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Compact condensers/gas coolers – GGHC CD_GGVC
CD
Product line: CO2condensers/gas coolers
Series description: Flat/Vertical Compact
Series: GGHC CD_GGVC CD
www.guentner.de
GGHC CD_GGVC CD | 2018-04
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Contents
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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
2 Safety..........................................................................................11
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2.1 Labelling on the unit:.....................................................................11
2.1.1 Safety signs on the unit................................................................... 13
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.......................................................... 16
2.3 Proper intended use.......................................................................17
2.3.1 Proper intended use.........................................................................17
2.3.2 Operating conditions.........................................................................17
2.3.3 Improper use.................................................................................... 18
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
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2.6 Thermal residual hazards..............................................................21
2.6.1 Danger of burns............................................................................... 21
2.7 Residual hazards due to carbon dioxide (CO2)........................... 21
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............................................................ 33
7 Set-up and start-up...................................................................34
7.1 Safety............................................................................................... 34
7.1.1 Safety instructions for set-up and start-up....................................... 34
7.1.2 System-side safety requirements..................................................... 35
7.1.3 Customer-side safety precautions.................................................... 36
7.2 Requirements at the set-up point.................................................37
7.3 Unpacking the unit......................................................................... 40
7.4 Installation....................................................................................... 45
7.4.1 System-side requirements for stress-free installation...................... 45
7.4.2 Mounting the feet............................................................................. 46
7.4.3 Mounting the vibration dampers (optional).......................................50
7.4.4 Mounting the unit..............................................................................50
7.5 Notes on connecting the unit....................................................... 53
7.5.1 Connect the unit to the system........................................................ 53
7.5.2 Unit electrical connection and protection......................................... 54
7.6 Perform acceptance test................................................................54
7.7 Test readiness for operation......................................................... 55
7.8 Putting the unit into operation for the first time......................... 55
8 Operation................................................................................... 57
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8.1 Safety............................................................................................... 57
8.2 Putting the unit into operation......................................................57
8.3 Taking the unit out of operation................................................... 57
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8.4 Shutting the unit down.................................................................. 57
8.5 Putting the unit into operation after a shutdown........................ 58
8.6 Changing the unit over to another working fluid........................ 58
9 Troubleshooting........................................................................ 60
9.1 Safety............................................................................................... 60
9.2 Service............................................................................................. 60
9.3 Troubleshooting table....................................................................60
10 Maintenance...............................................................................61
10.1 Safety............................................................................................... 61
10.1.1 Before starting all maintenance........................................................61
10.1.2 With all maintenance work............................................................... 61
10.1.3 After all maintenance work...............................................................62
10.2 Inspection and maintenance plan................................................ 63
10.2.1 Fans.................................................................................................. 63
10.2.2 Unit heat exchanger......................................................................... 63
10.3 Maintenance work.......................................................................... 65
10.3.1 Remove leaks...................................................................................65
10.4 Clean unit........................................................................................ 65
10.4.1 General............................................................................................. 65
10.4.2 Clean heat exchanger...................................................................... 65
10.4.3 Cleaning fans....................................................................................67
11 Plans/diagrams..........................................................................68
11.1 Electrics documentation................................................................68
11.1.1 Fan motor connection diagram........................................................ 68
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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).
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).
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.
The working fluid-carrying parts of the unit are configured so that they remain tight with the foreseeable mechanical, thermal and chemical stresses, and withstand the maximum permissible operating
pressure.
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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 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 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 , the working fluid and version must not deviate from the order-related information specified in the order-related documents.
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The installer of the system 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 .
1.3.3 Owner or operator responsibilities
The owner or operator responsibilities are documented in the operation, maintenance, servicing
and recovery of the system 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 .
The operating personnel for the system must have sufficient knowledge and experience with regard
to the mode of operation, operation and daily monitoring of this system .
Before starting up the system, 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 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
the 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.
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Responsibility remains with the owner or operator of the system , if the system 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.
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1.5 Operating instructions
1.5.1 Scope
1.5.2 Set-up and other applicable documents
These operating instructions apply for all condensers of the series GGHC CD_GGVC CD.
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
– 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 .
NOTICE
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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
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CO
2
EN 378 European Norm 378: Refrigeration systems and heat pumps; safety-related
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
CO2 refrigerant (R744)
and environmental requirements
1~ 1-phase alternating current
VDE “Verband der Elektrotechnik, Elektronik und Informationstechnik” (Association
TCC Technical Connection Conditions
EPC Electric Power Company
VDI “Verein Deutscher Ingenieure” (German engineers’ association)
GGHC CD_GGVC CD | 2018-04
for Electrical, Electronic & Information Technologies)
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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.
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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 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.
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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.
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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!
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.
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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)
Use protective clothing!
Personal protective clothing must be suitable for the working fluid used and for low
temperatures, and must have good heat insulation properties.
Activate before work!
Activate the electrical system and secure against switching on again before starting installation, maintenance and repair work.
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2 Safety
2.1 Labelling on the unit:
Units with finoox technology
Identifiers' placed on the unit
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2.1.1 Safety signs on the unit
Art. Code 60325
Safety signs on the unit individually:
940 - “Transportation filling” warning sign next to Schrader valve
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946 - Fork-lift transport
64620 - Lifting point
64551 - Notice regarding cable tension
60325 - “Do not load. Do not lift!” warning sign.
