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INSTALLATION, OPERATION & MAINTENANCE MANUAL

Water Defrost
GHN.2
Freon applications

AGHN.2
Ammonia applications

GGHN.2
Glycol applications

1. 2. 3. 4. 5. 6. 7. 8.

Index Warranty statement General Information Functional description Description of components Set-up and installation Information for operation Maintenance and cleaning Defrost

2 3 3 4 5 9 10 12

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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, 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, providing 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 incorrect modifications or repair work being carried out by the purchaser or a third party 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 information
These operating instructions are valid for the following Gntner series; GHN.2, AGHN.2, GGHN.2 with the option "water defrost". This manual is intended as additional information to the existing general operating instructions of the respective unit series. The option "water defrost" is restricted to the use in normal cooling applications with room temperatures (RT) > 23 F. Units with water defrost differ from units with or without other defrost modes (e.g. electric defrost, hot gas defrost) in the following important points: - the unit is higher - the unit is deeper - higher empty and operating weight Additional elements: - drains - distribution tray - suspension to ceiling (increased load on brackets; spacer sleeve system) Water defrost operating instructions are such as water quality, temperature and flow rate are specified on the following sections.

3 Functional description of water defrost


For this option, the cold component parts such as heat exchanger coil, the connection system and heat exchanger piping of the evaporator or air cooler are defrosted with water. The defrost system is not suited for cleaning the unit. The defrosting procedure has a certain cleaning effect on the surfaces that get into direct contact with the water, but this cannot replace a thorough manual cleaning of the entire unit. Description of functions: During the defrost cycle, the defrost water is evenly distributed over the heat exchanger coil, the connection systems and the heat exchanger piping. As the water trickles through the heat exchanger coil, the frost and ice is defrosted by the direct contact with the defrost water and also by the heat from the heat exchanger coil. The water is collected below the heat exchanger coil, connection system and the piping in a drip tray. The accumulation of water also improves defrost efficiency because the residual heat from the accumulated water is used. In addition, all of the ice in the defrost water is melted.

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4 Description of the water defrost component parts


Figure A: Side view Figure B: Detail A

Figure C: Top view of side cover

Figure D: Expanded view of the top tray

Drain tray Figure A 10 Drain tray 11 Support for drain tray 12 Drip collection tray in drain tray 13 Drip tray drain R 3 (AC: BGAB300) 14 Drain heater, mounted by customer Other parts Figure A 15 Mounting brackets 16 Spacer sleeve for suspension to ceiling 17 Electric heater fan Gasket Figure B 6 Silicone gasket between tray and casing 7 Angle for drip tray rail and mounting of silicone gasket (6) 8 Heat exchanger coil 9 Casings metal sheet (top) Chamber Figure C 18 Separation sheet for chamber division into wet and dry sections 19 Insulation door 20 Insulation of chamber casing 21 Refrigerant distributor (only for evaporators) Defrost water distribution system Figure D 1 Pipe connection for defrost water supply line 1 (AC: 239) 2 Distribution tube (pressure distribution over width of coil) 3 Intermediate distribution sheet (slots parallel to coil depth) 4 Distribution tray (slots parallel to coil depth) 5 Drip tray cover Page 4 of 13 Gntner de Mexico SA de CV ++52 (81) 81 56 06 09

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5 Set-up and installation


5.1 Unloading and Unpacking For information on unloading and unpacking, please refer to the main operating instructions. 5.2 Installation For units with water defrost it is especially important to pay attention to a correct horizontal positioning of the distributor tray in width and in depth of air direction.
(16)

For units that are suspended, (e.g. hung from the ceiling) it is very important to observe the following: The general operating and maintenance instructions have to be observed. For the water defrost option, one spacer sleeve (16) has to be mounted per connection between the mounting bracket of the unit and the suspension point at the building structure (e.g. ceiling or bracket). There should be enough free space above the distribution tray(s), so that the tray can be lifted out of the guide rail for cleaning and maintenance. The space has to be at least 13/16 in.

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After the installation, all legs for transportation have to be removed, and at the air inlet side, the spacers for the legs have to be removed. The transportation legs and the corresponding parts have to be removed, because they are not considered for the static unit load in its operating state. They also have to be removed from the unit for the following reasons: frost formation, corrosion, cleanliness and visual appearance.

