AHE - AXIAL CONDENSERS

AlfaV Single Row VCM (T, S, L, Q and R) models

INSTRUCTIONS MANUAL IM100519-EN 2010-01 Rev 00

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Index

• To the User ................................................................................. 3

• System Warranty ....................................................................... 3

• Safety ......................................................................................... 4

• General Description .................................................................. 6

Codification Way: ...................................................................... 6

Product Range: ......................................................................... 7

Reception ................................................................................... 8

Storage ....................................................................................... 8

• Provisions for Mounting ........................................................... 8

Layout ......................................................................................... 8

Bases .......................................................................................... 9

Lifting Procedure ..................................................................... 10

• Mounting .................................................................................. 11

Vibration isolators ................................................................... 11

Piping Connections................................................................. 12

Electrical options ..................................................................... 13

• Operation ................................................................................. 14

Starting the Condenser .......................................................... 14

• Maintenance ............................................................................. 15

Periodic preventive controls .................................................. 15

Cleaning the equipment ......................................................... 15

Tools and accessories for maintenance ............................. 16

Troubleshooting: ..................................................................... 16

Disassembling the fan motor ................................................ 17

Replacement of Fan Motor .................................................... 17

How to contact Alfa Laval

The contact information for each country is constantly updated in our website. Visit www.alfalaval.com to get this information. TH E TECHNICAL INFORMATION SUPPLIED AND OTHER MINOR CHANGES CAN BE MODIFY WITHOUT NOTIFICATION

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To the User

This instructions’ manual is intended to be your permanent guide for the different situations you may encounter when using this equipment. Alfa Laval recommends you to study it carefully and mainly, to make it available for the personnel who normally install, operate and maintain the equipment. This manual will be useless if can not be reached by the personnel who may need it. In the unlikely case that you may have some problem not contemplated in this manual, don't hesitate to contact the closest Alfa Laval's representative. We can offer you our help wherever you may be located.

NOTE!

Alfa Laval won't become responsible for any equipment failure if the user misinterpret the instructions of this manual.

System Warranty This equipment is designed to operate properly and produce rated capacity when installed in accordance with accepted industry standards. Failure to meet the following conditions may results in voiding of the system warranty:

• System piping must be installed following industry standards for good piping practices.

• Inert gas must be charged into piping during welding.

• System must be thoroughly leak checked and evacuated before initial charging.

• The electrical connections must comply with the following conditions: o All voltages must not exceed ±10% of nameplate ratings. Frequency 50-60 Hz. o Current absorption per phase imbalance not to exceed 2%.

• Factory installed wiring must not be changed without written Alfa Laval’s approval.

• Refrigerant, temperature and pressure must agree with the data on the product sticker of the relevant air cooler.

• As the cooler is supplied indirectly, the producer is not acquainted with its actual application. The cooler is not an independently functioning machine, but rather a component, and is consequently supplied with a 2B declaration based on Machinery Directive 2006/42/EC.

• Heat exchangers supplied by Alfa Laval are normally not equipped with a high-pressure cut out.

• The fitter is responsible for fitting a high pressure cut out on the system in which the heat exchanger is used.

• The heat exchanger may not be blocked in. If the ambient temperature rises, the pressure could rise and exceed the design pressure.

• It is not permitted to use the heat exchanger for any purpose other than the one it was designed for by Alfa Laval.

NOTE! FREEZING RISK A standard dry cooler cannot be fully drained simply by opening the drain fitting orifices. For an application with plain water and when the ambient temperature may drop below 0°C, a special coil design is required. Please contact us.

Safety The hazardous operations and other important information are emphasized in this section.are highlighted by means of special signs.

ATTENTION! Indicate that special procedures

people.

BE CAREFUL! Indicate that special procedures should be followed to avoid

the equipment.

NOTE! Indicate important information to simplify the operations or to

understandable.

Warning signs:

General precaution sign

Danger loads in movement sign

Danger parts in movement sign

Electrical danger sign

Important information

Always read this manual before using the

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The hazardous operations and other important information are emphasized in this section.special signs.

Indicate that special procedures must be followed to avoid

Indicate that special procedures should be followed to avoid

the equipment.

Indicate important information to simplify the operations or to

understandable.

General precaution sign

Danger loads in movement sign

Danger parts in movement sign

Electrical danger sign

Important information

Always read this manual before using the equipment!

In this page all the warning signs of this manualare summarized

The hazardous operations and other important information are emphasized in this section. The warnings

followed to avoid serious injuries to

Indicate that special procedures should be followed to avoid serious damages to

Indicate important information to simplify the operations or to make them more

In this page all the warning signs of this manual

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Operation for the transportation of the equipment

Lifting Operation

ATTENTION! Before lifting the equipment

• Attach the belts or hooks, only to the provided elements the equipment is equipped with.