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2.1.2 Other signs and notes on the unit
2483 - Sample view of a manufacturer’s nameplate
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4819 or 4817 - Logo
943 and 943.1 - Connections IN and OUT
4822 - "Güntner profile" on units with 2 or more fans
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60785 - Transport regulation
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3872 - Earthing identifier
61073 - Transport instructions for two-row units
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2.2 Basic safety notices
2.2.1 How to act in an emergency
Danger of injuries and damage to property!
CO2 is an irritant gas and when inhaled causes agitation, dizziness, vomiting and
cramps; with heavy concentrations suffocation and life-threatening pulmonary oedema.
Irritation of the respiratory centre with 30,000 to 50,000 ppm (3 to 5 vol %).
Unconsciousness with 70,000 to 100,000 ppm (7 to 10 vol%).
Safety measures and procedure:
•
In the event of serious unexpected leakage of refrigerant, leave the set-up room immediately and activate the emergency measures provided, e.g. if:
– Visibly escaping refrigerant liquid or vapour from the heat exchanger or tube
components.
– Sudden large release (release and evaporation of the greater part of the entire
refrigerant filling in a short time, e.g. in less than 5 minutes).
– Sudden irritation of the respiratory centre
– Activation of the NH2 alarm device (NH3 concentration > 5,000 ppm - MAC val-
ue):
•
Have experienced, trained personnel with appropriate protective clothing perform all
necessary protective and other measures:
– Use respiratory protection.
– Use a room air-independent breathing apparatus for maintenance work in high
CO2concentrations in the room air.
– Ensure the set-up room is well ventilated.
– Divert escaped refrigerant vapour and escaped refrigerant liquid safely.
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WARNING
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, . This operating personnel may not make any interventions or settings on the system.
Changes to the unit, which the manufacturer has first agreed to in writing, may only be made by the instructed and qualified personnel.
CAUTION
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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.
2.3 Proper intended use
2.3.1 Proper intended use
Gas cooler condensers of the GGHC CD_GGVC CD series are intended for installation in a refrigeration system or air-conditioning system; for cooling supercritical CO2 vapour (summer operation)
and for condensing and supercooling subcritical CO2 vapour (winter operation) with air for outdoor
installation.
The unit is delivered for operation with a specific operating point:
•
Condensation temperature
•
Airflow volume
•
Air inlet temperature
•
Relative air humidity.
The specified operating point is given in the order-related documents.
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The unit is subject to the following load limits:
Earthquake: 0.1 g (perform an inspection after every earthquake)
Snow load: GGHC 2,85 kN/m2, GGVC 5,19 kN/m
Wind load: GGHC 1.14 kN/m2, GGVC 1.32 kN/m
2.3.2 Operating conditions
The unit is a component 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 carbon dioxide
(CO2), page 21.
Danger of injuries and damage to property!
, gas coolers/condensers of the GGHC CD_GGVC CD series work with a very high operating pressure.
Danger from high operating pressure: 120 bar!
Breaks in pressurised tubes or pressurised components of the unit can cause injuries or damage to
property caused by flying debris ( see Residual hazards caused by pressurised parts, page 24).
2
2
WARNING
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.
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WARNING
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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.
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 CO2. 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.
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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
– danger of frostbite (caused by liquid coolant squirting/splashing),
– Suffocation hazard
– hazards caused by panic reactions, agitation, dizziness, vomiting and cramps,
– Environmental pollution
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WARNING
Warning!
the , gas coolers/condensers in this GGHC CD_GGVC CD series use a very high operating pressure.
Danger from high operating pressure: 120 bar!
Breaks in pressurised tubes or pressurised components of the unit can cause injuries or damage to
property caused by flying debris ( see Residual hazards caused by pressurised parts, page 24).
WARNING
CO2Gas coolers/condensers may not be used
■
where it is possible that short or prolonged effect caused by contact, inhalation or ingestion of the
working fluid CO2 might result in harmful hazards.
■
where the possibility exists of a sudden large release (release and evaporation) of the greater part of
the entire working fluid filling in a short time (e.g. in less than 5 minutes).
■
where the possibility exists that the longest time that people are exposed to a large release of the
CO2 refrigerant is more than 60 minutes when the refrigerant concentration exceeds 5,000 ppm
(MAC value) and the number of clearly identified emergency exits for the number of usually present
people are not available.
■
where the number of clearly identified emergency exits for the number of usually present people are
not available.
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)
■
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.
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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!
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WARNING
2.4.2 Fans
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.
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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
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WARNING
2.6.1 Danger of burns
WARNING
Warns against hot surfaces!
Use hand protection!
2.7 Residual hazards due to carbon dioxide (CO2)
The unit is operated with carbon dioxide (CO2). Carbon dioxide is a group L1/A1 refrigerant in ac-
cordance with classification according to flammability (L) and toxicity (A) in compliance with EU Directive 97/23/EG on pressure equipment (Pressure Equipment Directive):
– Refrigerants that, when gaseous, are non-flammable irrelevant of their concentration in air.
– Refrigerants with a time-weighted, averaged concentration that have no adverse effects on the
majority of staff that are exposed every day during a normal 8 hour working day and a 40 hour
working week to this concentration, which is greater than or equal to 400 ml/m3 (400 ppm (V/V)).
