Güntner GFH, GFW Operating Instructions Manual
Drycoolers – GFH
Product line: Drycooler
Series variant description: Drycooler - Axial, Horizontal
Series: GFH
www.guentner.de
GFH | 2010-09
Contents
page 2 / 59
1 Important basic information........................................................5
1.1 Safety instructions............................................................................. 5
1.1.1 Observing operating instructions.......................................................... 5
1.2 Importance of the EN 378 series of standards – refrigeration sys-
tems and heat pumps – safety-related and environmental require-
ments................................................................................................... 5
1.3 Responsibilities.................................................................................. 5
1.3.1 Manufacturer's responsibilities............................................................. 5
1.3.2 Responsibilities of the system's installer.............................................. 6
1.3.3 Owner or operator responsibilities....................................................... 6
1.4 Legal notes..........................................................................................7
1.5 Operating instructions....................................................................... 7
1.5.1 Scope....................................................................................................7
1.5.2 Set-up and other applicable documents.............................................. 7
1.6 Conventions........................................................................................ 8
1.6.1 Typographical conventions................................................................... 8
1.6.2 List of abbreviations............................................................................. 8
1.7 Conventions for safety signs and notices.......................................9
1.7.1 General safety signs and their meaning in these operating instruc-
tions...................................................................................................... 9
1.7.2 Warning signs and their meaning in these operating instructions.........9
1.7.3 Prohibitory signs and their meaning in these operating instruc-
tions.................................................................................................... 10
1.7.4 Mandatory signs and their meaning in these operating instruc-
tions.................................................................................................... 10
2 Safety........................................................................................... 12
2.1 Labelling on the unit:.......................................................................12
2.1.1 Safety signs on the unit..................................................................... 12
2.1.2 Other signs and notes on the unit......................................................13
2.2 Basic safety notices.........................................................................15
2.2.1 How to act in an emergency.............................................................. 15
2.2.2 Personnel, care requirements............................................................ 16
2.3 Proper intended use.........................................................................16
2.3.1 Proper intended use........................................................................... 16
2.3.2 Operating conditions...........................................................................16
2.3.3 Improper use...................................................................................... 17
2.4 Mechanical residual hazards...........................................................18
2.4.1 Fins, sharp unit corners and edges................................................... 18
2.4.2 Fans.................................................................................................... 19
2.5 Electrical residual hazards.............................................................. 19
2.6 Thermal residual hazards................................................................ 20
GFH | 2010-09
© Güntner AG & Co. KG
page 3 / 59
2.6.1 Danger of burns................................................................................. 20
2.6.2 Frostbite hazard..................................................................................20
2.7 Residual hazards with the brine glycol..........................................20
2.8 Residual hazards caused by vibrations.........................................22
2.9 Residual hazards caused by pressurised parts............................22
2.10 Residual hazards caused by defective installation.......................23
2.11 Residual hazards with break during operation............................. 24
2.12 Residual hazards caused by escaping objects or liquids............ 24
2.13 Residual hazards with disposal...................................................... 25
3 Technical data............................................................................. 26
3.1 Unit..................................................................................................... 26
3.2 Fans....................................................................................................26
4 Set-up and function....................................................................28
5 Fan motor.................................................................................... 29
6 Transportation and storage....................................................... 30
6.1 Safety................................................................................................. 30
6.2 Transportation and storage.............................................................30
6.3 Storage before installation.............................................................. 32
7 Set-up and start-up.................................................................... 33
7.1 Safety................................................................................................. 33
7.1.1 Safety instructions for set-up and start-up......................................... 33
7.1.2 System-side safety requirements....................................................... 34
7.1.3 Customer-side safety precautions...................................................... 35
7.2 Requirements at the set-up point...................................................36
7.3 Unpacking the unit........................................................................... 41
7.4 Installation......................................................................................... 42
7.4.1 System-side requirements for stress-free installation........................ 42
7.4.2 Mounting the unit................................................................................42
7.5 Notes on connecting the unit......................................................... 43
7.5.1 Operation with water spray system....................................................43
7.5.2 Connect the unit to the heat carrier circuit of the system................... 43
7.5.3 Unit electrical connection and protection........................................... 44
7.6 Perform acceptance test..................................................................45
7.7 Test readiness for operation........................................................... 46
