COMMERCIAL AIR COOLERS AIR AND ELECTRIC DEFROST

Transcription

1 INSTALLATION, OPERATION & MAINTENANCE MANUAL CAH CEH CDH High profile unit coolers COMMERCIAL AIR COOLERS AIR AND ELECTRIC DEFROST Index 1. Warranty statement 2 2. General Safety Information 3 3. Inspection 4 4. Unloading 4 5. Mounting 5 6. Refrigerant piping 6 7. Expansion valve 6 8. Drain line 7 9. Wiring Evacuation Installation Start-up Maintenance and service Electrical data Spare Parts Trouble shooting Reference data 13 1

2 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 and operated within the recommended limits of the manufacturer s technical documentation. The supplier at its option shall repair, or replace, free of charge to the purchaser all goods which become 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 the supplier s 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 costs in particular, shall be borne by the purchaser himself. The supplier shall not be liable for costs incurred in dismantling or fitting replacement parts or for any independent inspection undertaken by the purchaser. The purchaser shall return any allegedly defective goods, carriage paid, to the supplier s works. Upon receipt of the goods and inspection thereof the supplier shall repair or replace, at the supplier s discretion, the defective goods and return freight, carriage paid, and without any further expenses. This shall constitute full compliance of the supplier s obligations. No liability is accepted for the consequences of modifications or repair work being carried out by the purchaser 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 for damage 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 or indirect damages, injury to persons or property or any consequential loss or loss of profits arising from defective goods or workmanship or from any other cause whatsoever. To obtain warranty service, please contact: quality@guentner.com.mx 2

3 2. GENERAL SAFETY INFORMATION All installation and maintenance procedures should be performed by qualified personnel already familiarized with the equipment. All field wiring should match the requirements of the equipment, as well as any local or national codes. Coil edges and other sharp objects should be met with caution, as they can cause serious injury. Fan blades are especially sharp, and therefore should be handled only while wearing protective gloves. All power sources should be disconnected before any type of service work is performed on the equipment. For cleaning the equipment, reinstall the drain pan after every cleaning session. Failure to follow these steps can result in damaged equipment or personal injury. Inhalation of certain refrigerants can be harmful, or even fatal. Failure to implement proper detection devices, ventilation, and procedures can result in serious injury or death. Ventilation of all refrigerants should follow all related regulations, as certain refrigerants are harmful to the environment. For more information, refer to any local or national codes that may apply. High temperatures can cause damage to the equipment. The expansion valve must be covered in heat absorbent material and the suction line sensor removed while brazing the refrigerant connections. Never use the refrigeration compressor to evacuate the equipment. Never start the refrigeration compressor if it is in a vacuum. Fan motors are sealed and do not need lubrication 3

4 3. INSPECTION Each shipment should be carefully checked against the bill of loading at time of receipt. The shipping receipt should not be signed until all items listed on the bill of loading have been accounted for. Check carefully for any damage. Any and all shortages or damages should be reported to the delivery carrier. Damaged equipment during shipment becomes the delivery agent s responsibility and should not be returned unless prior approval has been given. The equipment is pressurized with 29 psi (2 Bars) dry air during manufacturing. If the unit lost pressure during transportation, contact the Sales Department (sales@guentner.com.mx). For special requirements please contact our factory. 4. UNLOADING Normal care should be taken while unpacking and uncrating equipment so that damage and injury can be prevented. Heavy equipment should be kept on the original pallet until ready for final installation. While using lifting belts, ensure that a spreader bar is used, and that the belts do not compress the sheet metal construction. When using a truck lift, ensure that the unit is positioned as shown in the picture below. 2