Carbon dioxide (CO2) as a refrigerant has the following properties:
– Non-flammable, known fire extinguisher agent
– Non-toxic, food safety-approved and declaration-free
– Odourless
– Colourless
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– Taste-neutral
– Heavier than air
– Stable compound, used under normal ambient conditions as an inert gas
– Combination with water CO2 + H2O = H2CO3. Of dissolved CO2 gas in water, only 0.1% is
present as acid. The pH value of watery CO2 solutions at normal pressure is 3.7. Under pres-
sure it falls to a limit value of 3.3. CO2 is therefore suitable as a neutralisation medium for basic
solutions.
– Medical applications: Inhalations of 3 to 5% CO2 in breathing gas.
There is no imminent danger for the staff. With good air ventilation and removal by suction, it will fall
easily and clearly below the allowed limit values.
WARNING
Danger of harm to health and environmental damage!
Refrigerants of the Group L1/A1 are generally 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
are the following hazards – especially near to the floor:
– Irritation of the respiratory centre with 30,000 to 50,000 ppm (3 to 5 vol %).
– Unconsciousness with 70,000 to 100,000 ppm (7 to 10 vol %) due to lack of oxygen.
– CO2 is an irritant gas and causes agitation, dizziness, vomiting and cramps, with high concentrations
causing suffocation and life-threatening pulmonary oedema.
Always observe the following safety instructions:
•
Unauthorised people must not have access to the unit.
•
Ensure working rooms are well-ventilated in order to prevent inhalation of high vapour concentrations. MAC value 5,000 ml/m3 (ppm) as 8 h average value; a concentration of 10,000 ppm (instantaneous value) for 60 min. three times per shift is permitted a peak limit.
•
Ensure that the CFC/HFC refrigerant escaping from the unit cannot penetrate the interior of the
building or put people at risk in any other way. CO2 refrigerant vapour or gas must be kept from pen-
etrating neighbouring rooms, staircases, yards, passages or drainage systems and must be discharged without risk.
•
Monitor the CO2 refrigerant concentration in the ambient air to ensure constant compliance with lim-
it values. With good air ventilation and removal by suction, it will fall easily and clearly below the allowed limit values.
•
With emergency work in high CO2 refrigerant concentrations in the room air wear a room air-inde-
pendent breathing apparatus.
•
Prevent the refrigerant or oil from escaping: Test the tightness of the unit regularly, as specified in
these operating instructions ( see Inspection and maintenance plan, page 63).
•
With leaks on the evaporator (escaping CO2), if hazard-free handling is guaranteed, the emergency
STOP switch must be pressed and the endangered unit shut off.
•
Harmful to the environment effects: CO2 must not be released into the atmosphere – environmental
damage (with a 50% content CO2 is one of the most significant anthropogenic greenhouse gases)
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Ignition and fire hazard!
•
With work involving fire or sparks, e.g. grinding, welding, etc., ensure suitable fire
fighting equipment is on-site.
•
In particular be aware of the danger of ignition of oil residues unintentionally carried
in in the CO2 refrigerant.
•
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
CO2 refrigerant.
•
Smoke during work is forbidden!
Frostbite hazard
Frostbite if CO2 comes into contact with the skin or eyes (-57°C). Leaks in the unit
can cause the CO2 refrigerant to escape into the set-up room.
•
When removing faults after spills of CO2 refrigerant, you must be vigilant for any re-
maining superheated CO2 refrigerant as splashes can cause frostbite and evapora-
tion can cause irritation.
Danger of poisoning!
CO2 refrigerant contact with fire can form toxic combustion products.
•
Prevent CO2 refrigerant contact with open fire.
•
Welding and soldering may therefore take place only after completely draining the
relevant section of the system of the CO2 refrigerant. Ensure good ventilation here!
•
With emergency work in high CO2 refrigerant concentrations in the room air wear a
room air-independent breathing apparatus.
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, 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.
NOTICE
Damage to property caused by vibrations!
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2.9 Residual hazards caused by pressurised parts
WARNING
Injury and damage to property caused by pressurised parts that contain CO2 refrigerant!
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:
■
Irritation of the respiratory centre
■
Frostbite (caused by liquid refrigerant squirting/splashing)
■
Suffocation
■
Panic, agitation, dizziness, vomiting and cramps
■
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.
Perform maintenance work – especially soldering and welding – on the unit in question only after completely removing the working fluid from the unit.
page 24 / 68
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!
■
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.
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.
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•
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 61,
•
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:
– Provision of measures to safeguard people from a CO2 concentration of more than 5,000 ppm
(MAC value).
– 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.
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
17).
•
Caution!, gas coolers/condensers of the GGHC CD_GGVC CD series work with a very high op-
erating pressure. Danger from high operating pressure: 120 bar! Breakage of pressurised pipes or
pressurised components in the unit can cause injuries or damage to property from flying debris ( see
Residual hazards caused by pressurised parts, page 24).
•
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 carbon dioxide (CO2), page 21).
Ensure that:
•
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.
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•
Vibrations from the refrigeration system (vibrations caused by the complete system’s compressors,
components and lines,) 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.
