Installation Instruction eat Exchanger Coils - · PDF fileInstallation. Instruction H. eat Exchanger Coils . thermofin GmbH, ... tightness of refrigeration systems and heat pumps,

Installation Instruction Heat Exchanger Coils

thermofin GmbH, Am Windrad 1, 08468 Heinsdorfergrund Phone: +49 (0)3765-3800-0 heat exchanger coils, state: 2010-04-08 © thermofin GmbH

1. Preliminary Notes...................................................................................................3 1.1 Fundamentals ............................................................................................................................... 3 1.2 Range of application .................................................................................................................... 3 1.3 Applied standards and directives ................................................................................................. 4 2. Technical Data ........................................................................................................5 2.1 Method of operation..................................................................................................................... 5 2.2 Application and intended use....................................................................................................... 5 2.3 Material data ................................................................................................................................ 5 2.5 Unit key........................................................................................................................................ 6 2.6 Data on the type plate .................................................................................................................. 7 3. Safety .......................................................................................................................8 3.1 General information on device safety .......................................................................................... 8 3.2 Safety instructions for the site of operation ................................................................................. 8 3.3 Safety instructions for the machine.............................................................................................. 9 3.4 Safety instructions for the operating supplies ............................................................................ 10 3.4.1 Refrigerants of the group A1, fluid group 2............................................................................ 10 3.4.2 Ammonia................................................................................................................................. 10 3.4.3 Ethylene glycol ....................................................................................................................... 11 4. Assembly, Installation, Commissioning and Maintenance...............................13 4.1 General ....................................................................................................................................... 13 4.2 Transport and positioning .......................................................................................................... 13 4.2.1 Packing.................................................................................................................................... 15 4.3 Assembly Instructions................................................................................................................ 16 4.3.1 Installation............................................................................................................................... 16 4.3.2 Pipe connections ..................................................................................................................... 17 4.3.2.1 Defrost water drain............................................................................................................... 17 4.3.3 Electrical connections ............................................................................................................. 18 4.3.4 Start of operation..................................................................................................................... 19 4.3.4.1 Return to service after a longer period of standstill ............................................................. 19 4.4 Maintenance and hygiene........................................................................................................... 20 4.4.1 Cleaning of the fins ................................................................................................................. 20 4.5 Defrosting................................................................................................................................... 21 4.5.1 Recommendations for the positioning of the defrost sensor................................................... 21 4.5.2 Further notes regarding the defrosting process ....................................................................... 22 5. Operation and shutdown .....................................................................................22 5.1 Normal operation ....................................................................................................................... 22 5.2 Shutdown ................................................................................................................................... 22 6. Spare parts ............................................................................................................22

thermofin GmbH, Am Windrad 1, 08468 Heinsdorfergrund Phone: +49 (0)3765-3800-0 heat exchanger coils, state: 2010-04-08 © thermofin GmbH page 2 of 22

1. Preliminary Notes The purpose of assembly and operating manuals is to prevent dangers to persons and to the environment, which may be caused by a machine and by the work performed in connection with the machine, particularly during transport, assembly, commissioning and operation of the machine. Therefore, all points of this manual must be carefully read and observed.

1.1 Fundamentals The present assembly and operating manual refers to the heat exchanger coils of the following type series:

(TB)-A, -B, -C, -H, -N, -S: exact specification according to data sheet - with or without defrosting device. The corresponding technical data can be seen from the current catalogue, the machine data sheet and the type plate.

1.2 Range of application thermofin® heat exchanger coils are designed and manufactured according to the specifications of the customer and are intended for the integration into heat exchanger systems which are existent on site of the customer. The construction and the used materials are specially adjusted to the respective case of application. The limits of application with regard to pressure and temperature, which are indicated on the type plate, have to be observed.


