MANUAL. for installation and start up of cooling hydraulic module HMC30 MkI

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1 MANUAL for installation and start up of cooling hydraulic module HMC30 MkI IM HMC30MkI EN

2 Table of Contents General information Main parts of hydraulic module Overall and mounting dimensions..4 Legend and specifications. 5 Storage and handling Safety requirements Installation and connection Installation of hydraulic module Prior to connection Connection of primary and secondary circuits...9 Filling of primary and secondary circuits...10 Balancing of hydraulic system Warranty Warranty terms and conditions IM HMC30MkI EN 02

3 General information Main parts of hydraulic module (heat insulation is not shown) Balancing valve of primary circuit Connection flanges 3-way valve Heat exchanger Expansion tank Pump Balancing valve of heat exchanger Drain valve of secondary circuit feed line Pump drain valve Drain valve of primary circuit feed line Balancing valve of secondary circuit IM HMC30MkI EN 02 3

4 Overall and mounting dimensions (heat insulation is not shown) To cooling heat exchanger of ventilation unit (Х12, +7 С) To plant network of chilled water (Х21, +8 С) From cooling heat exchanger of ventilation unit (Х22, +12 С) From plant network of chilled water (Х11, +3 С) DN80 - To ventilation unit (supply of secondary circuit) DN80 - From plant network (supply of primary circuit) DN80 - To plant network (return of primary circuit) DN80 - From ventilation unit (return of secondary circuit) kg 4 IM HMC30MkI EN 02

5 Legend HM C 30 MkI Generation Size Type (Н heating, С cooling) НМ hydraulic module Specifications Module specifications are listed in metal nameplate on its frame: IM HMC30MkI EN 02 5

6 Storage and handling Store hydraulic module in dry and dust-free place. Handle hydraulic module only in vertical position on wooden pallet using a fork truck. Never use the frame or other parts of module for this purpose. Unpacked module shall be handled using a properly operating palette jack. All handling operations shall be performed with care. Fall of module may result in its damage and personal injuries. Module with mechanical damages will not be covered by warranty. Safety requirements Hydraulic module shall be installed in sufficiently firm and even floor. No mechanical forces shall be transmitted to the module by adjacent equipment and pipelines. Never make any modifications to the module. Never use any part of module to attach other equipment or pipelines. Installation and start-up operations shall be performed by qualified persons instructed on safety issues. These persons shall be provided with protective clothing, tools in good working conditions and required protective equipment. Any installation and start-up operations shall be performed in accordance with Consumer s Electrical Installations Operating Regulations, Safety Rules for Operation of Pressure Pipelines and Consumer s Steam Pipelines, rules of Gosenergonadzor and Rostekhnadzor, as well as other regulatory documents. Prior to any installation, dismantling and repair operations switch out power supply of control cabinet, shut off connection valves and drain heating medium. Connection valves and power switch of control cabinet shall be locked according to LOTO requirements. During high pressure tests and first start-up of the installed module the personnel shall be located at a safe distance from the module. 6 IM HMC30MkI EN 02

7 Installation and connection Installation of hydraulic module Remove the packing. Check the module for external damages. Verify the sensors according to packaging list. If any fault or missing part is detected, please contact Supplier immediately. All parts of hydraulic module shall be accessible for maintenance. This requirement shall be taken in account when choosing a place for installation. In case of installation in an elevated platform, a safe access and a space required for maintenance in these conditions shall be provided. Heating hydraulic module Control cabinet Cooling hydraulic module AHU30 ( m 3 /h) Air supply to premise Inlet air Heat recovery exchangers Outlet air Air intake from premise Cooling hydraulic module HMC30-MkI (end view) Control cabinet ATM30 (end view) IM HMC30MkI EN 02 7

8 Prior to connection Check that plant chilled water network pressure is below maximum allowed value specified in the nameplate for primary circuit. Choose the frame height above floor according to the plant standards. Level the module horizontally using adjustable feet of the frame. Ensure that the pipelines to be connected are securely fastened and not stressed. This will allow to avoid damage of module parts and personal injuries. Close drain and connection valves, as well as expansion tank valves IM HMC30MkI EN 02

9 Attention! Ensure that the section to be connected is: Isolated by isolation valves locked according to LOTO requirements Does not contain heating medium (drained) and is not pressurized Has normal temperature Connection of primary and secondary circuits Connection shall be done using included loose flanges DN 80 PN 10 made of AISI 304 steel. When connecting the circuits, take care of the flow direction (supply and return). 1. Connect primary circuit of hydraulic module to the plant chilled water network. 2. Connect secondary circuit of hydraulic module to the cooling heat exchanger of ventilation unit. 3. Ensure that all connections are properly tightened. 4. Check flow directions in the primary and secondary circuits against arrows on the nameplate of hydraulic module. Supply of secondary circuit (Х12, +7 С) Return of primary circuit (Х21, +8 С). Service side Return of secondary circuit (Х22, +12 С) Supply of primary circuit (Х11, +3 С) IM HMC30MkI EN 02 9

10 Filling of primary circuit 1. Open ventilation valve on the top point of primary circuit return pipeline. 2. Open valve of primary circuit return pipeline. 3. Slowly partially open supply valve of primary circuit. Fill the circuit slowly to avoid pressure surges. 4. When water arrives at the ventilation valve, close it and fully open supply valve of primary circuit. Filling of secondary circuit 1. Check pressure in the expansion tank using a car pressure gauge. The measured value shall be equal to 2 bar. In case of higher pressure reduce it by pushing the nipple. In case of lower pressure use a cycle pump or a car compressor. 2. Open ventilation valve on the top point of secondary circuit return pipeline. 3. Open valves of supply and return pipelines of secondary circuit. 4. Connect pressurizing pump to the drain valve of secondary circuit supply line. Open this valve. 5. Fill secondary circuit and air heater of the supply and exhaust ventilation unit by 40% propylene glycol solution until it arrives at ventilation valve. 10 IM HMC30MkI EN 02

11 6. Close ventilation valve on the top point of secondary circuit return pipeline. 7. Open valve of expansion tank and lock the handle in open position. 8. Continue filling until 2 bar pressure is reached. 9. Close drain valve of secondary circuit feed line. 10. Install plugs on valves Note: After connection of electric system and start of circulation the volume of heating medium will slightly decrease due to cooling. So, when commissioning is completed, additional volume of heating medium shall be added to secondary circuit until it's pressure reach 2 bar. When system is filled with heating medium, the hydraulic module and air heater shall be maintained at working pressure during 1 hour to check tightness. If no leakages or heating medium traces are detected, the electric system could be connected. Balancing of hydraulic system Balancing of hydraulic system shall be performed after completion of commissioning by a serviceman of OOO SK CO-Vostok with the use of special equipment. IM HMC30MkI EN 02 11

12 Warranty Warranty terms and conditions The Warranty is subject to conditions stated in this Manual. The Manual contains information required for correct installation and start-up of hydraulic modules. To avoid Warranty cancellation, read this Manual prior to start working. Hydraulic modules are manufactured and tested in the factory and supplied completely assembled and ready for connection. Disassembled, modified and mechanically damaged modules are not covered by the Warranty. The manufacturer declines any responsibility for hydraulic module failure, damage to property or damage to human health, resulted from failure to observe the rules of installation, commissioning and operation stated in this Manual. Specifications of hydraulic modules may be modified by the manufacturer without prior notice. 12 IM HMC30MkI EN 02

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