operating instructions gco eng 2011

8/3/2019 Operating Instructions GCO Eng 2011

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INSTALLATION, OPERATION &MAINTENANCE MANUAL

GCO UNIT

Heat Exchanger Coil

Series Description: (Finned) HeatExchanger Coil withor without Droplet

Separator

Series: Heater and Cooler

CONFORMS TO UL STD 207;

CERTIFIED TO CSA STD C22.2 NO. 140.3

RECOGNIZED COMPONENT.


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Gntner de Mxico 2/22

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Table of Contents

1. Warranty Statement

2. General Safety Information

2.1. General Information2.2 Safety Information

3. Technical Data, Application, Definition

3.1. Application

3.2. Definition

4. Transport, Delivery, Installation

4.1. Packaging

4.2. Delivery and Unloading

4.3. Storage

4.4. Assembly, Installation

4.4.1. Assembly

4.4.2. Assembly Information

4.4.3. Assembly Guidelines

4.4.4. Installation

5. Initial Operation, Operation

5.1. Initial Operation

5.2. Operation

5.2.1. Normal Operation

5.2.2. Shut-down, Decommissioning

5.2.3. Modifications to the System, Non-permissible Operating Conditions and Modes of Operation

6. Maintenance / Cleaning

6.1. General

6.2. Cleaning

6.3 Maintenance, Repair

7. Contact Address


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1. Warranty Statement

The supplier warrants against defects in workmanship and materials of the product supplied for a

period of 24 months from the time of transfer of risk, provided that they are correctly installed andoperated within the recommended limits of the manufacturers technical documentation.

The supplier at its option shall repair, or replace, free of charge to the purchaser all goods whichbecome defective during the warranty period as a result of defects in design, workmanship or materials,fair wear and tear excluded, provided, however, that;

- the application is correct- operating and installation instructions are complied with- system component and piping design is in accordance with good refrigeration practice- Nitrogen or an inert gas must be introduced into the piping during the brazing of the piping

installation

In order to execute the corrective work or replacement supply that appears necessary, within thesuppliers reasonable discretion, the purchaser must, following communication with the supplier,provide the necessary time and opportunity, or the supplier will be freed from the liability of the defect.

The costs arising directly from the corrective work or replacement supply, transport and exchange costsin particular, shall be borne by the purchaser himself. The supplier shall not be liable for costs incurredin dismantling or fitting replacement parts or for any independent inspection undertaken by thepurchaser. The purchaser shall return any allegedly defective goods, carriage paid, to the suppliersworks. Upon receipt of the goods and inspection thereof the supplier shall repair or replace, at thesuppliers discretion, the defective goods and return freight, carriage paid, and without any furtherexpenses. This shall constitute full compliance of the suppliers obligations.

No liability is accepted for the consequences of modifications or repair work being carried out by thepurchaser or a third party incorrectly or without the prior permission of the supplier.

It is clearly understood and agreed that any further claims, in particular claims for compensation fordamage and consequential damages not occurring on the supplied item itself, are excluded.

Furthermore the supplier shall not be liable to the purchaser, or client of the purchaser, for any direct orindirect damages, injury to persons or property or any consequential loss or loss of profits arising fromdefective goods or workmanship or from any other cause whatsoever.

To obtain warranty service, please contact: [email protected]


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2. General Safety Information

2.1. General Information

Purpose:Safety information contains instructions designed to reduce or minimize any possible hazards causedby the (finned) heat exchanger (and droplet separator) during

- Transport, delivery, installation- Initial operation- Maintenance / cleaning

For persons, property and the environment.

Binding Regulations:

Valid national and international regulations: "Klteanlagen und Wrmepumpen,sicherheitstechnische und umweltrelevante Anforderungen" (systems and heat pumps, safetyand environmental requirements).

This operation manual applies exclusively to the delivered systems: GCO.

It is restricted to descriptions for

transport and installation initial operation maintenance / cleaning

To avoid indirect damage caused by malfunctions, an alarm system must be installed whichsignals any malfunction immediately. Emergency measures must be planned and prepared toprevent indirect damage in case of malfunction.

