Witt HDB Series User manual

TH. WITT Kältemaschinenfabrik GmbH
Lukasstrasse 32, D-52070 Aachen
Tel. [phone], Fax. [phone]
https://www.th-witt.com, [e-mail]
State of documentation: August 2019
3133-603_E_2019_08

Content
INTRODUCTION.................................................................................................................3
1.1 Intended use............................................................................................................................ 3
1.2 Safety Requirements............................................................................................................... 3
1.3 Disclaimer................................................................................................................................ 4
TERMS OF WARRENTY....................................................................................................4
TECHNICAL INFORMATION..............................................................................................5
3.1 Scope of delivery..................................................................................................................... 5
Optional scope of delivery................................................................................................................... 5
TECHNICAL DATA.............................................................................................................5
4.1 Materials.................................................................................................................................. 5
4.2 Zugelassene Medien ............................................................................................................... 6
4.3 Dimensions.............................................................................................................................. 6
4.4 Sectional Views....................................................................................................................... 6
4.6 FUNCTIONAL DESCRIPTION................................................................................................. 7
4.7 Oil collection tank and drain vessel ......................................................................................... 7
4.8 Oil collection and distribution vessel........................................................................................ 8
TRANSPORT AND STORAGE...........................................................................................9
ASSEMBLY........................................................................................................................9
COMMISSIONING ............................................................................................................10
7.1 Before commissioning.............................................................................................................10
OPERATION.....................................................................................................................10
MAINTENANCE AND INSPECTION.................................................................................10
OPTIONAL FILL LEVEL SENSOR ...............................................................................11
10.1 Mechanical installation............................................................................................................11
OPTIONAL CRANKCASE HEATER.............................................................................12
11.1 Mechanical installation............................................................................................................12

3 - Introduction -
INTRODUCTION
Please read the entire manual careful before selecting, installing, commissioning and servicing
the HDB.
1.1 Intended use
The HDB oil collector is used exclusively for collecting settling, insoluble refrigerant oil in refriger-
ant circuits. For low-temperature applications, the oil in the HDB can be heated up.
1.2 Safety Requirements
All the work carried out on refrigeration systems must be performedby qualified personnel, trained
in handling refrigeration systems. The safety regulations and accident prevention measures that
apply to the handling of refrigerants must be observed.
The applicable guidelines for setting up and operating refrigeration systems, e.g. EN 378, must
be observed. Thelegal regulationsgoverning the commissioning and operationof pressureequip-
ment valid at the site of the respective country must be followed. Under no circumstances may
temperature and pressure information specified on the nameplate and drawings be exceeded.
Pressure vessels that can be shut off by other parts of the refrigeration system must
be equipped with a pressure relief device to prevent an unacceptable increase in
pressure in accordance with EN 378.
Welding work must not be carried out on the pressure vessel (other than on the
designated connections), otherwise this will render the certificates invalid.
If an electric heating element is used, a qualified electrician must carry out the
electrical connection in accordance with the relevant safety regulations. It must be
taken into account that condensation will form on the surface of the HDB.
In order to protect people from burns or frostbite, a form of protection must be
provided depending on the temperature (below -10°C or above +60°C), e.g.
insulation.
The corresponding fire safety precautions must be taken to prevent the pressure vessel from
overheating.
The safety devices must be checked before commissioning the system. The safety devices must
also be inspected after the system is disassembled or after a reaction.

- Terms of warrenty - 4
1.3 Disclaimer
Even when using the pump for the intended purpose it cannot be entirely excluded that a danger
may remain during its working lifetime.
Translations have been made to the best of our knowledge. We are unable to accept any liability
for errors in translation.
We reserve the right to change descriptions, graphs and technical information due to future de-
velopment of the product.
TERMS OF WARRENTY
In order to avoid accidents and to ensure the safety of the system, no modifications or changes
may be made to the HDB that have not been expressly approved by TH. WITT KÄLTEMASCHI-
NENFABRIK GmbH.
All the information and instructions for the operation and maintenance of the pressure vessel are
made to the best of our knowledge, based our previous experience and knowledge.
All liability or warranty claims are excluded if:
•the references and instructions in the operating manual are not observed,
•the HDB, including its equipment, is not operated correctly, or it has been handled in a way
that does not correspond to the prescribed sequence,
•the HDB is used for purposes other than its intended use,
•safety devices are not used or are disabled,
•functional changes of any kind are made without our written consent,
•the relevant safety regulations and accident prevention regulations are not observed during
the operation of the HDB.

