Page 1
Drycoolers – GFH
Product line: Dry coolers
Series description: Axial dry coolers, horizontal
Series: GFH
www.guentner.de
GFH | 2018-04
Page 2
Contents
page 2 / 62
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
systems and heat pumps – safety-related and environmental re-
quirements.........................................................................................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 symbols and their meaning in these operating instruc-
tions.................................................................................................... 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.................................................................................................. 10
GFH | 2018-04
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....................................................14
2.2 Basic safety notices.......................................................................16
2.2.1 How to act in an emergency............................................................ 16
2.2.2 Personnel, care requirements.......................................................... 17
2.3 Proper intended use.......................................................................18
2.3.1 Proper intended use.........................................................................18
2.3.2 Operating conditions.........................................................................18
2.3.3 Improper use.................................................................................... 19
2.4 Mechanical residual hazards.........................................................20
2.4.1 Fins, sharp unit corners and edges................................................. 20
2.4.2 Fans.................................................................................................. 20
2.5 Electrical residual hazards............................................................ 21
© Güntner GmbH & Co. KG
Page 3
page 3 / 62
2.6 Thermal residual hazards..............................................................21
2.6.1 Danger of burns............................................................................... 21
2.6.2 Frostbite hazard................................................................................21
2.7 Residual hazards due to the heat carrier glycol......................... 22
2.8 Residual hazards caused by vibrations.......................................23
2.9 Residual hazards caused by pressurised parts.......................... 24
2.10 Residual hazards caused by defective installation.....................24
2.11 Residual hazards with break during operation........................... 25
2.12 Residual hazards caused by escaping objects or liquids.......... 26
2.13 Residual hazards with disposal....................................................26
3 Technical data........................................................................... 28
3.1 Heat exchanger (typical values)................................................... 28
3.2 Fans..................................................................................................28
4 Set-up and function.................................................................. 30
5 Fan motor.................................................................................. 31
6 Transportation and storage..................................................... 32
6.1 Safety............................................................................................... 32
6.2 Transportation and storage...........................................................32
6.3 Storage before installation............................................................ 34
7 Set-up and start-up...................................................................35
7.1 Safety............................................................................................... 35
7.1.1 Safety instructions for set-up and start-up....................................... 35
7.1.2 System-side safety requirements..................................................... 36
7.1.3 Customer-side safety precautions.................................................... 37
7.2 Requirements at the set-up point.................................................38
7.3 Unpacking the unit......................................................................... 43
7.4 Installation....................................................................................... 44
7.4.1 System-side requirements for stress-free installation...................... 44
7.4.2 Mounting the unit..............................................................................44
7.5 Notes on connecting the unit....................................................... 45
7.5.1 Connect the unit to the heat carrier circuit of the system................. 45
7.5.2 Unit electrical connection and protection......................................... 47
7.6 Perform acceptance test................................................................48
7.7 Test readiness for operation......................................................... 49
7.8 Putting the unit into operation for the first time......................... 49
GFH | 2018-04
8 Operation................................................................................... 50
8.1 Safety............................................................................................... 50
8.2 Putting the unit into operation......................................................50
8.3 Taking the unit out of operation................................................... 50
8.4 Shutting the unit down.................................................................. 51
© Güntner GmbH & Co. KG
Page 4
page 4 / 62
8.5 Putting the unit into operation after a shutdown........................ 52
8.6 Changing the unit over to another working fluid........................ 52
9 Troubleshooting........................................................................ 53
9.1 Safety............................................................................................... 53
9.2 Service............................................................................................. 53
9.3 Troubleshooting table....................................................................53
10 Maintenance...............................................................................54
10.1 Safety............................................................................................... 54
10.1.1 Before starting all maintenance........................................................54
10.1.2 With all maintenance work............................................................... 54
10.1.3 After all maintenance work...............................................................55
10.2 Inspection and maintenance plan................................................ 56
10.2.1 Fans.................................................................................................. 56
10.2.2 Unit heat exchanger......................................................................... 56
10.3 Maintenance work.......................................................................... 57
10.3.1 Remove leaks...................................................................................57
10.4 Clean unit........................................................................................ 58
10.4.1 General............................................................................................. 58
10.4.2 Clean heat exchanger...................................................................... 58
10.4.3 Cleaning fans....................................................................................61
11 Plans/diagrams..........................................................................62
11.1 Electrics documentation................................................................62
11.1.1 Fan motor connection diagram........................................................ 62
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 5
page 5 / 62
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)
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.
The manufacturer's responsibilities are documented in the unit's version in acc. with EN 378-2 (design, manufacture and testing).
GFH | 2018-04
The materials used in the construction and for soldering and welding are designed to withstand
the foreseeable mechanical, thermal and chemical stresses, and are resistant to the working fluids
used and to mixtures of such working fluids and the oils used to lubricate refrigeration compressors.
© Güntner GmbH & Co. KG
Page 6
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 responsibility for the 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 including the heat carrier circuit/are documented in the
system’s version (design, manufacture and testing – in accordance with EN 378-2.
Component supplier-system installer interfaces :
•
In the event of any malfunction, inform Güntner GmbH & Co. KG :
Inform Güntner GmbH & Co. KG immediately if faults occur during the set-up, installation, startup 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.
•
Specify checking and maintenance intervals:
The system including the heat carrier circuit must be configured and equipped with all required
equipment for maintenance and sufficient servicing and testing in accordance with EN 378-4.
When the unit is integrated into the refrigeration system’s heat carrier circuit , the working fluid and
version must not deviate from the order-related information specified in the order-related documents.
page 6 / 62
The installer of the system including the heat carrier circuit must refer to the requirement for sufficient instruction of the operating and supervision staff when operating and maintaining the equipment .
It is recommended that the future customer staff – if possible – be present during the set-up and installation, for tightness tests and cleaning, while the system is being filled with working fluid and for
the adjustment of the equipment including the heat carrier circuit.
1.3.3 Owner or operator responsibilities
The owner or operator responsibilities are documented in the operation, maintenance, servicing
and recovery of the system including the heat carrier circuit in accordance 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 including the heat carrier circuit/.
The operating personnel for the system and the heat carrier circuit must have sufficient knowledge
and experience with regard to the mode of operation, operation and daily monitoring of this system
including the heat carrier circuit .
Before starting up the system, including the heat carrier circuit the owner or operator must ensure
that the operating personnel are sufficiently instructed about 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 heat carrier circuit and the safety measures to be observed, and with regard to
the properties and handling of the working fluid to be used.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 7
The owner or operator must ensure that when operating, monitoring and maintaining the system including the cooling plantthe working fluid and version must not deviate from the details specified in
the order-related 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 including the heat carrier circuit ,
if the system including the heat carrier circuit are used by anybody else, unless there is a contrary
agreement on sharing responsibility.
If you operate devices that are wetted or sprayed with water, you must observe the contents of the
VDI guideline 2047-2 “Requirements for the hygienic operation of cooling towers” and the VDMA
leaflet “Notes and recommendations for operating and maintaining evaporative cooling plants”.
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
GmbH & Co. KG’s prior explicit written approval.
page 7 / 62
1.5 Operating instructions
1.5.1 Scope
1.5.2 Set-up and other applicable documents
These operating instructions apply for all drycoolers of the GFH series.
You will find the precise type of your unit in the attached order-related documents.
The unit's operating instructions include the following parts:
•
These instructions
•
Order-related documents
The order-related documents are included with these instructions and contain the following in-
formation:
– The order-related proper use as specified
– The order-related scope of delivery
NOTICE
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 8
– 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 including the heat carrier circuit/.
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
Abbreviations Meaning
page 8 / 62
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 .
°C Degrees Celsius (Celsius scale temperature)
is 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 part”.
Hz Hertz (frequency)
D Delta connection (alternating current: high speed)
S Star connection (alternating current: low speed)
3~ 3-phase current
1~ 1-phase alternating current
GFH | 2018-04
VDE “Verband der Elektrotechnik, Elektronik und Informationstechnik” (Association
for Electrical, Electronic & Information Technologies)
TCC Technical Connection Conditions
EPC Electric Power Company
VDI “Verein Deutscher Ingenieure” (German engineers’ association)
© Güntner GmbH & Co. KG
Page 9
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.
CAUTION
Dangerous situation that could cause slight to moderate injury if it is not avoided.
NOTICE
Refers you to possible damage to property.
page 9 / 62
1.7.2 Warning symbols and their meaning in these operating instructions
Warns against hand injuries!
Failure to comply with warnings may result in hands or fingers being crushed,
dragged in or otherwise injured.
Warns against hot surfaces!
The temperature is over +45°C (at which protein clots) and can cause burns.
Warns against dangerous electrical voltage!
Danger of an electric shock if voltage-carrying parts are touched.
Warns against fire-risk substances at set-up point.
Use of ignition sources can cause fire at set-up point.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 10
Warns against harmful to health or irritant substances at set-up point
Contact with or inhaling substances that are irritant or harmful to health can cause
injuries or damage peoples’ health.
Warning of automatic start-up
If the unit starts up automatically during maintenance work there is a danger of
pinching/trapping the hands and fingers.
1.7.3 Prohibitory signs and their meaning in these operating instructions
Fire, open fire and smoking prohibited!
Ignition sources must be kept away and ignition sources must not develop!
page 10 / 62
No smoking!
Smoking is forbidden.
