Danfoss Optyma Trio Application guide

Application Guide
Optyma™ Trio
http://RA.danfoss.com.br
Application Guide
Content
1. Introduction ...................................................................................................................... 4
2. General Information ........................................................................................................ 5
2.1 Application envelope of the Condensing Units for R404A / R507 .............................................................5
2.2 Applications ...................................................................................................................................................................5
2.3 Features ........................................................................................................................................................................... 5
3. Specifications ................................................................................................................... 6
3.1 Illustrative Image .......................................................................................................................................................... 6
3.2 Nomenclature ............................................................................................................................................................. 7
3.3 Performance data ........................................................................................................................................................ 8
3.2 General Data .................................................................................................................................................................. 8
3.6 Dimensional Data ....................................................................................................................................................... 9
4. Installation and Operation ............................................................................................ 10
4.1 Storage and Handling ...............................................................................................................................................10
4.2 Precautions ..................................................................................................................................................................10
4.3 Mechanical Installation ............................................................................................................................................ 11
4.4 Leak detection ............................................................................................................................................................ 12
4.5 Vacuum dehydration ................................................................................................................................................ 12
4.6 Electrical Installation.................................................................................................................................................12
4.7 Refrigerant and oil charge ......................................................................................................................................13
4.8 Verification before operating ................................................................................................................................13
4.9 First start-up ................................................................................................................................................................. 13
4.10 Verification of the unit while operating .......................................................................................................... 13
5. Maintenance ................................................................................................................... 14
6. Spare parts ...................................................................................................................... 15
7. Warranty .......................................................................................................................... 16
8. Danfoss Guideline .......................................................................................................... 17
3© Danfoss | Climate Solutions | 2022.03 AB260116321450en-000301
Application Guide

1. Introduction

The content of this material applies only to “Optyma
TM
TRIO” condensing units. This product is a Danfoss technology solution with the use of three in parallel connected scroll compressors in a robust foil framework with high efficiency micro-channel (MCHE) Danfoss condenser.
Even though a lot of benefits for the use of in parallel compressor systems exist, the more important benefits are the use of less equipment, flexibility on the capacity control, use of few tubing lines, better control of energy consumption and reduction of installation time when compared to the use of different equipment with single compressor systems to obtain the same capacity.
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Application Guide

2. General Information

2.1 Application envelope of the Condensing Units for R404A / R507

Figure 1
50
45
40
35
30
25
20
T amb (°C)
15
10
5
0
-35 -30 -25 -20 -15 -10 -5 0510 15

2.2 Applications

T evap (°C)
This unit is intended for diverse applications, such as:
• Medium capability refrigeration systems, in general;
• Medium and small sized supermarkets;
MBP

2.3 Features

• Scroll Compressors;
• High efficiency micro-channel condenser;
• Designed to operate in locations with high ambient temperature;
• Motorized fans of high performance and low energy consumption to obtain the maximum thermal efficiency;
• Motorized fans developed specially to guarantee the perfect operation in humid environments and great diversity of dirt;
• 6 pole motorized fans selected to assist in low noise level operations with dynamic balancing;
• Designed for use in outdoor environments;
• Designed for easy installation and maintenance;
• Framework assembled in galvanized steel with electrostatic painting resistant to corrosion;
• Distribution centers for freezing and food preservation;
• Industrial systems;
• Cold water and liquid cooling units, etc.
• Removable fan guards to facilitate the cleaning of the serpentine and general maintenance;
• Service valves in the liquid line and suction;
• Liquid receiver with service valves in the inlet and outlet connections, according to the NR10 norm;
• Combined oil separator and oil reservoir;
• Individual oil control for each compressor through the electronic level regulators;
• Compressor with thermal shield for motor protection against high temperatures and currents;
• Applications for R404A;
• Electric panel according to the NR13 norm;
• There is enough space for the installation of additional controls, if necessary.
2.4 Benefits
• Compact, light and resistant unit;
• Easy handling;
• Low noise level, 6-pole fan;
• High performance;
• Low energy consumption.
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Application Guide