1.3 Applied standards and directives

• Directive 97 / 23 / EC for pressure equipment (Pressure Equipment Directive) • EN 378; parts 1 to 4; "Refrigeration systems and heat pumps, safety and environmental

requirements"; state: June 2008 • German Equipment and Product Safety Act (GPSG); including the regulations (GPSGV)

applicable in the Federal Republic of Germany • BGR 500 (directive of the employer’s liability insurance association) "Operation of Work

Equipment"; chapt. "Operation of refrigeration systems, heat pumps and cooling equipment"; applicable in the Federal Republic of Germany

• VDMA (German Federation of Machinery and Plant Construction) norm 24243 (08/2005) „Refrigerating machines and plants, tightness of refrigeration systems and heat pumps, leak detection and leak test“

• The present operating manual „ thermofin® heat exchanger coils“ • The labels attached to the machine, which contain instructions and information of the

manufacturer The operator is obliged to observe – in addition to the regulations stated in this operating manual – all possible local particularities and / or applicable regulations.


2. Technical Data

2.1 Method of operation A heat exchanger is part of a refrigeration or cooling cycle, in which a circulating medium gives off heat to its environment or absorbs heat from its environment.

2.2 Application and intended use The heat exchanger is intended for the application in refrigeration systems according to DIN EN 378. Despite meeting the requirements of intended use and handling the machine properly, residual risks cannot be completely avoided. The machine may only be used in places where the materials applied are not affected by the surrounding atmosphere or the medium flowing inside. Any cases of application differing from the one described above require consultation with the manufacturer. The manufacturer does not assume liability for any damages resulting from the non-compliance with these provisions. The unit may not be put into operation until the conformity of the complete plant has been declared! 2.3 Material data pipes: made from copper, steel or stainless steel, hard soldered or welded fins: made from AlMg3, aluminium, aluminium coated with epoxy resin, steel, stainless steel or copper


2.5 Unit key


2.6 Data on the type plate

The type plate contains the following data:

• model description according to the unit key (see 2.5 Unit key) • article number of the manufacturer • project or serial number • month / year of manufacture • tube volume of the heat exchanger • empty weight of the machine • test overpressure PT • maximum working pressure PS • allowed temperature range of the medium TS • pressure test medium of the heat exchanger


3. Safety

3.1 General information on device safety The unit is state-of-the-art and reliable in operation. The machine may only be used in accordance with the specifications in the catalogue and the data given on the type plate. The unit may only be installed, commissioned and maintained by competent personnel. For installing the system, the installation conditions according to standard DIN EN 378 are to be observed. Furthermore, the applicable national rules and regulations, such as the water resources law, accident prevention regulations etc. are to be complied with. The company installing the system has to ensure the observance of all pressure and temperature limit values given on the type plate.

Compliance with the instructions of this operating manual does not release the plant operator from the obligation to install an appropriate warning system indicating each kind of malfunction immediately. In addition, emergency measures must be planned and prepared in order to prevent consequential damages in case of malfunctions.

3.2 Safety instructions for the site of operation

The erection and installation conditions according to DIN EN 378 are to be observed. Pipes and fittings must be protected against misuse. Emergency facilities, such as lighting, venting, escape routes and the marking of which according to DIN EN 378 must be provided. The machine must be lockable in case of leakage. Devices which are used for the discharge of released refrigerants must be operable from a safe location. Refrigerant detectors and alarm systems which warn of hazardous concentrations have to comply with the assembly conditions of the DIN EN 378-3, chapt. 7 and 8.

No smoking at the installation site. Open fire is prohibited. The fire extinguishing equipment must meet the requirements of DIN EN 378-3.

There must be sufficient free space around the machine in order to prevent dangers to the machine and its connections and to ensure smooth execution of maintenance and repair work on the machine as well as on all fittings and components. In particular, it must be possible to completely extricate potentially existent heater rods.


3.3 Safety instructions for the machine Before performing installation, repair and maintenance works, the power supply must be interrupted at all circuits. An unauthorized and / or unintentional (automatic) restart must be prevented. Zero potential must be checked and - if applicable - ensured by the means of earthing or short circuiting. Adjacent energized parts need to be covered.

thermofin GmbH, Am Windrad 1, 08468 Heinsdorfergrund Phone: +49 (0)3765-3800-0

Do not touch the fin edges – risk of cuts!

