HOW TO DETERMINE THE HIGHEST APPLICABLE CATEGORY OF THE
PRESSURE EQUIPMENT
Consider the volume, the pressure PS and the usable fluids in the nameplate:
PRESSURE
USABLE
FLUIDS
VOLUME
Multiply the volume (L) of each cicuit by the pressure PS (bar)
n = V * PS
In order to find the highest applicable category compare n with the values in the table below
n < 25 fluid gr.1 – not CE* ; fluid gr.2 - not CE*
25< n <50 fluid gr.1 - cat I ; fluid gr.2 - not CE
50< n <200 fluid gr.1 - cat. II ; fluid gr.2 - cat. I
200< n <1000 fluid gr.1 - cat. III ; fluid gr.2 - cat. II
1000< n <3000 fluid gr.1 - cat. IV ; fluid gr.2 - cat. III
n > 3000 fluid gr.1 - cat. IV ; fluid gr.2 - cat. IV
* art. 3 par. 3 97/23/EC
where
Fluid group 1: NH3
Fluid group 2: HFC, CFC, HCFC
NB: The calculation finds out the highest category of the hat exchanger by considering the max
allowable pressure written in the nameplate
To calculate the effective category please consider the pressure value declared for the plant.
16
1. PRELIMINARY REMARKS
This Operating Instructions book must be kept in good conditions and in a place easily accessible
from the assigned personnel.
• This Operating Instructions book does not relieve of respecting the laws in force regarding
safety and accident - prevention rules.
• ONDA S.p.A. DECLINES ALL RESPONSABILITY in case of:
Ö Inadequate use of the pressure equipment;
Ö modifications to the pressure equipment;
Ö breach of laws in force regarding safety and accident - prevention;
Ö default of what written in this Operating Instructions book.
2. INTRODUCTION
The main applications of our dry-expansion Evaporators are the water chilling in air conditioning
plants, the liquid or brine solutions cooling in refrigeration plants and the hot water production in
heat pumps.
Water cooling occurs as a consequence of the evaporation of the refrigerant inside the evaporator.
Inside the tubes the refrigerant evaporates with the cooling of the fluids flowing outside the tubes.
Heat transfer is favoured by the path of the secondary fluid throughout the bundle, created by
baffles inside the heat exchanger.
As water is one of the most used secondary fluid, we will write “water” instead of the words
“secondary fluid “ in the following pages.
The standard construction of ONDA Evaporators consists of: carbon steel for the header, tube
sheet, shell, refrigerant and the water connections; copper for the exchanger tubes, brass or
carbon steel for the baffles.
On request other materials can be used.
2.1 Water storage Evaporators
ONDA Shell and Tubes evaporators, compatibly with their length, can be fit in water accumulators.
Water accumulators are a water storage, allowing a more constant working of the plant.
The Water storages are made of carbon steel.
Refrigerant
The usable refrigerants are: HCFC, HFC, and others unless compatible with material construction.
Different refrigerants will yield different capacities under the same conditions.
Secondary Fluids
Heat exchanger’s performance depends on the type of secondary fluids as well.
If the evaporation temperature is less than O°C an antifreeze solution must be used.
Most common solutions are ethylene or propylene glycol type. Other types of solutions can be
used (brines) unless compatible with the material of construction of the heat exchanger.
Most common antifreeze solutions have higher density and viscosity than water.
Be advised that glycol solution’s viscosity changes as temperature changes, with a consequence
of an increase of pressure drop as temperature decreases.
17
3. MATERIAL INSPECTION
Before any operation on the Evaporator/Water storage Evaporator make sure the delivered
equipment is what you have ordered, verifying the correctness of the name plate.
In the standard Evaporators the name plate is located between the in/out water connections.
In the standard Water storage Evaporators the name plate is located on the fund of the
accumulators.
The model, the serial number of the Water storage Evaporator, the year of construction, the
maximum allowable pressure and temperature and the usable fluids are written on the name plate.
