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GGBK Series
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Güntner GGBK Series Operating Instructions Manual

Air coolers – GGBK
Product line: Air cooler
Series variant description: Processing room glycol unit cooler
Series: GGBK
www.guentner.de
GGBK | 2010-09

Contents

page 2 / 61
1 Important basic information........................................................5
1.1 Safety instructions............................................................................. 5
1.1.1 Observing operating instructions.......................................................... 5
1.2 Importance of the EN 378 series of standards – refrigeration sys-
tems and heat pumps – safety-related and environmental require-
ments................................................................................................... 5
1.3 Responsibilities.................................................................................. 5
1.3.1 Manufacturer's responsibilities............................................................. 5
1.3.2 Responsibilities of the system's installer.............................................. 6
1.3.3 Owner or operator responsibilities....................................................... 6
1.4 Legal notes..........................................................................................7
1.5 Operating instructions....................................................................... 7
1.5.1 Scope....................................................................................................7
1.5.2 Set-up and other applicable documents.............................................. 7
1.6 Conventions........................................................................................ 8
1.6.1 Typographical conventions................................................................... 8
1.6.2 List of abbreviations............................................................................. 8
1.7 Conventions for safety signs and notices.......................................9
1.7.1 General safety signs and their meaning in these operating instruc-
tions...................................................................................................... 9
1.7.2 Warning signs and their meaning in these operating instructions.........9
1.7.3 Prohibitory signs and their meaning in these operating instruc-
tions.................................................................................................... 10
1.7.4 Mandatory signs and their meaning in these operating instruc-
tions.................................................................................................... 11
2 Safety........................................................................................... 12
2.1 Labelling on the unit:.......................................................................12
2.1.1 Safety signs on the unit..................................................................... 12
2.1.2 Other signs and notes on the unit......................................................13
2.2 Basic safety notices.........................................................................15
2.2.1 How to act in an emergency.............................................................. 15
2.2.2 Personnel, care requirements............................................................ 16
2.3 Proper intended use.........................................................................16
2.3.1 Proper intended use........................................................................... 16
2.3.2 Operating conditions...........................................................................16
2.3.3 Improper use...................................................................................... 17
2.4 Mechanical residual hazards...........................................................18
2.4.1 Fins, sharp unit corners and edges................................................... 18
2.4.2 Fans.................................................................................................... 19
2.5 Electrical residual hazards.............................................................. 19
2.6 Thermal residual hazards................................................................ 20
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2.6.1 Danger of burns................................................................................. 20
2.6.2 Frostbite hazard..................................................................................20
2.6.3 Frostbite hazard..................................................................................20
2.7 Residual hazards with the coolant/glycol......................................20
2.8 Residual hazards caused by vibrations.........................................22
2.9 Residual hazards caused by pressurised parts............................22
2.10 Residual hazards caused by defective installation.......................23
2.11 Residual hazards with break during operation............................. 24
2.12 Residual hazards caused by escaping objects or liquids............ 25
2.13 Residual hazards with disposal...................................................... 25
3 Technical data............................................................................. 26
3.1 Unit..................................................................................................... 26
3.2 Fans....................................................................................................26
4 Set-up and function....................................................................28
5 Fan motor.................................................................................... 29
6 Transportation and storage....................................................... 30
6.1 Safety................................................................................................. 30
6.2 Transportation and storage.............................................................30
6.3 Storage before installation.............................................................. 32
7 Set-up and start-up.................................................................... 33
7.1 Safety................................................................................................. 33
7.1.1 Safety instructions for set-up and start-up......................................... 33
7.1.2 System-side safety requirements....................................................... 34
7.1.3 Customer-side safety precautions...................................................... 35
7.2 Requirements at the set-up point...................................................36
7.3 Unpacking the unit........................................................................... 37
7.4 Installation......................................................................................... 38
7.4.1 System-side requirements for stress-free installation........................ 38
7.4.2 Mounting the unit................................................................................41
7.5 Notes on connecting the unit......................................................... 42
7.5.1 Connecting the drain line to the drip tray...........................................43
7.5.2 Connect the unit to the cooling equipment of the system.................. 43
7.5.3 Unit electrical connection and protection........................................... 44
7.6 Perform acceptance test..................................................................44
7.7 Test readiness for operation........................................................... 46
7.8 Putting the unit into operation for the first time........................... 46
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8 Operation..................................................................................... 47
8.1 Safety................................................................................................. 47
8.2 Putting the unit into operation........................................................47
8.3 Taking the unit out of operation..................................................... 48
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8.4 Shutting the unit down.................................................................... 48
8.5 Putting the unit into operation after a shutdown.......................... 49
8.6 Changing the unit over to another working fluid.......................... 49
9 Troubleshooting..........................................................................50
9.1 Safety................................................................................................. 50
9.2 Service............................................................................................... 50
9.3 Troubleshooting table...................................................................... 50
10 Maintenance................................................................................ 51
10.1 Safety................................................................................................. 51
10.1.1 Before starting all maintenance..........................................................51
10.1.2 With all maintenance work................................................................. 51
10.1.3 After all maintenance work................................................................. 52
10.2 Inspection and maintenance plan.................................................. 53
10.2.1 Fans.................................................................................................... 53
10.2.2 Unit heat exchanger........................................................................... 53
10.3 Maintenance work............................................................................ 55
10.3.1 Remove leaks.....................................................................................55
10.4 Clean unit.......................................................................................... 55
10.4.1 General............................................................................................... 55
10.4.2 Clean and defrost heat exchanger.....................................................55
10.4.3 Cleaning fans......................................................................................57
10.5 Defrosting the unit........................................................................... 58
10.5.1 Notes on defrosting............................................................................ 58
10.5.2 Defrost control.................................................................................... 59
10.5.3 Circulation air defrosting.....................................................................59
10.5.4 Electric defrosting ..............................................................................60
10.5.5 Further notes on defrosting................................................................ 60
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11 Plans/diagrams........................................................................... 61
11.1 Electrics documentation..................................................................61
11.1.1 Fan motor connection diagram.......................................................... 61
11.1.2 Connection diagram electrical defrost (selectable option; accessory on
customer request)...............................................................................61
11.2 Working fluidconnection diagram.................................................. 61
page 5 / 61

