ECRE cascade cooler
Installation, operation and maintenance manual EN
Vessel manual – ECRE cascade cooler
0011001 en 2022.04 3/9
Cascade cooler, design type ECRE
Cascade cooler, design type ECRE
The vessel is a horizontal cascade cooler of the “plate and shell” type. It is equipped with an in-
ternal liquid separator and finalised with welded heads. The vessel is used as a component for
HeatPAC, PAC and DualPAC chillers.
The cascade cooler is a fully welded plate heat exchanger where plates are welded together
into cassettes. The refrigerant from the primary circuit (heat pump) evaporates between the
two welded plates which make up the cassettes. The refrigerant droplets are separated from
the vapour in the separator room above the plates.
Function
The discharge gas from the secondary circuit (refrigeration plant) is cooled and condensed in-
side the cassettes.
The upper connection (DN100) is the discharge gas inlet and the bottom connection (DN100)
is the liquid outlet. A cascade cooler minimises the refrigerant charge and eliminates problems
when mixing different oil types.
There is very little volume on the condensing side, which makes the cascade evaporator very
sensitive to non-condensable gasses.
A by-pass with a 2 mm orifice must therefore be installed between the liquid outlet connection
and the low-pressure side of the refrigerant plant. Alternatively, an automatic purge system for
non-condensable gasses can be installed.
The cascade cooler has one or two sets of secondary refrigerant connections depending on
size and operating conditions.
A sight glass is mounted at the end cover.
Note: The refrigerant liquid level must never be visible in the inspection glass.
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Application
Application
Refrigerant R717, (R507, R134a, R22, R404 or R410A)
Ambient temperature 0 – 55 [°C]
Capacity 55 – 1800 [kW]
Temperature sides
- Evaporator Tmin = –40[°C] | Tmax =150 [°C]1
- Secondary side Tmin = –40[°C] | Tmax =150 [°C]
Pressure
- Shell side
Normal version
High pressure version
Pmax = 22.0 [bar ] | Pmin = –1.0 [bar]
Pmax = 26.0 [bar ] | Pmin = –1.0 [bar]
The pressure of your specific vessel is stated on
the name plate sketch delivered with this manual.
- Plate side
Normal version
High pressure version
Pmax = 22.0 [bar ] | Pmin = –1.0 [bar]
Pmax = 26.0 [bar ] | Pmin = –1.0 [bar]
The pressure of your specific vessel is stated on
the name plate sketch delivered with this manual.
Function Flooded evaporator (outside)
Condensation (inside)
1The operating temperature must not be less than the compressor oil temperature corre-
sponding to a maximum dynamic viscosity of ν = 3000 [cSt]. E.g. PAO68,ν=3000[cSt] = –25[°C].
Designation code
Materials
Description Material
Shell P265GH EN10028-2
End cover P295GH EN10028-2
Plate stack AISI 316L DIN 17440
Connections P265GH EN 10028-2 / S235JRG2 EN10025-2
E C R E 7 0 0 9 0 2 2 Number of passes on brine side
090 Number of cassettes in plate stack
70 Nominal element diameter [cm].
E Type designation
R Stainless steel plates
EC Evaporating outside / Condensing inside
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Dimensions
Dimensions
ECRE cascade cooler
1 Mixture inlet, primary side DN 40
2 Gas outlet, primary side DN 125
3, 3a Discharge inlet, secondary side DN 100
4, 4a Liquid outlet, secondary side DN 100
5Safety valve DN 25
6 Oil return DN 25
7 High-level switch G 1
8 Sight glass mm Ø 45/90
A Vessel length mm 300–1800
B Vessel diameter mm Ø 703
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Dimensions
Pos. no. Flange no. Description
1 2342.1002 Flange DN 40
2 2342.260 Flange DN 65
2 2342.261 Flange DN 80
2 2342.1011 Flange DN 100
2 2342.261 Flange DN 125
3, 4 2342.275 Flange welding, DN 100
3a, 4a 1344.388 Flange blind, DN 100
51344.122 Flange DN 25
6 1344.122 Flange DN 25
8 1226.008 Fusite
Pos. no. Gasket no. Description
1 1331.566 O-ring 66.27x3.53
2 1331.588 O-ring 164.69x3.53
2 1331.588 O-ring 164.69x3.53
2 1331.588 O-ring 164.69x3.53
2 1331.588 O-ring 164.69x3.53
3 1331.703 O-ring 126.59 x 3.53
4 1331.703 O-ring 126.59 x 3.53
52356.258 Gasket 39/29x2
6 2356.258 Gasket 39/29x2 2pcs.
8 1331.543 Ring 52x2
Pos. no. Bolt no. Description
1 1424.1009 M16x2x45 4 pcs.
2 1424.320 M24x3x50 4 pcs.
2 1424.320 M24x3x50 4 pcs.
2 1424.320 M24x3x50 4 pcs.
2 1424.320 M24x3x50 4 pcs.
3 1424.1009 M16x2x45 8 pcs.
4 1424.1009 M16x2x45 8 pcs.
51424.332 M14x2x45 2 pcs.
6 1424.332 M14x2x45 4 pcs.
8 1424.190 M10x1.5x20 6 pcs.
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Shipping
Shipping
The vessel is delivered primed and with blinded connections. This ensures sufficient surface
protection during normal operating conditions. If, however, the vessel is going to be stored out-
side, the surface must be protected against corrosion. If operation is disengaged and vessel
storage is needed, preventive measures must be taken to eliminate any contamination through
open ports.