3.1 Illustrative Image

Figure 2
3. Specifications
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Components
1 - Fan 2 - Micro-channel type condenser 3 - Electronic oil level control valve 4 - Scroll Compressors 5 - Combined separator and oil reservoir 6 - Oil filter 7 - Liquid receiver 8 - Base 9 - Service valve ( GBC) liquid line 10 - Service valve (GBC) suction line
11 - Sight glass 12 - Suction filters and liquid line 13 - High and low security pressure switch 14 - Fan’s control pressure switch 15 - Suction accumulator 16 - Complete electric panel (including
sectionalizers, compressor contactor, overload relay, fan contactor, circuit breaker, timers, fault relay/ phase sequence).
Application Guide
3. Specifications

3.2 Nomenclature

3.2.1 Code and model
Nomenclature for the Optyma™ Trio line
H U D Q5100 50
1 2 3 4 5 6
1
H - High and medium evaporating temperature
Application
2
U - R404A / R507
Coolant gas
3
Compressors’
51(00) - 51000 Kcal/h for HBP/MBP
capacity (Kcal/h)
4
Condenser’s
D - Micro-channel
technology
5
Table 1
Productconfiguration
6
Electrical Codes
Q - 220V/3F/60Hz V - 380V/3F/60Hz
Table 1 - Productconfiguration
Pressure
switch
Code
Application
50 HBP 3 2 1 1 1 1 1 1 1 1 1 3 4 3 4 3
KP5 Fa n
KP15 S afety
Separator
Liquid receiver
andoilreservoir
Filter Drier
Suction
accumulator
Suction
L. Liquid
Service Valve Electric Component
Contactor Circuit breaker
Liquid
Sight Glass
Suction
line
General
Key
Compressor Fan Compressor Fan
Sequence
protector
phase
3.2.2 Label
Figure 3
Model:
Code:
Serial:
Fan (4):
HP Pressure (bar/psi):
LP Pressure (bar/psi):
A: Model B: Code C: Serial number and Bar code D: Compressors Information E: Fans Information F: HP pressure test
Apparent P.
Active P. (kw)
G: LP pressure test H: Apparent power I: Active power J: RLA nominal current
e
K: Maximum current of MCC application
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Application Guide

3.3 Performance data

3. Specifications
HBP R404A/R507 60Hz
Condensing Unit
Model Electrical Code Code C.R. P.C. C.R. P.C. C.R. P.C. C.R. P.C. C.R. P.C. C.R. P.C. C.R. P.C.
HU4500D50
HU510 0D50
KEY
C. R. capacity ( Kcal/h ) P.C. Total power including fans (KW)
Q V
Q V
115F05 59 115F05 60
115F05 61 115F05 62
Ambient
32 22170 22.35 27880 22.68 34510 23.22 42030 23.93 50390 24.74 5954 0 25.64 69420 26.58
35 ---- ---- 26120 23.95 32430 24.43 39590 25.09 47560 25.89 56290 26.78 65730 27. 73
38 ---- ---- 24070 25.34 30290 25. 76 37090 26.36 44650 27. 12 52950 27. 99 61950 28.94
43 ---- ---- 20900 28.00 26610 28.26 32760 2 8.74 39630 2 9.41 47210 30.23 ---- ----
32 26090 25.90 32180 26.58 3920 0 27. 45 4 7170 28.47 56080 29.60 65900 30.79 7660 0 31.99
35 ---- ---- 30490 2 7.98 37210 28.83 44830 29.84 53330 30.96 62720 32.14 72990 33.34
38 ---- ---- 28840 28.43 3518 0 30. 31 42430 31.3 0 50540 32.40 5950 0 33.57 69320 34.77
43 ---- ---- 25880 31.05 3178 0 31.81 38320 33.96 4576 0 35.02 54000 36.16 ---- ----
-25 -20 -15 -10 -5 0 5
Temperature (°C)
OPERATING CONDITIONS:
Overheating: 20 K Sub-cooling: 0 K
Cooling capacity in (Kcal/h) - Evaporating temperature in (°C)

