kec-kme manual

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Installation and Maintenance Instructions ENGLISH GEA Searle: KEC/KMe, KECX, KMCX, KECP, KMCP

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Page 1: KEC-KMe Manual

Installation and Maintenance Instructions ENGLISH

GEA Searle: KEC/KMe, KECX, KMCX, KECP, KMCP

Page 2: KEC-KMe Manual

1.HEALTH AND SAFETY

This concerns the hazards, which may be encountered when installing and maintaining this equipment. It is therefore important that these instructions are followed.

1.1 Before installation

Ensure that:

a) Thevoltage,workingfluidandthemaximum working pressure stated on the product nameplate are suitable for the working environment.

b) The proposed method of mounting is adequate to support the total operational weight of the units.

1.2 During installation and maintenance

Ensure that:

a) Theunitisinstalledandmaintainedbyqualified personnel only.

b) The electrical supply is isolated and secured from accidental reconnection.

c) The working area is adequately ventilated.

d) Thetemperatureofcoilswithvinylcoatedfins doesnotexceed150°C(e.g.duringbrazing)as toxicfumeswouldbeproduced.

2. INSTALLATION

2.1 General

Upon receipt, the units should be visually inspected and the sup-pliernotified(withinsevendays)ofanydamageorshortages. The units are designed for ceiling mounting using the fixingholesprovided.Unitsarenotportableandareonlyforper-manent installation. Knockouts in the side of the unit give access for the connection of services.

2.2 Location

The location of the unit should be carefully selected toensure that:

a) Air distribution from the cooler is not adversely affected by obstructions and is appropriate for the size and shape of the room, optimum air distribution should be targeted. Product loading must be in ac cordance with good refrigeration practice.

b) Air entering the cooler is not obstructed

c) The unit must be installed level in both directions

d) Maintenance access should be considered when locating the product, including adequate space for heater withdrawal when appropriate

e) The unit is not subjected to physical loads

2.3 Handling

For transportation the unit is inverted and bolted to the base of thepackingcase.Caremustbetakenwhileremovingthepack-agingandinstallingtopreventdamage,particularlyofthefinnedcoil.

The drainpan is fitted to the unit (in its transit/lifting position)for transportation. Remove the draintray by removing the four fixingsandthenfitthehexagonaldrainconnectionandgasketinto thehexagonalwell inside thedraintray.Hand tighten thisassembly using the knurled nut on the outside.

Refit the draintray in its transit position (fixings loose)makinguse of the slots in the tray so that it moves into contact with the underside of the cooler bottom plate so that the weight is transferreddirectlytothechassisoftheunitwhenlifingintopo-sition.

When the cooler is in position ensure that the drainpan is dropped downintotheoperatingpositionbeforetighteningitsfixings.

2.4 Pipework

Refrigeration Pipework

Pipework to and from the unit should be selected to suit the application and not the connection size of the unit. It should be supported independently from the unit and in a way that pre-vents the transmission of vibration to the unit . A competent engineer should install refrigeration pipwork to a high standard of refrigeration practice. The distributor must be vertical.

Condensate Drainage

Once the unit is in place the drain tray MUST slope downwards towardsthedrainconnection.OntheKECandKMethefixingsatthe rear of the drain tray should be loosened to allow the back of the drain tray to drop into it’s operating position. The drain con-nectionis1”BSP(M)nylonontheKMeandKECandshouldbehand tightened when connected to the drain. Ensure that drain-line size is equivalent to that of the drain connection and that it has an adequate fall. It is essential that the drainline includes a trap,fittedoutsidethecoldroom.

TEV Selection

It is important that the TEV is correctly sized. The TEV size should be determined using the maximum design capacity and theminimum valve pressure drop. This occurs at the minimumcondensingpressure.AnexternallyequalisedTEVmustbe used. When calculating the minimum valve pressure drop, al-lowance must be made for the cooler’s distributor system. R404A,R407C,R410A,R507A,R744 1.5barR134a 1.0bar

Evacuation

To avoid potential moisture related problems; it is necessary to evacuatethecompletesystemtoaminimumof1torr(1.3mbar).All parts of the system must be above freezing and ideally higher than+10°Cduringevacuation.

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Page 3: KEC-KMe Manual

2.5 Electrical

Motors, and defrost heaterswhen fitted, are factorywired toa junctionbox.An internalwiringdiagram isaffixed to the lidof thisbox, exceptaerofoil fans that require thesupply tobeconnected direct to themotors’ terminal box.Generally ‘cageclamp’ type terminals are used. These are opened by pushing a correctly sized screwdriver into the square aperture adjacent totheconductorentry. Conductorsshouldbebetween1and2.5mm².KMesinglefanunitsuseascrewtypeterminalblockfor motor supply.

Internal and site wiring share common terminals, so care must be exercised to ensure that the internalwiring is undisturbed.All single phase motors have automatic internal overload protec-tion,andcanbeusedinconjunctionwithahighquality‘triac’type speed controller. Three phase motors MUST be protected against overload and single phasing. Overloads must be set to cutoutatFLC+15%@10°CroomtemperatureandFLC+25%@minus30°Croomtemperature(proportionforothertemperatures).Checkthatthefanrotationof3phaseunitsis correct.

ThestandardrotationonKMeandKECunitsisclockwisewhenlookingintothefandischarge.On3phaseunitstherotationcanbe changed by reversing any two phases of the motor supply. SomeKMeunitswithelectricdefrosthaveanauxiliaryterminalboxattherefrigerantconnectionendoftheunit.Itisnotnecessarytomakeanyelectricalconnectiontothisbox.