7.8 Putting the unit into operation for the first time........................... 46
GFH | 2010-09
8 Operation..................................................................................... 47
8.1 Safety................................................................................................. 47
8.2 Putting the unit into operation........................................................47
8.3 Taking the unit out of operation..................................................... 47
8.4 Shutting the unit down.................................................................... 48
© Güntner AG & Co. KG
page 4 / 59
8.5 Putting the unit into operation after a shutdown.......................... 49
8.6 Changing the unit over to another working fluid.......................... 49
9 Troubleshooting..........................................................................50
9.1 Safety................................................................................................. 50
9.2 Service............................................................................................... 50
9.3 Troubleshooting table...................................................................... 50
10 Maintenance................................................................................ 51
10.1 Safety................................................................................................. 51
10.1.1 Before starting all maintenance..........................................................51
10.1.2 With all maintenance work................................................................. 51
10.1.3 After all maintenance work................................................................. 52
10.2 Inspection and maintenance plan.................................................. 53
10.2.1 Fans.................................................................................................... 53
10.2.2 Unit heat exchanger........................................................................... 53
10.3 Maintenance work............................................................................ 55
10.3.1 Remove leaks.....................................................................................55
10.4 Clean unit.......................................................................................... 55
10.4.1 General............................................................................................... 55
10.4.2 Clean heat exchanger........................................................................ 55
10.4.3 Cleaning fans......................................................................................58
11 Plans/diagrams........................................................................... 59
11.1 Electrics documentation..................................................................59
11.1.1 Fan motor connection diagram.......................................................... 59
11.2 Working fluidconnection diagram.................................................. 59
GFH | 2010-09
© Güntner AG & Co. KG
page 5 / 59
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 | 2010-09
The construction, soldering and welding materials are configured so that they withstand the foreseeable mechanical, thermal and chemical stresses, and are resistant to the working fluid and the
working fluid/refrigerator oil mixture used.
© Güntner AG & Co. KG
The working fluid-carrying parts of the unit (core tubes, distributor tube and header outlet) are configured so that they remain tight with the foreseeable mechanical, thermal and chemical stresses,
and withstand the maximum permissible operating pressure.
Material, wall thickness, tensile strength, corrosive resistance, shaping process and testing are suitable for the working fluid used and withstand the possible pressures and stresses that might occur.
All responsibilities regarding the 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 brine circuit/are documented in the
system's version (design, manufacture and testing – cooling equipment and refrigeration system) in
acc. with EN 378-2.
Component supplier-system installer interfaces :
•
Inform Güntner AG & Co. KG if faults occur:
Inform Güntner AG & Co. KG immediately if faults occur during the set-up, installation, start-up
and operation.
The responsibilities of the system installer in particular include:
page 6 / 59
•
Planning and preparing emergency measures:
To avoid consequential damage caused by operational disruptions, a warning system which immediately signals all faults must be provided on-site. Prepare emergency measures that prevent
consequential damage for people and property should faults occur.
•
Install emergency STOP switches that can be actuated without danger.
•
Specify checking and maintenance intervals:
The system including the brine circuit/(complete system:must be configured and equipped with
all required equipment for maintenance and sufficient servicing and testing in acc. with EN
378-4.
With the integration of the unit into the refrigeration system's brine circuit/ the working fluid and version must not deviate from the order-related information specified in the order-related offer documents.
The installer of the system including the brine 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 with the set-up and installation, with the tightness test and cleaning, with the filling with working fluid and with the setting
of the equipment including the brine 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 brine circuit in acc. with EN 378-4.
GFH | 2010-09
The owner or operator must ensure that the proper people are sufficiently trained and qualified for
operating, monitoring and servicing the system including the brine circuit/.
The operating personnel for the system and the brine circuit must have sufficient knowledge and
experience with regard to the mode of operation, operation and daily monitoring of this system including the brine circuit .
© Güntner AG & Co. KG
Before the system start-up including the brine circuit/the owner or operator must ensure that the operating personnel are sufficiently instructed with the system's documentation (which is part of the
operating instructions) on the set-up, monitoring, mode of operation and servicing of the system including the brine circuit/and the safety measures to be observed, and with regard to the properties
and handling of the working fluid to be used.
The owner or operator must ensure that when operating, monitoring and maintaining the system including the brine circuit the working fluid and version must not deviate from the details specified in
the order-related offer documents.
Planning and preparing emergency measures: To avoid consequential damage caused by operational disruptions, a warning system must be installed on the customer's premises. Prepare emergency measures that prevent consequential damage for people and property should faults occur.
Responsibility remains with the owner or operator of the system including brine circuit, if the system including brine circuitare used by somebody else, unless there is an agreement on sharing responsibility.
1.4 Legal notes
Warranty claim expires as follows:
page 7 / 59
•
With faults and damages that can be attributed to non-compliance with the specifications of
these operating instructions.
•
With complaints that can be attributed to use of spare parts other than the original spare parts
specified in the order-related offer documents.