3.2 General Data

Condensing Unit Compressor Fan Condenser
(HP)
Chassis
Application
HBP
23
C
27
Model
HU4500D50Q 115F05 59 MLZ058T2 121L8 816
HU4500D50V 115 F056 0 MLZ058T9 121L88 24
HU510 0D50Q 115F05 61 MLZ066T2 121L88 26
HU510 0D50V 115 F0562 MLZ066T9 121L8 852
Code
Qty
Model
Code
3 26.4 2.7 630 6 4 33600 Q8 2.54 x 2 40 2 1/8 1 1/8 485 500 64 78 86
3 31.2 2.7 630 6 4 33600 Q8 2.54 x 2 40 2 1/8 1 1/8 485 500 64 78 86
Diam.
(m3/h)
Qty
(mm)
No. Poles
(m3/h)
Air flow
(L)
Oil
Off
(L)
Typ e
Internal Vol.
Connection Weight Sound level
(in)
(in)
Liq.
(Kg)
(Kg)
Liquid Receiver
L. Liq.
L. Suction
Raw
dB2mdB
5m
60Hz
Sound Power dBA

3.5 Electrical Data

60Hz
Condensing Unit Compressor Fan
Model
HU4500D50Q 115F05 59 33.53 230V-3F-60Hz 88.00 MLZ058T2 121L8 816 3 230V-3F-60Hz 190. 0 25.6 40.0 630 4 6 870 230V-3F-60Hz 2.9 1.65
HU4500D50V 115 F056 0 35.80 380V-3F-60Hz 54.40 MLZ058T9 121L 8824 3 380V-3F-60Hz 13 5.0 16.0 25.0 630 4 6 870 380V-3F-60Hz 2.9 1.65
HU510 0D50Q 115F05 61 37.99 230V-3F-60Hz 99.70 MLZ066T2 121L88 26 3 230V-3F-60Hz 235.0 29. 5 46.0 630 4 6 870 230V-3F-60Hz 2.9 1. 65
HU510 0D50V 115 F0562 43.70 380V-3F-60Hz 66.40 MLZ066T9 121L88 52 3 380V-3F-60Hz 135 .0 20.0 28.0 630 4 6 870 380V-3F-60Hz 2.9 1.65
LRA: Rotor amps blocked, RLA: Nominal current, MCC: Maximum direct current, FLA: Full charge current
Code
Tot al po wer
kVA MCC LRA RLA MCC mm W 230V (A) 380V (A)
Frequency
Voltage, Phases,
Amps
Model
Qty
Code
Frequency
Voltage, Phases,
Amps
Diam. Model
Power
Qty
No. Poles
Frequency
Voltage, Phases,
FLA (60Hz)
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Application Guide
3. Specifications

3.6 Dimensional Data

Dimensions (mm) Connections
Condensing Unit
HU4500D50Q 14 85 2057 1368 15 85 2157 14 68 250 224 24 6 348
HU4500D50V 1485 2057 1368 158 5 2157 14 68 250 224 246 348
HU510 0D50Q 1485 2057 1368 15 85 2157 14 68 250 224 24 6 348
HU510 0D50V 1485 2057 136 8 158 5 2157 1468 250 224 246 348
Without packaging With packaging Liquid Line Liquid Line
W L H X Y Z A B C D
Figure 4
9© Danfoss | Climate Solutions | 2022.03 AB260116321450en-000301
Application Guide