• Be sure that the belts or the slings with hooks will lift the equipment in a balanced way.

Installation and maintenance operations

ATTENTION! Before performing any maintenance operation, the power supply from the general board should be switched off, and the safety switch should be in the OFF position to avoid accidents.

ATTENTION! For no reason, a person should walk or step over the equipment, since besides the damage, it can generate an accident or a risky situation.

ATTENTION! Whenever Fans maintenance task should be carry out, be sure they are not running and the security switch is in the OFF position. When the operation is completed, place back the corresponding protection.

Pay attention to the following instructions to avoid serious injuries to people and / or damages to the equipment.

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General Description Thanks to the combination of the innovative waviness of the fins (designed by Alfa Laval) and the use of copper pipes for fluid flow, the heat exchanger guarantees an excellent heat transfer. The heat exchanger is built with aluminum sheets and copper tubes that goes together to the collectors, 2.1 mm. is the standard space between fins. The fan motors are class IP 54 according to DIN 40050. The cabinet is built in galvanized steel sheet, pre-painted with an epoxy finish (RAL9002). Separated fan sections are provided.

Codification Way:

Code AlfaV Single Row Condenser

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Product Range:

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Reception The equipment is normally shipped as it is, without any kind of pallet and wrapped with nylon.

The condition of the unit should be verified at the moment of reception: the equipment left the factory in perfect

condition; eventual damages should be claimed immediately to the transportation company in writing in the

Document of Delivery before being signed. Alfa Laval or its Agents should be informed as soon as possible about

the significance

of the damage. The Client should complete a written report including photographs concerning each relevant

damage.

Storage

If the equipment has to be stored before its installation (one or more months) it is convenient to take the following precautions:

• Leave the equipment in its packing.

• Store it indoors, in a room with adequate conditions, temperature (15 to 25 º C) and humidity (50 to 70 %).

• In an environment without corrosive liquids or vapors.

Provisions for Mounting

Layout

The following aspects should be considered before mounting:

• Verify the structure supporting capacity regarding the weight of the equipment.

• Avoid the installation in closed locations.

• When walls are present, follow the distances recommended by Alfa Laval.

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• Special care should be taking in following the minimum distances recommended, particularly in cases for

installations with two or more units in areas with strong winds.

Fan Diameter A [mm] B [mm] C [mm]

800mm 800 1000 500 910mm 900 1100 500

Bases To avoid the oxidation of the equipment's legs, it is recommended to lean them on concrete bases (one base for each leg) of about 4 inches (10 cm.) high and 2 inches (5 cm.) exceeding the equipment leg.

Verify that the lifting components support the equipment weight plus 10%, before performing any lifting task.

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Lifting Procedure

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Mounting

Vibration isolators For active and passive isolation of vibrations and reducing noise transmission, Alfa Laval strictly recommends the installation of anti-vibration dampers. MATERIAL

Isolator: Natural rubber 60° ShA..

Frame: Galvanized steel, with yellow Zinc treatment.

Install the anti-vibration attachment between the equipment and the base. (For Horizontal mounting)

Mounting scheme

Fan Diameter

Screw

Weight min

Weight max

Cod.60626227

M10 - 200daN

Cod.60626031

M12 210daN

335daN

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Piping Connections

Condensers: The equipment is delivered with the following connections BW Type Cooper tube connection for welding. The following diagram shows the recommended installation: 1. Anti-vibration device. 2. Silencer. 3. Condenser. 4. Liquid receiver. 5. Thermal expansion valve. 6. Evaporator. 7. Compressor.

Important Size the pipes to minimize the pressure drop and to obtain the coolant speed values to assure the oil drifting. In the drive line, between the compressor and the condenser, install an anti vibration device (1) and a silencer (2) to reduce the noise and vibration transmission along the line. Be sure that the line for liquid should have a minimum gradient of 1%, between the liquid discharge and the receiver.

Important! Before making the connections, verify the presence of the preloaded nitrogen for the dry maintenance of the circuit. In the multi- circuit condensers the refrigerating lines goes from the LEFT to the RIGHT (H version) or from above to down (V version).

Welding the pipes: To weld the external piping to the equipment, (cooper pipes) an overlapped welding is suggested, for the double purpose of assuring the staunchness and reducing the breaking risks in the welded area, generated by inducted vibrations. If the diameter of the pipes don’t allow this solution, special female threaded unions should be used.

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Before making the welding, disassembly the cap-label of the ½ ” gas valve and eliminate the preloaded nitrogen completely.

