Adiabatic Systems° - BSJ

Adiabatic Systems°for heat exchangers and condensers

Demand, idea, seriesThe adiabatic cooling system is a patented condenser system with up to two subcooling

sections. Depending on the installation location and operating conditions, a condensing temperature of 35°C can be

achieved although the liquid is actually cooled by a further 10 K. This makes it possible to supply a refrigeration machine

with liquid (for example R134a) at a maximum temperature of 25°C. In many cases this allows a refrigeration machine

one or two rating classes lower to be selected whilst still providing the same refrigeration capacity. The system has been

developed in response to customer demand and is now installed as standard.

Given the high exchanger surfaces in the adiabatic heat exchanger systems, a high hourly rate of free cooling is also

possible. With medium temperatures from 18°C to 12°C, this account for around 3000 - 4000 hours a year in many sectors

in Germany. During this period, no refrigeration machine is needed. Energy can therefore be saved hour for hour.

Adiabatic Systems°Strategic all-rounders among heat exchangers and condensers

Adiabatic heat exchangers and condensers have a pipe construction which runs underneath or to the side of the heat

exchanger with integral spray jets, allowing the intake temperature to be reduced by adiabatic means where external

temperatures are high. Water in aerosol form is sprayed into the intake air from the spray jets, with evaporative cooling

achieving a marked cooling effect.

Customised for a precisely defi ned application, they therefore extract as much as is needed in the given performance

framework and emit as little as possible in the name of effi ciency.

The CABERO product range distinguishes offers two distinct systems. Different spray patterns, droplet sizes and pre-

pressure at the jet form the basis of these decisions and are suitable for a variety of requirements. The LPSS system is

mainly defi ned by its saturation of the incoming air, whereas the HPSS produces partially hybrid operation.

LPSS - Low Pressure Spray Systemwith a system pressure of 1.5 - 2.5 bar.

HPSS - High Pressure Spray System with a system pressure of 2.0 - 4.0 bar. The additional volume of water produces a partially hybrid system for saturation

of the air.

With both systems, medium outlet temperatures are below the ambient temperature, depending on the design.

With CABERO's economic calculations, you can quickly fi nd the ideal solution for your needs. Your CABERO adviser

will be happy to show you the device and calculate your investment versus your savings in running costs.

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Typical applications°

Adiabatic systems are predestined for use in combination with absorption refrigeration systems and in compression

refrigeration systems with screw and turbo condensers, in process cooling and power plant technology.

Adiabatic systems deliver impressively high free cooling performance in dry operation.

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Dry and adiabatic operation°

Depending on the medium temperature and ambient temperature, the levels of adiabatic operation engage accordingly:

In dry mode, heat is output convectively via the ambient temperature. If the temperature of the ambient air rises, the

air volume fl ow is increased fi rst via the speed of the fans. If the fan reaches 100% of its available capacity and the air

temperature increases above the dry switching point, the adiabatic stages are activated in succession. The outer surface

of the heat exchanger blocks are gradually sprayed with water. This transports the heat away both using convection and

through evaporative cooling. Once the temperature falls again, the spray levels are deactivated again with closure of the

actuators. This is done with a very small hysteresis in order to use as little water as possible.

The switching points in the next-higher adiabatic stage are regulated as a function of the load. In other words, the next

stage is only released if the load is 100%. If the load point is below 100%, the dry switching point is automatically raised

by the regulator. Only if the fi nal confi guration is reached and the load point is 100% are all stages released.

Adiabatic equipment from CABERO has the particular feature of being highly effi cient in terms of its cost effectiveness.

This also has a very positive effect on the refrigeration equipment's overall energy consumption. The overall system's

comparatively lower power and water consumption mean that investment costs can be recouped quickly.

With the same cooling performance, a higher ambient temperature can

be achieved using an adiabatic device than with a dry heat exchanger.

Dry mode 1st adiabatic stage 2nd adiabatic stage 3rd adiabatic stage

HighMedium

LowLittle

Sprayed volume of water

100%

0%

Speed of fans

100%

0%

Possible cooling power

Required cooling power

Switching point: T/A, e.g. 21 °Cexternal temperature

A1/A2, e.g. 26 °Cexternaltemperature

A2/A3, e.g. 34 °Cexternal temperature

Design point:e.g. 38 °C

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Structure and material°

All CABERO equipment is measured by neutral testing institutions (such as DMT) before it is series-produced.

CABERO also maintains contact with many operators to continue monitoring equipment measurements and to assess the

energy consumption of different systems. This information is used for further development and optimisation purposes.

Possible constructions Tabletop equipment, V-shape, W-shape, jumbo

The carriers are made from zinc-plated, powder-coated steel and come in the standard colour RAL 9010. Any further RAL

colour can be produced as a special order.