Beware of hot gas lines and hot brine lines– risk of burns! Any unauthorized reconstructions or modifications affecting the functions or the safety of the heat exchanger are prohibited!

Any external forces acting on the equipment are to be avoided. In particular, equipment connections and manifolds may not be stressed (e.g. do not step on them). Never use connections, sheet metal parts or additions (fans) as a means to lift the machine.

Before performing welding and soldering work, the machine must be depressurized! During the performance of welding and soldering work, the cooling medium residues are exposed to high temperatures. In the process, highly toxic decomposition products like hydrogen chloride, hydrogen fluoride, or phosgene are developing.

In the event that refrigerants escape, use your personal protective equipment. Avoid any contact with the refrigerant; liquid refrigerants cause severe frostbite. In case of eye contact, seek medical advice immediately!

heat exchanger coils, state: 2010-04-08 © thermofin GmbH page 9 of 22

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3.4 Safety instructions for the operating supplies

3.4.1 Refrigerants of the group A1, fluid group 2 The utilized refrigerants R134a, R404A, R507, R407C … are so called safety refrigerants of the group A1 according to the classification to DIN EN 378, which are neither inflammable nor toxic. However, in general refrigerants of the group A1 are heavier than air and can drain off into rooms which are located at a lower level. At ground level, the concentration may increase in quiescent air. In case of high concentrations, there is a risk of suffocation due to the reduced oxygen percentage in the breathable air, as well as the danger of cardiac arrhythmia.

Do not expose the refrigerants to unshielded flames or hot surfaces. Be careful when executing soldering and welding works!


The operating supplies must be prevented from escaping. Refrigerants contain compressor oil in solution which must not enter into the ground!

During troubleshooting, avoid eye and skin contact as well as contact with clothes. Use your personal protective equipment. Diverted compressor oil which circulates and remains inside the pipe system is inflammable!

Further and more detailed information and direction for use and first aid as well as provisions resulting therefrom are to be found in the corresponding safety data sheet.

3.4.2 Ammonia The utilized refrigerant ammonia (NH3) corresponds to the fluid group 1 according to DGRL (Pressure Equipment Directive) 97 / 23 EG or B2 according to DIN EN 378-1: 2008 and requires particular safety measures. NH3 is a toxic, pungent smelling gas. A health risk, though, only arises well above the odour threshold (warning effect of NH3). Although NH3 is inflammable as well as explosive, the danger of fire and explosion is relatively low due to the high ignition temperature, the narrow flammable range and the high affinity to humidity.

NH3 causes agitation, dizziness, vomitus and spasms; with strong concentrations it also causes suffocation and pulmonary oedemas.

NH3 has perilous to lethal effects from a concentration of 0.2 vol%.

NH3 has a strongly corrosive effect, especially on eyes and mucous membranes. If NH3 reaches the eyes, those effects cannot be stopped disorientation: Inhaled NH3 causes an interruption of the respiratory airflow panic:


NH3-fluid on the skin causes frostbite and chemical burns. NH3 is very toxic to aquatic organisms and may under no circumstances enter drainage systems! In case of leakages on the evaporator, it has to be locked and the emergency stop switch has to be pressed, provided that this is possible without causing dangers. During the elimination of the malfunction, attention has to be paid to residual NH3 under boiling retardation. NH3-gas may not enter into neighbouring rooms, corridors or staircases. Repair work is to be carried out on completely emptied plant components or segments only. Ensure proper ventilation. In case of works or sojourns in areas with high concentrations, use a respirator which is working independently of the ambient air!

The exposure to NH3 requires the strict observation of the regulations and standards with regard to occupational safety. Particularly, measures according to the own safety have to be taken. This includes the wearing of safety equipment for the body according to the situation:


safety gloves

eye protection

respiratory protection (independent of ambient air)

personal protective equipment Further and more detailed information and direction for use and first aid as well as provisions resulting therefrom are to be found in the corresponding safety data sheet.