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5.3 Feed line for defrost water

I II III IV L1 L2 L3 L4 1 2 3 4 5 6 7

Mechanical diagram Mechanical diagram Mechanical diagram Mechanical diagram

with one-piece distribution tray with two-piece distribution tray with three-piece distribution tray with four-piece distribution tray

Length of distribution tray (total length of all trays) Finned length (length of heat exchanger coil) Length of distribution tray above connection chamber (connection side (ANS) in air direction (LR) right) Length of distribution tray above tube bend chamber (connection side (ANS) in air direction (LR) right) Cold room Wall or insulation Warm room RT>32 F Connecting tube and if applicable branch regulation valves and stop valves (mounted on site) Feed line always in middle Throttle valve mounted on site, no ball valve Soil filter

If the unit is operated at room temperatures < 32 F, one of the following measures has to be used to keep the piping of the defrost water feed line free of ice: The connecting tubes in the cold room (1) have to be sufficiently angled towards the distribution tray. The connecting tubes in the cold room (1) have to be sufficiently angled towards the warm room (3), and have to be equipped with an automatic drain of the tubes after each defrost cycle. Equip piping with permanent trace heating and insulation. The water defrost should be operated simultaneously with another type of defrost such as hot gas or glycol defrost.
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For wide units with several fans, the tray is assembled with several parts and consists of 1 - 4 individual segments. The precise amount of distribution trays is indicated in the drawings on page 6, in chapter 4.3. Each distribution tray has to be connected on site according to the drawings. The connecting piece for the defrost water feed line is consistently designed as a 1 copper thread connection (the stainless steel design can differ). It should be possible to undo the connection for cleaning and maintenance purposes. The pre-distribution provided on site to the individual trays has to be provided in such a way that an even distribution of the water volume flow is possible. If necessary, throttle valves have to be integrated in each branch. For recommendations concerning the water volume flow, see chapter 5.2. No soil particles may enter the distribution tray system. Appropriate soil filters have to be implemented in the feed line on site by the customer. 5.4 Defrost Water Drain The precise number of drip tray drains is specified in the drawing of the unit. Each drip tray drain is equipped with R 3" plastic screw threads that can be connected to the drain pipe. The incline and the tube cross section have to be designed in such a way that the cross sections of the tube system is large enough for the volume flow of the defrost water and the ice water. At RT < 32 F, heating has to be installed for the drain pipes and the piping has to be insulated. The drain pipes are designed for the maximum water flow rates. For the recommended defrost water volume, please refer to chapter 5.2. Drip Tray Drain [pieces] x [size] 1 x 3 2 x 3 3 x 3 4 x 3 Inside Diameter [pieces] x [size] 1 x 3 3/16 in diameter 2 x 3 3/16 in diameter 3 x 3 3/16 in diameter 4 x 3 3/16 in diameter Max. water flow rate [gpm] 48.43 96.86 145.3 193.73

Note: The water flow rates are calculated for non-pressurized drains (w = 0.6 m/s).

5.5 Position the refrigerant distributor(s) This paragraph only concerns evaporators with refrigerant distributor(s). The refrigerant distributor(s) for evaporators have to be positioned in the connection chamber where the water defrost is effective. This means the distributor must be in direct contact with a sufficient amount of defrost water. The ice that is formed during refrigeration has to be completely defrosted during the defrost phase.

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6. Information for operation


6.1 Defrost Water Quality The water that is used for the water defrost has to possess the following properties: Property Appearance Color Odor Microbiological purity Temperature pH value at 68 F El. conductivity (77 F) mS/m El. conductivity (77 F) mS/m Alkaline earths (Ca2+, Mg2+) mol/m Total hardness dGH Chloride (Cl- ) g/m Sulfate (SO42-)g/m Desired Quality clear, without sediments, free of suspended solids and particles colorless odorless drinking water quality 50 - 86 F F 6.5 - 8.3 < 10 (Is this correct?) < 100 (Is this correct?) < 0.05 < 0.25 < 10 < 15

6.2 Defrost water volume flow Water flow rate (defined value) per m coil and chamber surface: 5.6 [m/(hxm)] Example: L finned = finned length T finned = finned width L connection chamber (L3) L tube bend chamber (L4) = 1600 mm = 400 mm = 200 mm = 100 mm = 1.6 m = 0.4 m = 0.2 m = 0.1 m

Note: For this calculation, only the area of L connection chamber (L3) and L tube bend chamber (L4) above the bare coil is considered. The defrost water is distributed in this area. See drawing on page 6, chapter 4.3 Area connection chamber + Area bare coil + Area tube bend chamber = Total covering area (0.2 m x 0.4 m) + (1.6 m x 0.4 m)+ (0.1 m x 0.4 m)= (0.2 m + 1.6 m + 0.1 m) x 0.4 m = 0.94 m Total volume flow = 5.6 m/(hxm) x 0.94 m = 5.26 m/h 1 m/h = 4.4 gpm If a volume flow meter or volume sensor is installed in the feed line for the defrost water, this meter should be used to adjust the design value. When using a volume sensor, e.g. a water meter, it is additionally necessary to measure the time with a stop watch. If there is no possibility to measure the volume flow, the openings of the connection side and the tube bend side have to be opened and the water amount has to be adjusted in such a way that it is evenly distributed across the depth of the coil in air direction. If the set water amount
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is too low, the center of gravity at the outlet is in the middle and the danger of insufficient defrost exists especially in the air inlet area. If the water amount is too high, this leads to disproportionate water distribution at the edges which results in water leaking into the unit from the heat exchanger coil. Another result is that the ice in the middle of the coil defrosts slower than the edges. Additionally, the water amount must be enough so that the defrost water, that gathers in the bottom drain tray, reaches the level of the baffle plates. This means that some of the water drains off via the baffle plates.

