Bitzer OW941B Manuale utente
DB-200-5
Pressure vessels: Water-cooled condensers and oil coolers
Translation of the original Operating Instructions
English....................................................................................................................................................... 2
Druckbehälter: Wassergekühlte Verflüssiger und Ölkühler
Originalbetriebsanleitung
Deutsch ..................................................................................................................................................... 15
Réservoirs sous pression: Condenseurs à eau et refroidisseur d'huile
Traduction des instructions de service d'origine
Français..................................................................................................................................................... 28
K033N/H(P) .. K4803T(P)
K033N/HB(P) .. K4803TB(P)
OW401 .. OW941
OW401B .. OW941B
Installer
Monteur
Monteur
DB-200-52
Table of contents
1 Introduction............................................................................................................................................................3
2 Safety ....................................................................................................................................................................3
2.1 Authorized staff..............................................................................................................................................3
2.2 Residual hazards ...........................................................................................................................................3
2.3 Safety references...........................................................................................................................................3
2.3.1 General safety instructions ................................................................................................................ 3
3 Application ranges.................................................................................................................................................5
3.1 Plant registration............................................................................................................................................5
3.2 Conformity .....................................................................................................................................................6
4 Mounting................................................................................................................................................................6
4.1 Transporting the pressure vessel ..................................................................................................................6
4.2 Installation location ........................................................................................................................................6
4.3 Plant design ...................................................................................................................................................6
4.4 Refrigerant / oil side.......................................................................................................................................7
4.5 Coolant side...................................................................................................................................................7
4.6 Delivery condition ..........................................................................................................................................7
4.7 Connecting the pipelines ...............................................................................................................................7
4.7.1 Mounting the pressure relief valve..................................................................................................... 8
4.7.2 Connection for pressure gauge.......................................................................................................... 8
4.8 Connections for water-cooled condensers and oil coolers ............................................................................9
4.9 Connection dimensions for coolant pipes ....................................................................................................11
4.10 Coolant passes............................................................................................................................................12
5 Commissioning ....................................................................................................................................................12
5.1 Checking tightness ......................................................................................................................................12
5.2 Charging refrigerant.....................................................................................................................................12
5.3 Coolant ........................................................................................................................................................12
6 Operation.............................................................................................................................................................13
6.1 Standstill ......................................................................................................................................................13
7 Maintenance........................................................................................................................................................13
7.1 Cleaning.......................................................................................................................................................13
7.2 Extracting the refrigerant .............................................................................................................................13
7.3 Draining the oil.............................................................................................................................................14
8 Decommissioning ................................................................................................................................................14
DB-200-5 3
1 Introduction
This pressure equipment is designed for installation in
refrigeration systems according to the EC Machinery
Directive 2006/42/EC and the Pressure Equipment Dir-
ective 2014/68/EU. They may only be put into operation
if they have been installed in the machines according to
these Assembly/Operating Instructions and if the over-
all system complies with the applicable legal provisions
(applied standards: see Declaration of Conformity).
The pressure equipment has been built in accordance
with state-of-the-art methods and current regulations.
Particular importance was placed on user safety.
Always keep these operations instructions near the re-
frigeration system for the whole lifetime of the pressure
vessel.
2 Safety
2.1 Authorized staff
All work done on the pressure equipment and refrigera-
tion systems may only be performed by qualified and
authorized staff who have been trained and instructed
accordingly. Local regulations and guidelines apply with
respect to the staff's qualification and expertise.
2.2 Residual hazards
The pressure equipment may present unavoidable re-
sidual risks. That is why any person working on this
device must carefully read these Operating Instruc-
tions!
The following regulations shall apply:
• the relevant safety regulations and standards (for ex-
ample, EN 378)
• generally accepted safety rules,
• EU directives,
• national regulations.
2.3 Safety references
are instructions intended to prevent hazards. Safety ref-
erences must be stringently observed!
!
!
NOTICE
Safety reference to avoid situations which may
result in damage to a device or its equipment.
CAUTION
Safety reference to avoid a potentially hazard-
ous situation which may result in minor or mod-
erate injury.