If you should detect defects on the (finned) heat exchanger, you are required to notify themanufacturer immediately in order to enable the manufacturer to participate in the curing

of such defects.


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2.2. Safety InformationGeneral:

Symbols used:

Attention!

Caution!

Warning!

In principle, the hazard information contained in the binding regulations pursuant to section 1.1.General Information applies.

The (finned) heat exchangers are designed for mounting inside facilities. They may only be operated ifthey have been installed in these systems according to this manual and if they, as a whole, comply withthe respective statutory regulations.

ny work on (finned) heat exchangers must be carried out by qualified and authorizedpersonnel.

Only approved materials must be used.

(Finned) Heat Exchangers:The (finned) heat exchangers are built according to the latest technology and theapplicable regulations. The safety of the users was a prime concern.

(Finned) heat exchangers may be the source of unavoidable residual hazards. Eachperson working on this (finned) heat exchanger must therefore carefully read thisoperation manual. Please label accessible areas!

Sharp edges and corners on the systems, especially on the fins, can cut fingers andhands wear protective gloves!

When working on the (finned) heat exchanger: The (finned) heat exchanger may be underpressure (maximum operation pressure)! Risk of injury! De-pressurize the (finned) heatexchanger to neutral pressure!

During maintenance: use only original replacement parts when exchanging components!

Design and operation of the system: the maximum operating pressure specified on thename plate of the (finned) heat exchanger must not be exceeded!

Depending on local regulations, pressure limiting safety switches must be provided.


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Operating Fluids:The operating fluid used is a brine according to EN378-1; section 3.7.2. It does not inherit any riskpotential for humans.

3. Technical Data, Application, Definition

According to the manufacturers plate on the respective system.

3.1. Application

As component of a plant

3.2. Definitions

(Finned) heat exchangers are systems for the heat transfer between a fluid and the ambient air.

The heat exchange area is the entire outer surface of the refrigeration unit ((finned) heat exchanger),which is exposed to the airflow to be cooled or heated.

The coolant/refrigerant is the fluid (working fluid) used for the heat exchange in a refrigeration unit. Itremains fluid during heat absorption, thus no changes in the physical condition of the fluid take place.The used coolant / refrigerant, glycol, has no inherent risk potential with regards to flammability (safetygroups 1, 2 or 3) and toxicity (safety groups A or B), and therefore does not have any detrimental effectson the workers.


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4. Transport, Delivery, Installation

4.1. Packaging

Palets, crates, boxes HPE Directive on packaging by the BundesverbandHolzmittel, Paletten, Exportverpackung e.V. (Federal Assn.for Wood Packaging Materials, Pallets and ExportPackaging) and the VDM (German Assn. of Metal Traders)

Transport packaging Gntner transport packaging is made fromenvironmentally compatible material and is sutiable forrecycling.

4.2. Delivery and Unloading

(Finned) heat exchangers scheduled to be shipped must be appropriately protected from detrimentaleffects caused by the atmosphere (packaging units).

During shipping, the (finned) heat exchanger is closed and filled with clean and dry air. The excesspressure (transport pressure) is 0.5 to 1 bar.

1 Schrader valve

2 Sealing plate

3 Flange gasket

All flange connectors are locked to the sealing plate via companion flanges.

Please inspect the delivery contents to ensure that the delivery is complete. Note any possible transportdamage and / or missing parts on the shipping order. Inform the manufacturer immediately in writingof the situation.

It is imperative that the instructions on the shipping labels of the (finned) heat exchanger packagingunits be observed during loading and unloading of the (finned) heat exchanger packaging units(transport with forklifts or cranes using two slings around the entire package is possible).

The unloading system used must be designed to handle the weight of the (finned) heat exchanger, andthe operators must be trained to properly unload the system. Transport by forklift is preferred.

The (finned) heat exchangers must be protected from hard impact against surfaces and the

ground, slipping as well as mechanical damage!

A-A

A

AA

1

22 3


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Transport by crane must be carried out with a maximum angle of the transportation rope of 60 (option1) or, if needed, using a crossbeam (option 2), or, if possible without risk, with a rope sling around thebox!