5 5. MOUNTING The equipment can be mounted using rod hangers, lag screws and/or bolts. Units should be hung with no degree of inclination so that the condensate drainage can be properly maintained. Proper airflow through the unit is essential for efficient performance and maintenance of design storage temperatures. Never install an evaporator over a doorway. The drain pan should be fitted only after the installation of the equipment. DIMENSIONS CAH CEH - CDH CEH - CDH (ELECTRIC DEFROST) Dimensions Model Dimensions Connections Weight L H B E Liquid Suction Drain No Fan in mm in mm in mm in mm lbs kg in mm in mm in mm CEH 6 FPI /8 1, / / / / / / /8 1, / / / / / / , / / / / / / , / / / / / / /8 3, / / / / / / /8 3, / / / / / / /4 4, / / / / / / /4 4, / / / / / /4 32 CDH 4 FPI /8 1, / / / / / / /8 1, / / / / / / , / / / / / / , / / / / / / /8 3, / / / / / / /8 3, / / / / / / /4 4, / / / / / / /4 4, / / / / / /4 32 CAH (AIR DEFROST) Dimensions Model Dimensions Connections Weight L H B E Liquid Suction Drain No Fan in mm in mm in mm in mm lbs kg in mm in mm in mm CAH 6 FPI /8 1, / / / / / / /8 1, / / / / / / , / / / / / / , / / / / / / /8 3, / / / / / / /8 3, / / / / / / /4 4, / / / / / / /4 4, / / / / / /4 32 5

6 CAH-CEH-CDH Mounting reference n = number of units to install Lr = length of room NOTES Do not place the cooler directly over or next to a door. Do not place produce directly in front of the cooler. Do not place coolers in front of each other at a distance less than their air throw indicated in the technical specification sheet. In the case of electric defrost units, make sure to leave a free space of at least the length of the unit on the electric connection side to remove the heaters in case of failure. The minimum distance between units must be 6 for hot gas and air defrost units. If you have reduced space or special room construction, please contact your local sales office to receive the correct advice on unit mounting. 6. REFRIGERANT PIPING Type, sizing and installation of all piping must be in accordance with the recommended and accepted practices for Freon refrigeration applications. All low temperature piping should also be insulated in accordance with standards ASHRAE. Suction traps should be used when and if the suction line rises above the unit cooler. 7. EXPANSION VALVE For direct expansion units, select an expansion valve in accordance with capacity data and as required by expansion valve manufacturer. Expansion valves with external equalizers should be used. After the temperature has reached design conditions, adjust the expansion valve to obtain 8 to 10º F superheat at the suction line. Expansion valves are to be installed in accordance with the specific manufacturer s recommendations. Units that require an external equalized expansion valve must have that line connected. Proper location of the bulb is extremely important to the performance of the coil. Good thermal contact to the suction line is also essential. On solder type valves, a wet cloth wrapped around the valve during installation will protect it from overheating and damage. On multiple evaporator systems, the piping should be arranged such that the flow from any valve cannot affect the bulb of another. 2

7 8. DRAIN LINE The drain line must be pitched to effectively drain condensate. All drain lines subject to freezing temperatures must have drain line heaters and be insulated. Drain line traps must also be heated to prevent freezing up of the drain line and trap. 9. WIRING All wiring must be done in strict accordance with local and national electrical codes. Fan motor(s), local isolators, electrical heater elements and controllers must be wired in accordance with the electrical wiring diagrams provided. Use copper conductors of appropriate size only. All electrical installations should only be performed by qualified and authorized personnel. For thermal motor protection, the installed thermal contacts must be used and wired according to the circuit diagram attached to the unit. 10. EVACUATION Proper evacuation is essential prior to charging the refrigerant for the system. This avoids many problems that can arise due to lack of detail within this step. The system should be checked through all cycles to ensure proper operation. 11. INSTALLATION The installation and maintenance of this equipment should be performed only by qualified professional personnel who are familiar with this type of equipment. The equipment is pressurized with dry air. All equipment must be evacuated before charging the system with refrigerant. All field wiring should be checked and be in strict conformity with the equipment requirements, as well as all national and local codes. Use the name plate electrical data for conductor and fuse sizing. Avoid contact with any sharp edges or sharp coil surfaces. These can be a potential injury hazard. Make sure that all power sources are disconnected before any service work is done on equipment. CAUTION: BEFORE STARTING UP UNIT MAKE SURE ALL ACCESSIBLE ELECTRICAL PARTS ARE SECURED! 12. START-UP At start-up the following items should be checked: - Check all screwed connections, especially at moveable parts. - Check tube connections, make sure that brackets are in place and connection screws are secured. - Check electrical connections of motors, heater elements and any additional components, if applicable. - Run the fans and check the direction of rotation. Make sure that there is no transport damage. The system should be properly evacuated. - During the test run observe the equipment and take notice of the following: o Silent operation of the fans (bearings, contacts, balance) o Power requirements of electrical motors o Leakages o Check superheat - After 48 hours of operation re-check the equipment, especially all rotating parts. 7