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)
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 11
page 11 / 62
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.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 12
2 Safety
2.1 Labelling on the unit:
Identifiers' placed on the unit
1 Unit type plate on front plate 6 "Protection grill" warning sign – only with
2 Güntner logo 7 Connections ON, OFF
3 "Transportation filling" warning sign next to
Schrader valve
4 Operative range for fork lifts; affix in the
struts area
5 Inspection door, only on units with inspec-
tion doors
page 12 / 62
units with individual removable fan protection, e.g. Woods fans.
8 Transportation regulation; affix on both
sides between the lifting lugs; also affix at
the front/end sides; and on the packaging
if required
11 Installation instructions for vibration
dampers (enclosed with vibration
dampers)
2.1.1 Safety signs on the unit
Safety signs on the unit individually:
940 - “Transportation filling” warning sign next to Schrader valve
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 13
5969 - Warning on inspection door and hinged fan plate
page 13 / 62
3083 - “Protection grill” warning sign (only used with separate removable protection grill)
941 - Notice pointing out frost risk
For frost risk see Frostbite hazard, page 21
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 14
2.1.2 Other signs and notes on the unit
page 14 / 62
2483 - Example of a manufacturer’s nameplate
943 and 943.1 - Connections IN and OUT
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 15
page 15 / 62
21 - Transport regulation in accordance with SP 11
79 - “Vibration dampers” notice
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 16
Only for units with the option of vibration dampers; for assembly of the separately enclosed vibration dampers see Mounting the vibration dampers (optional), page
4 - Usage area for forklifts in accordance with SP 34
2.2 Basic safety notices
2.2.1 How to act in an emergency
page 16 / 62
WARNING
Danger of injuries and damage to property!
The unit is operated as standard with the heat carrier/ , ethylene glycol (synonyms:
ethane-1,2-diol, glycol). When using other heat carriers/ , 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 heat carrier/ escaping from the unit cannot penetrate the interior of the
building or put people at risk in any other way.
Safety measures and procedure:
•
In the event of serious unexpected leakage of heat carrier/ , activate the emergency
measures provided, e.g. if:
– Visibly escaping heat carrier / from the heat exchanger or pipe components.
– Sudden large release (release and evaporation of the greater part of the entire
heat carrier / in a short time, e.g. in less than 5 minutes).
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 17
page 17 / 62
•
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 for maintenance work in high
heat carrier / concentrations in the room air.
– Ensure the set-up room is well ventilated.
– Divert escaped heat carrier / liquid safely in accordance with EN 378-3.
2.2.2 Personnel, care requirements
The unit may be installed, put into operation, operated, maintained and repaired only by trained, experienced and qualified personnel. In order to be considered qualified, people who are to be responsible
for the operation, maintenance, repair and evaluation of systems and their components must have the
necessary training and specialist knowledge for such work, as stipulated in EN 378-1. Qualified or expert means the ability to satisfactorily perform the activities required for the operation, maintenance, repair and evaluation of refrigeration systems 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, including the heat carrier circuit . This operating personnel may not
make any interventions or settings on the system including the heat carrier circuit .
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.
CAUTION
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 18
2.3 Proper intended use
2.3.1 Proper intended use
Dry coolers of the GFH series are intended for installation in the heat carrier circuit of a refrigeration
system and for outdoor installations. The dry coolers cool the heat carrier by giving off heat to the
air that is being moved by fans over the dry heat exchanger surface.
The unit is delivered for operation with a specific operating point:
•
Heat carrier flow temperature
•
Heat carrier return temperature or circulating heat carrier volume
•
Airflow volume
•
Air inlet temperature
The specified operating point is given in the order-related documents.
The hinged fan plates of the movable fans (optional) are gas spring-operated. The gas springs are only
suitable for use in a temperature range of -30 °C to +80 °C.
page 18 / 62
NOTICE
2.3.2 Operating conditions
The unit is a component of the heat carrier circuit 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 minimise the danger to people and property and the
environment from the unit and the working fluid used in it. 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 due to
the heat carrier glycol, page 22.
Danger of injuries and damage to property!
The unit may be used only in accordance with the proper intended use. The operator must ensure that
when operating, monitoring and maintaining the unit, the fluid used and the mode of operation do not
deviate from the order-related information specified in the order-specific documents.
The operator must ensure that maintenance measures are performed in compliance with the system’s
operating instructions manual.
Filling the unit with a different fluid is permitted only following written approval by the manufacturer. You
will find the order-related proper use as intended in the order-specific documents.
Do not exceed the max. operating pressure given on the unit’s type plate.
WARNING
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 19
2.3.3 Improper use
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
may be pressurised only with heat carrier. Pressurising the unit with another working fluid would have
the effect that
■
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 would not be resistant to the other working fluid and the combination of the other working fluid and
■
the unit not remaining tight during operation and when shut down.
■
a possible sudden escape of working fluids could directly endanger people and/or property and the
environment.
page 19 / 62
WARNING
The maximum permissible operating temperature specified on the type plate must not be exceeded! If
the operating temperature is exceeded,
•
the unit would be exposed to an impermissibly high pressure (pressure/temperature correlation),
•
signs of material fatigue would emerge,
The maximum permissible operating pressure specified on the type plate must not be exceeded! If the
operating pressure is exceeded,
■
the parts of the unit carrying the working fluid might not withstand the foreseeable mechanical, thermal and chemical stresses and the pressures that may occur during operation and when shut down,
■
the unit would 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 working fluid-carrying components, which would result in the following dangers:
– Danger of escaping materials
– Strong chemical reactivity
– hazards caused by panic reactions,
– Environmental pollution
WARNING
Dry coolers may 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 it is possible that the specific concentrations of the coolant in a homogeneous mixture with air
could ignite.
The unit must not be changed without the prior written consent of Güntner GmbH & Co. KG . Changes
to the unit are:
■
Changing the operating point (as specified in section see Heat exchanger (typical values), page
28)
■
Changing the fan capacity (air volume)
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 20
■
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 damage and faults must be
reported to Güntner GmbH & Co. KG immediately and dealt with promptly.
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.
page 20 / 62
WARNING
2.4.2 Fans
Use reliable hand protection!
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.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 21
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 may be performed only 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.
2.6 Thermal residual hazards
page 21 / 62
WARNING
2.6.1 Danger of burns
2.6.2 Frostbite hazard
WARNING
Warns against hot surfaces!
In operation the unit's heat exchanger and pipes have temperatures of over +45 °C.
Contact can cause burns.
Use hand protection!
WARNING
Warns against frostbite!
The unit cannot be fully drained without the use of tools!
With insufficient frost protection filling and operation in areas with frost hazard the unit
can cause frostbite.
Operation, standstill and pressure tests are permitted only using the specified resources and agents. At no time during operation, standstill or pressure tests may the
operating agent fall below its freezing point, as otherwise the unit (heat exchanger
block) will be destroyed. In the case of risk of freezing, the unit must be fully drained
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 22
or rinsed with an anti-frost agent until adequate freeze protection is assured. When
draining, the unit must be sufficiently ventilated. Draining must be possible at all times
by a descending drain pipe outside the unit. The pressure drop may need to be increased with pressurised air during draining.
2.7 Residual hazards due to the heat carrier glycol
WARNING
Danger of injuries and damage to property!
General description of hazards:
The unit is operated as standard with a heat carrier/ (water/glycol mixture – for example, ethylene glycol;
synonyms: ethane-1,2-diol, glycol) or with . When using other heat carriers/, 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.
Unauthorised people must not have access to the unit. When setting up it must be ensured that the
heat carrier/ escaping from the unit cannot penetrate the interior of the building or put people at risk.
page 22 / 62
WARNING
Care must be taken during installation to ensure that no heat carrier / issuing from the unit can enter water or waste water systems.
Danger of environmental pollution!
Ensure that no heat carrier / enters water or waste water systems.
WARNING
Danger of harm to health!
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.
•
Avoid contact with skin, eyes and clothing! Remove contaminated, soaked clothing immediately!
•
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.
•
To avoid the inhalation of high vapour concentrations, the working rooms must be well aired.
•
Test the tightness of the unit regularly, as specified in these operating instructions.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 23
page 23 / 62
Ignition and fire hazard!
Ethylene glycol is flammable and explosive at higher temperatures in a vapour/
gaseous state.
•
Keep ethylene glycol away from ignition sources.
•
Suitable fire fighting equipment must be provided on site when working with
flames, such as grinding or soldering, for example.
•
Ensure that the provided fire fighting equipment is provided in sufficient quantities,
that it functions properly and that the extinguishing agent does not react with the
heat carrier/ .
•
No smoking!
Danger of poisoning!
Contact of the heat carrier/ with open fire must be prevented, as toxic combustion
products can form.
•
Prevent heat carrier/ contact with open fire!
•
Welding and soldering may therefore take place only after completely draining the
relevant section of the system of the heat carrier/. Ensure good ventilation here!
•
Do not allow contact with powerful oxidation agents (chromo-sulphuric acid, potassium permanganate, fuming sulphuric acid, or similar)! Danger of strong reactions!
Frostbite hazard!
With insufficient frost protection filling and operation in areas with frost hazard the unit
can cause frostbite. With units that cannot be drained completely the hazard of frostbite also remains after draining.
•
It is imperative that the proper ventilation be ensured when draining the unit.
•
With pressure test, operation and shutdown of units filled with water or insufficient
frost protection filling or insufficient setting of the heat carrier/, these are disrupted at
minus temperatures.