1 Important basic information

1.1 Safety instructions

1.1.1 Observing operating instructions

CAUTION
Always keep the operating instructions in the unit's immediate vicinity at all times.
Ensure that the operating instructions are accessible to all people that have anything at all to do with the unit at all times.
Ensure that the operating instructions are read and understood by all people that have any­thing at all to do with the unit.
1.2 Importance of the EN 378 series of standards – refrigeration sys­tems and heat pumps – safety-related and environmental require­ments
EN 378 deals with safety-related and environmental requirements for designing, constructing, pro­ducing, installing, operating, maintaining and disposing of refrigeration systems and cooling equip­ment.
EN 378 is oriented towards manufacturers, installers and operators of refrigeration systems and cooling equipment (see section 1.2. Responsibilities).
The objective of EN 378 is to restrict the possible hazards of refrigeration systems, cooling equip­ment and their working fluids (refrigerants and coolants) for people, property and the environment to a minimum.
Insufficient safety measures or non-compliance with safety-relevant regulations can result in:
•
Breaks or ruptures on components with the danger of escaping materials (hazards caused by the influence of low temperatures, excess pressure, direct influence of the fluid phase, moving machine parts).
•
Escaping working fluid after a break or leak because of defective design, improper operation, in­sufficient maintenance, repairs, filling and disposal (hazards caused by flammability, explosion hazard, disturbance of nervous system, suffocation, panic)
•
Escaping working fluid after a break or leak because of defective design, improper operation, in­sufficient maintenance, repairs, filling and disposal (hazards caused by flammability, explosion hazard, disturbance of nervous system, oxygen displacement, chemical reactivity, irritation of respiratory centre, agitation, dizziness, vomiting and cramps, toxicity, chemical burns, frostbite, panic)

1.3 Responsibilities

1.3.1 Manufacturer's responsibilities

The notes provided in these operating instructions on maintaining the unit's functional safety, pre­venting possible hazards when transporting, setting up and installing, start-up and operation, and with maintenance activities (cleaning, servicing and repairing) refer exclusively to the unit.
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The manufacturer's responsibilities are documented in the unit's version in acc. with EN 378-2 (de­sign, manufacture and testing).
The construction, soldering and welding materials are configured so that they withstand the fore­seeable mechanical, thermal and chemical stresses, and are resistant to the working fluid and the working fluid/refrigerator oil mixture used.
The working fluid-carrying parts of the unit (core tubes, distributor tube and header outlet) are con­figured so that they remain tight with the foreseeable mechanical, thermal and chemical stresses, and withstand the maximum permissible operating pressure.
Material, wall thickness, tensile strength, corrosive resistance, shaping process and testing are suit­able for the working fluid used and withstand the possible pressures and stresses that might occur.
All responsibilities regarding the system's cooling equipment,, into which the unit is integrated, are the exclusive responsibility of the people involved in the individual workflows.