8 13. MAINTENANCE AND SERVICE CAUTION: DISCONNECT ALL POWER BEFORE SERVICE! PREVENTIVE MAINTENANCE FOR COMMERCIAL EVAPORATORS CLEAN using a brush, pressurized water, or a mild detergent. Make sure the product you use is approved for your particular application. NEVER USE ACID BASED CLEANER. RINSE coil until no residue remains CHECK each fan rotates freely and quietly. Replace any motor that vibrates or makes unusual noise INSPECT unit for unusual vibration in ventilators or casing. Determine which ventilator is causing vibration INSPECT Drain pan to insure that drain is clear of any obstructions, including ice buildup INSPECT for ice accumulation in coil CHECK all blades for wear, cracks or dents. CHECK calibration of defrost controller CHECK that heaters are working accordingly during defrost CHECK heater current consumption against the electrical schematic CHECK drain line heater is working properly CHECK all fan screws are tight, and torque if needed AS REQUIRED MONTHLY EVERY 3 MONTHS EVERY 6 MONTHS EVERY YEAR INSPECT unit for corrosion on fins, tray, casing, soldered joints, copper tubes INSPECT unit for oil stains in headers, return bends and coil fins. Check for possible leaks INSPECT all wiring for wear, tears, and unprotected wire. Replace any wiring necessary INSPECT all ground connections are tight 13.1 FAN MOTORS AND HEATERS The only electrical components vulnerable to potential malfunction are the fan, motors, and electrical defrost heaters. In the event of motor or heater failure, the affected motor should be removed from the unit and tested separately. If the motor and/or heaters continue to malfunction then they will need to be replaced DRAIN PAN Periodic inspection of the drain pan is recommended. Accumulated dirt and dust should be cleaned out with soap and warm water. If a sign of improper drainage is apparent then the drain line pitch, drain line heater (if applicable) and drain trap should be checked for proper operation. Unit can be cleaned using warm water and soap. Special care should be taken when cleaning the unit around the electrical areas including motor, wiring and junction boxes. Water could potentially damage the electrical motor INSPECTION AND MAINTENANCE Verify the following points when visually inspecting the equipment: - Secured screw connections - Leakages - Silent operation of the fans 2

9 - General state of the unit such as cleanliness and corrosion The cleaning of the finned heat exchanger is of the upmost importance to ensure smooth operation and long life of the equipment. - There is no general rule how often it should be cleaned. Frequency and method of cleaning depend on the customer and must be determined by the customer s operating personnel. If need be, ice must be defrosted with a hot air drier or hot water. - The equipment is always supplied in a clean condition. If, during installation and/or first operation hours, contamination reaches a state where capacity can be affected, it is necessary that the unit is cleaned before operation. When cleaning the unit it must be out of operation and all electrical power disconnected. Mechanical Cleaning of the Heat Exchanger - Blow down the fins with air (only suitable for light, dry and dusty deposits). - Cleaning with compressed air (maximum pressure 6 bar, minimum distance from fins 8 inches). - If some contamination is located mainly at the inlet of the fins, clean with a soft brush or use an industrial vacuum cleaner. Hydraulic Cleaning of the Heat Exchanger - For oil containing deposits, it is acceptable to add detergent to the water. Make sure not to deform the fins. - When using chemical substances, make sure they do not corrode the heat exchanger material and casing. Rinse the heat exchanger and casing after treatment. - When cleaning with liquid or compressed air, the fans must be switched off. Do not spray them directly. - Clean the coil from top to bottom in order to allow the contamination to drain downwards. Cleaning must be continued until all contamination has been removed. - Always clean/spray in the direction of the fins. Never clean at 90 to the fins! - Maximum allowed vapor pressure is 6 bar. Maximum allowed water pressure before the outlet is 80 to 100 bar. 14. ELECTRICAL DATA CAH (AIR DEFROST) Electrical Data Fan Data Fan motor Data Model Fans Diameter Voltage "L" 460/3/60 Voltage "V" 230/3/60 # in mm Watts Amps Total Amps rpm Watts Amps Total Amps rpm CAH 6 FPI , , , , , , , , , , , , , , , ,370 9