2.8 Residual hazards caused by vibrations
WARNING
Danger of injuries and damage to property caused by escaping materials!
If fans are damaged during fan operation, flying parts of the fan blades can injure people or cause damage to property close to the fan.
Fans, components and cables in system, including the heat carrier circuit must be designed, constructed
and integrated so that dangers caused by vibrations that it or other parts of the system generate ,, are
reduced to an absolute minimum, while incorporating all available means for reducing vibrations, preferably at the source.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 24
NOTICE
Damage to property caused by vibrations!
Vibrations that are increased by imbalances, as created by dirt or fan blade damage, are regularly
caused with fan operation. The vibrations are transferred to the unit, where they can cause damage
and damage the unit mounting or heat carrier circuit components connected to the unit.
Check fan blades and protection grill regularly for contamination and make sure the fans run smoothly
(see Fans, page 56).
2.9 Residual hazards caused by pressurised parts
WARNING
Injury and damage to property caused by pressurised components that contain heat carrier/ !
Breaks in pressurised pipes or pressurised components of the unit can cause injuries or damage to
property caused by escaping materials ( A sudden large release of the working fluid with its hazardous
properties after a break or leak on pressurised components of the unit can cause the following hazards:
■
Irritations and health hazards
■
Strong chemical reactivity
■
Flammability
■
Suffocation
■
Panic,
■
Environmental pollution
Ensure that the unit in question is pressure-free before maintenance work begins or remove the working
fluid from the unit in question.
page 24 / 62
Perform maintenance work – especially soldering and welding – on the unit in question only after completely removing the working fluid from the unit.
2.10 Residual hazards caused by defective installation
WARNING
Injuries and damage to property caused by defective installation!
Defective installation results in hazards caused by:
■
Break or leak on liquid-carrying unit components and pipes
■
Uneven load distribution on the fixtures with the danger of stresses within the unit or unit displace-
ment (breaks or leaks on fluid-carrying components of the unit and pipes; danger of breaking off).
■
Insufficient securing of working fluid-carrying lines against mechanical damage! On-site connections:
loaded installation; effect of forces on the distribution and header pipes with the danger of breaks or
leaks on fluid-carrying components of the unit and pipes; danger of breaking off!
■
Break-off danger of the unit with hazard of escaping working fluid and exposed electrical cables.
■
Danger of damage caused by environment-conditional hazard sources (production, transport and
other processes at the set-up point).
■
Unit functional faults caused by air inlet/outlet obstructions.
■
Obstruction of all-side inspection, checks and maintenance, i.e. no unobstructed accessibility to the
working fluid-carrying and electrical components, connections and cables, no recognisable identifiers
on the pipes and insufficient space for tests.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 25
page 25 / 62
Ensure that:
•
The units are to be installed on the fixing points corresponding with their weights and tightened with
fixing bolts. The operator or installer is responsible for ensuring that the bolted connections are of an
adequate strength.
•
The diameters of the mounting holes have been statically determined by the manufacturer and the
fixing bolts are adapted accordingly.
•
The fixing bolts are secured against loosening by means of an appropriate locking device.
•
The fixing bolts are not overtightened or stripped.
•
All fixing bolts are tightened equally to achieve a load distribution on the connections that is as bal-
anced as possible.
•
All fixing points maintain the same spacing to the fixing level permanently and under load, so that no
mechanical stress occurs in the unit structure. The units are anchored in their fixing position in order
to prevent the equipment from moving.
•
The functional safety of the fixing bolts is tested as part of the maintenance periods. see Mainte-
nance, page 54,
•
The unit is fixed and set up so that it is not damaged by environment-conditional hazard sources
(production, transport and other processes at the set-up point) or its functioning is not disturbed by
the interventions of unauthorised persons.
•
The units are fixed and set up so that unobstructed air inlet/outlet is constantly available without any
air short circuiting.
•
The units are fixed so that they can be inspected, checked and maintained from all sides at all
times, i.e. there must be unobstructed access to the refrigerant-carrying and electrical components,
connections and lines, the pipeline labelling must be identifiable and adequate space must be avail-
able for testing.
•
The working fluid-carrying lines must be protected against mechanical damage. On-site connec-
tions: when installing keep the unit free of load; force must not be exerted on the distribution and
header pipes.
•
The following must be observed without fail when installing the unit:
– Imperative adherence to spacing from objects that could be endangered heat carrier/ effects.
– Easily flammable materials must not be placed below the unit.
– Set up and fix units as follows: In areas that are used for inner-plant traffic, the pipelines to and
from the unit must be installed only with connections and fittings that cannot be removed.
– Release devices to prevent liquid escapes must be provided and available.
2.11 Residual hazards with break during operation
WARNING
Injuries and damage to property caused by break during operation!
•
Defective installation (see Residual hazards caused by defective installation, page 24).
•
Non-compliance with maximum permissible operating pressure ( see Operating conditions, page
18).
•
Disregarding pressurised line sections with maintenance ( see Residual hazards caused by pres-
surised parts, page 24).
•
Disregarding residual hazards caused by vibrations ( see Residual hazards caused by vibrations,
page 23).
result in ruptures during operation and maintenance. This results in dangers caused by
•
escaping materials (see Residual hazards caused by pressurised parts, page 24).
•
released working fluid (see Residual hazards due to the heat carrier glycol, page 22).
Ensure that:
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 26
•
The installation is fault-free.
•
The maximum permissible operating pressure is always adhered to.
•
Pressurised line sections are de-pressurised before all maintenance and repair work.
•
Vibrations from the refrigeration system including the heat carrier circuit, (vibrations caused by the
complete system’s compressors, components and lines, including the heat carrier circuit ) and from
the fan (imbalances caused by frost, ice, accumulations of dirt or damage) are reduced with all
available means and brought down to an absolute minimum.
•
Release devices to prevent liquid escapes are provided and available.
2.12 Residual hazards caused by escaping objects or liquids
WARNING
Injuries and damage to property caused by escaping objects or liquids!
Residual hazards caused by escaping objects and liquids ( see Residual hazards with break during oper-
ation, page 25).
2.13 Residual hazards with disposal
page 26 / 62
WARNING
Danger of injuries and damage to property caused by working fluid, , , glycol!
The following notes are recommendations for the proper professional disposal of the unit. Applicable
waste disposal laws are binding for the country of operation:
■
Disposal must only be carried out by experts.
■
All unit components, e.g. working fluids, heat carrier, heat exchangers, fans, must be disposed of
properly as specified.
■
Used working fluid that is not determined for reuse, must be treated as waste and safely disposed
of. There must be no emissions into the environment.
■
A disposable single-use container must not be used, as it is possible that heat carrier/ residues in
the container may escape during disposal.
■
The working liquid receiver must not be overfilled. The maximum permissible pressure of the working
fluid container must not be exceeded during the work process.
■
The working fluid must not be filled in a liquid container that contains another or an unknown working
fluid. This other or unknown working fluid must not be released into the atmosphere, but rather identi-
fied, treated again, or properly disposed of as specified.
■
An officially authorised facility can be used for destroying the working fluid.
■
It must be ensured that all unit components containing working fluids and heat carrier/are disposed
of properly as specified.
■
The unit consists predominantly of the basic materials, copper, aluminium, galvanized steel (heat ex-
changers and casings), steel, aluminium, copper, polyamide (motors). These materials can be han-
dled by the waste industry, including in paint-treated state, to recycling via mechanical and thermal
separation.
■
Before scrapping the working fluid-carrying unit components must be drained, whereby the pressure
must be reduced to at least 0.6 bar absolute for a unit pipe volume up to and including 200 l, and
to 0.3 bar absolute for a unit pipe volume over 200 l. The pressure reduction process is then ended
when the pressure no longer increases and remains constant, and the unit is at ambient tempera-
ture.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 27
page 27 / 62
WARNING
Danger of environmental pollution!
Ensure that no heat carrier enters water systems or sewage.
Operate the facility for recovering or disposing of working fluids so that the danger of a working fluid
emission into the environment is kept as low as possible.
Güntner GmbH & Co. KG’s transportation packaging is made from environmentally compatible material and is suitable for recycling.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 28
3 Technical data
3.1 Heat exchanger (typical values)
The typical values given here refer to standard types of this series. The following is valid especially for
special equipment: Please observe the data in the calculation (Annex) and on the nameplate.
The fans’ capacity values depend on the ambient temperature and on the air resistance at the set-up
point.
All electrical parts must be installed in accordance with EN standards.
Project number See order-related documents
Unit name See order-related documents
page 28 / 62
NOTICE
NOTICE
3.2 Fans
Manufacturer number See order-related documents
Production year See order-related documents
Heat carriers See order-related documents
Volume See order-related documents
Maximum permissible pressure (PS) 0 - 10 bar
Permissible air humidity > 100%
Test date See order-related documents
Test medium Dry air
Airborne noise emitted See order-related documents In accordance with the
standard procedure for calculating sound level described
in EN 13487; Annex C (normative).
Weight See order-related documents
The GFH series uses axial AC fans with 1250 mm diameter.
230V 1~ 50 Hz is switched in alternating current for GFH fans used with 450 to 650 mm diameter.
The fans with 800 to 1000 mm diameter can be speed-controlled with Güntner control units. The alternating current fans can generally by operated with 2 different speeds by D-S changeover. 5 capacity/sound levels (N, M, L, S, E) can be delivered.
