Issue: 10/2016

Operating Manual W 3934-6.01-.E

High Performance Separator (HAD) Sheet 1 / 8 JOe

Please read the operating manual carefully in full before you install or
operate the high-performance separators (hereinafter also referred to as
HAD)!
1 Intended use
The WITT HAD is a unique, highly efficient compact separa-
tor. The HAD reliably separates liquid refrigerant, meaning
that the quantity of the existing separator can be increased to
its maximum capacity.
The HAD can be used to extend existing systems, or any-
where where a dry suction line is required. The installation is
done mostly in the existing piping system without the need for
major assembly work.

2 Safety regulations
All the work carried out on refrigeration systems must be performed
by 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.

The legal regulations governing the commissioning and operation of

pressure equipment 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.

It must be ensured that emergency and escape routes are marked

and their access is unrestricted.

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 connec-
tions), otherwise this will render the certificates invalid.

Only a qualified technician may change the filling capacity of the system! The level specified on the
drawing must not be exceeded.

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.

3 Warranty provisions
In order to avoid accidents and to ensure the safety of the system, no modifications or changes may be
made to the HAD that have not been expressly approved by TH.WITT KÄLTEMASCHINENFABRIK GmbH.
All the information and instructions for the operation and maintenance of the HAD 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,
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 2 / 8 JOe

 the HAD, including its equipment, is not operated correctly, or it has been handled in a way that does
not correspond to the prescribed sequence,
 the HAD 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,
 additional compressor power is connected or changes are made on the evaporator side so that the
intended power is exceeded
 the relevant safety regulations and accident prevention regulations are not observed during the op-
eration of the HAD.

4 Scope of delivery

 HAD vessel made of steel, manufactured according to AD2000 and DGRL module H1
 Connection for suction gas humid, inlet
 Connection for suction gas dry, outlet
 Connection for condensate, outlet
 Connection DN32, Reserve
 2 mounting brackets, U-profile
 Lifting eyelets on top

The angle of the connection and mounting brackets on the periphery can be freely selected

5 Technical data
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.

Outlet on PS (t0 75)

Condensate PS (t0 100)
Diameter Height Weight top TS (t0 75): -10°C/-
Type below TS (t0 100): -10°C/+50°C
60°C
Inlet below
[mm] [mm] [kg] DN DN [bar] [bar]
HAD-250 273 1520 90 150 50 -1 / 16 -1 / 12
HAD-400 406 1780 200 200 80 -1 / 16 -1 / 12
HAD-550 559 2140 320 250 100 -1 / 16 -1 / 12

The pressure vessel must be protected from higher temperatures by suitable measures (setup, insulation,
etc.).

5.1 Approved media

The HAD can be operated with all common refrigerants (NH3, HFC refrigerants, HFO refrigerants and FC
refrigerants), taking into account the maximum permissible pressures. If a 25 bar application is required, this
must be specified when placing the order.
With CO2 as a refrigerant, a special 40 bar version can be requested from TH.WITT.

5.2 Materials used

Housing 1.0345 / 1.0425
Connections 1.0345
Internal parts 1.0038 / PE 1000 (PE-UHMW)
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 3 / 8 JOe

5.3 Dimensions
Type
Variable HAD-250 HAD-400 HAD-550 Unit
L1 1516 1778 2137 [ mm ]
1
L2 1255 1519 1877 [ mm ]
L3 945 1135 1385 [ mm ]
L4 600 750 950 [ mm ]
L5 201 199 200 [ mm ]
2 L6 45 60 90 [ mm ]
L7 200 200 200 [ mm ]
L8 246 246 246 [ mm ]
L9 180 235 315 [ mm ]
3
L10 765 900 1070 [ mm ]
1 = suction gas outlet L11 764 898 1052 [ mm ]
2 = suction gas inlet
3 = condensate L12 469 602 755 [ mm ]
D1 273 406,4 559 [ mm ]
D2 168,3 219,1 273 [ mm ]
D3 60,3 88,9 114,3 [ mm ]
D4 42,4 42,4 42,4 [ mm ]
S2 4,5 6,3 6,3 [ mm ]
S3 2,9 3,2 3,6 [ mm ]
S4 2,6 2,6 2,6 [ mm ]

6 Functional description (retrofitting on existing systems)

6.1 Task
The high-performance HAD separator relia-
bly separates liquid refrigerants in the suction
line. A dry suction line prevents liquid slug-
ging. In addition to this, a good separation is
indispensable in order to increase the effi-
ciency and service life of the compressor.

The filling capacity of an existing separator

can be maximised by installing the HAD
high-performance separator.

The system is usually installed in the existing

pipeline system without the need for major
installation work.
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 4 / 8 JOe

Function within the system

6.1.1 Single-level system (standard arrangement)

H
A
D

6.1.2 Single-level system (in case of height problems)

H
A
D
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 5 / 8 JOe

6.1.3 Two-level system

H
A
D

On the LP side

7 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 HAD is to be stored for more than two
months or it has to be transported overseas, the HAD must be filled with inert gas to protect it from corrosion.
If the high-performance HAD separator has been filled with inert gas in the factory, the bleeder chokes must
be removed immediately before the HAD is incorporated into the refrigeration circuit. It is important that no
chips or dirt get into the HAD! If necessary, the pressure vessel should be thoroughly cleaned inside.

