INSTALLATION, OPERATION & MAINTENANCE MANUAL

GCO UNIT
Heat Exchanger Coil

Series Description:

(Finned) Heat Exchanger Coil with or without Droplet Separator Heater and Cooler

Series:

CONFORMS TO UL STD 207; CERTIFIED TO CSA STD C22.2 NO. 140.3 RECOGNIZED COMPONENT.

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Table of Contents
1. Warranty Statement 2. General Safety Information 2.1. General Information 2.2 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 and operated 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 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 suppliers 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 suppliers works. Upon receipt of the goods and inspection thereof the supplier shall repair or replace, at the suppliers discretion, the defective goods and return freight, carriage paid, and without any further expenses. 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 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

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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 caused by 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, safety and 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

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

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

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2.2. Safety Information

General:
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 if they have been installed in these systems according to this manual and if they, as a whole, comply with the respective statutory regulations. Any work on (finned) heat exchangers must be carried out by qualified and authorized personnel.

Only approved materials must be used.

(Finned) Heat Exchangers:

The (finned) heat exchangers are built according to the latest technology and the applicable regulations. The safety of the users was a prime concern. (Finned) heat exchangers may be the source of unavoidable residual hazards. Each person working on this (finned) heat exchanger must therefore carefully read this operation manual. Please label accessible areas! Sharp edges and corners on the systems, especially on the fins, can cut fingers and hands wear protective gloves! When working on the (finned) heat exchanger: The (finned) heat exchanger may be under pressure (maximum operation pressure)! Risk of injury! De-pressurize the (finned) heat exchanger 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 the name 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 risk potential 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. It remains 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 (safety groups 1, 2 or 3) and toxicity (safety groups A or B), and therefore does not have any detrimental effects on the workers.

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4. Transport, Delivery, Installation

4.1. Packaging
Palets, crates, boxes HPE Directive on packaging by the Bundesverband Holzmittel, Paletten, Exportverpackung e.V. (Federal Assn. for Wood Packaging Materials, Pallets and Export Packaging) and the VDM (German Assn. of Metal Traders) Gntner transport packaging is made from environmentally compatible material and is sutiable for recycling.

Transport packaging

4.2. Delivery and Unloading

(Finned) heat exchangers scheduled to be shipped must be appropriately protected from detrimental effects caused by the atmosphere (packaging units). During shipping, the (finned) heat exchanger is closed and filled with clean and dry air. The excess pressure (transport pressure) is 0.5 to 1 bar.

A-A
2 3

1 Schrader valve 2 Sealing plate 3 Flange gasket

A
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 transport damage and / or missing parts on the shipping order. Inform the manufacturer immediately in writing of the situation. It is imperative that the instructions on the shipping labels of the (finned) heat exchanger packaging units 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, and the 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!

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Transport by crane must be carried out with a maximum angle of the transportation rope of 60 (option 1) or, if needed, using a crossbeam (option 2), or, if possible without risk, with a rope sling around the box!

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 the load.

When transporting the (finned) heat exchangers by forklift or crane, it is imperative that equal weight 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 at the 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, prevent moisture and dirt from permeating into the opened (finned) heat exchanger. The (finned) heat exchanger 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 of injury 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 2 Gasket Open valve carefully! Excess pressure! Open connectors carefully!

3 Valve mechanism 4 Schrader valve

The (finned) heat exchangers are transported as system components with mounted droplet separators and included drip trays in packaging units. If the (finned) heat exchangers are not to be shipped premounted, 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 to airflow 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 and must 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 M10 8.8 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 fastening screws!)

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Transport by crane
1 2
M10 8.8

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 the manufacturer; 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 to ensure 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 from environmental 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 outside temperatures 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 basis and 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 is enough clearance to uninstall the droplet separator and other assembly parts!

The (finned) heat exchangers must be fixed or mounted as follows: Inspection, control and maintenance must be possible at all times, i.e. unobstructed access to the fluid-carrying and attached 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 inch measurements.

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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 freeze during operation. If the unit is designed to not be completely drained, it might freeze even after the unit has been emptied. When draining the unit ensure proper ventilation. At temperatures below the freezing point, units will be destroyed when filled with water or at insufficient levels of antifreeze during pressure checks, operation and standstill. The warranty excludes 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 not covered 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 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 connecting it to the (finned) heat exchanger! Soldering or welding work may only be carried out if the (finned) heat exchanger does not contain 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 in accordance 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, inspection of 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) heat exchanger 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 the following checklist: Test all joints in the system for leakages and correctness according to the applicable rules and regulations (see section 1. General Safety Information), and the system must be professionally evacuated 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 the procedure 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 vent connections 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 and discharge side of the entire system. After the operational data have been achieved (see order-specific bidding documents), the (finned) heat exchanger is ready for operation. The operational data: Airflow volume Air inlet temperature Air outlet temperature Flow volume of fluid Fluid inlet temperature Fluid outlet temperature must 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. Inspection intervals depend on the mode of operation. They must be determined by the operator according the section 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 and either replaced or repaired. If you should detect malfunctions or damage to the (finned) heat exchanger, you are required to notify the manufacturer immediately in order to enable the manufacturer to participate in the curing of such defects. 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 fluid should 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 maximum operating 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 the system 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 test pressure is present.

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5.2.3. Modifications to the System, Conditions and Modes of Operation

The following are considered changes to the system:

Non-permissible

Operating

- 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 as follows: 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 are subject 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 the operating conditions. Inspections should include in particular checks for leakage, corrosion, strong vibrations and the safety features.

6.2. Cleaning
The 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 the heat exchanger itself and its immediate surroundings. Dry dust or dirt can be removed with a brush, a hand brush or with pressurized air (maximum pressure 80 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 80 bar) or steam jet (maximum pressure 80 bar), with a minimum distance of 200 mm, equipped with a fan 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 5 degrees), 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 nonaggressive or non-corrosive! Mechanical cleaning with hard objects (e.g. steel brushes, screwdrivers, etc.) damages the heat exchanger: not permitted!

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6.3. Maintenance, Repair

Maintenance and repair measures arise as a result of malfunctions (see section 4.2.2. Shut-off and Decommissioning) 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 persons and 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
Partial cleaning Total cleaning mechanical

Mode

Interval
as needed (sight inspection) to operators

water or environmentally or according material compatible cleaning specifications agents exterior sight inspection (e.g. EN 378-2, annex A, B) - sight inspection

Leakage check Corrosion protection check

depending on leakage rate (e.g. EN 378-2, annex C) depending on leakage rate

- Inspection of fluid for inhibitors (e.g. EN 378-2, annex C) (refrigerant manufacturers specifications)

Recommended Inspection Schedule

Component / Check point Heat Exchanger / fluid joints Drip tray Frame / anchors Droplet separator monthly every three months monthly clean tighten repair or replace immediately immediately immediately monthly Interval Measure Timing

repair or replace*

immediately

*) During longer maintenance intervals, the (finned) heat exchanger (and droplet separator) may possibly be demounted for maintenance and repair measures. Observe and comply with the information 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.V Av. Rogelio Gonzlez Caballero No.1000, Parque Industrial Stiva Aeropuerto Apodaca Nuevo Len Mxico, cp 66600 Office tel: +52 81 81 56 06 00 Office fax: +52 81 81 56 06 07 sales@guentner.com.mx

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