•
Undercooled liquid is only present in the lowest possible amount in system sections in shutdown
state – minimized number of "fluid sacks".
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 / 68
WARNING
Danger of injuries and damage to property caused by working fluid, , CO2!
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, refrigerator oil, 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.
■
The CO2 refrigerant must be filled into a special refrigerant container in compliance with the respec-
tive safety measures. This special refrigerant container must be suitable for the CO2 refrigerant. It
must be easy to identify and labelled for the refrigerant, e.g. "Carbon dioxide (CO2) recovered".
■
A disposable single-use container must not be used, as refrigerant vapour residues in the container
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 refrigerator oil, are dis-
posed of properly as specified.
■
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.
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WARNING
Danger of environmental damage!
Carbon dioxide (CO2) is a greenhouse gas that appears in the most important natural compounds. Addi-
tional emissions from anthropogenic sources result in serious global warming and therefore damage to
the global climate:
– As an important, climate-relevant trace gas, carbon dioxide (CO2) contributes significantly to regula-
tion of the earth's heat balance. Carbon dioxide (CO2) changes the earth's radiation balance by al-
lowing (almost unobstructed) the short-wave solar radiation to pass through to the earth's surface,
and by partially absorbing the long-wave heat radiation emitted by the earth.
At 50 %, carbon dioxide (CO2) is one of the most significant anthropogenic greenhouse gases
•
Ensure that carbon dioxide (CO2) never enters the atmosphere uncontrolled!
Güntner GmbH & Co. KG’s transportation packaging is made from environmentally compatible material and is suitable for recycling.
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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 / 68
NOTICE
NOTICE
3.2 Fans
Manufacturer number See order-related documents
Production year See order-related documents
Working fluid R 744 (carbon dioxide, CO2)
Volume See order-related documents
Maximum permissible pressure (PS) 0 - 120 bar / -1 bar
Test pressure 172 bar
Permissible operating temperature
(TS)
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
Weight See order-related documents
The GGHC CD_GGVC CD series uses axial AC fans with 1250 mm diameter.
-50 ... +150°C
standard procedure for calculating sound level described
in EN 13487; Annex C (normative).
The GGHC CD_GGVC CD series uses fans 350 to 800 mm in diameter. Fans with diameters up to
500 mm are connected to AC, fans larger than 500 mm in diameter are connected to three-phase
current. Güntner control units can optionally be used to control the speed of fans.
Fan type See order-related documents
Protection rating At least IP 44, thermal class 155 (F) and DIN
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Voltage 400 V 3~ 50 Hz or
230 V 1~ 50 Hz
Balancing quality Q 6.3 in acc. with VDI 2060
Permissible air temperature Operating range: at least -30°C to +55°C
Protective devices
•
Thermal: Thermo-contacts (break contact)
•
Mechanical: Protective contact grille in acc.
with EN 294
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4 Set-up and function
The condenser/gas cooler consists of
•
a heat exchanger, consisting of tube coils fitted with fins (copper tube, aluminium fin),, distribution tubes and header outlets and tube connections to the tube system,
•
a self-supporting casing structure with Güntner support profiles for reducing the unit’s weight
and the number of legs, and for increasing rigidity against bending under load and torsion. The
casing consists of galvanized sheet steel, painted in RAL 7032, pebble grey.
•
and – depending on the version – with one or more fans.
Condensers/gas coolers in the GGHC CD_GGVC CD series condensers are intended for installation in a refrigeration system. The refrigeration system is a combination of refrigerant-carrying components and fittings connected with one another, which form a closed circuit, in which the refrigerant circulates.
The refrigerant absorbs heat at a low temperature and low pressure and evaporates (evaporator-side), and at a higher temperature and higher pressure gives off the heat again and condenses
itself (condenser-side). The condensers condense the refrigerant by giving off heat to the air that is
moved by fans over the dry heat exchanger surface.
There are two different modes of operation. In transcritical operation the device acts as a gas cooler
and in subcritical operation as a condenser.
In transcritical operation the incoming gaseous CO2 refrigerant is cooled by transferring heat to the
ambient air. There is no change of phase.
In subcritical operation the incoming gaseous CO2 refrigerant is cooled by transferring heat to the
ambient air, liquefied and sub-cooled.
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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.
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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 frequency converters are equipped with this function as standard. Conventional three-phase 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.
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6 Transportation and storage
6.1 Safety
Crushing danger with falling down!
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.
Use auxiliary transport equipment where required. Use a transporting device appropriate for the unit’s
weight. You will find the weight of the unit in the order-related documents (see Set-up and other applic-
able documents, page 7). Do not use connection pieces and header pipes as hooking points for lifting,
pulling, fixing or mounting. This can cause leaks.
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WARNING
Transport the unit carefully. Particularly avoid setting the unit down hard.
6.2 Transportation and storage
Read and observe all transport signs on the units’ packaging!
Prolonged mechanical stresses caused by uneven road surfaces and potholes and vibrations during
transport by ship can cause transportation damage. Before transportation by sea or in countries with difficult transport routes, attachment parts that are likely to vibrate – in particular fans and base stands –
must be removed for transportation.
Use suitable equipment to transport the packed unit to the destination installation site (for exam-
ple, a crane or fork-lift).
Unload the unit.
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.
NOTICE
WARNING
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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.