4. Installation and Operation

4.1 Storage and Handling

4.2 Precautions

To guarantee an adequate protection, it is necessary to observe all emphasized recommendations in this application guide.
• It is not recommended to open the packaging before the unit being at the installation site.
• Handle the unit carefully. The framework allows the use of a forklift or handling cart. Use appropriate and safe elevation equipment.
• Keep the unit in a vertical position both in storage and transport.
• Store the unit in an adequate and protected environment.
• Do not expose the packaging to rain or corrosive atmosphere.
• After unpacking, verify if the unit is complete and undamaged.
• The installation and maintenance of this unit must only be held by a certified installer / engineer / electrician and in accordance with the local regulatory guidelines.
• Never place the unit in a flammable atmosphere
• Place the unit in a way that it doesn’t block or complicate the passage areas, doors, windows, stairs and other accesses.
• Ensure adequate space around the unit for the air circulation and door opening. See Figure 5 to obtain the minimum distance values to the walls.
• Avoid installing the unit in aggressive environments and with difficult access.
• Ensure a base with strong horizontal surface that is stable enough to support all the unit’s weight and eliminate the vibrations by misalignment.
The next sections will provide necessary recommendations for the installation and operation of the Optyma safety data and appropriate use of the product.
All the equipment must be examined carefully upon product receipt in order to verify if no damages were caused by handling and transportation.
This equipment was carefully inspected in our factory, in case there is any apparent or hidden malfunction, notify immediately the establishment where it was purchased.
• Check if the power supply corresponds to the technical specifications of the unit (see product’s marking label).
• By installing units for HFC refrigerants, use specific equipment for that type of refrigerant, in other words, that have never been used before for CFC or HCFC.
• The suction tubing must be flexible in 3 dimensions
to muffle the vibrations. Furthermore, the tubing must be done in a way so that the return of the oil to the compressor is ensured and the return of liquid refrigerant to the compressor is avoided.
The installation at ground level rarely presents problems, none the less, if it is not installed at ground level, an additional tubing for drainage must be considered in the project.
TM
Trio unit, as well as
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Application Guide
4. Installation and Operation

4.3 Mechanical Installation

Figure 5
• The installation of the unit must comply with all the current safety local regulations, under all circumstances.
• The unit must be installed securely on a bracket or a steady and secure base, with the use of the vibration shock absorbers with mounting bolts provided together with the unit. See Figure 6.
• Remove the nitrogen load slowly through the schrader valves located in the suction GBC service valves and liquid line.
• Connect the unit to the system as quickly as possible to avoid the oil contamination from moisture present in the air.
• Avoid the penetration of solid residues derived from the tubing burr and others.
• Weld the tubing with proper material and always use nitrogen gas flow to make the environment inert, avoiding internal carbonation and forming of residue that may damage the system.
• It is recommended to isolate the suction tubing with insulation thickness that meets the specific project conditions for the installation.
• For the initial start-up, the oil level must be verified and completed with a parcial load, with the oil provided together with the condensing unit. If more oil is required, acquire from an oil distributor the oil of the same brand and specification provided with the condensing unit.
• After the operation, the sight glass of the oil compressor must be re-checked and the oil load completed to adjust to the installation tubing length, if necessary.
• It is recommended to put the oil through the service valve of the oil separator/trap through a vacuum pump connected to the high pressure line.
• The refrigerant charge must be done through the liquid’s tank service valve or through the schrader of the GBC service valve of the liquid line.
W
[mm]
Chassis - C 1092 1092 1000 190 0
Note: The specification of the chassis for each model can be found in section “3.6 Dimensional Data” in page 11.
X
[mm]
Y
[mm]
Z
[mm]
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Application Guide
4.3.1 Fixation
Figure 6
4. Installation and Operation
Fixation of 4 “vibra-stop” type shock absorbers included on the Danfoss supply for the support on the floor or laying base