1.3.2 Responsibilities of the system's installer

The responsibilities of the system installer are documented in the system's version (design, manu­facture and testing – complete system: cooling equipment and refrigeration system) in acc. with EN 378-2.
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Component supplier-system installer interfaces :
•
Inform Güntner AG & Co. KG if faults occur: Inform Güntner AG & Co. KG immediately if faults occur during the set-up, installation, start-up and operation.
The responsibilities of the system installer in particular include:
•
Planning and preparing emergency measures: To avoid consequential damage caused by operational disruptions, a warning system which im­mediately signals all faults must be provided on-site. Prepare emergency measures that prevent consequential damage for people and property should faults occur.
•
Install emergency STOP switches that can be actuated without danger.
•
Specify checking and maintenance intervals: The system (complete system: cooling equipment and cooling plant)must be configured and equipped with all required equipment for maintenance and sufficient servicing and testing in acc.
with EN 378-4. With the integration of the unit into the refrigeration system's cooling equipment/ the working fluid and version must not deviate from the order-related information specified in the order-related offer documents.
The installer of the system must refer to the requirement for sufficient instruction of the operating and supervision staff when operating and maintaining the system's cooling equipment .
It is recommended that the future customer staff – if possible – be present with the set-up and in­stallation, with the tightness test and cleaning, with the filling with working fluid and with the setting of the system's cooling equipment .

1.3.3 Owner or operator responsibilities

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The owner or operator responsibilities are documented in the operation, maintenance, servicing and recovery of the system in acc. with EN 378-4.
The owner or operator must ensure that the proper people are sufficiently trained and qualified for operating, monitoring and servicing the system (complete system: cooling equipment and refrigera­tion system) .
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The operating personnel for the system and cooling equipment must have sufficient knowledge and experience with regard to the mode of operation, operation and daily monitoring of this system and the cooling equipment .
Before the system start-up including the cooling equipment/the owner or operator must ensure that the operating personnel are sufficiently instructed with the system's documentation (which is part of the operating instructions) on the set-up, monitoring, mode of operation and servicing of the sys­tem including the cooling equipment/and the safety measures to be observed, and with regard to the properties and handling of the working fluid to be used.
The owner or operator must ensure that when operating, monitoring and maintaining the system and the cooling equipment/the working fluid and version must not deviate from the details specified in the order-related offer documents.
Planning and preparing emergency measures: To avoid consequential damage caused by opera­tional disruptions, a warning system must be installed on the customer's premises. Prepare emer­gency measures that prevent consequential damage for people and property should faults occur.
Responsibility remains with the owner or operator of the system and cooling equipement, if the system and the cooling equipmentare used by somebody else, unless there is an agreement on sharing responsibility.

1.4 Legal notes

Warranty claim expires as follows:
•
With faults and damages that can be attributed to non-compliance with the specifications of
these operating instructions.
•
With complaints that can be attributed to use of spare parts other than the original spare parts
specified in the order-related offer documents.
•
With changes to the unit (working fluid, version, function, operating parameters) vis-a-vis the or-
der-related information specified in the order-related offer documents without the manufacturer's
prior consent. The operating instructions may not be reproduced electronically or mechanically, circulated, changed passed on to third parties, translated or used otherwise, in full or in part, without Güntner AG & Co. KG's prior explicit written approval.

1.5 Operating instructions

1.5.1 Scope

These operating instructions apply for all air coolers of the GGBK series.
You will find the precise type of your unit in the attached order-related offer documents.
NOTICE

1.5.2 Set-up and other applicable documents

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The unit's operating instructions include the following parts:
•
These instructions
•
Order-related offer documents
The order-related offer documents are attached to these instructions and include the following
information:
– The order-related proper use as specified
– The order-related scope of delivery
– The order-related technical data
– The order-related drawings specifying customer, project number and order number
•
Motor connection wiring diagram in terminal boxes These operating instructions are part of the operating instructions manual of the system, provided by the system's installer .