The minimum transport weight of 2000 kg must be considered.

Lifting by forklift must be carried out only if the forks are extended to full length and extend beyond theload.

When transporting the (finned) heat exchangers by forklift or crane, it is imperative that equalweight distribution be ensured.

During lifting: pay attention to the centre of gravity!

During transport by crane: attach hooks and shackles of the load suspension device only atthe locations indicated by the manufacturer!

Connection pieces: never use suspension points for transport!


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4.3. Storage

Storage of the packaging units according to section QR-FAB04/FIN005 is imperative!

Storage of (finned) heat exchangers: Only with protective cover to protect from dust, dirt,moisture, damage and other adverse effects!

Do not leave the unit open unnecessarily. To avoid the risk of corrosion and contamination, preventmoisture and dirt from permeating into the opened (finned) heat exchanger. The (finned) heatexchanger must be installed / connected (mounted) immediately after opening of the package!

It is imperative that no atmospheric humidity permeate into the unit!Opened (finned) heat exchanger must be installed into the system immediately!During installation interruptions, the (finned) heat exchanger must be closed again!

This also applies to the unpacking of the (finned) heat exchangers, cleaning and the set-up before initial

operation.

General

Please observe the binding guidelines, regulations and accident prevention rules.

Hoisting devices Cranes Load suspension devices inside the hoisting device Powered industrial trucks

4.4. Assembly, Installation

4.4.1. Assembly

Check the heat exchangers (and, if existing, the droplet separators) before assembly and installation:

excess transport pressure is present sight inspection of the (finned) heat exchanger (for fins: check if fins are bent or damaged,

straighten with rib comb, if necessary)

At time of delivery, the (finned) heat exchanger contains excess pressure for transport! Risk ofinjury to skin and eyes if handled improperly!Wear protective goggles when working on the (finned) heat exchanger!Do not open connectors until excess transport pressure has been neutralized!

Before removal of the companion flanges check if excess transport pressure is still present.No pressure present in the (finned) heat exchanger indicates a possible leak (Transport damage!Leakage detection!).

Inform the manufacturer immediately if no pressure is present in the (finned) heat exchanger.

Release the excess transport pressure and remove the companion flanges before connecting the pipes.Removed companion flanges may not be reused!

They must be replaced by flanges mounted on the side of the pipes.

Release the excess transport pressure by operating the mechanism needle of the filling connection(Schrader valve). Bleed the valve with an appropriate tool and open the valve.


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Schrader valve

-1

-2

-3

-4

1. Retainer nut 3 Valve mechanism

2 Gasket 4 Schrader valve

Open valve carefully! Excess pressure!

Open connectors carefully!

The (finned) heat exchangers are transported as system components with mounted droplet separatorsand included drip trays in packaging units. If the (finned) heat exchangers are not to be shipped pre-mounted, installation must be carried out according to the drawings provided with the order.

Installation of droplet separator on site: Correct mounting position (Note and adhere toairflow direction and drain pipe!)

4.4.2. Assembly Information

The (finned) heat exchanger must be positioned on site according to the positioning schedule.

The (finned) heat exchanger must be fastened at anchor points designed for their respective weight andmust be screwed on with fastening screws:

The locations for the anchors of the onsite construction must be determined.

The (finned) heat exchangers must be screwed to all anchor points in a rotating manner (screws M108.8 or superior on site).

The operator or installer is responsible for the tightness of the screwed connections.

Do not exert excessive force while fastening the (finned) heat exchanger (risk of damage to the fasteningscrews!)


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Transport by crane

M10 8.8

1

2

1 Crane shackle, 2 Screw set M10 8.8 (clamping torque 50 Nm)

When fastening the (finned) heat exchangers, note as follows:

The cross section dimensions of the fastening holes are structurally verified by themanufacturer; the fastening screws must be adjusted accordingly.

The fastening screws must be secured against loosening by suitable screw locking devices.

Do not overwind the fastening screws. All fastening screws must be wound to equal torque in order to provide for even load

distribution.