GFH | 2018-04
Fan type See order-related documents
Protection rating IP 54, thermal class 155 and DIN VDE 0530
Current type Rotating or alternating current
Voltage 400 V 3~ 50 Hz or
230 V 1~ 50 Hz
Balancing quality Q 6.3 in acc. with VDI 2060
© Güntner GmbH & Co. KG
Page 29
page 29 / 62
Permissible air temperature Operating range: at least -30°C to +55°C
Protective devices
•
Thermal: Thermo-contacts (temperature
monitor for safeguarding against thermal
overload).
•
Mechanical: Protective contact grille in acc.
with EN 294
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 30
4 Set-up and function
The drycooler consists of,
•
a heat exchanger, consisting of tube coils fitted with fins (copper tube, aluminium fin), distribution tubes and header outlets (copper) and tube connections to the tube system,
•
a casing consisting of galvanized sheet steel, painted in RAL 7035 (light grey).
•
and – depending on the version – with one or more low noise axial fans with maintenance-free
motors.
The GFH series dry coolers are intended for installation in the heat carrying circuit of a cooling system. The cooling system is a combination of fluid-carrying components and fittings connected with
one another, which form a closed circuit, in which the fluid circulates.
The heat carrier is the working fluid that is used for the heat exchange, and which remains in the
liquid phase during the heat absorption.
The liquid used is a heat carrier in acc. with EN 378-1, para. 3.7.2. There is no imminent danger for
the staff.
The heat carrier absorbs heat at a low temperature, heats up, and gives the heat off again at a
higher temperature. The dry cooler cools the heat carrier by giving off heat to the air (air-side) that
is being moved by fans over the dry heat exchanger surface.
page 30 / 62
Fan motor
The fan motors for the 450 mm to 650 mm diameter fans are connected t AC, 230 V 1~ 50 Hz.
The fan motors for fan diameters 800 mm bis 1000 mm are connected in 3~ alternating current,
“delta connection” with 50 Hz (IP54). A “star connection” can be used to reduce the speed if required. The star connection / star = low voltage (S) or delta connection / delta = high voltage (D)
must be adjusted to the actual on-site mains voltage.
Güntner control units can be be used to control the speed of fans. The direction must be checked; a
change in the direction, if the direction is wrong, is made by interchanging two phases.
Water spray system (optional)
The system can be extended with optional water spraying for relieving capacity peaks. Water spraying can, however, be used only subject to restrictions (max. 50 hours a year). A corresponding pipe
system with nozzles is available.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 31
5 Fan motor
During longer periods of storage or standstill, the fans must be activated during 2 to 4 hours per month.
For fans with the protection rating IP55 or higher, existing closed condensation water holes must be
opened at least once every six months.
AC technology
The AC motors are protected against overheating by a thermocontact (or PTC resistor).
For motors with a thermocontact, the thermocontact must be switched in such a way that the motor
cannot be powered on when the thermocontact is triggered. A locking mechanism is recommended
to prevent renewed power-on.
Motors with a PTC resistor need an additional external trigger unit for the installed thermistors. A
locking mechanism is recommended to prevent renewed power-on. The test voltage at the thermistors is not permitted to exceed 2.5 V, or only current-limiting test devices may be used.
page 31 / 62
NOTICE
NOTICE
EC technology
When using a star-delta connection, a corresponding delay must be considered.
For motors with direct starting and a connection value > 4.0 kW, an inrush current limitation (soft
start using a thyristor) could be required.
If frequency converters are to be used for speed control, the following points must be considered for
external rotor fans:
Between the frequency converter and fans, all-pole sine-wave filters must always be installed (sine
wave-shaped output voltage; filter effect between phase to phase and phase to earth).
All Güntner frequency converters are equipped with this function as standard. Conventional threephase motors are suitable for direct operation with frequency converters.
With star-delta connection, the three-phase fan motors can be operated with two speeds or with
speed control. The direction of rotation must be checked. A change in the direction of rotation, if it is
wrong, is made by interchanging two phases.
NOTICE
The fan motors have their own electronic power component. This power component is controlled by
means of Güntner Motor Management (GMM). The motors can be operated using single-phase (1~,
200 – 277 V AC, 50/60 Hz) or three-phase (3~, 380 – 480 V AC, 50/60 Hz) voltage ratings. When operated without GMM, the fans should be controlled with a voltage of 0 - 10 V. Refer to the connection
plans or the information on the motor terminal box for details on the electrical connection.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 32
6 Transportation and storage
6.1 Safety
Crushing danger with falling down!
The unit weighs between 60 kg and 2750 kg. It can slip and fall off the transporting device, causing serious injuries or death. Heavy impacts or vibrations can damage the unit.
Ensure that the assigned staff is trained for proper unloading.
Ensure that nobody is under the unit or near the loaded area during the transport.
Ensure even weight distribution. Observe the transport labels on the packed unit ( see Other signs and
notes on the unit, page 14).
Secure the unit against slipping and mechanical damage.
When transporting by crane: The hooks and lifting gear of the load lifting equipment must be only attached at the points specified by the manufacturer. Ensure that the unit casing is not crushed by slings.
page 32 / 62
WARNING
Use auxiliary transport equipment where required. Use a transporting device appropriate for the unit’s
weight (see graphic in chapter Transportation and storage). You will find the weight of the unit in the order-related documents (see Set-up and other applicable documents, page 7). Do not use connection
pieces and header pipes as hooking points for lifting, pulling, fixing or mounting. This can cause leaks.
Transport the unit carefully. Particularly avoid setting the unit down hard.
Only step on to the units with firm, tough and safe footwear, and only when required.
If the units do not have any railings, always only walk on them with a safety device that prevents falling.
6.2 Transportation and storage
Read and observe all transport signs on the units’ packaging!
The units are transported as complete system components. Ensure the correct hooking points when
transporting with a crane:
Use suitable equipment to transport the packed unit to the destination installation site (for exam-
ple, a crane or fork-lift).
Unload the unit.
NOTICE
GFH | 2018-04
WARNING
Danger of damage to goods by falling when transporting by fork-lift!
Packed units that are not lifted with forks of appropriate length could slip and fall.
Only lift the packed unit with a fork-lift with full fork length. Be careful to comply with the positioning
specifications for the fork-lift.
Only lift the packed unit with a fork-lift that is appropriate for the unit's weight.
© Güntner GmbH & Co. KG
Page 33
page 33 / 62
GFH | 2018-04
21 - Transport specification for old series
© Güntner GmbH & Co. KG
Page 34
page 34 / 62
Transport specification for new series
4 - Usage area for forklifts in accordance with SP 34
6.3 Storage before installation
Danger of corrosion and dirt build-up!
Moisture and dirt must be prevented from entering the unit.
Protect the unit against dust, dirt, moisture and wetness, damage and other harmful effects. Harmful
effects: see Safety instructions for set-up and start-up, page 35
Do not store the unit for longer than necessary. Only store the units in their original packaging until
installation. Always only place packaging units of the same size on top of one another.
NOTICE
GFH | 2018-04
Store the unit at a protected place free of dust, dirt, moisture and damage-free until its set-up
(well-ventilated halls or roofed storage site).
If the unit set-up is delayed with regard to the planned installation time: protect the unit against
weather and other harmful effects and dirt and other contaminants with an appropriate cover.
The unit must also be well-ventilated here.
© Güntner GmbH & Co. KG
Page 35
7 Set-up and start-up
7.1 Safety
7.1.1 Safety instructions for set-up and start-up
WARNING
Danger of injuries and damage to property with escaping heat carrier!
Incorrect installation causes the danger of working fluid escaping when the unit is operated and injuries
or damage to property (see Residual hazards due to the heat carrier glycol, page 22).
Follow the set-up instructions in this chapter precisely and apply extreme care!
NOTICE
Damage to the system's !
Foreign materials and contaminants in the working fluid circuit can impair the effectiveness or damage
components. Particularly harmful contaminants are:
page 35 / 62
– Moisture
– Atmospheric air
– Welding and soldering residues
– Rust
– Soot/ash/cinders
– Metal cuttings
– Dust and dirt of all kinds
Moisture in the working fluid-carrying components of the unit can have the following consequences:
– Acidification
– Ageing and heat carrier decay
– Corrosion
– Changing the prescribed concentration of heat carrier corresponds to an increased danger of too lit-
tle frost protection in the dry cooler, which could result in the unit being destroyed when subjected to
minus temperatures.
Atmospheric air and other non-condensable gases can have the following consequences:
– Heat carrier/ oxidation
– Heat carrier/ chemical reactions
– Changing the concentration of heat carrier corresponds to an increased danger of too little frost pro-
tection in the dry cooler, which could result in the unit being destroyed when subjected to minus temperatures.
Heat carrier/ chemical reactions with the absence of moisture or atmospheric air with ageing and decay
can have the following consequences:
GFH | 2018-04
– Formation of organic and inorganic acids
– Corrosion
Other contaminants can cause:
– Accelerated chemical processes (decomposition)
– Mechanical and electrical faults in the heat carrier circuit
© Güntner GmbH & Co. KG
Page 36
page 36 / 62
During the installation (connecting the working fluid-carrying components of the unit to the working fluid-carrying system of the installation’s – or to the refrigeration system’s heat carrier circuit) ensure that internal contamination is strictly avoided.
Perform the installation with extreme cleanliness.
Finish all on-site pipe installation work before releasing the transport pressure!
