Operating Instructions (BA) for KÜBA condensors and KÜBA glycol cooling coils in accordance with DIN PDF

Küba Kältetechnik GmbH Operating Instructions (BA) for KÜBA condensors and KÜBA glycol cooling coils in accordance with DIN 8418 TÜV CERT TUV TÜV BAYERN SACHSEN DIN ISO 9001 / EN DIN GEPRÜFT TUV

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Küba Kältetechnik GmbH Operating Instructions (BA) for KÜBA condensors and KÜBA glycol cooling coils in accordance with DIN 8418 TÜV CERT TUV TÜV BAYERN SACHSEN DIN ISO 9001 / EN DIN GEPRÜFT TUV NACH ENV 327 GEPRÜFT VOM TÜV BAYERN Küba Kältetechnik GmbH Oberdiller Str. 23 D Baierbrunn Tel: 089/ Fax: -107/-222/ How to Use/Table of Contents How to use the operating instructions Be sure to read these instructions, and the Declaration by the Manufacturer, prior to the start-up of your condensor/glycol cooling coil. Safety symbols for working areas Within these instructions (BA), this symbol is found next to all recommendations for safety at work, i. e. for situations which are either a danger to human life or a risk of injury to persons. Please follow these instructions and act with particular care in all these situations. You are also requested to transmit all work safety instructions to other users. In addition to these instructions (BA), it is necessary to take into account the universally applicable safety and accidentpreventing rules. Attention sign Throughout these instructions (BA), this Attention sign marks all paragraphs requiring special attention so that the rules, regulations, recommendations as well as the correct course of the works are followed and the unit and/or parts of the installation are safeguarded from danger and from destruction. Recycling Whenever condensors/glycol cooling coils, unit parts or spare parts are renewed, the correct way of recycling for the exchanged parts is to be duly observed. On this subject please see sections 10.1 through 10.6 of this instructions. Table of Contents 1 Introductory Information Basic reference literature Range of application Proprietary Right, Copyright Law Changes Technical Data Characteristic data Operative range and purpose of destination Material data Model designation Safety Safety instructions for working areas Information on safety in general Mounting Mounting of electric parts Transportation Packing Type of packing KÜBA transport packing Pictoral symbols Table of Contents 4.2 Disassambly status Sensitiveness Handling with adequate care in transit, lifting & storing Gravity point Storage in transit Storage space Volume of delivery Securing loads by safety devices Rules for the prevention of accidents (UVV) Mounting General instruction for mounting Set-up conditions General set-up instruction Dimensions, floor space and weight Hoisting devices Mounting work General information on mounting works Mounting of electric parts Mounting of accessories Mounting of refrigeration equipment acc. to DIN 8975, DIN EN Starting Operation Instructions Test run Operation Normal operation Direct expansion Water and glycol water circulation Draining instructions in case of subzero temperatures Shutdown of the condensor/glycol cooling coil How to handle failure situations Maintenance Servicing and inspection After-Sales Service Stock keeping of spare parts Corrosion Disassembling and Recycling Disassembling Materials of the condensors/glycol cooling coils Synthetic construction materials Materials for motors Packing material Recycling concept Annexes Introductory Information 1 Introductory information 1.1 Basic reference literature Concerning the technical data we refer to our current planning aid literature on condensors/glycol cooling coils. As far as fan motors are concerned, the only binding data are those on the label. 1.2 Range of application The condensors/glycol cooling coils are applicable only in accordance with the operating conditions and the technical data in the current planning aid. 1.3 Proprietary right, copyright law KÜBA Kältetechnik GmbH is the holder of all rights, including claims for industrial property right as well as all rights of disposal including that of copying and passing on of KÜBA documents. 1.4 Changes Regarding descriptions and informative details as given in these operating instructions (BA), reservation is made for all technical changes which may become necessary for the purpose of updating and improving the condensors/glycol cooling coils manufactured by KÜBA. 4 Technical Data 2 Technical Data 2.1 Characteristic data See model designation and label data Typ Herstell-Nr./ Jahr Inhalt Liter Zul. Betr.-Überdruck/-Temperatur 25 bar/100 C Min. Temperatur/Überdruck -40 C/5bar KÜBA KÄLTETECHNIK GMBH - D Baierbrunn 2.2 Range of application and purpose of destination The condensor/glycol cooling coil is suitable only for refrigeration plant application according to DIN Any use beyond this application is considered as not being in accordance with the purpose of destinatio n. The manufacturer can not be held responsible for damages resulting from such improper use which is exclusively at the risk of the operator. The condensors/glycol cooling coils may be operated only in places where their material cannot be affected by corrosive atmosphere. 