All fastening screws must be inspected in connection with regular scheduled maintenance toensure their proper functioning (see also section 5 Maintenance / Cleaning).

The (finned) heat exchanger must be fastened or installed in a manner so as to prevent damage fromenvironmental hazard sources (production, transport and other processes in the room where installed)or interruption of operation by unauthorized persons.

When installing the unit in extreme locations (e.g. aggressive atmosphere, low outsidetemperatures or similar), appropriate measures must be taken!If necessary, contact the manufacturer.

All anchor points must maintain the distance to the fastening surface on a continuing basisand under load in order to avoid tension.The (finned) heat exchangers must be fixed in their anchor points to prevent shifting.

The (finned) heat exchangers must be fixed or mounted as follows: Ensure that there isenough clearance to uninstall the droplet separator and other assembly parts!

The (finned) heat exchangers must be fixed or mounted as follows: Inspection, control andmaintenance must be possible at all times, i.e. unobstructed access to the fluid-carrying andattached components, connectors and pipes, pipes must be labelled clearly and there must

be enough room for inspection!

The pipe connectors are designed to accommodate the commercially available millimetre and inchmeasurements.


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Fluid-carrying pipes: Safeguard against mechanical damage!On site connectors: Balanced installation; no stress on the pipes!

The order-specific bidding documents are used as installation schedule for the fastening of the (finned)heat exchangers.

In temperatures below the freezing point of 0C, there is a danger that the unit might freezeduring operation. If the unit is designed to not be completely drained, it might freeze evenafter the unit has been emptied. When draining the unit ensure proper ventilation. Attemperatures below the freezing point, units will be destroyed when filled with water or atinsufficient levels of antifreeze during pressure checks, operation and standstill. The warrantyexcludes such damage.


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4.4.3. Assembly Guidelines

The (finned) heat exchangers must be assembled according to the order-specific bidding documents.

Airflow direction

4.4.4. Installation

Installation must be carried out by qualified personnel. Damage caused by improper installation is notcovered by the manufacturers warranty.

The (finned) heat exchanger may be fastened to the specified anchor points only.

Please follow the accompanying information regarding the installation of the drip tray.The drip tray is delivered together with the unit and sits on top during transport (see section 3.4.1

Assembly).


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Unit variations

Wall anchors Canal installation / box unit (drip tray on site)

1 12

2

1 Heat exchanger; 2 Droplet separator

Wall anchors:

Install one connector per drip tray (even if three options are possible)!

If a droplet separator is included:

The droplet separator is included in the delivery and readily installed. Please fasten the screws.

After assembly (or after re-connection), the interior of the (finned) heat exchanger must be cleaned.

The (finned) heat exchanger is filled with dry air (see section 3.2 Delivery and Unloading).Before bleeding the dry air separate all onsite pipe connections!

Fluid connectors: Must be installed stress-free! Support onsite pipe system before connectingit to the (finned) heat exchanger!

Soldering or welding work may only be carried out if the (finned) heat exchanger does notcontain any pressure!

Keep the pipes as short as possible. Install the minimum amount of bends. Any installed

bends must have the largest possible radii.

Observe the general requirements regarding the assembly of the (finned) heat exchangers inaccordance with the applicable regulations (see section 1 General Safety Information).


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The clearance around the (finned) heat exchanger must be sufficient to prevent danger to the(finned) heat exchanger and to allow for regular maintenance of the components, inspectionof the components, pipes and fittings as well as repairs.

The (finned) heat exchanger must be lockable in the event of leakage.

The following applies to the pipework of the (finned) heat exchanger:

Installation of pipes, valves and their components for the pipe system to and from the (finned) heatexchanger must be carried out in accordance with the applicable national regulations.

In principle, use only pipes and system components which are clean and dry inside (no scales, metal filings, rust and phosphate layers or similar) are sealed airtight when delivered

Depending on the material, all joints are either brazed or welded Avoid butt solder joints; use copper pipe ends widened on one side (capillary brazing); avoid

leakage, solder carefully and precisely

Avoid overheating when brazing (danger of excessive scale loss)

Use shielding gas when brazing (prevents scale loss) After completion of the pipe installation and before connection to the (finned) heat exchanger, clean

the system professionally and carry out a pressure test.