Only release the transport pressure on the Schrader valve immediately before installation.
Only remove the sealing caps on the distribution and header pipe immediately before installation.
NOTICE
Danger of corrosion and dirt build-up!
Moisture and dirt must be prevented from entering the unit. If moisture and dirt penetrate the unit there
is also the danger of damage to fittings and other system components of the .
Protect the unit against dust, contamination, moisture and wetness, damage and other harmful influences. Harmful influences are, for example:
– Mechanical: Damages caused by impacts, objects falling on or against, collisions with transport
equipment, etc.
– Physical: Damages caused by close by concentrated flammable gases
– Chemical: Damages caused by contaminated atmospheres (salt, acid, chlorine, sulpher-containing,
or similar)
– Thermal: Damages caused by close by heat sources
Begin with the installation as soon as possible.
The electrical installation may be performed only by electricians (or by expert technicians with appropriate
qualifications) in compliance with the relevant VDE rules (or applicable national and international regulations) and the TCCs of the EPCs!
7.1.2 System-side safety requirements
The unit is a component of the heat carrier circuit of an installation and can only be operated in conjunction with the installation
•
All equipment required for operating the unit must be integrated into the switching and activation
equipment :
– Electrics: Fans and other electrical components
– Working fluids: valves and fittings
•
The heat carrier-side and electrical connections for the unit must be available for the unit on
the heat carrier circuit of the refrigeration system. The connections must be specified in the order-related offer documents.
•
The power supply of the fans must be provided in acc. with the specifications on the type plate
on the fan motors.
•
A switch-off device for preventing unexpected start-up (repairs switch), which separates all active conductors from the power supply (all-pole switch-off), must be provided for the fans in acc.
with EN 60204-1.
•
The fans' switch-on/off device must be secured (e.g. with a padlock) to prevent uncontrolled fan
start-up.
•
The electrical motor, repairs switch, terminal box and switching cabinet connections must be
provided in acc. with the respective connection diagrams.
WARNING
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 37
•
It must be possible to shut off the unit if a leak occurs.
•
People wearing ambient air-independent breathing apparatus in full protective clothing must also be able to activate all safety-relevant shut-off fittings.
•
It must be possible to activate all devices meant for diverting escaping working fluids from a
safe position.
7.1.3 Customer-side safety precautions
Danger of injuries!
The unit contains heat carrier/ (see Residual hazards due to the heat carrier glycol,
page 22).
The unit is operated as standard with the heat carrier/ , ethylene glycol (synonyms:
ethane-1,2-diol, glycol). Prior agreement with the manufacturer is imperative when using other coolants.
Ethylene glycol is a colourless, slightly viscous, not very fluid, water-mixable, deliquescent liquid with a sweet smell or taste.
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.
Ignition and fire hazard! Ethylene glycol is flammable and explosive at higher temperatures in a vapour/gaseous state. 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, eyes and clothing! Remove contaminated, soaked clothing immediately!
There is no imminent danger for the staff.
Do allow contact with heavy oxidation agents (chromic-sulphuric acid, potassium permanganate, smoking sulphuric acid, or similar)! Danger of strong reactions!
Unauthorised people must not have access to the unit. When setting the unit 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.
Comply with the requirements of EN 378-3 for coolants, filling weight and cold transfer systems.
Only install the unit in accordance with EN 378-1 in the commissioned configuration
and only in a set-up room that the unit manufacturer has configured the unit for.
Install the unit in accordance with EN 378-3, section 5 in a special machine room if
a coolant concentration of more than that specified in EN 378-3 could endanger the
work environment. Take effective protective precautions if such a spatial separation
were to be required, but is not possible.
Install the electrical equipment (for fan operation, for ventilation, for lighting and for the
alarm system) in the set-up room while observing the condensing-out of moisture and
drip water formation, as well as the risk level of the coolant in accordance with EN
378-3; section 6.
page 37 / 62
WARNING
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 38
Arrange alarm systems to warn about explosion or fire dangers or ammonia concentrations that are hazardous to health and for control purposes in the unit set-up room
in accordance with EN 378-3; section 7.
Ensure that the device in the set-up room is not exposed to any inadmissible high
temperature effects. Effectively protect the unit against heat sources or temporary
high temperatures.
Danger of environmental pollution!
•
Set up the unit so that heat carrier/ , which can escape from the unit in the event of a fault, cannot
enter water systems or sewage.
•
Operate the facility for recovering or disposing of heat carrier/ so that the danger of a heat carrier
emission into the environment is kept as low as possible.
7.2 Requirements at the set-up point
You will find the dimensions and weights in the order-related documents.
page 38 / 62
WARNING
Ensure that the unit is set up so that it is not damaged by environment-conditional hazard
sources (production, transport and other processes at the set-up point) and its functioning is not
disturbed by the interventions of unauthorised persons.
Position the unit so that it cannot be damaged by internal traffic or transport processes.
Enable optimum unit control and accessibility:
– Place the unit so that is can be monitored and controlled from all sides at all times.
– Ensure that sufficient space is provided for maintenance.
– Ensure that all liquid-carrying components, connections and lines and all electrical connec-
tions and lines are easy to access.
– Ensure that the pipes’ identification is well visible.
NOTICE
Danger of rusting of the vibration dampers or unit feet.
Installation of the unit in stagnant water or on surfaces on which water can collect (such as glycol
protectors) can lead to rust on vibration dampers and unit feet.
Rusting vibration dampers or unit feet can cause instability of the unit.
Several units with high nominal capacity can be compactly placed in rows to cover high capacities. With double or multiple row set-ups a substructure is required to guarantee sufficient airside pressurising.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 39
Free-standing set-up generally
page 39 / 62
1 Air-flow direction
2 Head space required
Unit dimensions: L = length, W = width, H = free flow height
Face area of heat exchanger coil: AA = L * W (in m2)
Inflow area below heat exchanger: AZ = 2(L+W) * H (in m2)
Condition: AZ ≥ AA * 0.7
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 40
Set-up next to a building wall
1 Air-flow direction
2 Free area for air suction
page 40 / 62
Unit standing lengthways alongside the building wall.
Legs must be extended, from serial length to customized length
400 mm to 800 mm
600 mm to 1000 mm
Set-up in a pit/hollow
1 Air-flow direction
2 Free area for air suction
Fans without additional device (without Güntner Streamer)
X ≥ 0.7 * W
Fans with Güntner Streamer
X ≥ 0.5 * W
Min. spacing X on both long sides
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 41
1 Air-flow direction
2 Free area for air suction
Fans with Güntner Streamer
(floor level is Streamer top edge)
X ≥ 0.6 * W
Min. spacing X on both long sides
page 41 / 62
1 Air-flow direction
2 Free area for air suction
Fans with ventilation channel and rectifier
X ≥ 0.5 * W
LD = 450 bis 650 mm
H1 = 200 to 340 mm (depending on fan diameter)
Min. spacing X on both long sides
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 42
Setting up several units
page 42 / 62
1 Air-flow direction
2 Free area for air suction
Recommended set-up
Minimum clearance B1 = 80 mm (necessary because of projection on vibration
dampers):
Face area of heat exchanger coil: AA = L * W * n (in m2) n... Number of units
Inflow area: AZ = 2 * L * H + 2 * n * W * H (in m2)
H results from the condition: AZ ≥ AA * 0.7 (in m2)
H = f (n; L, W)
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 43
7.3 Unpacking the unit
page 43 / 62
Remove side form boards, timbers and packaging material (1, 7, 8, 11, etc.).
Remove form boards and timbers (1, 2, 3, 4, 5, 8, 9, 10, 11).
Check the delivery for completeness. You will find a list of the contents of the package in the order-related documents.
Any transport damage and/or missing parts must be recorded on the bill of delivery. The facts
must be immediately reported to the manufacturer in writing. Damaged fins can be straightened
on-site with a fin comb.
Check transport overpressure: The units are delivered from the manufacturer with approx. 1 bar
transport overpressure (cleaned and dried air). Read the transport pressure on the Schrader
valve (pressure measurement). With unpressurised unit: Immediate report to manufacturer and
noting on bill of delivery. An unpressurised unit indicates a leak on the unit!
CAUTION! Danger of injuries and damage to property with escaping heat carrier! An unpressurised unit indicates a leak due to transport damage. Escaping heat carrier through leaks on
the unit can cause injuries ( see Residual hazards due to the heat carrier glycol, page 22). Do
not put the unit into operation!
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 44
1 Transport pressure filling
2 Check transport pressure; inform manufacturer with unpressurised unit
3 Release transport pressure
4 Remove blanking plugs.
NOTICE
Danger of corrosion and dirt build-up!
Moisture and dirt must be prevented from entering the unit.
Protect the unit against dust, dirt, moisture and wetness, damage and other harmful effects. Harmful effects: see Safety instructions for set-up and start-up, page 35
Begin with the installation as soon as possible.
7.4 Installation
7.4.1 System-side requirements for stress-free installation
Prevent stresses in the unit:
°
Ensure that all fixing points have the same spacing to the fixing level.
°
Ensure that all fixing points maintain the same spacing to the fixing level under load and permanently.
Set up and fix units as follows: Airflow must not be impaired by obstructions.
page 44 / 62
The units must be installed on fixing points that are appropriate for the unit's weight and then
bolted with fixing bolts. The operator or installer of the equipment is responsible for ensuring
that the bolted connections are of an adequate strength. The following instructions must be observed when fixing the units:
– The diameter of the mounting holes have been statically determined by the manufactur-
er; the fixing bolts must be adapted accordingly. When calculating the transferring bearing
strength it is imperative to take into account the total weight of the unit (= structural weight +
weight of pipe content + additional weight, such as water, frost, ice, dirt or similar).