1.6 Conventions

1.6.1 Typographical conventions

1.6.2 List of abbreviations

The following text markups are used in these operating instructions:
Bold Requires special attention!
Grey triangle Instructions
page 8 / 61
Abbreviations Meaning
EN 378 European Norm 378: Refrigeration systems and heat pumps; safety-related
and environmental requirements
EN European Norm
DIN German industrial standard (specification of a standard)
ISO International Standardization Organization
Emergency STOP
°C Degrees Celsius (Celsius scale temperature)
bar Unit of pressure
I Litre (liquid volume)
Vol % Volume percent (concentration level relative to a volume)
IP Insulation protection
Q 6.3 Balancing quality
ppm parts per million, concentration figure, stands for "millionth"
Hz Hertz (frequency)
D Delta connection (rotating current: high speed)
S Star connection (rotating current: low speed)
Switch for immediately switching off the refrigeration system
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3~ 3-phase rotating current
1~ 1-phase alternating current
VDE "Verband der Elektrotechnik, Elektronik und
Informationstechnik" (Association for Electrical, Electronic & Information Technologies)
Abbreviations Meaning
TCC Technical Connection Conditions
EPC Electric Power Company
VDI "Verein Deutscher Ingenieure" (German engineers' association)

1.7 Conventions for safety signs and notices

1.7.1 General safety signs and their meaning in these operating instructions

DANGER
Dangerous situation that will definitely cause serious injury or death if it is not avoided.
WARNING
Dangerous situation that could cause serious injury or death if it is not avoided.
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CAUTION
Dangerous situation that could cause slight to moderate injury if it is not avoided.
NOTICE
Refers you to possible damage to property.

1.7.2 Warning signs and their meaning in these operating instructions

Warns against hand injuries!
Hands or fingers can be crushed, pulled in or otherwise injured with non-compli­ance.
Warns against hot surfaces!
The temperature is over +45 °C (protein clotting) and can cause burns.
Warns against cold!
The temperature is below 0 °C and can cause frostbite.
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Warns against dangerous electrical voltage!
Danger of an electric shock if voltage-carrying parts are touched.
Warns against potentially explosive substances at set-up point
Use of ignition sources can cause explosions at set-up point.
Warns against fire-risk substances at set-up point.
Use of ignition sources can cause fire at set-up point.
Warns against harmful to health or irritant substances at set-up point
Contact with or inhaling harmful to health or irritant substances can cause injuries or damage the health.
Warns against toxic substances at set-up point
Contact with or inhaling toxic substances can cause injuries or damage the health.

1.7.3 Prohibitory signs and their meaning in these operating instructions

Feuer, offenes Licht und Rauchen verboten!
Ignition sources must be kept away and ignition sources must not develop!
No smoking!
Smoking is forbidden.
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1.7.4 Mandatory signs and their meaning in these operating instructions.

Use eye protection!
Eye protection: Use protective cover, protective glasses or face protection.
Use hand protection!
Protective gloves must protect against mechanical and chemical dangers (see im­printed pictograms).
Use respiratory protection!
Breathing apparatus must be suitable for the working fluid used. Breathing appara­tus must consist of:
•
At least two independent breathing devices (self-contained breathing apparatus)
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Use protective clothing!
Personal protective clothing must be suitable for the working fluid used and for low temperatures, and must have good heat insulation properties.
Activate before work!
Activate the electrical system and secure against switching on again before start­ing installation, maintenance and repair work.
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2 Safety

Schallbretter (Verpackung)

2.1 Labelling on the unit:

Placing of labels on the unit

2.1.1 Safety signs on the unit

Safety signs on the unit individually:
page 12 / 61
3 - "Transportation filling" warning sign next to Schrader valve
"Do not use wrench" warning sign beside tray drain
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2.1.2 Other signs and notes on the unit

1 - Unit type plate
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2 – Güntner logo
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12 - Connections ON and OFF
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17 - Trailer loading – Ceiling-mounted air cooler

