BevMax CO2 System Overview

CRANE CONFIDENTIAL
CO2 Refrigeration Overview Topics

Topics o Background
o Safety/Quality
o Product Requirements
o Key Differences
o Factory Process Equipment
o Field Support
o Questions

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CO2 Refrigeration Overview Background

o Coca-Cola has converted 100% of their company owned bottling operations to CO2
refrigeration effective January 1, 2016. This is a requirement for all ICE suppliers.

o This solution is currently exclusive to the Coca-Cola system.

o There is currently no expectation to remanufacture or upgrade the existing field

base to CO2

o Crane will continue to support existing base, field units with R134a systems as long
as allowed by regulation or law.

o The product model convention will be:

o DN5800-4C for the wide model
o DN3800-4C for the narrow model; the “C” denoting CO2

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CO2 Refrigeration Overview Safety/Quality
Product Safety:
— Components meet design pressure requirement
— High pressure cut off switch in place for additional
protection
— System tested at high pressure rating in production
— Software designed to prevent systems swapping
between R134a and CO2
Quality maintained and checked at several stages
— High Pressure test
— Pressure Decay Test
— Leak detection Test
— Final QC check (leak test after charging)
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CO2 Refrigeration Overview Product Requirements
Overall requirements
— System must fit in existing BevMax cabinet
— Meet Coca-Cola KORE Glass Front Vendor
requirements
— Meet DOE requirement
— Meet Energy Star Tier III requirement

Refrigeration requirements
— Compressor - Sanden SRABB 6401 (Coke
requirement)
— Other components designed/selected to match and
optimize the refrigeration system
— Overall system envelope - the same as existing
BevMax 5800/3800 - 4 refrigeration system, Cassette
concept

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CO2 Refrigeration Overview Key Differences

Key Differences Between CO2 and R134a

— Refrigeration System
— AC Distribution Box
— Wire Assemblies
— LED Assembly
— Additional labels on CO2 models for warning, caution
and identification

• CO2 decks are not backward compatible with R134a

decks and cannot be “swapped” in the field.

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CO2 Refrigeration Overview Key Differences

Key Differences Between CO2 and R134a

Physical Characteristics:
Attribute R134a System CO2 System
Total System Weight 60 lbs. 71 lbs.
Compressor Weight 25.2 lbs. 32.2 lbs.
Design Pressure (High Side) 335 Psig 1658 Psig
Design Pressure (Low Side) 162 Psig 995 Psig
Operating Pressure (High) 180 Psig 1350 Psig
Operating Pressure (Low) 32 Psig 400 Psig
Condenser/Gas Cooler Out 110°F 105°F
Temp
System Charge 10.2 oz. (289 grams) 13.5 oz. (383 grams)

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CO2 Refrigeration Overview Key Differences

Key Differences Between CO2 and R134a

Physical Characteristics:
Attribute R134a System CO2 System
Evaporator Temp 22°F 22°F
Pressure Switch No Yes
Pressure Switch Actuation N/A 1700 Psig
Start Capacitor Yes Yes
Run Capacitor No Yes
Full Load Amps 5.9A 5.5A
Rated Amps 10.2A 10.2A
Note: Temp & pressure will vary
depending on ambient conditions
and application.

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CO2 Refrigeration Overview Unique Safety Feature

Pressure Switch Operation

• As soon as a unit is turned on (in production), the software looks for the
pressure switch and it registers as a CO2 unit if detected.
• Once it registers as “switch present” it will not operate if the switch is not
present. This is the way to prevent from someone using a non-CO2 unit in
a CO2 cabinet.

• If the pressure in the system exceeds the upper limit (1700 psig), the
pressure switch will open and turn the system off.
• The system will remain off for minimum 2 minutes or until the pressure
gets below 1200 psig.
• If the system cuts off more than 3 times due to high pressure, the software
generate an error and turns the system off till someone clears the error
manually.