MODEL
SERIAL NUMBER
For any communication to ONDA S.p.A. we recommend you to report us always the serial number
written in the position as in the figure. The serial number, in fact, identifies definitely your own
equipment and allows a faster search for all the information you might need.
3.1 Documents
The Heat exchanger is always provided with this Operating Instructions book.
4. MOVEMENT AND TRASPORTATION
ONDA Evaporators/Water storage Evaporators are delivered on wood pallets or crates. In
conformity with the laws in force in your country, the packaging material must be recycled or
treated as waste material.
LIFTING AND TRANSPORTATION MUST ALWAYS BE DONE BY
EXPERT PERSONNEL.
Verify on the catalogue the dimensions and the weight of the Evaporator/Water storage Evaporator
in order to choose a suitable system of lifting.
An harness - of steel, chain or synthetic fibre - resistant to the load to move, can be used (see
appendix 13.1 for the location of the centre of gravity CG).
The figure below has representative character only.
18
ATTENTION: THE CENTRE OF GRAVITY IS LOCATED ON THE
HEADER’S SIDE OF THE HEAT EXCHANGER
Evaporators/Water storage Evaporators have connections leaning from the equipment. We
recommend, therefore, to be careful during the moving not to lead to damages to the leaning parts.
Before moving, be sure the paths inside the building are suitable to the dimensions of the pressure
equipment.
Use, if present, the lifting lugs to move and to lift the heat exchanger.
ATTENTION: DO NOT MOVE THE EVAPORATOR UNDER
PRESSURE
5. STORE
The Evaporator/Water storage Evaporator must be stored preferably indoors.
If the Evaporator/Water storage Evaporator is stored (see 5.1) outside the sunlight and the cooling
during the night time may cause the formation of damp inside the heat exchanger and of the
plastics of the package, if present.
Internal parts are, at any rate, protected by plastics plugs. Before storing make sure a plug is fitted
onto each connection.
5.1 Rust prevention
The ONDA Evaporators/Water storage Evaporators’ external surface is protected by a rustproof
primer.
This type of painting is igroscopic and must be completed with a final treatment. It is suitable to any
commercial finishing painting and adhesive for possible isolations. To avoid, therefore, the
formation of rust preserve the ONDA Evaporators/Water storage Evaporators from the atmospheric
agents or protect it with special finishing painting.
6. INSTALLATION
IT IS FORBIDDEN THE USE OF THE PRESSURE EQUIPMENT TO
PEOPLE NOT DUTY INSTRUCTED
After unpacking be sure of the integrity of the pressure equipment; do not use in case of doubt and
contact ONDA S.p.a..
Installation must allow maintenance and clearness.
In case of outdoor installation (see 5.1), protect the pressure equipment from accidental impacts.
19
Install the Evaporator/Water storage Evaporator in horizontal position. A slope may cause changes
in the performance of the heat exchanger.
6.1 Evaporator connections
The correct use of connections is described in the appendix (13.1, fig. 1, fig.2).
Number Connection
1 REFRIGERANT INLET
2 REFRIGERANT OUTLET
3 WATER INLET
4 WATER OUTLET
5 AUXILIARY SOCKET
6 PURGE
7 NAMEPLATE
6.1.1 Refrigerant Side
The number of refrigerant’s circuits can vary from 1 to 4.
../1 circuit .. / 2 circuits .. / 3 circuits ../4 circuits
The location of the inlet/outlet can also vary depending on the number of refrigerant’s passes.
For each circuit the refrigerant inlet must be in the lower connection of the header, the refrigerant
outlet must be in the higher one.
Depending on the model Refrigerant side connections may be soldering, Rotalock or flanged type
(see Appendix 13.2).
The Evaporator/Water storage Evaporator is provided with plastics plugs for the protection from
damp.
Absorbent fillers with igroscopic salts are present in each circuit of Evaporator.
Before installation remove the plastic plugs and the absorbent fillers.