Pipes Copper and stainless steel, depending on the application

Adiabatic system Stainless steel with plastic jets

Actuator / solenoid valve Electric ball valve, with hand switch, allowing the ball valve to be opened or closed manually in the event of a fault.

Fans EC technology with airflow rectifier

The EC fan units with airflow rectifiers in our adiabatic systems offer three crucial advantages while delivering the same

fan unit speed:

1st More air power: The devices achieve 7.5 % more volume of air based on current measurements

2nd Lower power consumption: The electrical power consumption fell on average by 6 %

3rd Low noise emissions: At a distance of 5 metres, the sound level falls by at least 4 dB(A)

The measured values relate to the EBM EC 900 L fan unit.

By using the airflow rectifier, a large proportion of the dynamic speed energy is converted into static pressure. This mark-

edly increases the level of effectiveness. This also allows the speed to be lowered and therefore the level of noise to be

kept down.

Other protective devices help to ensure the fans enjoy a long service life• Fault reporting relays with potential-free contacts

• Block protection

• Phase failure detection

• Gentle start-up of motors

• Mains under-voltage detection

• Overheating protection for the electronics and motor

• Short-circuit protection

FinsBlue fins with polyurethane coating. Only smooth fins are used which, thanks to their reduced dirt, are more robust and

continue to deliver high performance since they do not provide a base for biofilms to form on.

Optionally available: • Water purification

• Reverse osmosis

• Pressure-maintaining stations

Windshield Optionally attached to the side, allowing the device's level of effectiveness to be guaranteed.

What is a biofilm?

Amalgamations of micro-organisms that develop on bordering surfaces between media of different aggregate states.

Micro-organisms adhere to the solid substrate, forming a biofilm matrix made from extracellular polymer substances

and are therefore protected from being flushed away. Diffusion provides the biofilm with nutrients from the surround-

ing fluid. This causes the biofilm to expand further and can also deposit itself in other places.

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Application Air- conditioning

Refrigeration Industry

Output range (standard)* 20 - 1,350 kW

Refrigerant** All safety refrigerantsOptionally all natural refrigerants including NH

3 and CO

2

Pipe material Cu or stainless steel, depending on applica-tion

Smooth fins Blue fin, optionally AlMg3, AlMg2.5, double-coated

Air alignment Vertical / horizontal

Adiabatic condensers°LPSS & Adiabatic Subcooling Systems

Table design horizontal / vertical Double block V design

W shape Double block jumbo V design





3 and CO

2

Pipe material Cu or stainless steel, depending on application


Air alignment Vertical





3 and CO

2








3 and CO

2




* approximate figures, based on t 15 K, switching point to condensation temperature

** must not have a corrosive effect on the pipe material used

© CABERO

© CABERO

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© CABERO

© CABERO

Adiabatic condensers°LPSS & Adiabatic Subcooling Systems

York Swiss, Hospital Sion, 2010, 1,220 kW SEW

Carrier

Bruchsal

2009

200 kW

Condenser

LPSS

V shape

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Adiabatic heat exchangers°LPSS & HPSS

Table design horizontal / vertical Double block V design

W shape Double block jumbo V design


Industry Power plant


Medium** Anti-freeze mixtures, oils



Air alignment Vertical / horizontal










Output range (standard)* 60 - 900 kW












* approximate figures, according to DIN EN 1048, t1: 15 K, t

L: 5 K

** must not have a corrosive effect on the pipe material used, risk of frost if water is used

© CABERO

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© CABERO

© CABERO

© CABERO

Adiabatic heat exchangers°LPSS & HPSS

eShelter, Rüsselsheim, 2012, 6 x 1,350kW

IBM

Mainz

2010

2 x 750 kW

Adiabatic heat exchangers

W shape

LPSS

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CABERO controls it°

CABERO Adilog or DDC

HousingStable sheet steel construction comprising 1.25 mm or 1.5 mm steel plate, single piece, edged and welded.

Colour touch display (on DCC)• 4.3 or 7 inch

• Flow diagram illustration

• Additional medium entry display

• Active fault / operation display in colour

• Alarm archive

• RTU modbus

• TCP/IP modbus

• Trend recording via USB stick

• Data logger

Switchgear designed to match the adiabatic system

The switchgear is planned with EPLAN.

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Precisely controlled°Reliable operation thanks to the best technology and materials

Details• Central supply 400 V/3/50 Hz

• Control cabinet ventilation

• Pre-fuses for motor outlets wired to rail-mounted terminals

• Repair switch fi tted into front of control panel, wired in pairs, optionally individually

Optional special featuresEco-Boost: Function for switching off EC motors in standby in accordance with NAV (low voltage connection directive)

with dew point monitoring.