6.3 Storage before installation
Danger of corrosion and dirt build-up!
Moisture and dirt must be prevented from entering the unit.
page 33 / 68
NOTICE
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 34
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.
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.
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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 CO2 refrigerant!
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 carbon dioxide (CO2), page 21).
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 34 / 68
– Moisture
– Atmospheric air
– Welding and soldering residues
– Rust
– Soot/ash/cinders
– Metal cuttings
– Unstable oils
– Dust and dirt of all kinds
Moisture in the working fluid-carrying components of the unit can have the following consequences:
– Water separation and ice formation cause faults in the switching and control fittings of the refrigera-
tion system
– Acidification
– Ageing and refrigerator oil decay
– Corrosion
Atmospheric air and other non-condensable gases can have the following consequences:
– Refrigerator oil oxidation
– Chemical reactions between working fluid and refrigerator oil
– Increased condensing pressure in the system
Chemical reactions between working fluid and refrigerator oil with the absence of moisture or atmospheric air with ageing and working fluid and refrigerator oil decay can have the following consequences:
– Formation of organic and inorganic acids
– Increased compressed gas temperature in the system
– Corrosion
– Bad lubrication, increased wear and tear through to system or failure
Other contaminants can cause:
– Accelerated chemical processes (decomposition)
– Mechanical and electrical faults in the refrigeration system
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During the installation (connecting the working fluid-carrying components of the unit to the working fluid-carrying system of the installation’s ensure that internal contamination is strictly avoided.
Perform the installation with extreme cleanliness.
Caution! Low permissible water content in a CO2 refrigeration system! Ensure that the unit's level of dry-
ness corresponds with the low permissible water content in a CO2 refrigeration system!
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 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 working fluid-side and electrical connections must be available on the system. The connections must be specified in the order-related 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
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•
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 and damage to property!
The unit contains CO2 refrigerant (see Residual hazards due to carbon dioxide (CO2),
page 21).
CO2 is an irritant gas and causes agitation, dizziness, vomiting and cramps, with high
concentrations causing suffocation and life-threatening pulmonary oedema.
Irritation of the respiratory centre with 30,000 to 50,000 ppm (3 to 5 vol %). Unconsciousness with 70,000 to 100,000 ppm (70 to 100 vol %).
There is no imminent danger for the staff. However, refrigerants of the Group L1/A1
are generally 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 suffering from disordered cardiac rhythm and suffocation due to a
reduction of oxygen concentration, especially at ground level.
•
Ensure that unauthorised persons do not have access to the unit.
•
Ensure that the refrigerant 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 refrigerants, filling weight and cold
transfer systems.
•
Install the unit in accordance with EN 378-1 only 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 CO2 concentration of more than 5000 ppm (MAC value) could endanger the work
environment. Take effective protective precautions if such a spatial separation were
to be required, but is not possible.
•
Install the unit so that the MAC value – 5,000 ppm – as 8 h mean value is not exceeded. A concentration of 10,000 ppm (instantaneous value) for 60 min. three
times per shift is permitted as peak limit.
•
Install the electrical equipment (for fan operation, for ventilation, for lighting and for
the alarm system) in the set-up room while observing the condensation of moisture and formation of drip water, as well as the risk level of CO2 refrigerant in accor-
dance with EN 378-3; section 6.
•
Arrange CO2 refrigerant detectors and alarm systems to warn of CO2refrigerant
concentrations that are hazardous to health and for control purposes at the unit setup point in accordance with EN 378-3; section 7.
•
Ensure that the unit at the set-up point is not exposed to any inadmissible high
temperature effects. Effectively protect the unit against heat sources or temporary
high temperatures.
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WARNING
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Danger of environmental damage!
Carbon dioxide (CO2) is a greenhouse gas that appears in the most important natural compounds. Addi-
tional emissions from anthropogenic sources result in serious global warming and therefore damage to
the global climate:
– As an important, climate-relevant trace gas, carbon dioxide (CO2) contributes significantly to regula-
tion of the earth’s heat balance. Carbon dioxide (CO2) changes the earth’s radiation balance by al-
lowing (almost unobstructed) short-wave solar radiation to pass through to the earth’s surface, and
by partially absorbing the long-wave heat radiation emitted by the earth.
At 50%, carbon dioxide (CO2) is one of the most significant anthropogenic greenhouse gases
•
Ensure that carbon dioxide (CO2) never enters the atmosphere uncontrolled!
7.2 Requirements at the set-up point
You will find the dimensions and weights in the order-related documents.
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.
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WARNING
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.
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Installation instructions for condensers and liquid coolers
Horizontal units
Free-standing set-up
page 38 / 68
(1) Air flow direction
(2) Free area for air intake
(1) Air flow direction
(2) Free area for air intake
Set-up next to a building wall
Installation in an indoor shaft
Installation in an indoor shaft - air discharge nozzles
(1) Air flow direction
(2) Free area for air intake
X ≥ 0.5 x W
(1) Air flow direction
(2) Free area for air intake
Y ≤ D
X ≥ 0.5 x W
H ≥ 0.7 x X
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Installation in a group
Vertical units
Free-standing set-up
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(1) Air flow direction
(2) Free area for air intake
A
= 80 mm (necessary because of projection
min
at the vibration dampers)
n = number of units
(1) Air flow direction
(2) Cable tensioner
Please observe adhesive labels on the unit!