•
With changes to the unit (working fluid, version, function, operating parameters) vis-a-vis the or-
der-related information specified in the order-related offer documents without the manufacturer's
prior consent.
The operating instructions may not be reproduced electronically or mechanically, circulated,
changed passed on to third parties, translated or used otherwise, in full or in part, without Güntner
AG & Co. KG's prior explicit written approval.
1.5 Operating instructions
1.5.1 Scope
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 offer documents.
The unit's operating instructions include the following parts:
NOTICE
GFH | 2010-09
•
These instructions
•
Order-related offer documents
The order-related offer documents are attached to these instructions and include the following
information:
– The order-related proper use as specified
– The order-related scope of delivery
– The order-related technical data
© Güntner AG & Co. KG
– 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 brine 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
EN 378 European Norm 378: Refrigeration systems and heat pumps; safety-related
and environmental requirements
page 8 / 59
EN European Norm
DIN German industrial standard (specification of a standard)
ISO International Standardization Organization
Emergency
STOP
°C Degrees Celsius (Celsius scale temperature)
bar Unit of pressure
I Litre (liquid volume)
Vol % Volume percent (concentration level relative to a volume)
IP Insulation protection
Q 6.3 Balancing quality
ppm parts per million, concentration figure, stands for "millionth"
Hz Hertz (frequency)
D Delta connection (rotating current: high speed)
S Star connection (rotating current: low speed)
3~ 3-phase rotating current
1~ 1-phase alternating current
Switch for immediately switching off the refrigeration system
GFH | 2010-09
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 AG & Co. KG
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 / 59
1.7.2 Warning signs and their meaning in these operating instructions
Warns against hand injuries!
Hands or fingers can be crushed, pulled in or otherwise injured with non-compliance.
Warns against hot surfaces!
The temperature is over +45 °C (protein clotting) and can cause burns.
Warns against dangerous electrical voltage!
Danger of an electric shock if voltage-carrying parts are touched.
GFH | 2010-09
© Güntner AG & Co. KG
Warns against fire-risk substances at set-up point.
Use of ignition sources can cause fire at set-up point.
Warns against harmful to health or irritant substances at set-up point
Contact with or inhaling harmful to health or irritant substances can cause injuries
or damage the health.
1.7.3 Prohibitory signs and their meaning in these operating instructions
Feuer, offenes Licht und Rauchen verboten!
Ignition sources must be kept away and ignition sources must not develop!
page 10 / 59
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 | 2010-09
© Güntner AG & Co. KG
page 11 / 59
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 | 2010-09
© Güntner AG & Co. KG
2 Safety
2.1 Labelling on the unit:
1 Unit type plate on front plate 6 "Fan guard" warning sign – only with units
2 Güntner logo 7 Connections ON, OFF
3 "Transportation filling" warning sign next to
Schrader valve
4 Usage area for fork lifts; affix in the struts
area
5 Inspection door, only on units with inspec-
tion doors
page 12 / 59
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:
3 - "Transportation filling" warning sign next to Schrader valve
GFH | 2010-09
© Güntner AG & Co. KG
Note on inspection door (only with hinged fans)
page 13 / 59
7 - "Guard grille" warning sign (only used with separate removable guard grille)
2.1.2 Other signs and notes on the unit
1 - Unit type plate
GFH | 2010-09
2 – Güntner logo
© Güntner AG & Co. KG
12 - Connections ON and OFF
page 14 / 59
GFH | 2010-09
21 - Transport regulation in acc. with SP 11
4 - Usage area for forklifts in acc. with SP 34
© Güntner AG & Co. KG
2.2 Basic safety notices
2.2.1 How to act in an emergency
Danger of injuries and damage to property!
The unit is operated as standard with the brine, ethylene glycol (synonyms:
ethane-1,2-diol, glycol). When using other brines, 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 brine/ escaping from the unit cannot penetrate the interior of
the building or put people at risk in any other way.
Safety measures and procedure:
•
With unexpected serious brine/ breaks, activate the emergency STOP switch
set up in a safe place, e.g. with:
– Visibly escaping brine from the heat exchanger or pipe components.
– Sudden large release (release and evaporation of the greater part of the
entire brine/ in a short time, e.g. in less than 5 minutes).
•
Have experienced, trained personnel with prescribed protective clothing perform all necessary protective and other measures:
– Use respiratory protection.
– Use a room air-independent breathing apparatus with maintenance work
in high brine/ concentrations in the room air.
– Ensure the set-up room is well ventilated.