– The fixing bolts must be secured against loosening with an appropriate locking device.
– The fixing bolts must not be overtightened or stripped.
– All fixing bolts must be tightened equally.
Prevent the unit from shifting in its position. Fix the unit in its position. Tighten the fixing bolts
and secure then against loosening.
Only fix the unit to the intended fixing points.
7.4.2 Mounting the unit
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 45
7.5 Notes on connecting the unit
Danger of injuries and damage to property caused by escaping heat carrier .
Incorrect installation risks working fluid escaping when the unit is operated, causing injuries or damage to
property (see Residual hazards due to the heat carrier glycol, page 22).
Prevent working fluid from escaping from the unit into the environment.
•
Secure all working fluid-carrying lines against mechanical damage.
•
In areas that are used for internal traffic, only lay the pipelines to and from the unit with connections
and fittings that cannot be removed.
Ensure that the on-site connections do not exercise any forces upon the distribution and header points.
This can cause leaks on the working fluid connection points of the unit and on connection points of the
on-site pipe-laying.
Ensure that:
•
Release devices to prevent liquid escapes are provided and available.
page 45 / 62
WARNING
7.5.1 Connect the unit to the heat carrier circuit of the system
WARNING
Danger of injuries and damage to property!
Improper connection to the heat carrier circuit of the system causes hazards:
•
Leaks result in escaping heat carrier/ (see Residual hazards due to the heat carrier glycol, page 22).
•
Soldering and welding work on pressurised parts can result in fires or explosions.
•
Smoking or open light can cause fires or explosions.
•
Ensure that stresses and vibrations from the system including the heat carrier circuit are not passed
on to the unit.
•
Only lay working fluid-side connections stress-free! The on-site pipeline system must be braced be-
fore connecting to the unit!
•
Soldering and welding work is only permitted on unpressurised units!
•
Evacuate the unit professionally in acc. with EN 378-2.
•
The use of open fire at the installation site is forbidden. Fire extinguishers and extinguishing agents
used to protect the equipment and the operating staff must comply with the requirements of EN
378-3.
Install the pipes in acc. with EN 378-1 and EN 378-3. Ensure here:
– Release devices to prevent liquid escapes must be provided and available.
– Avoid transmitting vibrations to the unit via conduits or pipes. If necessary, use vibration
dampers.
– Route the return line with a continuous gradient of from 3 to 5° along the direction of flow. Make
sure it can drain freely into the expansion tank!
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 46
page 46 / 62
(1) Dry cooler (3) Free flow
(2) Return line (routed with a gradient)
– Always lay fluid supply and return lines separately from one another.
– The free space around the unit must be big enough to ensure there is no danger to the unit; reg-
ular maintenance of the components must be possible, and it must also be possible to check
and repair components, pipes and fittings.
– It must be possible to shut off the unit if a leak occurs. It must be possible to activate all devices
used for diverting escaping working fluids from a safe position.
– Electrical components, e.g. for fan operation, for ventilation, for illumination and for alarm sys-
tem on installation site, have to be designed with regard to condensation of air humidity and
droplet formation in acc. with EN 378-3; section 6.
– Observe the following when soldering:
°
All connections must be hard-soldered!
°
Avoid percussive soldering joints; use copper pipe ends that are widened on one side (capillary soldering)!
°
Prevent leaks, solder precisely and carefully!
°
Prevent overheating when soldering (danger of excessive scaling)!
°
Use shielding gas when soldering (prevent excessive scaling)!
After completing pipe installation and before connecting the units they must be professionally
cleaned internally and evacuated in acc. with EN 378-2.
Ensure that the unit is well ventilated.
°
Provide all bleed connections on the deflected collector with automatic bleed valves.
°
When you do so, make sure that you do not restrict the cross section of the bleed connec-
tions.
Prevent the bleed mechanism from freezing:
°
Provide the bleed valves and bleed connections with auxiliary heating. Make sure the auxil-
iary heating will always be in operation when the outside temperature is <+ 3°C.
°
Insulate the bleed valves and bleed connections. Make sure the insulation does not affect
the operation of the automatic bleed valve.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 47
WARNING
Risk of damage from inadequate ventilation!
Without proper ventilation, the unit can be damaged or destroyed by freezing liquid.
page 47 / 62
(1) Automatic bleed valve (3) Auxiliary heating
(2) Bleed connection (4) Insulation
7.5.2 Unit electrical connection and protection
All fans with rotating current drive can be operated via D-S switch-over with two different speeds:
•
D: high speed
•
S: lower speed
The fans can be speed-controlled with the use of Güntner control units.
Connect fan motors in acc. with motor connection circuit in terminal box or electric diagram and
check connection.
Provide power supply in acc. with the specifications on the fan motor's type plate or electric diagram:
■
The fan motors are operated in 1~ alternating current and 3~ rotating current (IP 54).
Necessary for the protection of the fans: Connect and evaluate thermo contacts for motor protection if they are there.
Seal all electrical lines to the connection boxes in acc. with EN60204-1 and their protection
class. Make sure the IP protection class is paid heed to. Pay heed to information on the electric
diagram. The protection class is specified in the chapter "Technical data - Fans".
WARNING
GFH | 2018-04
Danger of damaging! If the fuse rating is too high there is the danger of injuries to people
and damage to property.
© Güntner GmbH & Co. KG
Page 48
7.6 Perform acceptance test
Danger of injuries and damage to property!
Escaping heat carrier/ can cause injuries or even death ( see Residual hazards due to the heat carrier
glycol, page 22).
Perform the following acceptance test with an expert before starting up the unit after making important
changes and after a unit exchange.
Ensure that the temperature and air humidity at the set-up point are in line with the technical data (see Technical data, page 28).
Ensure that sufficient air can be sucked in and released.
Ensure that the supply feed is sufficient for the required energy. Compare the unit inside the
heat carrier circuit of the systemwith the plans of the systemincluding the heat carrier circuit and
the electrical wiring diagrams.
Test the unit for vibrations and movements that can be caused by the fans and operation of the
system including the heat carrier circuit . Remove oscillations, vibrations and movements following consultation with the manufacturer or independently.
Perform visual inspection of the structural design, the brackets and fixtures (materials, sequence, connections), the ability to operate and the arrangement of the fittings.
Check and if necessary re-tighten all threaded connections, especially on the fans.
page 48 / 62
WARNING
Check installation of pipe connections.
Check laying of working fluid-carrying connection pipes.
Ensure that the unit is protected against mechanical damage.
Ensure that the unit is protected against inadmissible heating up and cooling down.
Check the fan blades protection.
Ensure that optimum unit control and accessibility are guaranteed.
– Is the unit placed so that it can be monitored and controlled from all sides at all times?
– Is sufficient space provided for maintenance?
– Are all liquid-carrying components, connections and lines and all electrical connections and
lines easy to access?
– Are the pipes easy to identify?
Check heat exchanger surfaces for dirt and clean as required (see Clean unit, page 58).
Perform function tests on the fans (rotation direction, power consumption, etc.).
Check electrical connections of the fan motors for damage.
Check the soldering and welding connections, the electrical connections and the fixture connections.
Perform pressure test with test gas and with a test pressure of 1.1-times the permissible operating pressure: check the connection seals and detect leaks, e.g. with foaming agent, or similar.
Check corrosion protection: Perform a visual inspection on all bends, components and component holders that are not heat-insulated. Document and archive test results.
Perform test run. Observe and check unit during test run, in particular for:
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 49
– Fan smooth running (bearing noises, contact noises, imbalances, etc.).
– Fan power consumption:
– Leaks
Report all defects to the manufacturer immediately. Remove defects following consultation with
the manufacturer.
Check the unit and the unit’s interaction with the heat carrier circuit of the system again after 48
operating hours, especially on the connections and on the fans, and document the test results.
7.7 Test readiness for operation
Ensure that all electrical protective measures are ready to function.
Ensure that all working fluid-carrying connections are securely in place.
Ensure that all electrical connections (fans ) are effected securely.
7.8 Putting the unit into operation for the first time
WARNING
page 49 / 62
Danger of injuries and damage to property!
Escaping heat carrier/ can cause injuries or even death ( see Residual hazards due to the heat carrier
glycol, page 22).
You can put the unit into operation, only when:
•
The unit has been properly mounted and connected ( see Installation, page 44).
•
You have performed a complete acceptance test (see Perform acceptance test, page 48).
•
You have checked the unit’s readiness for operation (see Test readiness for operation, page 49).
•
All safety precautions (see Safety, page 35) have been taken.
Follow the operating instructions manual of the system!
Contact the manufacturer immediately if you want to operate the unit under different operating conditions
as those defined in the order-related offer documents.
Switch on the system including the heat carrier circuit and of the electrical system (see system).
Activate the unit:
– Open the valves on the inlet and outlet-side heat carrier circuit of the system.
– Activate fans
Wait until the operating point is reached. After the operating point is reach the unit is ready to
operate (see system).
Parameters for setting the operating point, see order-related offer documents.