7. Maintenance and cleaning


For general maintenance and cleaning of the unit, please observe Chapter 7 of the main operating instructions of the unit.

For maintenance or cleaning of the defrost water distribution system, the system can be disassembled from the main unit. At first the feed lines have to be disconnected. Then the two screw connections of the angle brackets at the side of the drip tray cover have to be unscrewed. For unscrewing the screw connections, the doors of the connection and tube bend side chambers have to be opened. If the tray consists of several parts, the screw connections of the center bracket(s) also have to be unscrewed. Now the tray can be lifted from the front and the back guide rails and then be turned and removed.

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Defrost water distribution system 1 Connecting pipe for defrost water supply line 1 (AC: 239) 2 Distribution tube (pressure distribution over width of coil) 3 Intermediate distribution sheet (slots parallel to coil depth) 4 Distribution tray (slots parallel to coil depth) 5 Drip tray cover 6 Support for distribution tube (2) 7 Cladding sheet 8 Polyform cushion

The distribution sheet can now be opened. For disassembly, all screw connections of the cover (5) have to be removed. If all single parts, such as the distribution tube (2) need to be cleaned then the cladding sheet will need to be removed. Note: The evaporator or air cooler does not function without distributor tray(s)! Without the distribution trays the unit would draw infiltrated air that does not flow across the heat exchanger coil as intended. The parts of the defrost water distribution system can now be cleaned and descaled. Clean outlet openings of the distribution tube (2) are import for even water distribution. For material tolerance, please observe the general unit operating instructions, when selecting and using detergents. Only use detergents that are neutral and not corrosive to the materials used! After the cleaning of the component parts the distribution tray has to be mounted as follows: Place the intermediate distribution sheet (3) into the outer distribution tray. Place the distribution tube (2) into the supports provided for this purpose (6) and screw the cladding sheet (7) to the distribution tray. Now the polyform cushions (8) have to be inserted and the drip tray cover (5) has to be screwed in place. When placing the distribution tray on the unit, please observe that it has to be positioned very precisely into the designated area.
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Before re-setting to refrigeration mode, no residual water may be left on any inside or outside sheet metal parts, because otherwise this can lead to the formation of ice particles and can result in further damage.

8 Defrost process
8.1. Defrost cycle The operator of the installation has to determine the defrost cycle (intervals for defrost). For example; twice a day, or once a day, or every two days, etc. The defrost cycle is mainly determined by: Specific Installation Parameters (the larger the difference between air inlet temperature and evaporating temperature, the shorter the defrost intervals) Goods to be cooled (packaged or unpackaged) Intervals of charging and withdrawal (and also the operating time per day or operating time on weekends) The moisture entering the room from the products to be cooled and through the opening of doors. Arrangement of pre-cooling room (with or without dehumidification of refrigerated goods) Arrangement of hot air curtain Each unit will have their own defrost cycle even if they are in the same room due to the different proximity to the doors. The defrost cycle has to be optimized on site by the plant contractor or operator. But it can also be adapted optimally to the refrigeration operation by an intelligent and adaptive defrost control system, especially for changing intervals of charging and withdrawal. All control devices, that regulate the defrost process; have to be installed by the operator. 8.2. Defrost process The operator is obliged to control the defrost process in such a way, that it can be ensured that the defrost process is entirely completed, i.e. that there are no ice residues in the heat exchanger coil or on any structural parts of the casing. During at least the first five defrost phases after commissioning (stationary operation), the operator is obliged to correct the defrost process accordingly via the control devices by adjusting the corresponding parameters (volume flow of defrost water and temperature) to ensure a complete defrost process. The operator is additionally obliged to check if the defrost process is complete and that there are no ice residues every month. An additional control is necessary if the operating conditions for the selected defrost process has been changed. The non-observance of these obligations leads to termination of the warranty claim.

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8.3 Visual inspection of the defrosting process The defrost procedure has to be monitored during the first operating phases of the refrigerating installation and it has to be checked that no ice residues are left after the defrost process. After the defrost process, the unit must be visually inspected to confirm that the unit has been defrosted completely: The defrost processes have to be controlled in such a way that only frost is left on the surface of the heat exchanger coil. The heat exchanger coil has to be thoroughly checked for ice particles. A strong light with a directed beam of light is necessary for this inspection. A strong formation of residual ice, especially on the evaporator tubes, can destroy the heat exchanger coil and can lead to refrigerant leaks! The space below the heat exchanger coil and the tray also need to be free of any ice. The defrosting process must be completed in the maximum defrost time. If necessary, contact the manufacturer. If the humidity in the casing is too high after the defrost process (vapor or increased formation of condensate on the inside walls of the casing) the defrost temperature has to be decreased, but only so far that a complete defrost process is still guaranteed. Too much humidity can reduce the life of the bearings and electrical parts.

Note: All of the information in this manual is subject to technical amendment without prior notice.

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