6.1.2 Water side
The water connections standard position is vertical, but on request can be placed horizontally, at
right (DX) or left (SX), side when facing the refrigerant header.
For each model the water inlet is located close the header, the water outlet is located close to the
fund of the evaporator.
Depending on the models water side connections may be ISO 228/1 (pipe threads where pressure-
tight joints are not made on the threads), flexible coupling type (Victaulic) or flanged (see Appendix
13.2).
The coupling and pipes Victaulic, in the case of flexible coupling connections, and the flanges in
the case of flanged connections, can be delivered as a kit not assembled on the evaporator.
20
Flexible coupling connections are not possible for Design temperature below –10°C
Kit Victaulic
Kit Victaulic have 2 coupling connections, with EPDM gaskets inside, and 2 to pipes to be
connected (see Appendix 13.2).
To assembly Kit Victaulic:
- Loosen the coupling connection and extract the gasket.
Fit the gasket between the soldered connection of the evaporator and the pipe, after you have
cleaned the surfaces. It is useful to wet the gasket’s surfaces with water or oil, unless it is
compatible with the gasket’s material.
- Tighten the coupling connections after you have verified the correct position of the gasket to
avoid leakages and break-ups.
Kit Flanges
Flanged connections are provided with pipes to be connected, gaskets and screws.
6.2 Water storage Evaporator connections
The correct use of connections is described in the appendix (13.1, fig. 3)
Number Connection
1 REFRIGERANT INLET
2 REFRIGERANT OUTLET
3 WATER INLET
4 WATER OUTLET
5 SAFETY VALVE
6 ELECTRICAL RESISTANCE
7 THERMOSTAT
8 AIR VENT
9 PURGE
6.2.1 Refrigerant side
See 6.1.1
6.2.1 Water Side
Inlet and outlet water connections are located at the fund of the accumulators.
Depending on the models water side connections may be threading inside or flexible coupling type
(Victaulic). For accumulator working at low temperature threading or flexible coupling connections
are available.
The coupling and pipes Victaulic, in the case of flexible coupling connections, and the flanges in
the case of flanged connections, can be furnished not assembled on the evaporator as a kit (see
6.1.2).
6.3 Protection from vibrations
We recommend to avoid the transmission of vibrations to the Evaporator through antivibrating
systems. Vibrations can, actually, cause damages to the equipment.
6.4 Insulation
Make removable the thermic insulation, if foreseen, for pressure equipment inspection.
21
6.5 Heating Protection
The permanent joints of connection, obtained by soldering or brazing must be made with adequate
heat protection systems; an extreme exposition could damage the; an extreme exposition could
damage the Evaporator.
6.6 Static Electricity
Precautions have to be taken in order to avoid the accumulation of static electricity (CENEL Report
R044-001).
All metallic parts of the equipment should be connected together and earthed.
6.7 Warnings
• Do not expose the Evaporator to localized solicitations due to supports (different from the
mounting feet), stiffening and connection pipes.
• Do not expose the Evaporator to dynamic loads and/or localized: the dynamic overpressure and
the ram-stroke could damage it.
• Do not expose the Evaporator to bending stress.
• Always foresee a filter before the water inlet connection of the Evaporator.
• Prevent freezing inside the heat exchanger using suitable safety systems (e.g. flow switch or
different pressure switch).
• Do not install any kind of variable by-pass (such as flow deflectors, filters etc) inside the pressure
vessel.
• Foresee a higher pressure in the outlet water side to avoid the entrance of air in the water circuit.
• Devices for the regulation of water flow rate have to be installed in the outlet of the Evaporator.
7. COMMISSIONING
Test all the connections.
Purge completely the air from the Evaporator/Water storage Evaporator during the filling through
the proper purge connection (see 13.1). During the work the presence of air can cause damages to
the equipment.
Before use, analyse the refrigerated water/antifreeze solutions verifying the compatibility with the
materials used for the Evaporator/Water storage Evaporator. The incompatibility with the material
of constructions can cause corrosion to the tubes, the baffles and the shell of the Evaporator.