2.2 Basic safety notices

2.2.1 How to act in an emergency

Danger of injuries and damage to property!
The unit is operated as standard with the coolant, ethylene glycol (synonyms: ethane-1,2-diol, glycol). When using other coolants, prior agreement with the manufacturer is an absolute must.
Ethylene glycol is a colourless, slightly viscous, not very fluid, water-mixable, deliquescent liquid with a sweet smell or taste.
Ethylene glycol is flammable and explosive at higher temperatures in a vapour/ gaseous state.
With skin contact ethylene glycol causes slight irritation with the danger of skin absorption; with eye contact mucous membrane irritation; with ingestion agita­tion with disruption of the central nervous system; with prolonged endangering effect – fatigue, coordination disruption, unconsciousness, kidney damage.
Keep ethylene glycol away from ignition sources. No smoking!
Ethylene glycol vapours are heavier than air and may flow off to rooms on a low­er level. In still air there may be an increase of the ground level concentration. With high concentrations, there is a danger of suffocation due to reduced oxy­gen concentration, especially at ground level.
Avoid contact with skin, floor, clothing! Remove contaminated, soaked clothing immediately!
Do allow contact with heavy oxidation agents (chromo-sulphuric acid, potassi­um permanganate, smoking sulphuric acid, or similar)! Danger of strong reac­tions!
Unauthorised people must not have access to the unit. When setting up it must be ensured that the coolant escaping from the unit cannot penetrate the interior of the building or put people at risk in any other way.
Safety measures and procedure:
•
With unexpected serious coolant breaks, activate the emergency STOP switch set up in a safe place, e.g. with: – Visibly escaping coolant from the heat exchanger or pipe components. – Sudden large release (release and evaporation of the greater part of the
entire coolant in a short time, e.g. in less than 5 minutes).
•
Have experienced, trained personnel with prescribed protective clothing per­form all necessary protective and other measures: – Use respiratory protection. – Use a room air-independent breathing apparatus with maintenance work
in high coolant concentrations in the room air. – Ensure the set-up room is well ventilated. – Divert escaped coolant liquid safely in acc. with EN 378-3.
page 15 / 61
WARNING
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2.2.2 Personnel, care requirements

The unit must only be put into operation, operated, maintained and repaired by trained, experi­enced and qualified personnel. People that are responsible for the operation, maintenance, repair and evaluation of systems and their components must have the required training and specialist knowledge for their work in acc. with EN 378-1 to be qualified. Qualified or expert means the abili­ty to satisfactorily perform the activities required for the operation, maintenance, repair and evalu­ation of refrigeration systems, cooling equipment and their components.
The unit may be operated by operating personnel that have no specific knowledge of refrigeration engineering, but have sufficient knowledge and experience with regard to the mode of operation, operation and daily monitoring of this system, and the cooling equipment. This operating person­nel may not make any interventions or settings on the system and the cooling equipment.
Changes to the unit, which the manufacturer has first agreed to in writing, may only be made by the instructed and qualified personnel.
Electrical installation: Work on the electrical equipment may only be performed by personnel that have the required ex­pertise (e.g. an electrician or an electro-technically instructed person), and who are authorised by the operator, in compliance with the respective VDE regulations (and national and international provisions) and the TCCs of the EPCs.
page 16 / 61
CAUTION

2.3 Proper intended use

2.3.1 Proper intended use

2.3.2 Operating conditions

Processing room air coolers of the GGBK series are intended for installation in a refrigeration sys­tem and are used for the draught-free cooling of processing rooms and draught-free, low noise air distribution in work areas and rooms.
The unit is delivered for operation with a specific operating point:
•
Coolant flow temperature
•
Coolant return temperature or circulating coolant volume
•
Airflow volume
•
Air inlet temperature
•
Relative air humidity.
The specified operating point is provided in the order-related offer documents.
The unit is a component of a cooling unit a cooling system including its working fluid circuit. The purpose of these operating instructions, as part of the operating instructions manual (of which these operating instructions are a part), is to restrict the dangers to people and property and the environ­ment from the unit and the working fluid used in it to a minimum. These dangers are essentially connected with the physical and chemical properties of the working fluid and with the pressures and temperatures that occur in the working fluid-carrying components of the unit see Residual hazards
with the coolant/glycol, page 20.
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Danger of injuries and damage to property!
The unit must only be used in acc. with the proper intended use. The operator must ensure that when operating, monitoring and maintaining the unit, the fluid and version do not deviate from the order-related information specified in the order-specific offer documents.
The operator must ensure that maintenance measures are performed in compliance with the system's operating instructions manual.
Filling the unit is only permitted following written approval by the manufacturer. You will find the order-related proper use as intended in the order-specific offer documents.
Do not exceed the max. operating pressure given on the unit's type plate.