– Divert escaped brine/ liquid safely in acc. with EN 378-3.
page 15 / 59
WARNING
GFH | 2010-09
© Güntner AG & Co. KG
2.2.2 Personnel, care requirements
The unit must only be put into operation, operated, maintained and repaired by trained, experienced and qualified personnel. People that are responsible for the operation, maintenance, repair
and evaluation of systems and their components must have the required training and specialist
knowledge for their work in acc. with EN 378-1 to be qualified. Qualified or expert means the ability to satisfactorily perform the activities required for the operation, maintenance, repair and evaluation of refrigeration systems 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 brine circuit . This operating personnel may not make any interventions or settings on the system including the brine 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.
page 16 / 59
CAUTION
2.3 Proper intended use
2.3.1 Proper intended use
2.3.2 Operating conditions
Drycoolers of the GFH series are intended for installation in the brine circuit of a refrigeration system and for outdoor installations. The drycoolers cool the brine 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:
•
Brine flow temperature
•
Brine return temperature or circulating brine volume
•
Airflow volume
•
Air inlet temperature
The specified operating point is provided in the order-related offer documents.
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 restrict the dangers to people and property and the environment from the unit and the working fluid used in it to a minimum. These dangers are essentially connected with the physical and chemical properties of the working fluid and with the pressures
and temperatures that occur in the working fluid-carrying components of the unit see Residual haz-
ards with the brine glycol, page 20.
GFH | 2010-09
© Güntner AG & Co. KG
Danger of injuries and damage to property!
The unit must only be used in acc. with the proper intended use. The operator must ensure that
when operating, monitoring and maintaining the unit, the fluid and version do not deviate from the
order-related information specified in the order-specific offer documents.
The operator must ensure that maintenance measures are performed in compliance with the
system's operating instructions manual.
Filling the unit is only permitted following written approval by the manufacturer. You will find the
order-related proper use as intended in the order-specific offer documents.
Do not exceed the max. operating pressure given on the unit's type plate.
2.3.3 Improper use
page 17 / 59
WARNING
WARNING
Danger of injuries and damage to property!
Working fluids and their combinations with water or other substances in the working fluid-carrying components have chemical and physical effects from the inside on the materials surrounding
them. The unit must only pressurised with brine glycol. Pressurising the unit with another working fluid results in,
■
the structural, soldering and welding materials used do not withstand the foreseeable mechanical, thermal and chemical stresses, and the pressure that can occur during operation
and when shut down is not withstood.
■
material, wall thickness, tensile strength, corrosive resistance, shaping process and testing
are not suitable for the working fluid used and do not withstand the possible pressures and
stresses that might occur.
■
the unit not being resistant to the other working fluid and the other working fluid mixture.
■
the unit not remaining tight during operation and when shut down.
■
a possible sudden escaping of working fluids could directly endanger people and/or property
and the environment.
The maximum permissible operating pressure specified on the type plate must not be exceeded!
If the operating pressure is exceeded,
■
the structural and welding materials will not withstand the foreseeable mechanical, thermal
and chemical stresses and the pressure that can occur during operation and when shut down.
■
the unit will not remain tight during operation and when shut down.
■
there may be a possible sudden escaping of working fluids after a break or leakage on work-
ing fluid-carrying components, which would result in the following dangers:
– Danger of escaping materials
– Suffocation hazard
– Hazards caused by panic reactions,
– Environmental pollution
GFH | 2010-09
© Güntner AG & Co. KG
page 18 / 59
WARNING
Drycoolermay not be used
■
where it is possible that short or prolonged effect caused by contact, inhalation or ingestion of
the working fluid glycol might result in harmful hazards.
■
where the possibility exists of a sudden large release of the greater part of the entire working
fluid filling in a short time (e.g. in less than 5 minutes).
The unit must not be changed without prior written consent by Güntner AG & Co. KG. Changes to
the unit are:
■
Changing the operating point (see chapter Unit)
■
Changing the fan capacity (air volume)
■
Changing the working fluid flow-through volume
■
Changing over to another working fluid
The unit must not be operated if safety devices recommended by the manufacturer are not available, not properly installed or not fully functional.
The unit must not be operated if it is damaged or demonstrates faults. All damages and faults
must be reported to Güntner AG & Co. KG immediately and must be removed immediately.
Work on the unit must not be performed without the personal protective equipment specified in
these operating instructions.
2.4 Mechanical residual hazards
2.4.1 Fins, sharp unit corners and edges
Warns against hand injuries!
Danger of cuts on hands and fingers on the fins and on sharp corners and
edges of the unit.
Use reliable hand protection!
WARNING
GFH | 2010-09
© Güntner AG & Co. KG
Loading...