WARNING
Safety reference to avoid a potentially hazard-
ous situation which could result in death or seri-
ous injury.
DANGER
Safety reference to avoid an imminently hazard-
ous situation which may result in death or seri-
ous injury.
2.3.1 General safety instructions
State of delivery
CAUTION
The pressure equipment is filled with a holding
charge: Overpressure 0.2.0.5 bar.
Risk of injury to skin and eyes.
Depressurise the pressure equipment!
Wear safety goggles!
DANGER
Risk of bursting the pressure device due to
mechanical stress.
Serious injuries are possible.
Connect the pipeline to the pressure unit without
stress!
DANGER
Risk of bursting of components and pipelines
due to hydraulic overpressure.
Serious injuries are possible.
Make sure not to exceed maximum admissible
pressures!
DB-200-54
For work on the pressure vessel after having put the
system into operation
CAUTION
Surface temperatures of more than 60°C or be-
low 0°C.
Risk of burns or frostbite.
Close off accessible areas and mark them.
Before performing any work on the pressure
device: switch off the installation and let it cool
down.
WARNING
The pressure equipment is under pressure!
Serious injuries are possible!
Depressurise the pressure equipment!
Wear safety goggles!
CAUTION
Refrigerant can be very cold
Risk of severe frostbite.
Avoid any contact with the refrigerant.
CAUTION
Oil can be very hot.
Serious burns are possible.
Allow the oil to cool.
For work on the pipework of the coolant, the following is
applicable
WARNING
Coolant can burn skin and eyes
Wear safety goggles!
DB-200-5 5
3 Application ranges
Type Fluid group ac-
cording to
2014/68/EU
(PED)
Safety group ac-
cording to EN 378
PS
Maximum
permitted
pressure
TS
Maximum and
minimum permit-
ted temperature
K033N/H(P)(B) .. K4803T(P)(B) 1 + 2 A1, A2, A2L, A3 33 bar 120°C / -10°C
OW401(B) .. OW941(B) 1 + 2 A1, A2, A2L, A3 28 bar 120°C / -10°C
OW401(B) .. OW941(B) Oil according to
ISO 6743-3, DIN 51503-1
28 bar 120°C / -10°C
Tab.1: Permitted fluids
Type Coolant PS
Maximum permitted oper-
ating pressure
TS
Maximum and minimum
permitted temperature
K033N/H(P) .. K4803T(P)
OW401 .. OW941
Water or brine 10 bar 95°C / -10°C
Anti-freeze!
K033N/H(P)B ..
K4803T(P)B
OW401B .. OW941B
Seawater, water or brine
For brine concentration see the BITZER SOFTWARE.
Tab.2: Coolants
!
!
NOTICE
Risk of corrosion!
The coolant must not react aggressively with the
pipe material of the pressure vessel or the ma-
terial of the end covers.
K033N/H(P) .. K4803T(P) / OW401 .. OW941
(Standard design)
pipes: copper, end covers: grey cast iron
K033N/H(P)B .. K4803T(P)B / OW401B .. OW941B
(seawater design)
pipes: copper-nickel-alloy, end covers: coated plastic
As a free service, BITZER will examine the suitability of
pipe materials if a water analysis is provided. The basis
for the examination is the current status of knowledge.
However, due to the complexity of the situation, no ab-
solute guarantee can be given that materials will be
corrosion proof.
3.1 Plant registration
Condensers and oil coolers are pressure vessels ac-
cording to the Pressure Equipment Directive 2014/68/
EU. For this reason the entire plant must be registered
with the supervisory authority and duly approved in ac-
cordance with the local regulations.
The category for the conformity assessment of each
pressure vessel is listed in the following table.
For the inspection before commissioning and recurring
inspections, national regulations must be considered
(for example the Industrial Safety Regulation (Be-
trSichV) in Germany).
In non EU countries local regulations must be complied
with.