Electrical options

Attention: To carry out safe maintenance operations, an ON / OFF Switch should be installed close to the equipment.

Safety switch ON / OFF Auxiliary contacts: 2

Rated current: 16 A

Voltage protection: 600 volts

Cable: VDE 7030

Protection class: IP 65

Grounding

Attention: The ground connection is required by law.

The ground connection should be made through a cable from the motor's frame to the equipment structure and from structure to the plant ground.

Attention: Ground resistance should be lower than 3 ohms

Electrical fan motor The fan motors have the following specifications:

• Type: Induction squirrel cage

• Protection type: IP 54

• Insulation type: F class

• S1: Continuous duty

• Sealed ball bearings for thermal range from –40 to 100°C

• Connection

o 3 Phase – 400 V + - 10% 50 Hz.

o Single phase - 230 V + - 10% 50 Hz.

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Operation

Starting the Condenser • Carry out a vacuum phase by connecting to the coupling for equipment loading.

• Load the system with cooling gas.

• Start the system and make sure that there are no gas leaks.

Shutdown When the unit should be emptied for maintenance or when the system is not in use, the following procedure should be performed:

• Isolate the equipment.

• Collect the cooling liquid.

• Disconnect the circuit and flush the equipment with nitrogen. When not in use, leave the equipment loaded with dry nitrogen.

For the correct operation of the equipment, Alfa Laval original spares should be used.

Attention!: Before attempting any maintenance operation, make sure that the power supply is properly disconnected.

Attention: Before attempting to make any maintenance, the power supply should be turned off from the sectional board. For further security, the operator can also turn the switch ON / OFF to the OFF position to avoid accidents.

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Maintenance

Periodic preventive controls Every three months the following controls should be performed:

• Check the equipment fastening.

• Verify that the electric connection terminal studs are properly tight, to avoid losses and wear due to sparks.

• Verify the good condition of the wiring (it should not have cuttings or deterioration signs).

• Check the electrical resistance of the ground connection (ohms).

• Use an ammeter to check that the current absorbed is equal to or slightly lower than the rated value when the fan(s) work(s) at rated speed.

If the equipment should remain without operation for long periods (three or more months), it is advisable to operate the fan(s), at least once per month, during 3 to 4 hours each time.

Cleaning the equipment To guarantee the thermal efficiency of the equipment, it is necessary to eliminate the dirt deposited in the coils, on the suction side. A low pressure water jet or non aggressive liquids can be used. A cleaning is recommended every three months, but this frequency should be defined according with the environment where the equipment is installed.

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Tools and accessories for maintenance

• Open end or combination wrenches kit (millimeters), (sizes from 10 to 20mm)

• Open end or combination wrench kit (inches), (sizes from ½” to 2”)

• Adjustable wrench (3” opening)

• Oxyacetylene welding equipment

• Current clamp tester

• Voltmeter

Troubleshooting:

PROBLEM POSSIBLE CAUSE SOLUTION

Condensation pressure too high

Air flow to condenser blocked by dirt on the coil with fins

Clean the coil with water and a degreaser or non corrosive liquid

Defective fan Replace

Wrong air flow direction through the coil

Invert the rotating direction of the fan, switching two of the three phases

Condensation pressure too low Air temperature too low Adjust the condenser pressure regulation

Excessive air flow through the condenser

Fans not running Faulty motor Replace

Line voltage lower than tolerance limits

Check the voltage value between phases with a voltmeter.

Lack of a phase Measure the voltage between phases, check the power supply line

Overloaded motor Check with an Ammeter

Fan break Blockage or shocked Replace

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Disassembling the fan motor

Attention: Before attempting to make any maintenance, the power supply should be turned off from the sectional board. For further security, the operator can also turn the switch ON / OFF to the OFF position to avoid accidents.

• Remove the fan protecting grid.

• Loose the fastening stud bolts and remove the impeller, if necessary disassemble the whole group.

• Disconnect the motor wires.

• Remove the bolts that hold the group to the frame support.

• If damaged, replace the impeller for a new one.

• To facilitate the installation, before mounting the impeller, lubricate the shaft.

• Place the impeller in position and tight the stud bolts.

• Clean the inner side of the grid and mount it.

Replacement of Fan Motor Control the correct operation of the electric fans periodically. In the event of electric or mechanical failures, the motor should be replaced as follows:

• Make sure that the power supply has been switched off, by placing the security switch in the OFF position.

• Then, open the electric motor derivation box, disconnect and remove the electric wires.

• Unscrew the fastening screws in the grid.

• Loose the screws that hold the motor to the support and remove the impeller group- motor.

• Place the impeller in the new motor shaft and install it.

• Place the protection grid.

• Make the electric connection.

• Check the correct rotating direction.