10 CEH - CDH (ELECTRIC DEFROST) Electrical Data Model Fan motor Data Heater Data Fan Data Voltage "L" 460/3/60 Voltage "V" 230/3/60 Voltage "L" 460/3/60 Voltage "V" 230/3/60 Fa n Diamete r T otal T otal T ray Coil T otal T otal T ray Coil T otal T otal Watts Amps rpm Watts Amps rpm # in mm Amps Amps Watts Watts Watts Amps Watts Watts Watts Amps CEH 6 FPI , , , , , , , , , , , , , , , , CDH 4 FPI , , , , , , , , , , , , , , , ,

11 15. SPARE PARTS CAH Fan Main J/Box VT.Num. Drain Model 460V-3Ph-60Hz 230V-3Ph-60Hz 230V-1Ph-50/60HZ CAH 0350 VT01163U VT01186U PC m UL BGAB114K CAH 0470 VT01163U VT01186U PC m UL BGAB114K CAH 0700 VT01163U VT01186U PC m UL BGAB114K CAH 0930 VT01163U VT01186U PC m UL BGAB114K CAH 0575 VT01163U VT01186U PC m UL BGAB114K CAH 1050 VT01163U VT01186U PC m UL BGAB114K CAH 1410 VT01163U VT01186U PC m UL BGAB114K CAH 0840 VT01163U VT01186U PC m UL BGAB114K CAH 1400 VT01163U VT01186U PC m UL BGAB114K CAH 1900 VT01163U VT01186U PC m UL BGAB114K CAH 1140 VT01163U VT01186U PC m UL BGAB114K CAH 1630 VT01163U VT01186U PC m UL BGAB114K CEH Fan Heater Coil Heater Tray VT.Num. Heater Number Heater Number Drain Model 460V-3Ph-60Hz 230V-3Ph-60Hz 460V-3Ph-60Hz 230V-3Ph-60Hz 460V-3Ph-60Hz 230V-3Ph-60Hz CEH 0300 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 0370 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 0600 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 0780 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 0520 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 0900 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 1200 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 0735 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CEH 1060 VT01163U VT01186U U07EB U04BB U07EB U07EB BGAB114K CEH 1400 VT01163U VT01186U U07EB U04BB U07EB U07EB BGAB114K CEH 0865 VT01163U VT01186U U07EB U04BB U07EB U07EB BGAB114K CEH 1220 VT01163U VT01186U U07EB U04BB U07EB U07EB BGAB114K CDH Fan Heater Coil Heater Tray VT.Num. Heater Number Heater Number Drain Model 460V-3Ph-60Hz 230V-3Ph-60Hz 460V-3Ph-60Hz 230V-3Ph-60Hz 460V-3Ph-60Hz 230V-3Ph-60Hz CDH 0280 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CDH 0360 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CDH 0550 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CDH 0740 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CDH 0890 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CDH 0980 VT01163U VT01186U U07EB U04BB U07EB U04CB BGAB114K CDH 1100 VT01163U VT01186U U07EB U04BB U07EB U07EB BGAB114K CDH 1080 VT01163U VT01186U U07EB U04BB U07EB U07EB BGAB114K 11