2.3.3 Improper use

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WARNING
WARNING
Danger of injuries and damage to property!
Working fluids and their combinations with water or other substances in the working fluid-carry­ing components have chemical and physical effects from the inside on the materials surrounding them. The unit must only pressurised with coolant/. Pressurising the unit with another working fluid results in,
■
the structural, soldering and welding materials used do not withstand the foreseeable me­chanical, thermal and chemical stresses, and the pressure that can occur during operation and when shut down is not withstood.
■
material, wall thickness, tensile strength, corrosive resistance, shaping process and testing are not suitable for the working fluid used and do not withstand the possible pressures and stresses that might occur.
■
the unit not being resistant to the other working fluid and the other working fluid mixture.
■
the unit not remaining tight during operation and when shut down.
■
a possible sudden escaping of working fluids could directly endanger people and/or property
and the environment. The maximum permissible operating pressure specified on the type plate must not be exceeded! If the operating pressure is exceeded,
■
the structural and welding materials will not withstand the foreseeable mechanical, thermal
and chemical stresses and the pressure that can occur during operation and when shut down.
■
the unit will not remain tight during operation and when shut down.
■
there may be a possible sudden escaping of working fluids after a break or leakage on work-
ing fluid-carrying components, which would result in the following dangers:
– Danger of escaping materials
– Irritations and health hazards
– Fire hazard
– Explosion hazard,
– Strong chemical reactivity
– Frostbite hazard
– Suffocation hazard
– Hazards caused by panic reactions,
– Environmental pollution
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page 18 / 61
WARNING
Air coolersmay not be used
■
where it is possible that short or prolonged effect caused by contact, inhalation or ingestion of
the working fluid glycol might result in harmful hazards.
■
where the possibility exists of a sudden large release of the greater part of the entire working
fluid filling in a short time (e.g. in less than 5 minutes). The unit must not be changed without prior written consent by Güntner AG & Co. KG. Changes to the unit are:
■
Changing the operating point (see chapter Unit)
■
Changing the fan capacity (air volume)
■
Changing the working fluid flow-through volume
■
Changing over to another working fluid The unit must not be operated if safety devices recommended by the manufacturer are not avail­able, not properly installed or not fully functional.
The unit must not be operated if it is damaged or demonstrates faults. All damages and faults must be reported to Güntner AG & Co. KG immediately and must be removed immediately.
Work on the unit must not be performed without the personal protective equipment specified in these operating instructions.

2.4 Mechanical residual hazards

2.4.1 Fins, sharp unit corners and edges

Warns against hand injuries!
Danger of cuts on hands and fingers on the fins and on sharp corners and edges of the unit.
Use reliable hand protection!
WARNING
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2.4.2 Fans

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WARNING
Danger of cutting off, pulling in!
There is a danger of cutting off fingers on the rotating fan blades, injury hazard for the hands and pulling in danger for loose elements such as hair, necklaces or clothing parts.
Do not operate fans without guard grille. Pinch/trap point hazard!
With automatic fan start during maintenance work there is a danger of pinch­ing/trapping for the hands and fingers.
Power off the unit before you begin maintenance work with which you must re­move the guard grille. Secure the unit against unintentional switching on again by removing the electric fuses for the unit. Secure the unit with a suitable warn­ing sign referring to unintentional switching on.

2.5 Electrical residual hazards

Warns against dangerous electrical voltage!
Direct and indirect contact with voltage-carrying parts of motors and electrical lines can cause serious injuries or death.
Power off the unit before you begin maintenance work. See the refrigeration system's system documentation for this. Secure the unit against unintentional switching on again by removing the electric fuses for the unit. Secure the unit with a suitable warning sign referring to unintentional switching on.
Please note that the mains cables may also be carrying voltage, even if the unit is powered off.
Work on electrical equipment must only be performed by people that have the required expertise (e.g. an electrician or an electro-technically instructed per­son) and who are authorised to do so by the operator.
WARNING
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