractor shall provide an analysis of the oil before acceptance of the installations,
another analysis one year after commissioning and an analysis two years after
commissioning. The contractor must supply the Project Owner, before final acceptance of the
installations, with analyses of the oil of each installation.
These oil analyses must show the moisture levels, contamination levels of the circuit by
metals and the acid levels.
These analyses shall be carried out by a competent laboratory and shall be accompanied by
comments regarding the residual water content (max. 10 ppm at evaporation -30 C).
Thus, three analyses shall be furnished.
In the event that the installations are not accepted due to non-compliance, or that they are
accepted subject to reservations, the contractor shall provide additional products, after the
modifications that he has to make to the installations.
This work package is, thus, responsible for the additional supply of refrigerant fluid and oil for
the installations.
12.3.9 PROVISION OF FINAL DOCUMENTS
Analysis of intermediate circuit sanitary hot water heat recovery water after 1st year of
operation;
Analysis of intermediate circuit sanitary hot water heat recovery water after 2nd year of
operation;
Analysis of intermediate circuit heating system heat recovery water after 1st year of
operation;
Analysis of intermediate circuit heating system heat recovery water after 2nd year of
operation;
Training report;
Commissioning report;
Oil analysis prior to technical acceptance;
Oil analysis after 1st year of operation;
Oil analysis after 2nd year of operation;
Maintenance documents;
Refrigeration assembly specification.
12.3.10 CHECKING REMOTE TRANSMISSION OF ALARMS
The contractor for this work package shall furnish a document certifying that each alarm is
transmitted to the remote monitoring company named in the protocol to this document. Faults
shall not be checked using a summary of faults, but shall each be independently checked.
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12.3.11 MARKING
After official commissioning, technical acceptance or quality checking shall be undertaken
with the Project Owner or their consulting engineers. Two weeks in advance, the company
shall inform the Project Owner or their consulting engineers, in writing, of their availability for
the acceptance meeting (by sending the "Ready for acceptance" declaration form, and
instructions for installation of the technical refrigeration section).
This work package is responsible for completes labelling of its installations and, in particular:
Labelling service valves, compressors and all safety and emergency devices;
Installation of a general installation plan, in the plant room. This plan shall be
mounted on a board and protected with plastic film. It shall show the marking of
regulator devices for all cold rooms, display cabinets and other installed equipment.
This plan shall set up clear references between the terms used for automated
temperature recording of the refrigeration units and the physical units As shown on
the plan. E.g. if the self-service meat display unit is coded "48", the number "48" shall
be shown on the plan;
Labelling all refrigeration units, showing the number of defrostings, the regulatory
temperature for the unit, the unit's reference in the temperature recording system.
E.g., if the self-service meat display unit is coded "48" on the recording system, the
number "48" shall be marked on the unit's label.
12.4 DOCUMENTATION*
*According to current local legislation
12.4.1 AS BUILT FILE

The following As Built documents must be submitted to the Project Owner or their consulting
engineers at least two (2) weeks before acceptance and one (1) copy in paper form (in a
binder):
1.
Acceptance protocols
2
Display on installations:
a list of refrigerated units showing temperature and cooling power;
booster configuration showing main technical data;
heat exchanger information;
gas cooler information;
liquid cooler information;
de-superheater information;
compressor information;
- store layout drawing;
safety valves design calculation;
all design calculations other than those furnished by the thermal energy audit
(TEA).
3.
Functional description notice of the installation and declarations in compliance with

Standard EN378.
4.
Commissioning and refrigeration output test protocols, showing settings, pressure tests
and inspection for leakproofness of the installation (according to current legislation).
5.
Commissioning and test protocol for refrigeration points, showing settings (according to
current legislation).
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6.
Refrigeration and hydraulic diagram on a single plan: one copy, under glass, mounted
on the wall in the plant room;
7.
Electrical diagram including IT equipment for programming automated systems;
8.
Temperature recording chart;
9.
Maintenance notice showing periodic inspections and maintenance work to be carried

out each day, each week, etc.;
10.
Service notice for particular cases (Danfoss, Bitzer, Gntner, speed regulators etc.);
11.
Coordination plans;
12.
Cold room plans;
13.
List of spare parts for the main components showing the make, type and reference
number and a suppliers address list;
14.
Risk analysis, compliance and instructional protocols;
15.
Certificate from the authorised body, confirming collection for recycling of used
refrigerant fluids collected during the works.
Plan to be installed on site in the refrigeration plant room:

Refrigeration diagram printed on a display panel [Artopex].
On-site store layout plan printed on a display panel.
No acceptance shall take place without the above-mentioned documents.
Technical acceptance shall not take place unless the premises are absolutely clean.
No later than acceptance, operating staff shall be instructed in the appropriate use and
upkeep of the installations.
After validation, three copies of the completed works folder must be submitted on paper, and
one copy on computer media.
The following shall be added to the computer media:
A copy, in Excel format, of all regulator settings of the refrigeration installation.
The acceptance file for the refrigeration installations.
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12.4.2 MISCELLANEOUS DOCUMENTS

The refrigeration equipment work package contractor shall also furnish:
A plasticised refrigeration diagram for display in the plant room;
Compliance reports for installed equipment with regard to current Standards;
The maintenance and service record book, enabling reference to the equipment
service history (faults, actions taken etc.).
The operation and maintenance handbook, including emergency measures.
The contractual documentation.
12.5 MARKING DESIGN

12.5.1 GENERAL
The requirements of Standard EN 2405 or local instructions must be observed.
Numbering of floors:
RL
1F
MF
GF
1B
= Roof Level
= 1st floor
= Mezzanine floor
= Ground floor
= 1st basement level
Colour:
Colour
CR
S
H
Colour of
background/panel
Black RAL 9005
Green RAL 6024
Red RAL 3020
Sanitary installations
Heating installations
Colour of
inscription
White
White
White
Positioning and description of the installation:

The refrigeration installations shall be marked according to the installation numbering plan.
Pos. A = Booster
refrigeration chiller units
Pos. A = Booster
refrigeration freezer units
Pos. B = Booster or chiller installation
Pos. B = Booster
Pos. C = Booster or chiller installation
Pos. C = Booster
Pos. D = Booster or chiller installation
Pos. D = Booster
Example of positioning:
Pos. A1.1 Self-service, refrigerated, glass-door display cabinet: fruit and vegetables (Booster
A)
Pos. B1.1 Self-service freezer cabinet (Booster A)
Pos. C1.1 Self-service, refrigerated, glass door display cabinet: meat (Booster A)
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12.5.2 DESCRIPTION OF ELECTRICAL CONTROL CABINETS

In compliance with the electrical planning instructions.
12.5.3 DESCRIPTION OF REFRIGERATION INSTALLATION
12.5.3.1 Conduits
Yellow colour adhesive sign
Medium type (Green = liquid conduit, Blue = suction conduit, Red = hot gas
conduit)
Type of fluid and description of installation to be added
Dimensions according to the above instructions
Label
dimensions
a1 x b1
126 x 148
52 x 297
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b2
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37
74
148
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12.5.3.2 Installation/Refrigerant agent

Black colour plastic label
White colour, engraved inscription
- Type of mounting: rivets or screws
Booster
R744 / CO2
12.5.3.3 Compressor
Chiller refrigeration
compressor 1
Freezer refrigeration
compressor 3
12.5.3.4 All components requiring electrical connection

Type of mounting: with small chain or cable clip (not glued) fixed onto the electric
cable
Installation
number/description
Electrical distribution
panel description
compressor 1
HP Pressure switch
Description of peripheral
unit / description
Number on electrical
diagram
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12.5.3.5 Refrigeration chiller/freezer cabinets

Electrical distribution
panel description
Installation
number/description
booster
Electrical diagram No.
Self-service, glass-door
display cabinet: cheese
Description of
refrigeration cabinet
Position No.
12.5.3.6 Adhesive label for defrosts

White colour, self-adhesive, synthetic film label
Black colour inscription
Defrosting timetables
Time
00
01
02
03
04
05
06
07
08
09
10
11
Time
12
13
14
15
16
17
18
19
20
21
22
23
Pos. ______ Target temperature ______ Name ______ Date __/__/____ Signature _________________
12.5.4 SANITARY INSTALLATION DESCRIPTION

In compliance with the sanitary installation planning instructions.
12.5.5 HEATING DESCRIPTION
In compliance with the heating installation planning instructions.
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13. WARRANTY
Warranty:
comprehensive warranty of the entire installation for two years;

five years for hidden defects.
This two-year, on-site warranty is specific to and assignable with the store and only concerns
installations modified during the works.
The Project Owner shall retain responsibility for water and electricity consumed.
Overall upkeep, maintenance, fault repair, cleaning, optimising energy performance and
remote monitoring of the refrigeration installations shall be the subject of a separate proposal
according to the following documents:
Framework contract for provision of comprehensive maintenance services for CO2
refrigeration installations;
Comprehensive service contact for CO2 refrigeration installations;
Worksheets for maintenance tasks on CO2 installations
A bid must be attached to this food products refrigeration work package, based on the
above-mentioned documents.
14. SERVICES NOT INCLUDED IN THE WORK PACKAGE / SCOPE