3.4.3 Ethylene glycol Ethylene glycol is a colourless, slightly viscous, slightly volatile and hygroscopic liquid that can be mixed with water. It has a sweetish smell and taste. Ethylene glycol vapours are heavier than air and thus they may enter lower spaces. At ground level, the concentration may increase in quiescent air. In case of high concentrations, there is a risk of suffocation due to the reduced oxygen percentage in the breathable air.

The operating supplies must be prevented from escaping. Ethylene glycol is combustible! When in vaporous or gaseous state, it is potentially explosive at higher temperatures!


After skin contact, ethylene glycol causes a slight irritation with the risk of skin resorption. Eye contact causes mucous membrane irritations. After being swallowed, the substance produces states of agitation with disorders of the central nervous system as well as fatigue, loss of consciousness, coordination disorders and kidney damage.


Keep ethylene glycol away from ignition sources, do not smoke! Avoid the contact of ethylene glycol with open flames or hot surfaces. Be careful when executing soldering and welding works!

During troubleshooting, avoid eye and skin contact as well as contact with clothes. Use your personal protective equipment. Take off soiled or soaked clothes immediately!

Further and more detailed information and direction for use and first aid as well as provisions resulting therefrom are to be found in the corresponding safety data sheet.


4. Assembly, Installation, Commissioning and Maintenance

4.1 General The unit may only be installed, integrated in a refrigeration system, operated, maintained and repaired by qualified personnel of specialist companies according to the definitions of expertise from DIN EN 378.

During production and before delivery, each machine is subjected to comprehensive quality testing. The machine is provided in good order and condition. Before assembly, the good order and condition of the machine (damages in transit) must be verified.

4.2 Transport and positioning

During transport, the machine must be handled with special care. In particular, always place the unit very carefully on the ground!

When transporting the equipment by crane, the lifting instructions which are possibly attached to the machine are to be observed. Furthermore, the appropriate lifting accessories must be used. The sheet metal components of the housings may not be deformed by the belts. If it is not possible to ensure sufficient rope length (angle to the perpendicular of max. 30°), a traverse must be used. The lifting accessories may only be attached to the suspension points intended for this purpose. Never use pipes or attachment parts for lifting.

The factory-provided transport weight (empty weight of the unit + transport packaging) is to be found on the corresponding label affixed to the transport packaging.

In case of using floor-borne vehicles is has to be paid heed to sufficient length of the load arms. Please pay attention to the position of the centre of gravity as well as to the information signs!


If the equipment or the packages are provided with further instruction labels for transport and storage, these labels must be followed!


4.2.1 Packing Decisive factors for packing are the route of transport, the size of the equipment and the regulations applicable in the country of importation. The pallets, crates and export boxes used for thermofin® machines meet the requirements of the HPE and VDM standards (HPE – German Federal Association for Wooden Packages, Pallets and Export Packaging; VDM – Association of the German Furniture Industries). If required they can be tailored to the standards of ISPM 15. thermofin® transport packages are made of environmental friendly materials and they are suitable for recycling. According to the German regulation on packaging, we are prepared to take back our packages if they are returned to us, delivered free to our location in Heinsdorfergrund. Usually, thermofin® heat exchangers are delivered in completely assembled condition. If a machine is delivered with loose parts due to transport or other reasons, those parts are to be assembled on site according to the enclosed order-specific drawings. Loading on road vehicles is performed in accordance with the VDI guideline 2700 "Securing of loads on road vehicles". In case of groupage traffic, responsibility lies with the forwarder.


4.3 Assembly Instructions

4.3.1 Installation The suitability and the load bearing capacity of the foundations, brackets, machine frames etc. – provided by the customer – are not the responsibility of the equipment manufacturer. It has to be ensured that the machine rests evenly on all contact points. It must be fixed on the supporting structure by using appropriate fasteners. For the bearing capacity of the construction provided by the customer, as well as for the dimensioning of the used screws, thread rods and the like, besides the empty weight printed onto the type plate and the quantity of the hangings, the filling weight and the possibility of icing has to be taken into account as well. Formula for the calculation of the suspension force:

(empty weight of machine + filling weight + additional weight) F max = quantity of hangings x safety factor

The heat exchanger has to be fastened in such a way that it is not damaged or affected in its functionality due to environmental dangers (production processes, transportation processes, other technical devices in close proximity etc.). Switches and shut-off devices have to be secured against unauthorised operation. After installation and before commissioning, all existing package parts and transport protection devices must be removed.