4.4 Leak detection

4.5 Vacuum dehydration

4.6 Electrical Installation

• Never pressurize the circuit with oxygen or dry air. This can cause fire or explosion.
• Do not use dye for leak detection.
• The use of nitrogen or the system’s own gas is recommended.
• Never use the compressor to empty the system.
• Connect a vacuum pump to the system’s lower sides LP and HP.
• The vacuum in the system must reach at least a complete 500 μm Hg (0.67 mbar).
• When the vacuum level is reached, keep it for a few hours to guarantee the sealing of the system.
• After this stage, isolate the vacuum pump and place the nitrogen with a pressure of 4 to 5 bar, keeping the system at this pressure for 4 hours.
• Switch off and isolate the main power supply.
• Make sure that the power supply can’t be switched on accidentally during installation.
• All the electrical components must be selected according to the local standards and according to the unit’s requirements.
• Consult the wiring diagram supplied with the installation manual for details on electrical connections.
• Make sure that the power supply matches the unit characteristics and that the energy source is stable (nominal voltage ± 10% and nominal frequency ± 2.5 Hz).
• Dimension the power supply cables according to the unit data on voltage and current.
• Protect the power supply and ensure that the grounding of the unit is done according to the current standards.
• Perform a leak detection test in the entire system.
• The maximum test pressure is 32 bar.
• When a leak is detected, repair the leak
and repeat the leak detection.
• If the pressure in the gauge connected to the suction line and discharge lowers in this period, locate the leak, perform the repair and restart the vacuum procedure and check the leak again.
• Do not apply energy to the unit while the system is under vacuum, as this might cause internal damage.
• The unit is equipped with high and low pressure
switches, which directly shut off the power supply to the compressor in case of activation. The unit is also equipped with a phase sequence relay to protect the unit against phase/ sequence loss / asymmetry and under voltage / over voltage.
• Observe the correct phase sequence in the condensing units which use three-phase compressors.
• Determine the sequence using a phase gauge to establish the sequences of the line phases L1, L2 e L3.
• Connect the line phases L1, L2 e L3 corresponding to the terminals of the compressor T1, T2 e T3 respectively.
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Application Guide
4. Installation and Operation

4.7 Refrigerant and oil charge

4.8 Verification before operating

4.9 First start-up

• Use individual protection equipment (IPE) such as safety glasses and gloves.
• Never start the compressor under vacuum. Keep the compressor switched off.
• Before performing the refrigerant charge, verify if the oil level is between ¼ and ¾ on the compressor oil display. If necessary, add oil to the compressors, refer to the compressor’s label for oil type.
• Only use the coolant for which the unit was designed for.
• Perform the refrigerant charge in liquid phase into the condenser and in the liquid receiver.
• Use safety devices according to locally applicable regulations and security standards.
• Verify if all electrical connections are attached
correctly and in accordance with the local regulations.
• Never switch on the unit without having performed a refrigerant charge .
• All service valves must be in the open position. See figure 5.
• Verify if the power supply is adequately
connected.
• Verify if the crankcase heater is working.
• Verify if the fan can rotate freely.
• Verify if high and low pressure are balanced.
• Energize the unit and verify the conformity of the wiring, the tension in the terminals and the phase sequence.
Make sure to perform a slow refrigerant charge until it reaches 4-5 bar in systems with R404A/507.
• Never put liquid refrigerant through the suction line.
• Never use additive or oil mixtures.
• The remaining charge is carried out until the installation has reached a stable nominal condition level during the operation.
• Never leave the filling cylinder connected to the system.
• Keep the crankcase heater switched on for at least 12 hours before the system start-up, for the guarantee of proper lubrication and elimination of the liquid refrigerant from the compressor's crankcase.
• The potential reverse rotation of a three-phased compressor can be detected by no pressure increase, an abnormal sound level of the compressor and a lower energy consumption than the one expected. In this case, immediately switch off the unit and connect the phases to their appropriate terminals.
• If the direction of rotation is correct, the indication of low pressure on the low pressure gauge must display a decreasing pressure and the indication of high pressure in the high pressure measurer must display an increasing pressure.
• The electronic buoys must comply with the indication.
4.10 Verification of the unit while operating
• Check the rotation direction of the fan. The air must flow from the condenser to the fan (air flow from bottom to top).
• Check the high pressure stabilization and the power supply stability.
• Check the suction overheating to reduce the risk of the return of liquid to the compressor.
• Observe the compressor oil level in the beginning and during the operation to confirm that the oil level remains visible.
• Verify all tubing with respect to unusual vibration. The movements exceeding 1.5mm require corrective measures, as the use of fixation supports in the tubing.
• Before leaving the installation site, perform a general inspection of the installation on cleanliness, detection of noise and leakage.
• Record type and amount of refrigerant charge, as well as operation conditions as reference for future inspections. Use data check sheet
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Application Guide