Bypass module: Allows manual control of fi eld equipment in manual mode without DDC.

Specifi cation of a 2nd working point from activation via PFC.

Control via potential-free contacts (PFC)• Regulation release

• Set point 2

• Night restriction

• Release of 2nd working point

• Manual drainage

Signals (PFC)• Operation of motors

• Adiabatic operation

• Drainage operation

• Collective fault

• Detailed individual signals via MOD BUS RTU or Ethernet TCP/IP

Switchable mains supply manual or automatic is optionally available.

Water quality°

Water quality requirements for equipment that uses adiabatic systems

Hygiene certifi cate compliant with VDI 6022

Additional water:

demineralised water

pH value 6.5 to 8.2

Total hardness 4 °d

Chloride 50 g/m3

Electrical conductivity

(T = 25°C)

500 S/cm

(max. 1,000 hours/year)

Sulfate 90 g/m3

Hygiene certifi cate compliant with VDI 6022

The latest edition of the document "Water

quality requirements for adiabatic systems"

applies in all cases.

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References°

Adiabatic systems

Client Project Country Service Device type Year

Caverion BMW Munich D 20 x 1200 kW GCD 2002

Carrier Nuremberg Siemens D GCH 2003

Brach+Moll Datev II Süd D GCH 2004

Carrier Bosch Nuremberg D GCD 2004

Tomic BMW Munich D ACV 2006

Carrier Praterstadion A 6000 kW GCD 2007

Aristotherm Klinikium rechts der Isar D 2007

WTC Shopping Center Suhl D 2007

Stangl Kaufering CHP D GCH 2007

Heima ENBW City Stuttgart D 6 x 750 kW GCD 2008

Ebling Deutsche Börse D 2 x 800 kW GCD 2008

Bischoff Westend Windows D GCD 2008

Grötsch Business Campus Garching D GCH 2008

Rütgers Berlin Tempelhof D 6 x 920 kW GCD 2008

AGO Porsche Zuffenhausen D 7 x 776 kW GCD 2009

Carrier Uni Tübingen D 2 x 643 kW GCD 2009

Josef Gruber Surgical 560-bed ward building D 2 x 276 kW GCH 2009

Carrier Karlsruhe public utility company D 120 kW GCD 2010

Grötsch Klinikum Aschaffenburg D 450 kW GCH 2010

HEATING s.r.o. Prague Samlmovsky palac CZ 303 kW GCH 2010

Johnson Controls International, spol s.r.o. Masaryku˚v Onkologický Ústav Brno CZ 4 x 480 kW ACD 2010

Wiegel MTU-Augsburg D 155 kW GCH 2010

Redeker Weinreich Chocolate Factory Herford D 980 kW GHD 2011

BSJ group s.r.o. Sigmaplast Liberec CZ 400 kW GCD 2011

Dimperl MPI server room, MUC D 2 x 177 kW GCH 2011

Herbert Service-Kälte Sparkasse Bensheim D 2 x 332 kW GCD 2011

Imtech Coperion Stuttgart D 400 kW S-GCH 2011

INSTOP, spol. s.r.o. Pošta Vítkovice CZ 300 kW GCD 2011

AGO Daimler Gaggenau D 1390 kW GCD 2012

Carrier Roche Mannheim D 84 kW GCW 2012

Carrier Sparkasse Bad Hersfeld D 562 kW JGCD 2012

BSJ group s.r.o. Rondo Ejpovice CZ 252 kW GCW 2012

Ing. Elmer Bey TU Darmstadt conversion + restoration D 2 x 612 kW GCD 2012

Redeker Dr. Oetker D 2956 kW GCW 2012

Trane Hotel Angelo Munich D 450 kW GCD 2012

Trane EKZ Riem Acarden Munich D 3 x 160 kW GCH 2012

eShelter eShelter, Rüsselsheim D 6 x 1350 KW JGCD 2013

Caverion Uni Thübingen D 1592 kW GCD 2013

Bösch Telekom Leonding A 3300 kW GCD 2013

ONI Wilkinson Sword Solingen D 580 kW GCD 2013

Gatec Bikini Berlin D 1 x 675 kW, 3 x 640 kW, 4 x 880 kW

GCD 2013

AHI CARRIER CZ s.r.o. CCAR Cˇeská 6 Brno CZ 184 kW GCW 2013

Carrier Rhode+Schwarz Teisnach D 1914 kW GCD 2013

Hofstetter Forum Plus Erlangen D 200 kW GCW 2013

Carrier DC Tower Vienna A 9600 kW GCD 2014

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engineered to succeed

CABERO Wärmetauscher GmbH & Co.KG

Jesenwanger Str. 50 D-82284 Grafrath Germany

www.cabero.de

Adiabatic Systems° - BSJ

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