4.3.2 Pipe connections The machines are delivered with an overpressure of approx. 1 bar (cleaned and dried air). (according to the directive for the transport of hazardous goods ADR 1.1.3.2 c) Before removing the closing caps it must be verified that the overpressure is present. A depressurized device indicates a leakage (Damage in transit! Leak test!) In case of depressurized devices, the manufacturer must be consulted immediately. Before the assembly, the transport pressure must be released and the closing caps must be removed. Pipe connections are to be designed in such a way that any force, stress and vibration effects on the machine are prevented.


The inlet and outlet must be observed according to the marking.

Refrigerant distributors must be arranged vertically. The capillary tubes of the distributor are not to be shortened.

4.3.2.1 Defrost water drain According to the machine type, the design of the defrost water drain can vary.

Screwed discharge nozzles made from plastic are only to be tightened by hand! Do not use pliers!

Pay attention to sufficient slope (at least 5%) in freezer rooms, provide for trace heating. Do not arrange siphons inside freezer rooms.


4.3.3 Electrical connections The electrical connection of the defrost heating and the electrical accessories, if existent, must be performed in accordance with the applicable regulations of DIN VDE 0100, DIN EN 60204 part 1, DIN EN 378-3, section 6, and the provisions of the local energy supply company. The electrical installation may only be carried out by qualified personnel. The local regulations must be observed. The data given on the respective identification labels are binding. Wiring may only be performed in accordance with the circuit and wiring diagrams provided. The existing strain-relief devices must always be used.


A suitable all-pole circuit breaker must be installed in the system.

Please note that during the performance of the installation, humidity can condense out in cold spaces, which can lead to an accumulation of dripping water inside the socket as well. For the installation of the unit or subsequent installations assurecompliance with the degree of protection.


4.3.4 Start of operation Before starting operation, the system’s readiness for operation must be verified according to the following points:

1. Has the machine been properly installed and fixed in accordance with the instructions of the present manual?

2. Have all fluid-carrying lines been connected and checked for tightness? Are the shut-off devices open?

3. Is the flow direction correct? 4. Are all cables properly installed and completely connected? Has cabling been done

according to the wiring diagrams provided? 5. Has the fuse protection been checked for proper functioning? 6. Have all bolted connections (e.g. fans, cable entries), fastenings, electrical connections

etc. been checked for tight fit? 7. Are all terminal boxes and cable entries firmly closed and tight?

During start of operation the following measures have to be taken:

1. Adjust the electrical switching and control devices and check for correct functioning (see the specific operating instructions of the respective control device).

2. Check the switch point settings of the safety equipment.

4.3.4.1 Return to service after a longer period of standstill If the machine is intended to be put into operation again after being shutdown and standing still for a longer period of time, the following points must checked in addition to those mentioned under „4.3.4 Start of operation“:

1. visual inspection of the heat exchanger coil; check for fouling and damages 2. leak test of the heat exchanger coil 3. check all pipe connections (including pipe clips), electrical components, housings and

attachment parts for tight fit


4.4 Maintenance and hygiene The manufacturer recommends performing particular maintenance works at regular intervals. The form and frequency of the measures strongly depend on the respective installation site of the heat exchanger. 4.4.1 Cleaning of the fins Depending on the installation site and the mode of operation, the heat exchanger fins are subject to fouling (varying degree). As this directly affects the hygiene of the freezing room and the performance of the machine, the cleanliness of the fin coil must always be ensured. Dry cleaning: with a broom or a soft brush from the outside towards the fins or from the inside towards the outside by using compressed air – opposite to the direction of the air flow of the fans.


Switch off the machine (regarding refrigeration and electricity)! Wet cleaning: with a water jet from the inside towards The outside and opposite to the direction of the air flow of the fans fans; and from top to bottom. The jet of the cleaning device must be vertical to the heat exchanger block (max. deviation ±5°), in order to prevent fin deformations.