2.3 Material data Tubes of copper (stainless steel), fins of aluminium. Option: Epoxy resin coating or copper (welded) Tube systems are solderd (brazed). Suitables for the refrigerants R22, R134a, R404a, R507 (R 717), water and glycol water. For further information see tender texts in accordance with the current planning aid. 2.4 Model designation Example: T EC... C X.. Glycol cooling coil Condensor Condensorcapacity Execution Fans N=normal L=silent S=super silent E=extremely silent Diametre of the fans (mm) Position of the fans in 1 or 2 rangs Execution H= horizontal air direction V= vertical air direction For more details see tender textes. 5 Safety 3 Safety The information given refers to the component condensor/glycol cooling coil but not to the entirety of the machine unit which incorporates the component. 3.1 Safety instructions for working areas Information on safety in general The condensor/glycol cooling coil has been built to the latest technical standards and is, therefore, safe in operation. Nevertheless, a condensor/glycol cooling coil improperly used by unskilled personnel in undue applications or installed in an incompetent manner can become a danger. Each person employed by the user being entrusted with the mounting, disassembling, starting, operating, and maintenance (inspection, servicing, repair work) of the condensor/glycol cooling coil, must have read and understood the complete BA instructions and in particular the safety instructions. With regard to refrigeration or electronics, the condensor/glycol cooling coil may be installed only by skilled personnel of specialized firms listed in the register of qualified craftsmen. For the use of R717/ammonia (with stainless steel tubing only) the relevant provisions must be observed Mounting The bearing capacity of all site-installed suspension systems is the responsibility of the installer. For refrigeration installations, the relevant regulations for the prevention of accidents, in particular the V 20 Kälteanlagen (= refrigeration plants) and DIN 8975, part 7.33, or the relevant national laws and regulations in the particular country must be observed. Before starting the unit, make sure that all protective devices, especially those regarding the mounting of the fan guard, are fixed. For mounting, repair, and maintenance work, disconnect electric voltage on all circuits. Be sure to avoid any contact with sharp fin edges. Attention: Danger of injury! Vor Arbeiten an stromführenden Teilen Spannung an allen Versorgungskreisen unterbrechen! Prior to working on live parts turn off power on all supply circuits! Avant de travailler à des pièces sous tension interrompre la tension de tous les cicuits d'alimentation! Unauthorized constructional changes and modifications with effect on safety and capacity of the condensor/glycol cooling coil are not permitted. Be sure to avoid any contact with refrigerant! No brazing or soldering on refrigerant-charged installations. Attention: Danger of poisoning! In case of liquid refrigerant getting in contact with the eye, be sure to see a doctor immediately! Mounting of electric parts For the electric installation, the VDE 0100/0700 and the DIN 8975, part 7.33, the local energy supply networks, and all other safety standards, as well as label data of the fan motors must be obeyed. Wiring should be carried out only in accordance with the wiring diagrams inserted in the mounting instructions and enclosed in the connection boxes of the motors. The only binding data are those on the data labels of the equipment. All fan motors have a thermal overload protection (thermal contact). 6 Transportation A.C. motors with two thermal contact terminals or with more than 1.1 A rated current as well as all threephase current motors must be connected via a contactor. If the thermal contact is not connected, no guarantee will be assumed for the case of motor defect caused by overload. If thermal overcurrent release devices are used, they have to be tested for correct functioning (see planning aid, chapter on motors). A divider with at least 3 mm contact gap width on each pole must be built into the installation (master switch or service switch). After the appropriate mounting or repair of the electric parts, the relevant protective measures have to be tested (e.g. ground resistor). Tight sealing and traction relief of feed lines must be observed. For application in flame-proof rooms, be sure to observe the relevant guidelines. Standarddesign KÜBA condensors are not suitable for Ex ranges. For Ex(e) and temperature class T1- T4 or T5, variants are available. In any case, the only binding data are those on the label of the unit. 4 Transportation 4.1 Packing Type of packing The transportation itinerary and size of an condensor/glycol cooling coil are, among others, two important aspects to be considered in the choice of right packing. The packing corresponds to the guideline mentioned under unless otherwise agreed Pallets, crates, export boxes These are in accordance with the HPE packing rules which have been defined by the German Federal Organisation for the use of Timber, Pallets, Export Packing Inc., and the Corporation of German Engineering Institutes KÜBA transport packings These are manufactured from ecologically desirable material apt for reutilisation after recycling. 