Operating point:
GFH | 2018-04
•
Heat carrier flow temperature
•
Heat carrier return temperature or circulating heat carrier volume
•
Airflow volume
•
Air inlet temperature
To ensure the specified operating point is complied with the actuators for the operating point setting
must be secured against unauthorized access (e.g. by sealing, screwing on caps, removing hand
wheels, etc.).
© Güntner GmbH & Co. KG
Page 50
8 Operation
8.1 Safety
Danger of cutting off, pulling in!
Burn hazard!
page 50 / 62
WARNING
There is a danger of cutting off fingers on the rotating fan blades, injury hazard for the
hands and pulling in danger with loose elements such as hair, necklaces or clothing
parts.
Do not operate fans without guard grille!
WARNING
Danger of burns if parts are touched ( see Thermal residual hazards, page 21).
Do not touch any parts of the unit without protective gloves when the unit is in operation or if it has not yet cooled down again after operation.
8.2 Putting the unit into operation
To operate the unit, the system must be in operation, including the brine circuit and the electrical
system. The unit must be started up by opening the respective valves on the inlet and outlet-side
of the brine circuit and by connecting to the electrical system (see refrigeration system operating instructions manual):
Switch on electrical system
Open working fluid-carrying lines
Switch on fans
8.3 Taking the unit out of operation
The units are system components of a refrigeration system, including the heat carrier circuit. The
unit is shut down by switching off the heat carrier circuit of the system in accordance with the system operating instructions manual. To do this, the working fluid-carrying lines must be shut off from
the system and the fans must be disconnected from the electrical system (see refrigeration system
operating instructions manual):
Switch fans off
Switch electrical system off
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 51
Close working fluid-carrying lines
NOTE! When shut down consider max. operating pressure! If necessary, take precautions to
ensure that it cannot be exceeded, or drain the device.
With shutdown times of a month or longer put the fans into operation for approx. 2-4 hours a month to
maintain their functionality.
8.4 Shutting the unit down
Danger of injuries and damage to property!
Escaping heat carrier/ can cause injuries ( see Residual hazards due to the heat carrier glycol, page 22,
and see Residual hazards caused by pressurised parts, page 24).
Ensure that the maximum operating pressure is not exceeded after the shutdown either!
page 51 / 62
NOTICE
WARNING
NOTICE
Danger of corrosion and dirt build-up!
Moisture and dirt must be prevented from entering the unit.
Protect the unit against dust, contamination, moisture and wetness, damage and other harmful influences (see Safety instructions for set-up and start-up, page 35).
With shutdown times of a month or longer put the fans into operation for approx. 2-4 hours a month to
maintain their functionality.
Take the unit out of operation (see Taking the unit out of operation, page 50).
Secure the unit:
– When shutdown consider max. operating pressure (see Technical data, page 28)! If neces-
sary, take precautions so that it cannot be exceeded.
– Secure the fan motor drives against switching on again
– Secure working fluid-carrying lines against pressurizing with working fluid.
– Protect against damaging effects at the set-up point or intermediate storage location (see
Safety instructions for set-up and start-up, page 35), so that the unit’s components are kept
properly looked after and the proper intentional use and usability of the unit are maintained.
The corresponding storage conditions must be provided for this (see Storage before instal-
lation, page 34); precautionary corrosion protection measures, regular checking of the fans’
functionality and regular checks on the shutdown unit.
Drain the unit: Completely release heat carrier/ (see Residual hazards with disposal, page 26).
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 52
8.5 Putting the unit into operation after a shutdown
The unit must be put back into operation after a shutdown in acc. with the system-specific set-up in
acc. with the operating instructions manual as follows:
Test the unit’s readiness for operation (see Test readiness for operation, page 49). Perform
pressure test and visual inspection for corrosion protection.
NOTE! The pressure test with recommissioning must only be carried out with appropriate media at appropriate test pressure.
Put the unit into operation (see Putting the unit into operation, page 50).
8.6 Changing the unit over to another working fluid
WARNING
Danger of injuries and damage to property!
Considerable dangers can be caused with operation with another working fluid without prior manufacturer approval (see Improper use, page 19).
page 52 / 62
Without prior written consent from Güntner GmbH & Co. KG , the unit must not be changed over to use
a different working fluid.
Ensure that the unit manufacturer has agreed to the changeover.
Ensure that the right working fluid is re-filled. Ensure that all materials used in the unit are compatible with the new working fluid.
Ensure that the permissible pressure is not exceeded.
Check that the new working fluid can be used without requiring a new test certificate for the unit.
Ensure that classification is complied with.
The safety device for the unit must be swapped out or reset.
Mixtures with residues of working fluid , for example, must be prevented.
All information concerning the new working fluid must be changed accordingly.
The complete documentation, including these operating instructions and the system operating
instructions manual must be changed accordingly.
Perform acceptance test (see Perform acceptance test, page 48).
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 53
9 Troubleshooting
9.1 Safety
Danger of injuries and damage to property!
Faults that are not described in these operating instructions may be resolved only by Güntner. Contact
the Güntner hotline.
Faults that are described in these operating instructions must only be removed by appropriately trained
personnel (see Personnel, care requirements, page 17).
If any faults occur during the operation, monitoring or maintenance of the system as a whole, inform
Güntner GmbH & Co. KG immediately.
9.2 Service
Office hours
page 53 / 62
WARNING
Tel. +49 8141 242-473
Fax. +49 8141 242-422
Email: service@guentner.de
Mon-Thurs: 7.30 am - 5 pm
Fri: 7.30 am - 1.30 pm
9.3 Troubleshooting table
Fault Possible cause(s) Remedy
Power supply interrupted Restore power supplyFan motor not
running
Bearing noises Defective fan motor Renew bearing or fan motor
Unit capacity not
achieved
Fan blade stuck Enable fan to rotate freely
Defective fan blades Change fan bladesUnit vibrating
Loose fan fixture Tighten fixtures
Heat exchanger is very dirty on the
air side
Fans not running properly or down Repair, exchange fans
Working fluid pressurising defective
(temperature and quantity insufficient)
Clean
Set working fluid pressurising values
(temperature and quantity) to reference values.
GFH | 2018-04
Unit capacity not
achieved
Working fluid escaping
Insufficient heat exchanger setting Set heat exchanger setting (concen-
tration, inhibition)
Unit working fluid-carrying components leaking
Switch off working fluid feed and
fans, close leak
© Güntner GmbH & Co. KG
Page 54
10 Maintenance
10.1 Safety
10.1.1 Before starting all maintenance
Danger of injuries and damage to property with escaping working fluid! see Residual hazards due to the
heat carrier glycol, page 22).
Only perform maintenance work – especially welding work – on the leaking unit after completely removing the working fluid from the leaking unit!
Perform the following safety measures before beginning all maintenance work:
■
Evacuate/ the unit's heat exchanger
■
Clean and blow out the unit's heat exchanger.
10.1.2 With all maintenance work
page 54 / 62
WARNING
WARNING
Danger of injuries and damage to property with escaping working fluid! see Residual hazards due to
the heat carrier glycol)!
Escaping working fluid with leaks on the unit can cause the following hazard situations and injuries:
Warns against hot surfaces!
In operation the unit's heat exchanger and pipes have temperatures of over +45 °C.
Contact can cause burns.
With heat carrier temperatures over +45 °C there is the hazard of burns on pipe components and distribution pipes. Use hand protection!
Warns against frostbite!
With insufficient frost protection filling and operation in areas with frost hazard the unit
can cause frostbite. With units that cannot be drained completely the hazard of frost-
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 55
page 55 / 62
bite also remains after draining. It is imperative that the proper ventilation be ensured
when draining the unit. With pressure test, operation and shutdown of units filled with
water or insufficient frost protection filling or insufficient setting of the heat carrier, these
are disrupted at minus temperatures.
•
Use eye protection!
•
Use hand protection!
•
Ensure that the unit in question is pressure-free before maintenance work begins or the working fluid
is sucked up from the unit in question.
•
Power off the electrical system and secure it against unintentional switching on again.
•
Separate the unit to be maintained from the heat carrier circuit of the system and secure it.
Danger of damage to property!
With work in the inlet and outlet feeds of the fans and heat exchanger, objects can get
into the fans and therefore cause faults and damage on the components.
•
Power off the fans before beginning maintenance work and secure them against
switching on again.
•
After the work has finished do not allow any objects to get back into the inlet and
outlet feeds of the fans or the set-up room.
Only step on to the units when required and only with firm, tough and safe footwear.
If the units do not have any railings, always only walk on them when required and with a safety device
that prevents falling.
10.1.3 After all maintenance work
Danger of injuries and damage to property caused by escaping heat carrier/ (see Residual hazards due
to the heat carrier glycol, page 22)!
NOTICE
WARNING
WARNING
GFH | 2018-04
Perform the following safety measures after finishing all maintenance work:
•
Ensure the switching and activation devices, the measuring and display devices and the safety devices function properly.
•
Ensure the working fluid fittings are functioning.
•
Check the identification of the pipelines and ensure this is visible and legible.
•
Check the fixing and corrosion protection of the components in question.
© Güntner GmbH & Co. KG
Page 56
•
Ensure the electrical connections (e.g. fans) are functioning.
•
Perform a pressure test and a tightness test (see operating instructions manual annex).
•
Perform an acceptance test ( see Perform acceptance test, page 48).
•
Perform a pressure test (see operating instructions manual annex).
10.2 Inspection and maintenance plan
10.2.1 Fans
The checks to be performed are listed in the following sections as time-scaled checklists.