“IfRCDs (ResidualCurrentDetectors)aretobeused,atriggerleveloflessthan100mAislikelytoresultin“nuisance”tripping.”

2.6 Low temperature models

Defrost

Natural defrost is not suitable for coolers operating with an air leavingtemperatureoflessthan3°C.Iftheinitiationofdefrostperiods is by a timing device then it is recommended that it be initiallysettotwodefrostperiodsper24hoursforKECunitsandfourforKMeunitsuntiloperatingexperienceisgained.(Speedcontrolled units may require more frequent defrosts). System ‘pumpdown’(fansrunning)isrecommended(essentialonverylow temperature applications) prior to defrost so that the result-ing defrost is neither prolonged nor uneven.

Initial Defrost Termination Settings

Time/Timedefrostsystem

Electricdefrost(230/400volts) KMe:30minutes KEC:30minutes (220/380volt:+5min,240,240/415volt:-5min)

Time/Temperatureterminationsystem

Electricdefrost:minimumsetting4.5°C

Time/Pressureterminationsystem

Reversecycle/hotgasdefrost Pressureequivalentto25°CSSTofthesystem refrigerant.

Drain Down Time

A‘draindown’time,withfansoffandnocooling,offiveminutes duration should be given immediately following a defrost termination.

Fan Delay Setting

a) WithThermostat:-7°C

b) With Pressure Switch: Refrigerant pressure at a saturationtemperatureof-12°C.

Defrost Termination Thermostat

Ifadefrostterminationthermostatistobefittedthencaremustbe taken in locating its sensor. It should initially be positioned between the coil fins on the air on side, away from heaterelements.Itmaybesecuredintopositionbywrappingthefinsaround it. Small sensors should be enclosed in a suitable copper tube to slow response. Once the system is in operation it may be necessary to relocate the phial to the area of the coil where ice remainsthelongestduringdefrost(possiblyairoffface).Gener-ally, it is possible to wire an internally located phial through the unit’sinternaljunctionbox.

Drain Line Heaters

Drain line heater cables or tapes should be permanently ener-gised and cover the drain pan connection.

2.7 Air Throwers

Airthrowerscanbefittedtotheguardsofthe400mmfansets,onKMeunitstheyfitovertheterminalboxandclipontothewiremesh guard.

3. INITIAL STARTING

Beforerunningtheunitforthefirsttime,checkthatallguards,motor mountings and electrical covers are secure, all un-necessary terminal block links are removed and fans rotate freely. Ensure that the drainpan has been lowered to the operating position. Once running, check that there are no unu-sual noises or vibrations. After allowing the unit to operate for at least 2 hours at conditions close to design, the TEV must be adjusted to provide the correct level of superheat. This is between 0.6and0.75xcoolerTD,toamaximumof8K.Similarly review all defrost settings.

4. MAINTENANCE (Routine)

WARNING!

UNIT MUST BE ELECTRICALLY ISOLATED BEFORE MAINTENANCE WORK IS UNDERTAKEN.

The following routine maintenance is required:Periodically inspect units for ice build up where the ambient tem-peratureisbelow5°C.

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Page 4: KEC-KMe Manual

KEC Wiring Diagrams

Every 12 months check

1) Securityoffixingsespeciallyfanmotormountings.

2) Refrigerant pipeline for damage and leaks.

3) Motor(s)rotatefreely.

4) Electrical connections for security of attachment.

5) Defrost,ifused,isoperatingeffectively.

When necessary

Cleanthefins,guard,drainpananddrainlinesandgeneralcasework.Caremustbetakenwhencleaningthefinstoprevent damage. A soft brush and mild detergent solution is rec-ommended.

1. Loosenendpanelscrewsandliftoffendcovers2. RemoveallM5poziscrews(4off)toremovefan plate3. RemoveM5countersunkscrews(2off)toremove fanset

Coil Block Heaters

Coilblockheatersareeither‘U’bentorstraightandtheyhavetobedisconnectedfromtheterminalboxattheelectricalconnectionendandsometimes fromtheauxiliary terminalboxat the refrigeration connection end of the cooler. These heaters are withdrawn and replaced from the refrigeration connectionendofthecoolertakingcaretoretainthe‘anti-creep’clips. These clips may be re-used but will possibly need retension-ing.Toavoiddamagetoeitherthecoilfinsortheheatercable,theheatercableshouldbeinsertedintoasimilarlengthof1/4”ODcoppertubeandfedcarefullythroughthefinswithatwist-ing motion. With care the heater element sheaths can be curved through90°(minimumradius600mm)forremovalandrefittingpurposes.Beforeattemptingtorefitaheateritisessentialtoen-sure that the coil heater hole has not become obstructed with ice and wherever possible the coil block should be above freezing point.

Drain Pan Heaters

Replacement is achieved by disconnecting the elements from the terminalbox(es)afterremovingtheendcoveranddrainpan,andunclipping/unscrewingtheheaterretainingclips.

5. INVALIDATION OF GUARANTEE

Failure to install, set up or put to work any part of the equipmentinthemannerspecifiedintheInstallationandMaintenance Instructions could invalidate the guarantees set out intheStandardTermsandConditionsofSale.

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Page 5: KEC-KMe Manual

KMe Wiring Diagrams

GEAHeatExchangers

GEA Searle

20DavisWay,NewgateLane,Fareham,Hants,PO141ARTel. + 44(0)1329823344,Fax+44(0)[email protected],www.searle.co.uk PartNumberOct2010272-000-315