Excessive water hardness can cause the formation of deposits on the external surfaces of tubes
and the consequent lost of performance.
8. USE
DO NOT EXCEED THE MAXIMUM ALLOWABLE PRESSURE (PS)
AND TEMPERATURE (TS) LIMITS WRITTEN ON THE NAMEPLATE
DO NOT EXCEED THE MAXIMUM FLOW RATE
For a correct use:
• Respect the value of velocity calculated by our selection program. Excessive flow rate increases
tubes’ consumption.
• Do not expose the Evaporator to any kind of excessive vibrations.
• Avoid foreign particles entering into the pressure equipment.
22
• Avoid the cavitation of the pump and the presence of gas in the hydraulic circuit.
• Do not expose the Evaporator to pressure or temperature fluctuations.
• Do not expose the pressure equipment to cyclical constant or variable loads.
• Use only water or brine solutions compatible with the materials of the Evaporator.
• Avoid the outlet of water from the Evaporator/Water storage Evaporator at the surrounding
pressure.
9. MAINTENANCE AND CONTROLS BY THE USER
FOLLOW WHAT PRESCRIBED BY THESE OPERATING
INSTRUCTIONS. DO NOT OPEN THE EVAPORATOR UNDER
PRESSURE.
• If Ammonia (R 717) in used as a refrigerant be careful to air-vent and drainage. Ammonia is
toxic.
• Use, when necessary, inhibited brine solutions and verify them periodically avoiding their contact
with the air. If such solutions are used be careful during the use verifying toxicity/danger.
9.1 Water quality
Water quality, as regard as chemical composition (salinity, pH), quantity of suspended solids,
dissolved oxygen content and biological fouling (bacteria, algae and macro organisms) is very
important for the performance and the life of the heat exchanger.
Because of the chemical compounds in solution or in suspension in the water, a layer of deposits
may form on the external surfaces of the tubes of the Evaporetor. The layer, that might form,
reduces heat transfer, decreasing the heat exchanger’s performance.
The quality of the water can influence both the performance and life of the heat exchanger.
Herewith we report some of the main factors that influence water quality:
Saliniy: An increase of salinity causes an increase of electric conductibility and therefore a
higher possibility of galvanic corrosion. Be advised that, if you use sea water, salinity’s values
change depending on the sea (i.e. salinity of Mediterranean Sea 25g/l, Persic Gulf 44g/l,
Baltic Sea 7,8 g/l)
pH: pH is normally on values around alkalinity (7,4 ÷ 8,4). For a correct work such values
have to be maintained.
Dissolved Oxygen : An increase of the dissolved oxygen content in water increases
corrosion.
Biofouling: it includes macrobiological fouling (invertebrates/plants). Biofouling can create
anaerobic conditions and make the attack of sulphate-reducing bacteria possible as well as
differential aeration conditions with the consequence of localized corrosion and degrade of
protective films.
Suspended solids: Suspended solids can form deposits and sediments, which decrease
performances and erosion and corrosion..
The preview list considers only some parameters. The elements, that have been briefly described,
can be present together and lead to graver effects.
For all these reasons:
• Always install a filter in the water aspiration circuit, to reduce the entry of the solid particles, as a
possible cause of erosion and formation of deposits.
• Do not clean the evaporator with not suitable mechanical systems, e.g. drills or too high
pressure jets.
23
• Do not clean with too aggressive chemical detergents. Before using any kind of detergent be
sure of its compatibility with the material of construction of Evaporator.
Drain totally the Evaporator with removable tube bundle before doing any maintenance
9.2 Gasket substitution and Assemblage of the header
• Be carefully during the moving of header of the Evaporator.
• Once the header is gotten off, the gasket must be replaced. First make sure you have a spare
gasket, which you can obtain from your ONDA dealer.
• Before apply the new gasket, remove all the traces of the old gasket and the dirt from the
surfaces, their presence can cause severe damages during the working of the evaporator.