DB-200-56
3.2 Conformity
Type Reservoir fluid capa-
city
dm3 (l)
Category according
to 2014/68/EU (PED)
Fluid group 2
Category according
to 2014/68/EU (PED)
Fluid group 1
Conformity assess-
ment depending on
the module
K033N/H(P)(B) 3.8 I II A2
K073H(P)(B) 3.4 I II A2
K123H(P)(B) 5.1 I II A2
K203H(P)(B) 11.8 II III B + D
K283H(P)(B) 11.3 II III B + D
K373H(P)(B) 14.5 II III B + D
K573H(P)(B) 29.4 II III B + D
K813H(P)(B) 27.7 II III B + D
K1053H(P)(B) 40.0 III IV B + D
K1353T(P)(B) 37.0 III IV B + D
K1973T(P)(B) 76.0 III IV B + D
K2923T(P)(B) 67.0 III IV B + D
K3803T(P)(B) 108.0 IV IV B + D
K4803T(P)(B) 98.0 III IV B + D
OW401(B) 10.5 II III B + D
OW501(B) 14.0 II III B + D
OW781(B) 18.0 II III B + D
OW941(B) 24.0 II III B + D
Tab.3: Category and evaluation of conformity
4 Mounting
4.1 Transporting the pressure vessel
Transport the pressure vessel screwed on a pallet. Lift
it using the eyebolts or the upper fastening brackets if
available.
DANGER
Suspended load!
Do not step under the machine!
4.2 Installation location
For outdoor installation, take suitable measures to pro-
tect the pressure vessel against corrosion (e.g. caused
by seawater or aggressive atmosphere) and low out-
side temperatures. Consultation with BITZER is recom-
mended.
!
!
NOTICE
Danger of freezing!
It is necessary to ensure that the temperature at
the location is high enough above the freezing
point of the coolant.
4.3 Plant design
If a compressor is mounted on the condenser:
!
!
NOTICE
No vibrations should be transmitted to the con-
denser!
Do not use the condenser as load-bearing ele-
ment! Mount the compressor on the condenser
only with damper elements!
The discharge line must be sufficiently elastic so that a
minimum of vibrations and movement is transferred to
the condenser. It may be necessary to fit flexible vibra-
tion dampers.
DB-200-5 7
Extreme pressure pulsations should be damped by fit-
ting pulsation mufflers.
4.4 Refrigerant / oil side
The whole system should be designed and operated in
order to guarantee that the maximum operating pres-
sure in the pressure vessel cannot be exceeded.
Pressure relief valves are essential if
• it is to be expected that the maximum operating
pressure will be exceeded due to external heat
sources (e.g. fire), or if
• the entire refrigerant charge of the plant is more than
90% of the receiver volume at 20°C (charge capa-
city). Receiver volume means the volume between
operationally lockable valves before and after a pres-
sure vessel. In case of two vessels being mounted in
series, it is the volume of both vessels and the con-
necting pipe.
In these cases relief devices should be installed that
lead the refrigerant or the oil to the low-pressure side of
the plant (emission reduction).
Safety switching device
According to the local regulations, safety switching
devices for pressure limiting must be provided.
4.5 Coolant side
The coolant should contain neither solids nor gases:
• Any solids must be separated out using suitable fil-
ters.
• The presence of gas should be avoided through suit-
able design measures.
Open circuits: The pressure vessel must not drain off
while not in use. For this reason, fit either
• a coolant regulator at the coolant outlet of the pres-
sure vessel, or
• a swan-neck at the outlet.
When using tap-water as a coolant, it is necessary to
check whether the installation of a pipe disconnector is
stipulated.
When cooling with seawater: If, due to local conditions,
the seawater in use can lead to scale or shell deposits,
suitable filters should be fitted. This also serves to pro-
tect the pipe lines from shell deposits.
4.6 Delivery condition
The pressure vessel is sealed in the delivery condition
and filled with inert gas. The inert gas overpressure is
0.2 .. 0.5 bar. All Rotalock and flange connections are
closed by blanking plates. These plates must be re-
moved before commissioning.
4.7 Connecting the pipelines
The pipe connections are suitable for pipes in all com-
mon dimensions in millimetres and inches. Brazed con-
nections have stepped diameters. The pipe will im-
merge more or less depending on its dimensions. If not
required the end with the largest diameter can be cut-
off.