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5. Initial Operation, Operation

5.1. Initial Operation

Before initial operation, check and confirm the operational readiness of the unit according to thefollowing checklist:

Test all joints in the system for leakages and correctness according to the applicable rules andregulations (see section 1. General Safety Information), and the system must be professionallyevacuated in accordance with the applicable local guidelines.

Evacuation:Open the existing shut-off and magnetic valves. Evacuate the entire system using a vacuum pump.When the vacuum pump is locked, a standing vacuum of < 1.5 mbar must remain. Repeat theprocedure several times.

The (finned) heat exchanger has been tested at the factory as a single pressure vessel. After assembly,re-test the joints and the pipe connections for leakage.

Testing for leakage:Create excess system test pressure using a suitable medium (e.g. dry nitrogen). Check the (finned) heat

exchanger and the pipe system including all fixtures for leakage.

The test pressure must not exceed the maximum operating pressure (see name plate)!It is imperative that the safety regulations (see section 1.2. Safety Information) be observed!

Check all screwed joints, anchors etc. for correct seat. Check all specified control devices for correct functioning. All safety features must be checked for the set on- and off switch positions. Check the entire system, especially the pipe systems and joints, for strong vibrations. Take

additional security measures if necessary.

Pipe bursts and leaks may occur in system components!Avoid strong vibrations!

During and after filling the system, the device must be properly deaerated. Maintain the ventconnections in the open position until no more air leaves the system.


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5.2. Operation

5.2.1. Normal Operation

To operate the (finned) heat exchanger, the entire system must be in operation.

The (finned) heat exchanger must be switched on by opening the respective valves on the feeding anddischarge side of the entire system.

After the operational data have been achieved (see order-specific bidding documents), the (finned) heatexchanger is ready for operation.

The operational data:

Airflow volume Air inlet temperature Air outlet temperature Flow volume of fluid Fluid inlet temperature Fluid outlet temperaturemust be checked according to section 2. Technical Data. Create a data protocol.

The (finned) heat exchanger must be inspected regularly by a qualified person, if necessary. Inspectionintervals depend on the mode of operation. They must be determined by the operator according thesection 1.2. Safety Information.

5.2.2. Shut-down, Decommissioning

In case of damage, the (finned) heat exchanger must be separated from the main power supply andeither replaced or repaired.

If you should detect malfunctions or damage to the (finned) heat exchanger, you are required to notifythe manufacturer immediately in order to enable the manufacturer to participate in the curing of suchdefects.

The (finned) heat exchanger is shut off by switching off the main power supply.In doing so, the fluid filled pipes must be locked from the system.The fluid must be drained.When shutting off or decommissioning the (finned) heat exchanger (repair, replacement etc.), the fluidshould be pumped out and disposed of in an environmentally compatible manner.

Any polluted fluid must be disposed of in accordance with environmental standards!

When decommissioning the system, observe maximum operating pressure and maximumoperating temperature!Take precautions to avoid that these parameters are exceeded.

The (finned) heat exchangers are system components of a system. Shutting off and re-starting thesystem must be carried out in accordance with the system specifics and the applicable regulations and

accident prevention regulations (see section 1. General Safety Information).

The pressure test after re-starting is permissible only when suitable media are used and the correct testpressure is present.


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5.2.3. Modifications to the System, Non-permissible OperatingConditions and Modes of Operation

The following are considered changes to the system:

- Modification of function according to section 2. Technical Data, Application and Definition- Modification of operational data according to section 2. Technical Data, Application and Definition

- Change to a different fluid

Non-permissible operating conditions and modes of operation as contemplated by the warranty are asfollows:

- Modification of function according to section 2. Technical Data, Application and Definition- Improper assembly (see section 2. Technical Data, Application and Definition)- Modification of operational data (see section 2. Technical Data, Application and Definition)- Changes to the fluid

In order to maintain the warranty, these modifications, operating conditions and modes of operation aresubject to discussion with and approval by the manufacturer.