7 Transportation Pictorial symbols The pictorial marks on the packing have to be observed, such as: min.pl Top Fragile Keep dry Keep away from heat PL Hold-on points under pallet for forklift 20 No hand hooks! Gravity point Stop device Stacking Height No hold-on points under pallet 4.2 Disassembly status Shipment of the condensors/glycol cooling coils as completely assembled units is the rule we seek to follow. However, in case the condensor/glycol cooling coil is delivered disassembled, the mounting must be carried out by following the drawings which are strictly related to the particular order. 4.3 Sensitiveness Handling with adequate care in transit, lifting and storing During transport, special care must be taken to avoid damage as a result of violence or of careless loading and unloading. Strictly avoid any harsh setting down of the condensor/glycol cooling coil. Do not pull on any tubes or connection pieces nor use them for fastening. This may cause leaks. Carrying ropes, chains, etc. may be fastened only on the adequate suspension points or hoisting brackets. For fork lifting watch the fork arms to be long enough to reach completely under the bottom planks of the item. Usually, the condensors/glycol cooling coils are brought into site, packed on pallets. 8 Transportation OK NO Centre of Gravity Before lifting the unit, watch out for the weight distribution. The centre of gravity is always on the side of the fan (H-version). 4.4 Storage in transit Storage place The condensors/glycol cooling coils should be stored in a protected place unaffected by shocks/strong vibrations. 4.5 Volume of delivery The contents of the packing must be checked for the pleteness on arrival. Any transport damages and/or missing parts must be reported immediately in writing. 4.6 Securing loads by safety devices The VDI standards 2700 Securing Loads on Road Vehicles are respected by us. Groupage traffic is the resonsability of the forwarding agent. 4.7 Rules for the prevention of accidents (UVV) The respective national rules for the prevention of accidents must be complied with; e.g. concerning: lifting devices cranes cargo carrying devices in lifting service powered conveyor vehicles 9 E1 Mounting 5 Mounting 5.1 General instructions for mounting All mounting work has to be carried out exclusively by skilled personnel. We expressly decline all responsibility for damages resulting from inexpert mounting. The condensors/glycol cooling coils must be fastened only at the point provided for this purpose. The pictures given in our literature are simplified. The bearing capacity of the fixing points and the strength of the bolts is the responsability of the installer. The fixing points are mentionned in the mounting instruction and in the planning aid. The mounting may be done without swing-elements (see ounting instructions). Küba Kältetechnik GmbH EC...C...H Montageanleitung EC...C...H EC...C...V Mounting Guide F Guide de montage E Instrucción para el montaje P Instruções para a montagem I Istruzioni per il montaggio NL Handleiding voor montage GR Οδηγία συναρµολόγησης DK Montage Vejledning 2 EC...C...H [mm] H B T L E 1 E 2 A 400-1x1H x1H x1H x1H x1H x1H x2H spurig 2-range 2-rangée H ±5 1-spurig 1-range H ±5 1-rangée L T ± ±5 A ±5 B ±10 = = = 90 = x2H x2H Set-up conditions General set-up instructions It is very umportant to reserve, in the floor space plan, sufficient room around the condensor/glycol cooling coil for mounting, function, serving and repair work (for the airvolume.see the mounting instructions). The fundament should be prepared in advance, according the weight and the number of legs of the condensor/glycol cooling coil. The bearing capacity of the suspension points and the strength of the bolts is the responsibility of the installer. 10 The number of legs is mentionned in the mounting instruction and in the planning aid Dimenions, floor space and weight Dimensions: See planning aid literature or mounting instructions. Floor space required: Providing for additional space on the connenction side and sufficient space for the air intake arround the condensor/ glycol cooling coil. A free air intake and outlet space should be provided with enough distance to wall and ceiling, ceiling joists, stacked products, shelves etc. for dimensions see also planning aid literature and mounting instructions. If the space is kept to narrow, this may lead to malfunctions in the system. Eliminate extra airresistance and possibility of airreflow for the condensors/ glycol cooling coils with axial fans. If the unit is placed in open field, the air outlet must show in the direction of the mean wind. Starting