(3) Prevailing wind direction
Floor installation; side view (above) and plan
view (below)
(1) Air flow direction
(2) Free area for air intake
X ≥ 0.35 x L
Y ≥ 0.5 x L
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(1) Air flow direction
(2) Free area for air intake
Y ≥ X
H ≥ X x 1.5
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Wall mount; side view (above) and plan view
(below)
7.3 Unpacking the unit
Cardboard packaging
Unit types with module width 500 mm are delivered in cardboard boxes. When a number of units
are delivered together, up to four boxes may be stacked on top of one another. When a number of
units are delivered: Place the boxes individually on the ground before unpacking them.
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finoox units
finoox unit with one fan
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Wooden packaging
finoox unit with two fans
Open the box, folding the flaps outwards.
Remove the legs, which are enclosed in the package separately (1).
Remove the protective cardboard (2).
Lift the unit (3) out of the box.
Unit types with module width 600 mm are delivered in wooden packaging. When a number of units
are delivered in a container, up to three units may be stacked on top of one another. When a number of units are delivered: Place the pallets individually on the ground before unpacking them.
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Unpacking units with wood packaging
Remove the external wood sheathing on all four sides.
Lift off the uppermost pallet containing the equipment legs and brackets and set it aside.
Lift the units individually off the stack on the pallet.
Lifting the units from the pallet: Make sure that all the packaging bolts have been removed!
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Single-row units Two-row units
Unpacking vertical units
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Unpacking horizontal units
Remove all transport bolts.
Lift up the unit and take it to the installation site.
Unpacking vertical units
Unpacking horizontal units
The following applies to all units:
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NOTICE
The unit is pressurised! The transport overpressure serves as leak tightness control and must be released immediately before mounting the unit!
(1) Screw off the cap.
(2) Check the transport overpressure: The units are delivered from the manufacturer with transport overpressure (cleaned and dried air). Release the transport pressure on the Schrader valve
(pressure measurement). With unpressurised unit: Immediate report to manufacturer and noting
on bill of delivery.
CAUTION
Danger of injuries and damage to property with escaping working fluid!
An unpressurised unit indicates a leak due to transport damage. Escaping working fluid from leaks in
the unit can cause injuries and damage to property. Residual hazards due to carbon dioxide (CO2)
Do not put the unit into operation!
(3) After releasing the transport overpressure (only do this immediately before the installation)
you can shorten the tube if necessary.
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 34
Begin with the installation as soon as possible.
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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.
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.
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7.4.2 Mounting the feet
Mounting feet on single-row units:
This applies to unit types with module width 500 mm, which are delivered in cardboard boxes. The
feet are separately enclosed with the unit.
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1. Check that the delivery is complete.
2. For easy mounting of the feet,
place the unit on a level surface that
is at least as high as the length of the
feet.
3. Attach the feet to the unit.
4. Screw the feet firmly to the unit.
5. Make sure that there are no gaps
between the feet and the unit. The
feet must be screwed flush with the
unit.
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Mounting feet on two-row units:
This applies to horizontal units with module width 600 mm, which are delivered packaged vertically.
The feet are separately enclosed with the unit.
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1. Transport the unit to the proposed
installation site. When transporting by
crane: Attach cables only to the crane
eyes provided.
2. For easy mounting of the feet,
place the unit on a level surface in order to avoid damaging the fins. The
height of the surface must be at least
as high as the length of the legs.
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3. Remove the transport brackets
from the unit.
4. Attach the feet to the unit.
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Screw on the brackets and feet as indicated in the instructions.
5. Once again, check all screw attachments. If used, attach the optionally supplied vibration dampers.
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7.4.3 Mounting the vibration dampers (optional)
The optional vibration dampers are separately enclosed with the unit.
Check that the list of package contents is complete.
Observe the specified torque.
Assemble the individual parts in the order shown.
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7.4.4 Mounting the unit
Bracing units for roof installation
General information:
The load on the cable depends on the size of the unit, the height of the building (impact pressure)
and the number of bracing cables.
The figures shown refer to an average unit (about 2.5 m high, 3 m wide) and a building height of up
to 20 m above ground level.
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The unit must be braced using at least two cables on opposite sides (specifically, the sides with the
longest edges).
The bracing must be carried out in such a way that the standard fittings/feet (e.g. vibration
dampers) do not exceed their max. permissible load.
The braces must be at an angle of 55°.
If there are significant changes to the static bracing system the forces will have to be recalculated.
1. Lift the unit off the pallet and transport
it to the installation site. Attach transport
cables only to the crane eyes provided.
2. Screw the unit firmly to the ground.
If used, mount the optional vibration
dampers supplied (see the section
“Mounting the vibration dampers (option-
al)”).
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Observe the information provided on
mounting the vibration dampers.
3. Attach bracing cables only to the eye-
lets provided. Position the bracing cables
according to the specification of the static
system.
Static system:
F
Cable tension:
Resultant forces:
The bracing cables must be suitable for the minimum tensile force F
= 3.5 kN
cable
FX = 2.1 kN
FY = 2.9 kN
cable
The attachment of the braces at the site will depend on local conditions.
.