12 16. TROUBLESHOOTING Symptoms Possible Causes Possible Corrective steps 1. Fan is not working 2. Room Temperature too High 1.1 Main switch Open Close Switch 1.2 Blown Fuses Check for short circuits or overloads. Replace damaged fuse 1.3 Damaged timer or defrost thermostat Replace controller 1.4 Unit in defrost cycle Wait until cycle completion 1.5 Coil does not get cold enough to reset thermostat Increase fan delay time after defrost cycle 1.6 Motor is burnt Check for Voltage surge and replace motor Check for any obstruction (ice, debris, etc..) and remove 1.7 Ventilator does not turn Check junction box in fan for any short circuit and repair 2.1 Room thermostat set too high Reduce thermostat setting Check if TXV is feeding correctly and clean strainer filter Check if bulb is placed in correct position and adjust if necessary Adjust the superheat on TXV. 2.2 Superheat too high Check for low refrigerant charge in system. Go to Low refrigerant in system Check for leaks and charge additional refrigerant in system 2.4 Coil blocked with Ice Make manual defrost in coil. Check defrost system. 2.5 Unit cooler too close to doors Relocate unit or add strip/air curtain to door Check for door seals and replace if necessary 2.6 Excessive Air infiltration due to open doors Keep doors closed as long as possible 2.7 Product has just been loaded into cold room Wait until product temperature is lower 2.8 System is turned off Turn on refrigeration system 2.9 Power surge in system fails Restore power surge 2.10 Poor air flow in room Make sure all fans turn in correct direction See Possible cause See Symptom Check unit placement recommendations 2.11 Pressure drop across evaporator too high Replace TXV with valve having external pressure equalization, adjust superheat on valve 2.12 Lack of subcooling in the system Establish a subcooling in the system 2.13 Pressure drop across the valve is larger than the design pressure of the valve Select a new valve with the desired pressure drop Expansion valve is blocked with ice due to moisture in the system Change drier filter, and clean ice off valve Clean the valve port, and strainer Clean the solenoid valve and its filter 2.15 Expansion valve is blocked with wax or other impurities Replace the oil in the refrigeration system 2.16 Expansion valve is too small Select and replace valve with higher capacity valve or orifice TXV Bulb charge lost Replace valve (or powerhead if possible) 2.18 Incorrect TXV powerhead selected Select a powerhead according to the application TXV Bulb is not making good contact with suction line Fasten bulb to suction line appropiately 2.20 TXV bulb is not insulated Place insulation over the whole bulb 2.21 TXV bulb is located near large valves, flanges, headers, or rising pipe Place TXV bulb in horizontal pipe between suction line and oil trap. 3. Ice build-up 3.1 Defrost cycle is too long Decrease time on defrost on ceiling 3.2 Fan delay not working after defrost cycle Adjust defrost thermostat correctly, or go to 3.3 around 3.3 Defective defrost thermostat or timer Replace component evaporator and/or on fan nozzles, blades, or grill 4. Coil not 3.4 Too many defrosts Reduce number of defrosts per day 4.1 Heater not working Make sure all heaters are working. clearing frost 4.2 Hot gas supply is not enough Make sure there is sufficient hot gas volume to defrost unit. 4.3 Not enough defrost cycles per day Increase the number of defrost cycles per day after defrost 4.4 Defrost cycle too short Increase time on defrost thermostat or timer for longer cycle cycle 4.5 Defrost Thermostat or timer not working Replace component 5. Uneven coil 5.1 Distributor in horizontal position Change distributor to vertical position frosting during 5.2 Distributor or capillaries are blocked Replace distributor with capillaries 5.3 After defrost, dripping time too short Increase time for dripping refrigeration 5.4 Incorrect or missing distributor nozzle Add or replace nozzle with appropiate size orifice for conditions cycle 5.5 Located too close to door opening Relocate evaporator 6.1 Drain line heater not working Check heater power supply Change drain line heater 6.2 Tray heater not working Check heater power supply Change tray heater 6. Ice 6.3 Unit tilted unproperly Level unit to horizontal position accumulation on drain pan 6.4 Drain line plugged Clean drain line Insulate drain line properly (if blocked with ice) 6.6 Thermostat not working Replace defective component 6.6 Drain line without water tramp Install water tramp in drain line outside cold room 6.7 Drain pan not placed properly in unit after mainteinance Make sure drain pan is close to heaters or hot gas coil. 7. Water 7.1 Drain line plugged Clean drain line accumulation on drain pan or 7.2 Drain pan not placed properly in unit after mainteinance Make sure drain pan is leveled towards the back water spreading outside unit 7.3 Unit tilted unproperly Level unit to horizontal position 2

13 17. REFERENCE DATA Service Record CAH / CEH / CDH A data sheet for each installation and each unit cooler must be filled out, with one copy for the owner, one copy for the installing contractor and the original for Coilexpert. Güntner. If another firm is to handle service and maintenance, additional copies should be prepared as necessary. System Reference Data The following information should be filled out and signed by the Refrigeration Installation Contractor Date System Installed: Installer and Address: Evaporator(s) Evaporator Model No. Evaporator Serial No. Electrical Volts Phase Expansion Valve Manufacturer/Model Ambient at Start-Up ºF Design Box Temperature ºF Operating Box Temperature ºF Thermostat Setting ºF Defrost Setting /day minutes fail-safe /day minutes fail-safe Suction Line Evaporator ºF Superheat at Evaporator ºF Evacuation No. times Final Micron No. Times Final Micron Evaporator Drain Line Trapped Outside of Box Yes No Güntner de México S.A. de C.V Av. Rogelio González Caballero No.1000, Parque Industrial Stiva Aeropuerto Apodaca Nuevo León México, cp Office tel: Office fax: sales@guentner.com.mx 13