Operation In- and outlet should be placed with enough distance from each other, to avoid thermical air circulations Weight: See planning aid literature or mounting instructions Hoisting devices The bearing capacity must correspond to a weight which is at least 1½ times the unit. 5.3 Mounting work General information on mounting works See section and Mounting of electric parts See section Mounting of accessories See mounting instructions as enclosure with accessory parts Mounting of refrigeration equipment in accordance with DIN 8975, DIN EN 378 Mounting of tubes in accordance with DIN 8975, part 6 / DIN EN Be sure not to transmit any tensions or vibrations on the condensor/ glycol cooling coil. Cleanness ans dryness of the condensor/ glycol cooling coil is in accordance with DIN 8964 standards. Strictly avoid inner contamination of the duct work during installation of the plant. For mounting of the solenoid valve follow instructions of the manufacturer. When evacuating and charging of the plant system be sure to follow VDMA guidelines. 6 Starting Operation 6.1 Instructions The starting operation may be effected only by skilled professional personnel of the line and only after checking all safety devices in accordance with the UVV regulations for the prevention of accidents relating to refrigeration plants (V 20). 6.2 Test run Be sure to control the current absorption as per label data and the sense of rotation of the fans. ZIEHL. ABEGG 3~ 400V +/-10% D/Y 50Hz 1,6/0,91KW AUFN. 3,3/1,7A 830/610/MIN COSPHI 0,70 IP54 INSCL F CC FE091-SDS.6N.6 38Kg 16/95 IEC 34-1 Test all connected control devices for correct performance. Test the safety devices for ON and OFF switching points. 11 Starting Operation 7 Operation 7.1 Normal operation Direct expansion The condensor is charged with refrigerant via the compressor. The refrigerant condenses in the tube system, changes the physical status and gives over heat through the wall of the tube. The glycol cooling coil is charged in refrigerant by pump. The refrigerant keeps his physical status and gives over the heat trough the wall of the tubes. The cold ambiance air then takes over the heat from the heated tubes and fins. The heat that has been extracted from the cold room, will be transferred to the outdoor via the condensor/glycol cooling coil Water and glycol water operation For water and glycol water operation the drycooler to be used must be of a special kind and with a special tubing circuitry Draining instructions in case of subzero temperatures When draining a glycol cooling coil after pressure testing with water the manufacturer cannot accept any guarantee complete coil evacuation as this depends on the tolerances which exist for its installation on the site. Whenever freezing temperatures are forecast or prevail it is therefore indispensable to rinse a coil repeadetly by using standard glycol after it has been pressure tested with water and reasonably drained. Prior to rinsing the normal water circuit must be disconnected from the cooler by means of shut- off valves (1) to be mounted on site. For rinsing a pump (2) must be used and connected to the drain socket(4) by means of hose connections(3). The water-glycol mixture leaves the coller through the bleed socket(5) into a collecting vessel(6) to be pumped back again into the unit. The rinsing procedure should continue until the residual water remaining in the heat exchanger and the glycol are sufficient well mixed. As a rule 10 circulations are quite sufficient.-30 C. Freeze resistance results from the concentration of glycol remaining in the collecting vessel(6) after rinsing. If 50% of the inner volume indicated in the catalogue are present in the form of pure glycol this will guarantee frost resistance down to a temperature of -30 C. Example: A glycol cooling coil has an inner volume of 25 dm 3. For the rinsing consequently 12,5l pure glycol are required Maintenance 7.2 Shutdown of the condensor/glycol cooling coil: The condensor/glycol cooling coil is a part of the refrigeration plant. The shutdown and the re-start is effected by the specific plant version in accordance with the VBG 20 regulations. If the motors are shut down for longer, we recommend 2 runs of 1-2 hours each per month. 7.3 How to handling failure situations Strictly avoid all contacts with the refrigerant! In case of any contact of liquid refrigerant with the eye, be sure to see a doctor immediately! Servicing and repair work should be carried out only by skilled professionals. 8 Maintenance 8.1 Servicing and inspection The KÜBA condensors/glycol cooling coils, in general, are maintenance-free. The degree of dirt contamination affects the efficiency of any condensor/glycol cooling coil. Therefore it should be cleansed regulary with shutof motors. The cleansing can be effected by: vapour-bath or high pression against the direction of the air with regular (material-competent) detergents bursting (with a non-metal burst)of the fins on the air inlet. The cleansing is necessa
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