• Also, if the deck is being replaced and the cabinet is unplugged, the error
code will be erased, so when a new deck is installed the software would go
through the same routine.
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CO2 Refrigeration Overview Key Differences
Overall Refrigeration Deck

CO2 Refrigeration Deck R134a Refrigeration Deck

Front Iso View – CAD rendering

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CO2 Refrigeration Overview Key Differences
Overall Refrigeration Deck

CO2 Refrigeration Deck R134a Refrigeration Deck

Rear Iso View – CAD rendering

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CO2 Refrigeration Overview Key Differences
Compressor comparison

Sanden Embraco
SRABB 6401 in FFU 130HAX
CO2 system used in R134a
System

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CO2 Refrigeration Overview Key Differences

CO2 Gas Cooler and R134a Condenser

CO2 Gas Cooler R134a Condenser

5 Rows 11 High, 4 Rows, 11 High
8 Fins per Inch 6 Fins per inch
7 mm Dia Tubes 5/16 inch Dia Tubes

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CO2 Refrigeration Overview Key Differences
Evaporator Surfaces

CO2 Evaporator R134a Evaporator

5 Rows 11 High, 4 Rows 9 High
8 Fins per Inch 6 Fins per Inch
7 mm Dia Tubes 3/8 Inch Dia Tubes

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CO2 Refrigeration Overview Key Differences
Filter Drier
• High pressure rated filter drier compared to simple
filter drier in R134a

CO2 Filter Drier R134a Filter Drier

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CO2 Refrigeration Overview Key Differences
Comparison of Fan Motors

Gas Cooler/Condenser Fan Motor

• Shaded Pole motor in R134a system
• ECM Motor in CO2 system to minimize the
energy consumption and improve the efficiency

Evaporator Fan Motor

• Both systems utilizes ECM motors but different
manufacturer
• EC Plus motor in R134a system
• EBM in CO2 system

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CO2 Refrigeration Overview Key Differences

Tubing Differences
— Heat Exchange, Suction Liquid Line – Capillary
Tube
• Significantly longer Heat Exchanger and Suction
line compare to R134a line for optimum
performance
— Capillary tube
• 120 Inch x 0.031 ID for CO2
• 84 Inch x 0.051 ID for R134a
— Discharge Tube Assembly
• Different assembly and length
• High Pressure cut off switch in CO2

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CO2 Refrigeration Overview Key Differences
Other Key Differences
AC Distribution Box:
— Transformer
• Energy efficient transformer compared to R134a

— Additional relay for high pressure cut off switch

Wire Assembly:
— Due to differences in various electrical components
— Different connection types in some areas
— Color-coded to harmonize with Coke standards

LED Lights:
— Energy saving feature in CO2 LED lights
Condensate Pan:
— New part in CO2 to match Sanden compressor foot print
Refrigeration Deck Panel:
— New part to match Sanden compressor foot print

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CO2 Refrigeration Overview Key Differences
CO2 Wiring Diagram

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CO2 Refrigeration Overview Key Differences
CO2 Wiring Diagram

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CO2 Refrigeration Overview Process Equipment
Crane invested significantly in CO2 project development,
equipment, tools, fixtures and setting up the assembly line.

New Assembly Line for CO2

Refrigeration System
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CO2 Refrigeration Overview Process Equipment
Test Station
Galileo
Astra III S120
For High Pressure Testing, Pressure Decay (leak) and
Helium Leak Testing

Clam Shell to test system at 1750 psig

Inficon for Helium Test

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CO2 Refrigeration Overview Process Equipment
Charging Station and Leak Test

Galileo
Habilis III
Automatic Evacuating and Charging Equipment for
CO2

Inficon for CO2 leak detection

Every system tested for leak
before leaving the station

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CO2 Refrigeration Overview Field Support

• Installation Instructions – No customer facing change in set-up or

installation – supplement notifying use of CO2 included in
documents shipped with machines.

• Refrigeration removal and replacement instructions (no field

service/repair mandate)
• Field serviceability will not be allowed or limited to the removal and return of
complete decks. All failed units MUST be returned to Crane.
o Decks and units will be distinctly labeled for CO2

o Developing “DO NOT SERVICE – ENTIRE DECK MUST BE RETURNED TO

CRANE” label.
COKE BEVMAX 4
MODEL 5800-4C & 3800-4C
Refrigeration System Removal
For CO2 Models
One identification of this model
is the view of the evaporator in
the bottom right hand corner of
the cabinet. This can be seen
from the outside thru the glass
or when the glass door is
opened. Is this different from
non CO2?

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Note: Non CO2 Refrigeration Systems
Will not operate in CO2 model cabinets

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CO2 Refrigeration Overview Field Support

• CO2 refrigeration removal document

generated and available.

• CO2 supplement included with instructions.

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CO2 Refrigeration Overview Questions

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Thank You

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