Hansen APPT08 User Manual

Specifications, Applications, Service
Instructions, & Parts
AUTO-PURGER
®
PLUS, APPT
Non-condensible Gas (Air) &
Water Purger for Ammonia
Bulletin APP-001f
SEPT 2016
For Models
APPT08, APPT16, APPT24,
AND APPTC
AUTO-PURGER
®
PLUS, APPT
SECTION 1 INTRODUCTION
Water contamination in an industrial ammonia refrigeration
system can lower system efficiency, and increase the
electrical costs required to run the system’s refrigeration
compressors. Ammonia refrigerant that is contaminated
with water requires a lower suction pressure to maintain
the same evaporator temperature than would pure ammonia
refrigerant. The requirement to maintain a lower suction
pressure than would be necessary if the water contamination
were removed is a waste of electrical energy.
For water removal, the AUTO-PURGER Plus has the
following capacities:
1% system water concentration – ½ gallon of water
removed per week,
5% system water concentration – 1 gallon of water removed
per day,
10% system water concentration – 3 gallons of water
removed per day,
20% or more system water concentration – 5 gallons of
water removed per day.
MATERIAL SPECIFICATIONS
Material of construction: steel, ASTM A53 Grade B, ASTM
A106 Grade B, ASTM A234 Grade WPB, ASTM A105,
ASTM A36
Safe working pressure: 400 psig (28 bar)
Operating temperature: -50F to +240F (-50C to +115C)
Internal volume: 0.7 cubic feet (20 liters)
Normal refrigerant inventory: 0.35 cubic feet (10 liters)
TABLE OF CONTENTS
Section 1 Introduction…………………….............Page 1
Section 2 Installation……………….....................Page 2
Section 3 Component Description……..............Page 6
Section 4 Purger Operation……………...............Page 19
Section 5 Service, Troubleshoot, Parts…..........Page 22
The AUTO-PURGER Plus is a totally automatic, electronically
controlled refrigerant noncondensible gas (air) and
water purger for reducing the energy costs of operating
an ammonia refrigeration system. All models are
preassembled, pre-wired, insulated, and include an
automatic water bubbler, a relief valve, and an isolation
service valve package. Installation requires piping the foul
gas line, low-pressure pumped-liquid line, low-pressure
liquid return line, suction line, water bubbler fill and drain
lines, relief valve vent line, water purge line to a customer
supplied container, a power connection, and wiring the
remote purge point solenoid valves. Purge point solenoid
valves must be purchased separately and must be a
minimum of ½” (13 mm) port size.
In addition to the APPT08, APPT16, and APPT24, a
computerized model—APPTC—is available where a
separate plant computer or programmable logic controller
(PLC) is used to independently operate the various remote
purge point solenoid valves.
The AUTO-PURGER Plus can operate over a wide range of
condensing pressures. This is important for refrigeration
systems that operate at low condensing pressures during
cold ambient conditions.
The number of purgers required for a system depends on
the number of installed purge points. Twenty-four purge
points is the maximum practical number per purger. For
example, a system with 24 points at 10 minutes per point
requires a 240 minute (4 hour) cycle. Each purge point
can be purged six times a day. If this is not adequate,
a second purger should be used and the purge points
divided equally between the two purgers.
In a system with normal noncondensible loads, all models
will handle a 750 ton (2600 kW) ammonia plant at suction
pressures below atmospheric pressure or a 1500 ton
(5300 kW) ammonia plant at positive suction pressures.
The amount of noncondensibles in the system is based
on many factors including age, maintenance practices,
and operating temperature.
.

Hansen APPT08 Specifications

General

Brand	Hansen
Model	APPT08
Category	Industrial Equipment
Language	English

Summary

Section 1 Introduction

Material Specifications

Details the materials used in the construction of the purger.

Section 2 Installation

Mounting Instructions

Guidelines for securely mounting the AUTO-PURGER Plus unit.

Foul Gas Piping

Instructions for connecting the foul gas line to the purger for optimal operation.

Evaporative Condenser Piping

Guidance on piping for evaporative condensers to prevent liquid issues.

Purge Point Locations

Recommendations for optimal placement of purge points for effective air removal.

Low-Pressure Pumped-Liquid Line

Requirements for the low-pressure pumped-liquid source connection.

Low-Pressure Liquid Return Line

Connection details for the low-pressure liquid return line.

Suction Line Connection

Specifies the connection requirements for the suction line.