• Before place the gasket on the header avoid any leakage from the gasket applying a thin coat of
adhesive on the gasket and on the furrows of the header (use Super Bond® 130 or similar).
• Contact ONDA S.p.A if you need further information.
• Put first the central screw, whenever present, applying a thin uniform coat of sealant (use Super
Bond® 415 or similar) then torque peripheric bolts in a criss-cross pattern as indicated in the
figure below:
• Torque to the values listed below for each size of header:
Ø Ø Screw Torque (Nm)
header
225
M12 90
270
340
420
520 M16 170
570
620
670 M 20 220
24
9.3 Summary of periodical checks
A series of checks and their frequency are present in the table below:
Frequenza
EVAPORATORS/ WATER STORAGE Quando
Periodica
EVAPORATOR necessaria
External inspection for contamination,
P
damage and corrosion
Control of anodes (if present)) P
Tightening of screws P
Water PH measurement P
Evaporation temperature measurement N
Super heating temperature measurement N
Water inlet/ outlet temperature
P
measurement
Pump P
Cleaning P
The User is responsible for the frequency of the checks. The frequency, in fact,
depends on the type of the plant and on the working conditions.
10. SAFETY
• Always install safety accessories in conformity with the essential safety requirements of the
national set of the rules of the country where the equipment is installed; a fire for external causes
produces the exceeding of the allowable limits for the pressure equipment.
• Do not expose the pressure equipment to any impact during the working.
• Do not do any welding on the body of the Evaporator.
• Do not use the pressure equipment for uses different from what prescribed.
• In case of leakage, stop immediately the working of the pressure equipment.
11. DISPOSAL
This pressure equipment contains recyclable materials; at the end of its useful life get information
about the laws in force in your country regarding recycling.
12. WARRANTY
A. ONDA S.p.A. warrants that the Products shall be free from defects in material and
workmanship for a period of 18 months from the date of the delivery.
25
Therefore, should ONDA S.p.A., within the warranty period, acknowledge and recognise in writing
the existence of the defects in the products and said defects be materially grounded, ONDA S.p.A.
shall, at its discretion, repair the defective Products at no costs for the Client or replace them by
delivering the substitutive products Ex works (Incoterms 2000) at ONDA S.p.A.’s premises.
ONDA’s facilities located at via LORD Baden Powell, 11 – 36045 Lonigo (VI).
B. Subject to loss of the warranty, notice of any defect shall be given by the Client in writing with
return receipt registered letter within, and not later than, 10 (ten) days from the date of receipt of
the products at the Client’s premises or in the different delivery place, previously indicated by the
latter.
Subject to loss of the warranty, notice of any latent defect of the Products by the Client shall be
given in writing, by return receipt registered letter, within and not later than 10 (ten) days from the
date of the relevant discovery. It is hereby understood that the burden of the proof of the date of
the discovery shall be borne by the Client.
C. ONDA S.p.A. also warrants that the Products are manufactured in compliance with the Italian
and European Laws and Regulations in force on the date of the confirmation by ONDA S.p.A. of
the relevant Client’s order. Unless otherwise expressly agreed in writings by the parties, Client
shall bear any other additional expenses related to the operations of repairing or replacing of the
defective products.
D. This warranty shall not apply should the defects of the Products be caused by:
• natural wear and tear;
• unauthorised repairs or modifications;
• unsuited use or application;
• thermal overexposure, also when occasional;
• electrical or mechanical over-stress;
• failure of respecting the functional and environmental parameters suggested by ONDA
S.p.A. for the correct use and exploitation of the products;
• installation of the products not in compliance with the technical specifications provided by
ONDA S.p.A.;
• any other cause due to the Client’s negligence or to occasional faults of the products as
consequence of mass-production procedures.