Switch off the machine (regarding refrigeration and electricity)!

Electrical components may not be exposed to the water jet!

When using cleaning agents, the compatibility of materials must be ensured. Never use aggressive or corrosive cleaning agents! In case of doubt, consult the manufacturer. Mechanical cleaning with hard objects, such as steel brushes or screwdrivers may destroy the heat exchanger, therefore it is not permitted.


4.5 Defrosting In order to guarantee the efficiency and the operational safety of the heat exchanger in the long turn, the heat exchanger has to be defrosted on time and at regular intervals. The defrosting process is automatically initiated via preset intervals, or as needed. The termination of the defrosting process has to be safeguarded two times (time / temperature or temperature / temperature). Common Defrosting methods are the defrosting by means of recirculating air, by means of hot gas, or the electronic defrosting. For a proper defrosting process, please pay attention to the following notes:

• Initiate the defrosting process on time. • The defrosting process has to be complete, which means that ice and frost need to

be defrosted completely after termination of the defrosting process. For this, the selection of the final defrosting temperature and the position of the defrost sensor are of vital importance.

• Between termination of the defrosting process and the re-engagement of the refrigeration system, a dripping time of 3 to 5 minutes is recommended, during which the heat exchanger coil can completely drain and the dripping water can drain from the machine via the discharge.

• If the connection of the fans is held up for yet another period of time (standard value 3 minutes), the defrosting heat is absorbed by the heat exchanger coil and is therefore not blown into the room as warm humid air or water drops via the fans.

Attention! Danger of burning on heater rods and hot gas lines!

4.5.1 Recommendations for the positioning of the defrost sensor Defrosting by means of recirculating air: If the machines are operated in rooms with temperatures above the freezing point ≥ +5°C, the defrosting by means of recirculating air is sufficient in many cases.

Recommended positioning of the sensor: At the bottom of the fin coil on air outlet side. Defrosting by means of hot gas: A sufficiently large amount of hot gas has to be available in order to ensure an efficient and complete defrosting process.

Recommended positioning of the sensor: In the fin coil in the outlet area of the hot gas, on air intake side. Electronic defrosting: Safety measures against an overheating (temperature limiter) of the machines as well as against excessive pressure (pump down system) are to be taken, according to the regulations from DIN EN 378 as well as EN 60519-2 and VDE 0721. An operation without temperature control is not permitted!

Recommended positioning of the sensor: In upper area or at the position of the fin coil which is furthest from the next heater rod, on air intake side.



4.5.2 Further notes regarding the defrosting process In rooms with temperatures below the freezing point, the discharges and pipes for condensation water have to be heated, so that a freezing of the condensate inside the pipes is prevented. Due to the same reason, no siphons or the like are to be arranged inside the room. The existent defrosting closure devices (flaps,...) are to be used.

5. Operation and shutdown

5.1 Normal operation For running the machine, the entire plant including the electrical system must be operating. The machine is integrated in the cooling circuit by opening the corresponding shut-off valves. It is turned on by activating the electrical system. After reaching the machine-specific operating point the machine is ready for operation. In case of operating conditions which differ from those stated in the offer, the manufacturer must be consulted.

5.2 Shutdown The machines are part of a refrigeration system. Machine shutdown and return to service must meet the system-dependent requirements as well as the requirements of the operating manual of the equipment manufacturer and of the applicable standards and accident prevention regulations (see also chapter „1.3 Applied standards and directives“). The shutdown is effected via the shutoff of the fluid-conducting lines as well as via the shutdown of the electrical system.

The following applies for all devices: Exceeding the maximum pressure must be prevented!

6. Spare parts After-sales services are to be performed by the responsible specialist company. Spare parts are stated in the spare parts list enclosed in the annex or in the specified drawing. They can also be requested from the manufacturer by indicating the device name and the project number on the type plate. Only use original spare parts for the replacement of equipment components.

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Installation Instruction eat Exchanger Coils - · PDF fileInstallation. Instruction H. eat Exchanger Coils . thermofin GmbH, ... tightness of refrigeration systems and heat pumps,