Relief Valve Vent Line

Guidelines for connecting the relief valve vent line.

Water Bubbler Fill Line

Instructions for connecting the water bubbler fill line.

Water Bubbler Drain Line

Details for connecting the water bubbler drain line.

Water Purge Line Routing

Guidance on directing the water purge line to a container.

Oil Drains Procedure

Procedure and precautions for draining oil from the purger.

Electrical Connections

Instructions for wiring the AUTO-PURGER Plus and purge point solenoids.

Leak Test Procedure

Procedure for confirming the AUTO-PURGER Plus is leak-free.

Section 3 Component Descriptions

Water Bubbler Function

Describes the function of the water bubbler in absorbing ammonia.

Liquid Drainer Operation

Explains how the liquid drainer separates condensed liquid.

Vapor Trap Function

Describes the function of the vapor trap in the pumped liquid line.

Check Valves Overview

Lists and describes the five check valves on the purger.

Purge Gas Orifice Details

Details the metering orifice for the purge gas line.

Metering Valve Functionality

Explains the function and operation of the metering valve.

High Side to Low Side Bypass Valve

Describes the purpose and operation of the bypass valve.

Temperature Sensors

Details the three temperature sensors and their functions.

Pressure Transducers

Describes the two pressure transducers and their output.

Single Point Level Sensors

Explains the operation of the two single point level sensors.

Water Concentration Sensor

Details the water concentration sensor and its readings.

Electric Heaters

Describes the two electric heaters used in Concentrating Water mode.

Purge Point Solenoid Valves

Recommendations for customer-supplied purge point solenoid valves.

Touchscreen Interface

Overview of the operator's interface and its display modes.

APPT Menu Screens

Details the various menu screens for APPT operation and settings.

Version Information

Information about the APPT's internal PLC and touchscreen programming versions.

Language Settings

Allows the user to change the language of menus and readouts.

Alarm History Log

Provides a list of error codes, dates, and times for troubleshooting.

Setup Screen Configuration

Accesses factory configured set-up parameters for the APPT.

Troubleshooting Help Guide

Accesses the built-in guide for error code meanings and solutions.

Data Acquisition Management

Enables or disables data collection and manages storage devices.

System Reset Procedure

Resets the APPT system similar to rebooting a computer.

HMI Display Settings

Configures the touchscreen to operate as HMI.

APPT Status Screens

Displays various operating conditions and status indicators of the APPT.

APPT Display Messages

Explains the various messages displayed on the APPT touchscreen.

Touchscreen Data Acquisition

Details the data collection feature and storage device management.

Touchscreen Troubleshooting Guide

Provides a guide for troubleshooting error conditions via the touchscreen.

Section 4 Auto-Purger Plus Operation

Start-Up Procedure

Step-by-step guide for starting up the AUTO-PURGER Plus.

Remote Relay Connections

Explains how to connect the remote relay for signaling and alarms.

Section 5 Service, Troubleshooting, & Parts

Purger Pump Out Procedure

Steps for safely pumping down and isolating the purger.

Service and Maintenance

Routine maintenance checks, including oil draining and sensor verification.

PLC Backup Battery Replacement

Instructions for replacing the PLC backup battery.

Touchscreen Troubleshooting (Displays 2222-4444)

Troubleshooting guide for specific touchscreen display codes 2222 through 4444.

Touchscreen Troubleshooting (Display 7777)

Troubleshooting guide for touchscreen display code 7777.

Noncondensibles and Ammonia Release Issues

Diagnoses and solutions for noncondensibles not releasing or ammonia release.

Water Release and System Issues

Troubleshooting water release problems and system operation issues.

PLC and Fuse Related Troubleshooting

Addresses PLC timeouts, blown fuses, and heater faults.

Touchscreen and System Error Troubleshooting

Solves touchscreen messages like "System Initializing", "Panel Not Set to HMI", and data logger issues.

Parts Identification

Lists mechanical, electrical, and controller components with part numbers.

Selecting an Auto-Purger

AUTO-PURGER AP Model

Description of the original AUTO-PURGER with solid-state control.

AUTO-PURGER APM Model

Description of the compact AUTO-PURGER APM for medium systems.

Nonelectrical AUTO-PURGER (NEAP)

Description of the nonelectrical AUTO-PURGER for small systems.

Cautionary Notes

Important safety precautions for using Hansen purgers.

Product Warranty Information

Details the warranty coverage for Hansen products.