When transporting, only the designated lifting eyelets are to be used for the lifting; s, pipelines, valves etc.
must not be used for this purpose.
Ropes should never be used. If transport belts are used, make sure that the anti-corrosive coating is not
damaged.

8 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 refrig-
eration engineer responsible for the planning has to ensure that the necessary equipment with safety de-
vices and control elements is adapted to the individual requirements.

The high-performance HAD separator 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
permission of TH.WITT KÄLTEMASCHINENFABRIK GmbH.
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 6 / 8 JOe

Since the HAD is usually installed in the existing pipeline system, the following installation and / or intercep-
tion options are provided:

Options for attaching the HAD with …

pipe clamp brackets

Pipe clamps and/or brackets and insulating plates are not included in the scope of delivery.

The HAD is installed in the existing pipeline according to the latest technology and practices. The AD2000
data sheets for the series HP 100 R and EN378 need to be followed in particular.

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.

Ensure there is sufficient space for inspections, maintenance work and insulation. The discharge valves,
safety valves and quick-release valves must be easily accessible.

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 HAD.

9 Before commissioning
After it has been assembled, the entire pipeline system must undergo a thorough visual inspection. 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.

Once the leak and pressure tests have been successfully carried out, ensure that the system has been suffi-
ciently dried out. To achieve this, the system has to be vacuumed to below 675 Pa (NH 3) or below 270 Pa
(Frigene) during the vacuum test. The period for which the vacuum is maintained depends on the size and
complexity of the system.

Large pressure vessels are not dried out in a heated vacuum, as is the case with small appliances.
WITT pressure vessels are emptied as much as possible after the water pressure test using tried
and tested crane movements and then dried with hot air for at least 5 hours. Despite all the care
taken during this procedure, it cannot be excluded with certainty that water residues will remain in
pouch-shaped areas. If a particularly thorough drying process is required (e.g. when using ester oils
in refrigerants), this must already be ordered when placing the order.

When emptying the system that has not been insulated, observe the drop in pressure. If the pressure display
remains at the steam pressure of the water pressure (see table) proceed as follows:
Heat the deepest areas where you think there may still be residues of water, one after the other, at approx.
30 to 40°C with a soft flame (do not damage the anti-corrosive coating in the process!). If the pressure in-
creases, continue applying the heat until the water residue evaporates.
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 7 / 8 JOe

Remember that the pipelines installed may also contain condensation or other water meaning that
24 hours or more is required to dry the system to exhaust it to under 675 Pa and/or to 270 Pa. A
thorough exhaust process should therefore be taken into consideration during the scheduling before
the insulation work!

Ambient temperature [°C ] 5 10 20 40

Steam pressure water [mbar] 9.0 12.3 23.4 73.8

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

10 Insulation
Insulated plant components are highly susceptible to corrosion especially in the dew point area and with
varying internal temperatures due to condensation or the formation of ice. The HAD is fitted with a perma-
nently sealed and elastic anti-corrosion coating. All the welded seams and any damage to the coating must
be carefully reworked in accordance with DIN EN ISO 12944 before the insulation work can proceed.

If, at the customer's request, the HAD has only been prepared for the coating system (e.g. only with the
primer), then the coating system must be supplemented according to DIN EN ISO 12944.

If an insulation has been applied, it must be designed according to the state of the art methods and materials
(e.g. DIN 4140) and must be sufficiently sealed against moisture (vapour barrier). The mounts should not
break or damage the insulation.

If the HAD has already been insulated in the factory, take extra care during transport to protect the insulation
from damage.

11 Commissioning
The HAD must not be commissioned until a safety analysis of the entire system has been carried out.

11.1 Approved media

The WITT high-performance separator HAD is suitable for all common evaporating refrigerants, e.g. NH3,
R134a, R404, R407c, R507, etc. (see 5.1 Approved media).

12 Operation
The HAD may only be operated within the range of its design data. The cooling engineer responsible for the
planning together with the operator, must ensure by taking the appropriate measures (maintaining the per-
missible filling level, setting the respective control units, etc.) that the overfilling of the HAD is excluded at all
times.

The pressure relief device must be set up and adjusted according to the rules and standards / local regula-
tions (this must never exceed the max. permissible pressure as specified on the nameplate!)

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.
 Issue: 10/2016
Operating Manual W 3934-6.01-.E
High Performance Separator (HAD) Sheet 8 / 8 JOe

13 Maintenance and inspection

The inspection of the HAD, including the 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 work has to be carried out on the HAD, the pressure must be released from the sys-
tem and the refrigerant must be completely sucked out before any screwed connections are loos-
ened. Under no circumstances must you remove all the screws when any refrigerant or pressure is
still in the system.

The HAD 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 inspection for corrosion.)

A corrosion allowance of 1mm is taken into account for all pressure-bearing components made of carbon
steel. The corrosion allowance for pressure-bearing components made of stainless steel is 0 mm.

If the corrosion protection is damaged, this must be repaired immediately.

14 Address
TH. WITT Kältemaschinenfabrik GmbH
Lukasstraße 32, D-52070 Aachen,
Tel. +49-241-18208-0, Fax. +49-241-18208-49
http://www.TH-WITT.com, [email protected]

Issued by:
Johannes Oellig, Head of Product Management