E. This warranty shall also not apply in case of:
• non compliance of the Products with Laws and/or Regulations in force in the place where
the Products are installed and/or assembled by the Client and/or in the place of their final
use, should the Client not expressly require the conformity of the Products to said Laws
and Regulations and not duly inform ONDA S.p.A. of their content before the date of
transmission of the latter's order confirmation.
• This limitation of the warranty is also applicable with reference to peculiar Laws and
Regulations valid and binding in States of the European Union independently of the
European Laws and Regulations.
F. In the case of non compliance of the Products with Italian and/or foreign Laws and/or
Regulations entered in force after the date of transmission of the order confirmation by ONDA
S.p.A., the replacement or any possible adjustment under warranty conditions will not be applied.
ONDA S.p.A. is, at any rate, not responsible for the use of the Products not conform to Italian and
foreign Laws and/or Regulations entered in force after the date of transmission of their order
confirmation by ONDA S.p.A.
G. The Client shall not sell or market Products not in compliance with the Laws and Regulations
mentioned under letter E-F above. In the negative, the Client shall keep ONDA S.p.A. harmless of
any damage or loss suffered by the latter, due to any third party's and/or authority's claim raised as
26
a consequence of the manufacture by ONDA S.p.A. of Products not in compliance with the above
mentioned Laws and Regulations.
H. Without prejudice to the application of DPR 224/1988 on product liability and liability for gross
negligence or wilful misconduct, ONDA S.p.A. shall never be liable for direct, indirect or occasional
damages which in any manner derived from defective products
27
13. APPENDICE/APPENDIX
13.1 USE OF CONNECTIONS
• EVAPORATORS
FIG. 1
FIG. 2
• WATER STORAGE EVAPORATORS
FIG. 3
28
13.2 TYPE OF CONNECTIONS
• CONNESSIONE A SALDARE/ SOLDERING CONNECTION
• CONNESSIONE ROTALOCK/ ROTALOCK CONNECTION
• CONNESSIONE FLANGIATA/ FLANGED CONNECTION
FLANGIA QUADRA/ SQUARE FLANGE FLANGIA CIRCOLARE/ CIRCLE
FLANGE
CONNESSIONE A GIUNTO FLESSIBILE (VICTAULIC) / FLEXIBLE COUPLING
CONNECTION (VICTAULIC)
29
ATTENTION
30
CONTIENE
DICHIARAZIONE DI CONFORMITA'
DECLARATION OF CONFORMITY INSIDE
Onda S.p.A. Via Lord Baden Powell, 11 36045 Lonigo (VI) ITALY tel. +39 0444720720
ISTRUZIONI OPERATIVE
OPERATING INSTRUCTIONS
EVAPORATORI A FASCIO TUBIERO
SHELL AND TUBE EVAPORATORS
EVAPORATORI A FASCIO TUBIERO ACCUMULO
WATER STORAGE SHELL AND TUBE EVAPORATORS
DECLARATION OF CONFORMITY
In comply with the Annex VII of the European Directive 97/23/EC
We hereby declare that the pressure equipments detailed below have been
designed, manufactured and tested
in accordance with the European Directive 97/23/EC:
(1) Type: Evaporator
(2) Commercial Name: TE, TBE, KTE, LPE, MPE
WT+TE, WT+TBE, WT+KTE, WT+LPE, WT+MPE
(3)Conformity assessment MODULE H 1 (Full quality assurance with
procedures followed: design examination and special surveillance of
the final assessment)
(4) Module H 1 certificate No. 1615 - 10/06/2005
(5) Notified Body: 0100, ISPESL
Dip. Omologazione e Certificazione
via Alessandria
220/E 00198 Roma (Italy)
(6) Technicalstandards used Raccolta VSR, S, M
for the design, production Rev.’95 – Ed. 1999
and testing
(7) Responsible signature authorized established
ONDA S.p.A.
within the European Community :
Manufacturer.
Onda S.p.A. Via Lord Baden Powell, 11 36045 Lonigo (VI) ITALY tel. +39 0444720720
Date of issue: 12/05/2006
Advanced Heat transfer Solutions