5 - Technical Information -
TECHNICAL INFORMATION
3.1 Scope of delivery
•HDB vessel made of steel, manufactured according to AD2000 and DGRL
•Connection DN40 for refrigerant / oil mixture (ON400)
•Connection DN25 for safety valve (ON610)
•Connection DN40 connection BDP / distribution (ON410)
•Connection DN25 for equalisation line/reserve (ON611)
•Connection G½" min and max. level + screw plugs (ON520/21)
•Oil drain plug with EA10GB/VA (ON500)
•SSV6 quick-closing valve connection to EA10 (loose)
•Thermowell G½" connection for optional electrical heater element (ON510)
•Mounting socketsM12 top/bottom
•Mounting brackets incl. fastening material
Optional scope of delivery
•Electrical heating elements 200 W
•Oil sensor G½“
with encased gasket
for installation into min/max connections
•Overflow valve
•BDP for automatic
oil return incl. connection valve
•EA10GBL/VA for the pressure gauge
•Pressure gauge with stand
TECHNICAL DATA
Total volume
[ltr]
39
Max. filling capacity
[ltr]
34
Usable volume
[ltr]
30
Test pressure
[bar]
42,6
Permissible operating
pressure
[bar +100°C / -10°C]
25
[bar -10°C / -60°C*]
18,75
4.1 Materials
Housing
1.4541 / 1.4301
Nozzles
1.4541

- Technical data - 6
4.2 Zugelassene Medien
The HDB is designed to be used with NH3 and the common refrigeration oils and can be operated
with these in compliance with the maximum permissible pressures.
4.3 Dimensions
The dimensions, year of manufacture, volume, maximum filling capacity, tare weight, pressure /
temperature range, group of fluids to be used and the materials used are specified in the drawings
and certificates of the order.
The pressure vessel must be protected from higher temperatures by suitable measures (setup,
insulation, etc.).
4.4 Sectional Views

7 - Technical data -
4.6 FUNCTIONAL DESCRIPTION
The HDB can be as a collection container for the refrigerating machine oil which settles in the
refrigerant separator.
4.7 Oil collection tank and drain vessel
To drain the oil, the shut-off valves (ON400 inlet
line) and (ON611 equalisation line) need to be
closed. Because of the heat input from the sur-
rounding environment, a pressure builds up in the
HDB which means the oil can be discharged
through the oil drainage valve (ON500) and quick-
closing valve. To speed up the process there is the
option of attaching a heating element (ON510). Af-
ter the oil has been drained, the shut-off valve
(ON400) and (ON611) need to be opened again.
The safety relief valve (ON610) must be used to
ensure that there is no impermissible increase in
pressure (above 25 bar) in the vessel. There is also
the option of using the gauge connection (ON520)
and (ON521) to check the oil level (MIN/MAX).

- Technical data - 8
4.8 Oil collection and distribution vessel
To use the HDB as an oil distribution
vessel (for returning the oil to the com-
pressor), you must use the functions
and controls of the distribution connec-
tions (ON410). (ON410) as described
in section 6.1. If there is not enough
pressure in the collection vessel to re-
turn the oil to the compressor, the oil
can also be driven out by means of a
hot gas connection set up by the cus-
tomer. Alternatively, the automatic oil
return system (BDP) can also be con-
nected to connection (ON410). In this
case the oil is also removed using
pressure (refer to the BDP operating
manual). The special procedures must
be observed when returning oil from
screw and/or piston compressors
(manufacturer's documentation). To
return the oil automatically, all the
valves can be equipped with actuators
and the optional level monitoring de-
vice (ON520 / min) and (ON521 / max)
can be used as an additional control
variable.