OF SERVICES
14.1 SCOPE OF SERVICES
14.1.1 WORKS INCLUDED IN THE FOOD PRODUCTS REFRIGERATION WORK
PACKAGE
The contractor for this work package is responsible for provision of the following services and
installations, this list not being exhaustive.
1)
Detailed design of the installations together with:
Detailed design notes;
Complete AutoCAD execution drawings of all installations proposed;
Drawings of boxing out and plinths with indication of loads;
Operational diagrams;
Operational and regulatory analyses;
Electrical and regulatory diagrams;
Drawings and files in relation to fire safety;
Drainage plan;
List of installed equipment with technical documents and manufacturers' references;
Test and performance record book, including test certificates, covering all plant and
installed equipment;
Furnishing test reports and reports on fire resistance of materials used;
Maintenance notice of operational and safety devices;
Furnishing all these documents to the Owner and to the supervising body according
to site requirements.
2)
Manufacture, provision, transport to site, provisional storage and installation of
equipment;
3)
Setting up and removing all lifting plant, bracing equipment and scaffolding required for
handling.
4)
Labour required for various drain downs and fillings as the works progress.
5)
Tests and trials, commissioning and regulating the whole installation.
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6)
7)
8)
9)
10)
11)
12)
13)
Measurements provided with tests, such as temperatures, pressures, electrical current

drawn, measurement devices being provided by the contractor for this work package.
With a view to acceptance of the works, the contractor must proceed with programmes
of measurements carried out on the premises by means of recorders (temperature,
speed, flow, pressure etc.) on a sampling basis, according to the Project Owner's
instructions.
The contractor shall be responsible for provision, leasing and setting up calibrated
measurement apparatus and drafting reports in table form. These tables shall be
attached to the in-house service file for the installation.
Participation in BMS tests.
Labelling and marketing all items of equipment and services installations, as well as
the various regulation and isolating devices.
General schematic outline diagrams: multicoloured, non-modifiable, plasticised. These
schematic diagrams shall be installed by the contractor for this work package in each
plant room in the proximity of the electrical cabinet.
General cleaning upon completion of works, in addition to routine cleaning.
Services in connection with the conduct, supervision and maintenance of the
installations between the completion of works and their acceptance.
Training management and maintenance personnel (also see Section 14.7.2).
All documents shall be the property of Carrefour and must be sent to Carrefour in
electronic format.
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14.1.2 WORKS EXCLUDED FROM THE FOOD PRODUCTS REFRIGERATION WORK

PACKAGE
Works in connection with the Food Products Refrigeration work package that are not within
the remit of the contractor of this work package, but that concern it, shall be designed and
executed under its supervision.
The contractor shall furnish, in good time, to the trades concerned, all information, schematic
diagrams and plans necessary for the said works.
The contractor shall confirm and specify or modify, with the prior agreement of the Project
Manager, without, however, there being financial consequences for any work package
covered in the draft call for tenders.
14.2 STRUCTURAL WORK PACKAGE

PACKAGE
Masonry plinths, blocks and bases for equipment supplied and installed under this
work package;
Masonry ducts for vertical conduits.
Boxings out larger than 15 x 15 cm in the walls and concrete slab or in existing or
new masonry.
Stopping up ducts to floors and walls after feeding through pipework.
NB.
Works not asked for in good time and that are not shown on the boxing out drawings shall be
performed at the cost of the contractor of this work package.
14.2.2 WORKS REQUIRED BY THE FOOD PRODUCTS REFRIGERATION WORK
PACKAGE
Design and implementation of boxings out, floor openings, plinths and structures
necessary for this work package;
All holes, chases, cemented fixings, fixings necessary for the passage of pipework
and assembly of equipment.
Restoration of fire rating to walls and floor slabs.
14.3 WATER-TIGHTNESS ROOF COVERING WORK PACKAGE

PACKAGE
Sealing around protrusions to flat roof.
Water-tightness surveys of roof protrusions.
PACKAGE
Enclosures (covers or cladding).
PACKAGE
Supply of pipework supports to refrigeration display unit downpipes.
Supply of supports for horizontal pipework, both exposed and ducted.
Cladding vertical stacks/stanchions on refrigerated display units in lacquered steel
sheeting.
14.4 PARTITIONS PAINTING FALSE CEILINGS WORK PACKAGE
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PACKAGE
Anti-rust paint to all metal parts implemented;
Painted finish to pipework in plant rooms;
Cutting out and drilling to partitions and false ceilings for pipework penetrations;
Painted finish to pipework.
Visual identification of services installations.
14.5 PLUMBING SANITARY FACILITIES WORK PACKAGE