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6. Maintenance / Cleaning

6.1. General(Finned) heat exchanger (and droplet separator) is designed for maintenance-free operation. However,regular inspections guarantee smooth operation. Inspection intervals depend on the location and theoperating conditions. Inspections should include in particular checks for leakage, corrosion, strong

vibrations and the safety features.

6.2. CleaningThe system can generate the projected heat exchange performance only if the (finned) heat exchanger(and droplet separator) system is clean. Dirt, dust, vapour accumulation etc. must be removed from theheat exchanger itself and its immediate surroundings.

Dry dust or dirt can be removed with a brush, a hand brush or with pressurized air (maximum pressure80 bar, against the airflow) or a strong industrial vacuum cleaner.

If possible, always brush or flush lengthwise along the fins.Use soft brushes!Never brush crosswise across the fins!

Heavier, moist or greasy dirt must be removed using a high pressure water jet (maximum pressure 80bar) or steam jet (maximum pressure 80 bar), with a minimum distance of 200 mm, equipped with afan nozzle, if necessary together with neutral cleaning agents, against the airflow direction.

For finned heat exchangers:

The jet of the cleaning device must be kept parallel to the heat exchanger (maximum deviation 5degrees), in order to avoid bending of the fins.

1 Heat exchanger unit

2 90 only

3 Do not move in this direction

4 Direction of steam cleaner

5 Fins of the system

6 Steam pressure from fan nozzle: maximum of 80 bar


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Cleaning and maintenance instructions:

- Clean the (finned) heat exchanger (and droplet separator) on both sides, if necessary.- Straighten out bent fins using a suitable comb.- Test all cleaning agents that come in contact with the heat exchanger for compatibility

with the materials of the heat exchanger.

Clean from the inside out and from top to bottom.

Continue cleaning until all dirt has been removed.

Use only cleaning agents that are neutral towards the system materials and are non-aggressive or non-corrosive!

Mechanical cleaning with hard objects (e.g. steel brushes, screwdrivers, etc.) damages theheat exchanger: not permitted!


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6.3. Maintenance, RepairMaintenance and repair measures arise as a result of malfunctions (see section 4.2.2. Shut-off andDecommissioning) and as a result of the inspections specified in section 5.1. General.

Drain the fluid before any maintenance or repair measures (see 4.2.2. Shut-off and Decommissioning)

Maintenance and repair measures must be carried out in a manner that prevents danger to personsand damage to property.

Maintenance and repair must be carried out according to applicable regulations.The repaired (finned) heat exchanger (and droplet separator) must be inspected according to applicable

regulations.

We recommend the following inspection schedule:

Recommended servicing and maintenance schedule

Measure Mode Interval

Partial cleaning mechanical as needed (sight inspection)

Total cleaning water or environmentally ormaterial compatible cleaning

agents

according to operatorsspecifications

Leakage check exterior sight inspection

(e.g. EN 378-2, annex A, B)

depending on leakage rate

(e.g. EN 378-2, annex C)

Corrosion protection check - sight inspection

- Inspection of fluid for inhibitors(refrigerant manufacturersspecifications)

depending on leakage rate

(e.g. EN 378-2, annex C)

Recommended Inspection Schedule

Component / Checkpoint

Interval Measure Timing

Heat Exchanger /

fluid joints

monthly repair or replace* immediately

Drip tray monthly clean immediately

Frame / anchors every three months tighten immediately

Droplet separator monthly repair or replace immediately

*) During longer maintenance intervals, the (finned) heat exchanger (and droplet separator) maypossibly be demounted for maintenance and repair measures. Observe and comply with theinformation is section 4.1. Initial Operation when starting the system up again.


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7. Contact Address

Gntner de Mxico S.A. de C.VAv. Rogelio Gonzlez Caballero No.1000,Parque Industrial Stiva AeropuertoApodaca Nuevo Len Mxico, cp 66600Office tel: +52 81 81 56 06 00

Office fax: +52 81 81 56 06 [email protected]

operating instructions gco eng 2011

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