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For concrete, depending on the quality of the concrete, you can use suitable anchors (e.g. supplied
by Fischer, Hilti, Upat, etc.) with the approval of the building standards inspectorate. The attachments must be suitable for the forces they will have to absorb.
In the case of roof locations, you must ensure that you do not affect the weatherproofing of the roof.
The forces present in the static system must be verified individually for every site.
7.5 Notes on connecting the unit
Danger of injuries and damage to property with escaping CO2 refrigerant!
Incorrect installation risks working fluid escaping when the unit is operated, causing injuries or damage to
property (see Residual hazards due to carbon dioxide (CO2), page 21).
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.
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WARNING
7.5.1 Connect the unit to the system
Danger of injuries and damage to property!
Improper connection to the the system causes hazards:
•
Leaks result in escaping CO2 refrigerant (see Residual hazards due to carbon dioxide (CO2), page
21).
•
Soldering and welding work on pressurised parts can result in fires or explosions.
•
Ensure that stresses and vibrations from the system 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!
•
Ensure that the unit's level of dryness corresponds with the low permissible water content in a CO
refrigeration system!
•
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:
– Avoid transmitting vibrations to the unit via conduits or pipes. If necessary, use vibration
dampers.
Caution! Low permissible water content in a CO2 refrigeration system! Ensure that the unit's lev-
el of dryness corresponds with the low permissible water content in a CO2 refrigeration system!
WARNING
2
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7.5.2 Unit electrical connection and protection
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:
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".
Danger of damaging! If the fuse rating is too high there is the danger of injuries to people
and damage to property.
7.6 Perform acceptance test
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WARNING
WARNING
Danger of injuries and damage to property!
Escaping CO2 refrigerant can cause injuries or even death ( see Residual hazards due to carbon dioxide
(CO2), page 21).
Perform the following acceptance test with an expert before starting up the unit after making important
changes and after a unit exchange.
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 of the
systemwith the plans of the systemand the electrical wiring diagrams.
Test the unit for vibrations and movements that can be caused by the fans and operation of the
system . 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.
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?
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– 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 65).
Perform function tests on the fans (rotation direction, power consumption, etc.).
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 , 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:
– 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 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
Danger of injuries and damage to property!
Escaping CO2 refrigerant can cause injuries or even death ( see Residual hazards due to carbon dioxide
(CO2), page 21).
You can put the unit into operation, only when:
•
The unit has been properly mounted and connected ( see Installation, page 45).
•
You have performed a complete acceptance test (see Perform acceptance test, page 54).
•
You have checked the unit’s readiness for operation (see Test readiness for operation, page 55).
•
All safety precautions (see Safety, page 34) 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 of the electrical system (see system).
Activate the unit:
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– Open the valves on the inlet and outlet-side 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:
•
Condensation temperature
•
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.).
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8 Operation
8.1 Safety
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 with loose elements such as hair, necklaces or clothing
parts.
Do not operate fans without guard grille!
8.2 Putting the unit into operation
Switch on electrical system
Open working fluid-carrying lines
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WARNING
Switch on fans
8.3 Taking the unit out of operation
Switch fans off
Switch electrical system off
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!
NOTICE
WARNING
Escaping CO2 refrigerant can cause injuries ( see Residual hazards due to carbon dioxide (CO2), page
21, and see Residual hazards caused by pressurised parts, page 24).
Ensure that the maximum operating pressure is not exceeded after the shutdown either!
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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 34).
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 57).
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 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 34), 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 33); precautionary corrosion protection measures, regular checking of the fans’
functionality and regular checks on the shutdown unit.
Evacuate the unit: Completely release working fluid and, if applicable, refrigerator oil (see
Residual hazards with disposal, page 26).
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 55). 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.
Caution! Low permissible water content in a CO2 system! Ensure that the unit's level of dryness
corresponds with the low permissible water content in a CO2 system!
Put the unit into operation (see Putting the unit into operation, page 57).
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 18).
Without prior written consent from Güntner GmbH & Co. KG , the unit must not be changed over to use
a different working fluid.
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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 and oil, 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 54).
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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 . 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 16).
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
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WARNING
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
Working fluid escaping
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)
Unit working fluid-carrying components leaking
Clean
Set working fluid pressurising values
(temperature and quantity) to reference values.
Switch off working fluid feed and
fans, close leak
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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 car-
bon dioxide (CO2), page 21).
At 50 % CO2, is one of the most significant anthropogenic greenhouse gases)!
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:
■
drain the unit's heat exchanger
■
Clean and blow out the unit's heat exchanger.
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WARNING
10.1.2 With all maintenance work
Danger of injuries and damage to property with escaping CO2 refrigerant!
Escaping refrigerant with leaks on the evaporator can cause the following hazard situations and injuries:
Warns against fire-risk substances at set-up point.
Unintentionally carried in oil residues can ignite.
•
Ensure that there is no unintentionally carried in oil in the set-up room .
•
Keep the risk area free of direct and indirect ignition sources.
•
Before releasing for maintenance obtain the required approvals for work for the unit
that can involve ignition sources (e.g. grinding, welding, soldering, etc.).
•
With all work involving ignition sources (e.g. grinding, welding, soldering, etc.) in the
work area, keep suitable fire extinguishing equipment that meets the requirements
of EN 378-3 at hand.