Mobility
The vessel may only be relocated in an empty state. Any excessive impact suffered during
transportation or relocation may damage the vessel substantially. If the vessel should be
craned on its own, slings must be used, and they must be strapped around the vessel arch.
Installation
Safety on site and the safety of personnel must be in compliance with the EN 378-3 standard.
Post-transport inspections must be carried out on arrival. In case of damage to the vessel, in-
stallation must be aborted immediately.
When relocating the vessel on site, make sure to leave sufficient space for inspection, mainte-
nance and emergency escape routes.
The bedplate or foundation must be robust to withstand the strains inflicted by the vessel and
absorb external vibrations.
During installation, all vessel ports and openings must be protected against impurities. Do not
expose any ports or openings until their services are needed.
Before the vessel is taken into service, make sure that the entire system is clean of impurities
and foreign substances. Piping connections must not induce further mechanical stress in the
vessel, under any circumstances. Vibrations should be minimised by using vibration dampers
or the like.
Welding or other externally induced thermal stress is not permitted. Protective measures must
be taken to safeguard the vessel from exceeding the maximum allowable pressure and
temperature.
If the vessel is going to be installed in a harsh environment, further corrosive protection must
be applied to all exposed areas.
Safety equipment
The site operator is responsible for all personal and site related safety equipment needed to
safely relocate, install and operate the vessel. Safety equipment is not part of the delivery. The
vessel manufacturer cannot be held liable for any defective or missing safety equipment.
Initial start-up and operation
Upon commissioning of the vessel, it is the site manager’s responsibility to ensure that all rele-
vant personnel and staff are briefed and trained in compliance with EN 378-3. This includes
training in maintenance of the vessel construction and operation of the vessel.
Refrigerant charging and draining must be carried out according to the instructions in the unit
documentation. Always perform leak testing before any charging.
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Bolted connections
Bolted connections
Yielding may occur over time in the gasket
joints, thus enhancing the risk of gasket fail-
ure. To minimise the risk, all external bolted
joints must be preloaded again after installa-
tion. When the vessel has reached its operat-
ing temperature, the preloading procedure
must be repeated.
All bolts are preloaded in a diametrically stag-
gered pattern, see Figure 1. The bolts are pre-
loaded to approximately 90 percent of the
yielding strength relative to the specific bolt
quality (i.e. 8.8, 10.9, 12.9).
Fig. 1: Diametrically staggered bolt preload pattern.
Metric thread (ISO 8.8)
M 4 5 6 8 10 12 14 16 18 20 22 24 27
[Nm] 2.7 5.2 9.2 22 40 69 108 147 225 295 375 510 670
[Kpm] 0.28 0.53 0.94 2.2 4.1 7.0 11 15 23 30 38 52 68
[ft.lbf.] 2.1 3.9 6.8 16 30 50 80 110 170 220 270 370 490
Metric thread (ISO 12.9)
M 4 5 6 8 10 12 14 16 18 20 22 24 27
[Nm] 4.1 7.6 14 31 60 98 157 225 335 430 540 745 980
[Kpm] 0.42 0.78 1.4 3.2 6.1 10 16 23 34 44 55 76 100
[ft.lbf.] 3.0 5.7 10 23 44 75 120 160 240 320 400 550 720
Maintenance
Competent personnel must inspect the vessel regularly. Johnson Controls Denmark recom-
mends an inspection interval of one month during the first six months of operation. A mainte-
nance plan must then be made based on the service needed during the first six months. The
maintenance plan must meet the requirements of EN 378-2 at all times.
If any weakening of the vessel is detected (e.g. corrosion, erosion, dents or cracks) the vessel
must be taken out of operation immediately. The circumstances and immediate danger posed
by the defect(s) must be assessed by a third party, and the third party must decide whether op-
eration with the vessel can continue.
For further information on water quality in secondary water systems, please see the guide
Water quality in secondary systems – Guidelines to avoid corrosion and scaling in heat
exchangers.
Danger!
Do not, under any circumstances, decrease the bolt tension of the connections, and never dis-
assemble the bolts, when the vessel is pressurised. Failure to comply with this can lead to se-
vere personal injury.
Disassembly
Some vessel types can be disassembled for cleaning and inspection purposes. Before initialis-
ing disassembly, the operator must make absolutely certain that the entire vessel has been
START
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Gasket connections
drained, depressurised and thoroughly vented. Any aggressive substances that are dangerous
to personnel must be neutralised or removed.
Gasket connections
To ensure gas tight connections, the gasket contact surfaces must be clean of any impurities.
Excessive scratches and dents on the contact surfaces or reuse of any gasket materials will in-
crease the risk of leakage. Always use a fresh set of gaskets when reassembling any gas tight
connections.
Spare parts and replacements
Please refer to the manufacturer for further information about spare parts.
Final disposal of the vessel
To make reusing materials from the vessel easy, the variety of material is kept to a minimum.
The vessel contains no asbestos, rare-earth materials, mercury or any other heavy metal in
any form.
After depressurising, thorough bleeding and correct disposal of the refrigerant the vessel can
be scrapped or used as a cast component.
Johnson Controls Denmark ApS
Sabroe Factory
Christian X's Vej 201 ∙ 8270 Højbjerg
Denmark
Phone +45 87 36 70 00
www.sabroe.com
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