DANGER
Risk of bursting the pressure device due to
mechanical stress.
Serious injuries are possible.
Connect the pipeline to the pressure unit without
stress!
First relieve the excess pressure from the pressure
vessel: Open the connections carefully.
WARNING
The pressure equipment is under pressure!
Serious injuries are possible!
Depressurise the pressure equipment!
Wear safety goggles!
Remove shut-off valves and/or solder connections.
!
!
NOTICE
Potential chemical reactions due to air penetra-
tion!
Install the open pressure vessel immediately in
the system.
Reseal the pressure vessel during installation breaks.
!
!
NOTICE
Do not overheat the shut-off valves!
Cool the valve body during and after the brazing
operation.
Maximum brazing temperature 700°C!
When brazing or welding, rinse the corresponding con-
ductive parts with inert gas.
DB-200-58
Clean the pipes
Use only pipelines and system components which are
• clean and dry inside (free from slag, metal filings,
rust and phosphate coatings) and
• which are delivered with an air-tight seal.
4.7.1 Mounting the pressure relief valve
Internal thread 3/8-18 NPTF: Screw in the pressure re-
lief valve.
External thread 1 1/4-12 UNF: Screw the pressure re-
lief valve into the adaptor. Then fasten the adaptor at
the pressure vessel with the union nut.
Available adaptors see figure 1, page 8.
366 005 03
SW 22
1/2"-14 NPTF
1 1/4"-12 UNF
366 005 04
SW 12
G 1/2
1 1/4"-12 UNF
366 005 05
SW 22
3/8"-18 NPTF
1 1/4"-12 UNF
366 005 01
SW 12
1 1/4"-12 UNF
1/2"-14 NPTF
366 005 02
SW 22
G 1/2
1 1/4"-12 UNF
Fig.1: Adaptors for the pressure relief valve
4.7.2 Connection for pressure gauge
Only use it for maintenance work, not during operation.
Never connect a pressure limiter to it!
DB-200-5 9
4.8 Connections for water-cooled condensers and oil
coolers
2a
6
7/ 1 6 " - 2 0 U N F
21
1 2
1 0
1 0 3 a / 3 b
4 b
4 a / 3 b
81 11 1
T O P
7
Fig.2: K033N/H(P)(B) .. K373H(P)(B)
2
5
4 P a s s
IN
O U T
T O P
1 0
6
7 / 1 6 " - 2 0 U N F
2 a 3 a
1 1
14 a
1 0
1 2
8 1 1
7
Fig.3: K573H(P)(B) + K1053H(P)
TO P
4P a s s
I N
O U T
8
51 0 6
7 / 1 6 " - 2 0 U N F
3 a2 a
14 a
1 0
1 2
21 1 1 1
7
Fig.4: K1053H(P)B + K1353T(P)(B) .. K4803T(P)(B)
DB-200-510
TO P
I N
O U T
2
5
7 / 1 6 " - 2 0 U N F
6
7 / 1 6 " - 2 0 U N F
61
3 a / 3 b1 0
4 a / 3 b
4 b 9 1 0
Fig.5: OW401(B) .. OW941(B)
Connection positions
1 Refrigerant or oil inlet
2 Refrigerant or oil outlet
2a Alternative refrigerant outlet (only for sea
water version)
3 Coolant inlet
3a 4 or 6 pass
3b 2 or 3 pass
4 Coolant outlet
4a 4 or 6 pass
4b 2 or 3 pass
5 Coolant drain
6 Connection for pressure gauge
7 Connection for pressure relief valve
Internal thread 3/8-18 NPTF, external
thread 1 1/4-12 UNF
8 Sight glass
9 Oil drain
10 End cover, removable
11 Fixing rail, bottom
12 Fixing rail, top
Tab.4: Connection positions
Dimensions (if specified) may have tolerances accord-
ing to ENISO13920-B.
The legend applies to all water-cooled BITZER con-
densers and oil coolers and contains connection posi-
tions that do not occur in every series.
Questo manuale è adatto per i seguenti modelli
49
Indice
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