PACKAGE
Works for evacuation of evaporator condensates;
Tapping off, valve and water supply to rooftop tap.
PACKAGE
Condensate collectors up to connection points;
Positioning of collection points for compensate evacuation.
14.6 ELECTRICITY HIGH-VOLTAGE

PACKAGE
Power supply to upper floor refrigeration plant room;
Power supply to automatic control enclosure circuit;
Power supply for lighting refrigerated display units including remote control from the
refrigeration cabinet.
PACKAGE
Confirmation of requirements for power supply;
Connection of the entire installation from the upper floor refrigeration plant room;
Connection of lighting to refrigerated display units.
14.7 MISCELLANEOUS
As well as the works and installations set out in the Best Practice document and the
drawings, the overall lump sum price also includes, in a specific provision, costs in
connection with execution of works and supply of goods and services with regard to:
Bringing the refrigeration into operation before opening of the store.
Conduct, supervision and maintenance until acceptance and opening of the store.
Training operational staff and providing As Built file.
14.7.1 CONDUCT SUPERVISION MAINTENANCE UNTIL ACCEPTANCE
At completion of installation works of this work package, the contractor shall be required to
conduct, supervise and maintain the installations in good operational order.
Maintenance shall include all works and equipment according to the maintenance contract.
14.7.2 TRAINING OPERATIONAL STAFF AND PROVIDING AS BUILT FILE
This work package is responsible in particular for:
Training in operation of installations, to take place prior to acceptance.
Furnishing 4 No. copies of a maintenance manual including, in addition, contact
details of all suppliers, all plans and schematic diagrams as executed (see: Scope of
Services).
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14.7.3 REFRIGERANT FLUIDS

Implementation of refrigerants shall comply with the following regulations:
According to current legislation in the country concerned.
14.7.4 PRESSURISED EQUIPMENT
According to current legislation in the country concerned.
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industrial refrigeration part

industrial refrigeration part

2.4.1 COLD ROOMS ......................................................................................... 12

industrial refrigeration part

6.3 FREEZER ROOM TRAPPED PERSON ALARM ............................................ 75

industrial refrigeration part

8.3.4 EVAPORATION PRESSURE REGULATION ........................................... 98

industrial refrigeration part

12.3.7 DRAFTING THE COMMISSIONING REPORT ................................... 120

industrial refrigeration part

14.2.2 WORKS REQUIRED BY THE FOOD PRODUCTS REFRIGERATION

industrial refrigeration part

1.2 DOCUMENTS TO BE APPLIED

industrial refrigeration part

industrial refrigeration part

industrial refrigeration part

1.4 DEFINITION OF THE SERVICES TO BE PROVIDED

1.5 TECHNICAL DOCUMENTS

industrial refrigeration part

2.2 BASIC INDOOR CONDITIONS

2.3 PERFORMANCE OBLIGATION

industrial refrigeration part

2.4 THERMAL REQUIREMENTS

FRESH CAKES &

industrial refrigeration part

Refrigeration power in negative

100% Refrigeration power in

Refrigeration power in positive

2.4.2 REFRIGERATED SALES FIXTURES

industrial refrigeration part

Refrigeration power in negative

100% Refrigeration power in

Refrigeration power in positive

industrial refrigeration part

High pressure regulator

industrial refrigeration part

3.2 CENTRALIZED LOCATION

Example for indoor installation in the form of a complete refrigeration unit

Example of an outdoor installation in the form of a complete refrigeration unit

industrial refrigeration part

3.3 GENERAL AND TECHNICAL PRESCRIPTIONS

100% Refrigeration power in

Refrigeration power in negative

Necessary power to compressors at

Equivalent refrigeration power

Refrigeration power in positive

Fanout factor for chiller installation depending on country _________%

industrial refrigeration part

Example of anti-vibration elements (Mafund pads)

industrial refrigeration part

industrial refrigeration part

The level monitoring must include 3 alarm contacts as follows:

3.3.2 REFRIGERATED DISPLAY CABINETS

industrial refrigeration part

Example of protection for refrigerated units

Example of linear protection

industrial refrigeration part

Number of defrosts, depending on

Example of a refrigerated unit satellite dis. panel

Example of a satellite placed on the floor

industrial refrigeration part

Example of a water drain beneath the refrigerated unit