•
Do no bring any open flames or hot gases (e.g. candles, matches, welding beads,
welding sparks, glowing cinders or tobacco) into the set-up room.
•
Ensure that there are no warmed up or hot surfaces (e.g. heaters, hotplates,
bulbs, motor housings) in the set-up room.
•
Ensure that no frictional heat develops in the set-up room (e.g. overheated stores).
WARNING
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Warns against health-endangering irritants in the set-up room!
NH2 refrigerant under defervescence still present can evaporate. Inhalation of refriger-
ant vapour causes irritation of the respiratory centre, agitation, diziness and vomitting.
•
Escaping refrigerant vapour and escaping refrigerant liquid must not reach adjacent
rooms, staircases, yards, passages or drainage systems.
•
Use respiratory protection.
•
Use a room air-independent breathing apparatus with maintenance work in high
CO2 refrigerant concentrations in the room air.
•
Ensure the set-up room is well ventilated.
•
Divert escaped refrigerant vapour and escaped refrigerant liquid safely.
Warns against cold!
NH2 refrigerant still under defervescence has a temperature of -57 °C. Contact with
NH2 refrigerant still under defervescence caused by spraying causes frostbite.
•
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 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.
•
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.
10.1.3 After all maintenance work
Danger of injuries and damage to property with escaping CO2 refrigerant (see Residual hazards due to
carbon dioxide (CO2), page 21)!
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.
NOTICE
WARNING
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•
Check the identification of the pipelines and ensure this is visible and legible.
•
Check the fixing and corrosion protection of the components in question.
•
Ensure the electrical connections (e.g. fans) are functioning.
•
Perform a pressure test and a tightness test (see operating instructions manual annex).
•
Caution! Low permissible water content in a CO2 refrigeration system! Ensure that the unit's level of
dryness corresponds with the low permissible water content in a CO2 refrigeration system!
•
Perform an acceptance test ( see Perform acceptance test, page 54).
•
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 63 / 68
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
Danger of injuries and damage to property with escaping CO2 refrigerant (see Residual hazards due to
carbon dioxide (CO2), page 21)!
X
*
X
*
X
*
X
*
X
*
WARNING
Caution! , Gas coolers/condensers of the GGHC CD_GGVC CD series work with a very high operat-
ing pressure. Danger from high operating pressure: 120 bar! Breaks in pressurised tubes or pressurised
components of the unit can cause injuries or damage to property caused by flying debris ( see Residual
hazards caused by pressurised parts, page 24).
GGHC CD_GGVC CD | 2018-04
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Page 64
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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
65).
Check heat exchanger’s general condition.
•
Damage found: Repair damage
Check heat exchanger’s operating point (see Operation, page 57).
•
Change in fan capacity found: restore required system-side conditions .
•
Change in surface temperatures found: restore required system-side conditions .
Check heat exchanger and connections for tightness.
•
Repair unit sections (see Remove leaks, page 65).
Check heat exchanger for working fluid pressurising. X
Check heat exchanger for corrosion.
•
Corrosion or damage on support structures, tube connections, fixtures: repair unit sections affected.
*) Recommended: every six months
Care and maintenance plan
X*
X*
X*
X
*
X
*
Measure Cleaning agent Interval
Component cleaning Mechanically As required (visual inspection)
Complete cleaning Warm water or environmental-
ly safe cleaning agent
Leak check After 6 months
Heat exchanger setting check After 6 months
Corrosion protection check After 6 months
According to local conditions
(visual inspection)
GGHC CD_GGVC CD | 2018-04
© Güntner GmbH & Co. KG
Page 65
10.3 Maintenance work
10.3.1 Remove leaks
Danger of injuries with CO2 refrigerant (see Residual hazards due to carbon dioxide (CO2), page 21)!
•
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.
Warning! Low admissible water content in a CO2plant! Ensure that the desiccation ratio of the unit com-
plies with the low admissible water content in a CO2 system.
Perform all work including pressure, acceptance and functional test (see Perform acceptance
test, page 54, and see Test readiness for operation, page 55).
10.4 Clean unit
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WARNING
10.4.1 General
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 55).
10.4.2 Clean heat exchanger
Drain the unit (see system).
Shut off the unit (see system).
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 66).
– Hydraulic cleaning (see Hydraulic cleaning, page 66).
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.
GGHC CD_GGVC CD | 2018-04
NOTICE
© Güntner GmbH & Co. KG
Page 66
•
Use a pressure of max. 50 bar with hydraulic cleaning and max. 80 bar with cleaning with com-
pressed 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).
10.4.2.1 Cleaning with compressed air
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.
10.4.2.2 Hydraulic cleaning
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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
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 set-
up 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.
Continue cleaning until all dirt has been removed.
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Page 67
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 switch-
ing 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 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 similar)! Continue cleaning until all dirt has been removed.
Mount guard grille
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WARNING
Switch unit on
GGHC CD_GGVC CD | 2018-04
© Güntner GmbH & Co. KG
Page 68
11 Plans/diagrams
11.1 Electrics documentation
11.1.1 Fan motor connection diagram
See motor terminal box cover inside on the fan.
page 68 / 68
GGHC CD_GGVC CD | 2018-04
© Güntner GmbH & Co. KG
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