9 - Transport and storage -
TRANSPORT AND STORAGE
All openings (connections, etc.) are fitted with yellow plastic protective caps to prevent the entry
of water, dirt particles, etc.
It should be stored in a dry location and protected from dirt. If the HDB is to be stored for more
than two months or it has to be transported overseas, the HDB can optionally be filled with inert
gas to protect it for reasons of a possible condensate formation.
If the HDB oil collector has been filled with inert gas in the factory, the bleeder chokes must be
removed immediately before the HDB is incorporated into the refrigeration circuit. It is important
that no grinding chips ordirt get into the surface or into the HDB! If necessary, the pressure vessel
should be thoroughly cleaned inside and outside.
During transport, the mounting sockets M12 can be used together with an eyebolt –by way of
example. If other transport and lifting devices are used, it must be ensured that the vessel and
connections are not damaged / bent.
ASSEMBLY
Packing material and the yellow plastic protective caps used to protect all openings (connections,
etc.), must be removed immediately before assembly.
Please follow the instructions on the drawings relating to the order when assembling the system!
The refrigeration engineer responsible for the planning has to ensure that the necessary equip-
ment with safety devices and control elements is adapted to the individual requirements.
The HDB is designed to be installed in buildings. (Earthquakes, traffic, wind and snow loads are
not included in the statics). It is only possible to install the system externally with the written per-
mission of TH. WITT KÄLTEMASCHINENFABRIK GmbH.
Ensure there is sufficient space for inspections, maintenance work and insulation. The discharge
valves, safety valves and quick-release valves must be easily accessible.
All the exhaust lines must be routed in accordance with the recognised rules of
engineering (e.g. EN 378) so that nobody is put at risk.
It is important to ensure that the inlet of the separator is placed at the lowest point of
the separator so that the oil can flow freely to the HDB.
When welding the piping to the connections (or valves) provided for this purpose,
ensure that the installation is not under and strain or stress!
No additional forces may be applied to the connections or the HDB.
If a heating element is used, then thermal transfer paste should be used to improve
the transfer of heat.

- Commissioning - 10
COMMISSIONING
Die Inbetriebnahme desHDB darf erst erfolgen, wenn eine Sicherheitsanalyse der Gesamtanlage
vorgenommen wurde.
7.1 Before commissioning
After it has been assembled, the entire pipeline system must undergo a thorough visual inspec-
tion. All the screwed and flanged connections must be tightened. A leak and pressure test must
then be carried out and documented. At this stage, particular attention should be paid to the
welded seams created after the factory test and to any flanged or screwed connections.
Before commissioning it must be checked, in particular, that:
•all the piping has been connected according to the technical drawings
•the necessary safety devices have been installed and tested
OPERATION
The HDB may only be operated within the range of its design data.
The pressure relief device must be set up and adjusted according to the rules and standards /
local regulations (this mustnever exceed the max. permissible pressure asspecified on the name-
plate!)
The pressure device is designed for predominantly static pressure loads with a maximum of 1000
full load changes. The range of the change in pressure must not exceed 10% of the maximum
permissible pressure.
Regularly check that the safety valve (ON610) is working properly! This is particularly
important before the oil drains through the quick-closing valve in order to avoid risks
and injuries.
MAINTENANCE AND INSPECTION
The inspection of the HDB, includingthe safety devices attached, must be carried out on a regular
basis in accordance with the applicable legal provisions and/or regulations and technical rules
and standards.
If maintenance workhas to be carriedout on the HDB, the pressure must be released
from the system and the refrigerant must be completely sucked out before any
screwed connections are loosened. Under no circumstances must you remove all
the screws when any refrigerant or pressure is still in the system.
The HDB has to undergo, for example, a visual inspection on a regular basis, in
accordance with DIN EN 378-2. (This includes, for example, an external visual in-
spection for corrosion.)