5. Maintenance

• Always switch off the unit with the main switch before removing the fan panel, or any other panel of the condensing unit.
• The internal pressure and the surface temperature are hazardous and can cause permanent injuries.
• The installers and/or maintenance operators must be certified in accordance with the current standards and with the use of appropriate tools.
• High pressure tubing temperature may exceed
100°C and cause severe burns.
• Make sure that periodical inspection services are carried out to guarantee the reliability of the system and to meet the mandatory local regulations.
• To ensure the good functioning of the unit and its energy efficiency, it is recommended:
• Periodic maintenance;
• Verify if the safety devices are operational
and properly set;
• Make sure the unit retains the fixation
steady without fragility;
• Check if the compressor’s current is correct;
• Confirm if the system is operating
consistently with previous maintenance records in the established conditions;
• Check if all electrical connections still are
properly attached;
• Keep the unit clean and without rust and
oxidation of the unit’s components, tubing and electrical connections.
• The condenser must be verified at least once a year regarding the blockage of the fins by impurities and must be cleaned if considered necessary. The access to the internal side of the condenser takes place through the fans panel (guard). The micro-channel coils tend to accumulate dirt on the surface and not in the interior, which makes them easier to clean comparing to the tube condensers and fins.
• Remove the dirt from the surface, leaves, fibers,
etc., with a vacuum, equipped with a brush or other soft accessory. Alternatively, blow the compressed air through the condenser inside out and brush with a soft bristle. Do not use a wire brush. Do not impact or scrape the condenser with the vacuum tube or air orifice.
• If the refrigeration system is open, the system
must be pressurized with nitrogen processed in vacuum to remove the moisture and a new filter drier must be installed.
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Application Guide
Condensing Units HU4500D50Q HU4500D50V HU5100 D50Q HU5100 D50V
Accumulator 191U0 068 191U00 68 191U 006 8 191U006 8
Acoustic Hood - - - -
Compressor 121L88 16 121L88 24 121L 8826 121L 885 2
MCHE Condenser 193U 064 6E 193U 064 6E 193U 064 6E 193U0 646 E
Crankcase Resistance - - - -
Motor Fan 191U135980 191U135980 191U135980 191U135980
Filter Drier 023U1392 023U1392 023U1392 023U1392
Oil Filter 191U008810 191U008810 191U008810 191U008810
Oil Level Regulator 191U0 0903 0 191U0 09030 191U0 090 30 191U00 9030
Lubricating Oil 120Z5 034 12 0Z5 034 12 0Z503 4 12 0Z50 34
Oil Separator 191U0 0795 0 191U00795 0 191U 007950 191U 0079 50
KP HP_LP Pressure Switch 06 0-1264 66 0 60-126 466 06 0-12 646 6 06 0-126 466
KP HP Pressure Switch 060 -117166 0 60 -1171 66 0 60 -11716 6 060 -11716 6

6. Spare parts

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Application Guide

7. Warranty

• Always have the model and serial number of the condensing unit available for any warranty claim.
• The warranty of the product can be rendered void in the following cases:
- Absence of nameplate.
- External modifications, mainly drilling, welding,
broken feet and shock markings.
- Open compressor or returned without sealing.
- Dye for rust detection, water or leak in the
compressor.
- Use of an off-specification refrigerant or lubricant.
- Any deviation from the recommended instructions regarding the installation, application or maintenance.
- Use of the unit in an environment with an explosive atmosphere.
- No model number or serial number was informed in the warranty claim.
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Application Guide

8. Danfoss Guideline

Danfoss recommends that gases, oils and other components that can adversely affect the environment be delivered to dedicated
companies in the recycling or disposal of those materials for environment protection.
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Danfoss Commercial Compressors
Danfoss variable speed scroll compressors
is a worldwide compressor and condensing units manufacturer for refrigeration and HVAC applications. With a wide range of innovative products of the best quality, we help your company to find the best possible solution in terms of environment and that reduces the total costs of the product’s life cycle.
We have over 40 years of experience in the development of hermetic compressors which placed us among the global leaders in our business and positioned us as variable speed technology specialists. Currently we act from the engineering and project up to the production stages in three continents.
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Our products can be found in diverse applications, such as rooftops, chillers, residential air conditioning, heat pumps, cold rooms, supermarkets, milk cooling tanks and industrial cooling processes.
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