The manufacturer’s operating specifications take priority for this component. Güntner GmbH & Co.
KG recommends proceeding according to the following inspection and maintenance plan:
d = daily, w = weekly, m = monthly, y = yearly
Work to be performed d w m y
page 56 / 62
Check the fans for dirt build-ups.
•
With dirt build-ups: Clean fans (see Clean unit, page 58).
Check the fan drive for smooth running.
•
Vibrations on the unit: remove imbalances
•
Where required, tighten and correct blade fixtures and blade settings
Fan bearing: Running sound and smoothness changes
•
Exchange bearing
Fan motor: Is a new bearing due?
•
Exchange bearing or motor; where applicable, clean and repair
motor
Fan wheel: corrosion on bolts (with threaded blades)
•
exchange bolts
Fan blades: Corrosion or damage on blades
•
Exchange blades or wheel
*) Recommended: every six months
10.2.2 Unit heat exchanger
X
*
X
*
X
*
X
*
X
*
X
*
GFH | 2018-04
WARNING
Danger of injuries and damage to property caused by escaping heat carrier/ (see Residual hazards due
to the heat carrier glycol, page 22)!
d = daily, w = weekly, m = monthly, y = yearly
Work to be performed d w m y
Check heat exchanger for dirt build-ups.
•
With dirt build-ups: Clean heat exchanger (see Clean unit, page
58).
© Güntner GmbH & Co. KG
X*
Page 57
page 57 / 62
d = daily, w = weekly, m = monthly, y = yearly
Work to be performed d w m y
Check heat exchanger’s general condition.
•
Damage found: Repair damage
Check heat exchanger’s operating point (see Operation, page 50).
•
Change in fan capacity found: restore required system-side conditions (including heat carrier circuit).
•
Change in surface temperatures found: restore required system-side conditions (including heat carrier circuit).
Change in heat exchanger setting found: restore required heat exchanger setting (concentration, inhibition)
Check heat exchanger and connections for tightness.
•
Repair unit sections (see Remove leaks, page 57).
Check heat exchanger for working fluid pressurising.
•
Restore required heat carrier-side conditions.
Check heat exchanger for corrosion.
•
Corrosion or damage on core tubes, fins, support structures, tube
connections, fixtures: repair unit sections affected.
*) Recommended: every six months
Care and maintenance plan
X*
X*
X
*
X
*
X
X
*
Measure Cleaning agent Interval
Component cleaning Mechanically As required (visual inspection)
Complete cleaning Warm water or environmental-
Leak check After 6 months
Heat exchanger setting check After 6 months
Corrosion protection check After 6 months
10.3 Maintenance work
10.3.1 Remove leaks
Danger of injuries with heat carrier/ (see Residual hazards due to the heat carrier glycol, page 22)!
•
Have leaks removed as quickly as possible by an expert.
•
Do not fill with a working fluid other than that specified in acc. with the order-related offer documents!
•
Only put the unit back into operation when all leaks have been repaired.
Perform all work including pressure, acceptance and functional test (see Perform acceptance
test, page 48, and see Test readiness for operation, page 49).
After 120 hours
ly safe cleaning agent
WARNING
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 58
10.4 Clean unit
10.4.1 General
10.4.2 Clean heat exchanger
The following applies for cleaning: The operator must ensure that the cleaning agents are environmental friendly and compatible for the materials in the system. Harmful to the environment substances, e.g. acid-forming, are forbidden.
Clean casing by rinsing with warm water (approx. +25°C) and/or with environmentally friendly
cleaning agents.
Rinse thoroughly with water after using cleaning agents.
Allow casing to dry completely.
Check working fluid-side and electrical connections (see Test readiness for operation, page 49).
Drain the unit (see system).
Shut off the unit (see system).
page 58 / 62
Power off the fans (see system).
Clean the heat exchanger with one of the following procedures:
– Cleaning with compressed air (see Cleaning with compressed air, page 58).
– Hydraulic cleaning (see Hydraulic cleaning, page 59).
NOTICE
Danger of damage to property!
The fins can be damaged with too high a pressure, too small a distance or a cleaning jet that hits the
fins at an angle. Mechanical cleaning with hard objects (e.g. steel brushes, screw drivers, or similar)
damages the heat exchanger.
•
Use a pressure of max. 50 bar with hydraulic cleaning and max. 80 bar with cleaning with compressed air!
•
Maintain a minimum distance from the fins of 200 mm!
•
Always aim the jet vertically (max. ±5 degree deviation) at the fins!
•
Do not use any hard objects when cleaning!
Switch fans on (see system).
Open drain side (see system operating instructions manual).
Open inlet side (see system operating instructions manual).
10.4.2.1 Cleaning with compressed air
GFH | 2018-04
Blast heat exchanger (max. 80 bar pressure) with compressed air to remove dirt and contaminants.
NOTE! Hold the jet of the cleaner vertical to the fins (max. deviation of ±5 degrees) to prevent
fins from bending.
© Güntner GmbH & Co. KG
Page 59
10.4.2.2 Hydraulic cleaning
Danger of damage to property!
Water or steam jets can damage fans, electrical lines or other components.
•
Ensure that electrical connections and motors, as well as components and stored goods at the setup point are not touched by water or steam jets. Cover these if required.
Heavier moisture or greasy dirt must be removed with a high-pressure water jet (max. 50 bar
pressure), steam pressure jet (max. 50 bar pressure), min. 200 mm distance with flat jet nozzle,
or using neutral cleaning agent where applicable, always against the airflow direction. Ensure
here:
– With oily and greasy dirt it helps to add a cleaning agent to the water.
– When applying chemical agents ensure that they are not aggressive towards the unit's mate-
rials. Rinse the unit off after the treatment.
– Cleaning should be done from inside to the outside (but always opposing the dirt onset) and
from top to bottom, so that the dirt can be removed without returning.
– Hold the jet of the cleaner vertical to the fins (heat exchanger – max. deviation of ±5 de-
grees) to prevent fins from bending.
page 59 / 62
WARNING
Warns against dangerous electrical voltage!
Direct and indirect contact with voltage-carrying parts of motors and electrical lines can
cause serious injuries or death. Water and cleaning agents conduct electricity.
•
Power off the fans for cleaning with water or steam jet and ensure them against
switching on again.
NOTICE
GFH | 2018-04
Continue cleaning until all dirt has been removed.
© Güntner GmbH & Co. KG
Page 60
10.4.2.3 Cleaning the pipe insides
Rinsing with solvents removes dirt build-ups formed by limescale, paint-type layers, oil residues,
etc. A solvent appropriate to the deposits should always be selected. The following chemicals have
been proved to be useful:
•
10%-content formic acid
•
Trichlorethylene for organic layers
Generally speaking, the cleaning agent must be suitable for copper and/or non-ferrous metals. The
information can be found in the product data sheet for the cleaning agent (request from the relevant
manufacturer).
Cleaning principle:
page 60 / 62
1
2
3
Chemical cleaning is applied where the dirt is stubborn or with heat exchangers with lime scaled
pipes and collectors.
Pump
Heat exchanger
Containers for catching cleaning liquid
Select the pump’s supply rate so that a speed that is adjusted to the cleaning effect is achieved
(2.5 to 5 m/s).
Neutralise and rinse the heat exchanger well after cleaning.
WARNING
Toxic hazard!
Trichlorethylene is harmful to the health and highly narcotic: inhalation of air with 200
ppm causes tiredness. It has been classified by the MAC Commission as carcinogenic
(category 2) and germ cell mutagenic (category 3B). It must be identified as "Toxic".
Acute poisoning causes brain damage, blindness and destruction of the smell and
taste senses.
•
Only use trichlorethylene in closed systems with complete recovery.
•
Exclude all open flames or spark sources.
•
Smoking is forbidden.
•
Protect the skin and eyes with suitable protective materials.
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 61
10.4.3 Cleaning fans
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.
•
Power off the unit before you begin maintenance work. 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.
•
Put fans and guard grilles that were removed or opened for maintenance back into their original
status without fail before you put the unit back into operation!
Dirt build-ups on the fans, the streamers or air outlet connectors (if installed) and the fan guard
grilles must be removed regularly, otherwise they will cause imbalances or destruction and power
losses. The fan motors themselves are maintenance-free.
Power off the unit and secure it against unintentional switching on.
Clean fans with one of the following procedures:
NOTE! Danger of damage to property! Mechanical cleaning with hard objects (e.g. steel
brushes, screw drivers, or similar) damages the fan. Forbidden!
– Cleaning with compressed air: Blow fans with compressed air (max. 10 bar pressure; min.
distance 200 mm) to remove dirt and contaminants. Continue cleaning until all dirt has been
removed.
– Cleaning with compressed air and brushes: Remove dry dust or dirt with a brush, a hand
brush or with compressed air (max. 10 bar pressure, min. distance of 200 mm) or with a
powerful industrial vacuum cleaner. Ensure here: use soft brushes (no steel brushes or simi-
lar)! Continue cleaning until all dirt has been removed.
Mount guard grille, streamer or air inlet connections (if installed)
page 61 / 62
WARNING
Switch unit on
GFH | 2018-04
© Güntner GmbH & Co. KG
Page 62
11 Plans/diagrams
11.1 Electrics documentation
11.1.1 Fan motor connection diagram
See motor terminal box cover inside on the fan.
page 62 / 62
GFH | 2018-04
© Güntner GmbH & Co. KG
Loading...