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INSTRUCTIONS MANUAL AIR – LIQUID COOLERS AND CONDENSERS BCD (BCDT, BCDS, BCDL, BCDQ, BCDR) and BDD (BDDT, BDDS, BDDL, BDDQ, BDDR MODELS) IM100527-GB EN 2006-01
INSTRUCTIONS MANUAL
AIR – LIQUID COOLERS AND CONDENSERS BCD (BCDT, BCDS, BCDL, BCDQ, BCDR) and BDD (BDDT, BDDS, BDDL, BDDQ, BDDR MODELS)
IM100527-GB EN 2006-01
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1
Table of contents
• GENERALo To the user ...................................…………........…. page 2o Warranty ...............................……......................….. page 2o Safety ......................………….............................…. page 3o Equipment Description..... …….............................… page 5o Reception ........………........................................…. page 14o Storage …………................................................…. page 14o Unpacking …......................................................... page 15
• PROVISIONS FOR MOUNTINGo Layout ………….................................................…. page 16o Bases .............…...............................................….. page 17
• MOUNTINGo Anti-vibration Dampers ............................................. page 18o Lifting Tables ............................................................ page 18o Vertical Installation ................................................... page 19o Horizontal Installation ............................................... page 19o Piping Connections: Condensers ............................. page 22o Piping Connections: Dry Coolers ............................. page 22o Mounting (Optional) .................................................. page 24o Electric Installation .................................................. page 25
• OPERATIONo Starting the Dry Coolers ........................................... page 27o Operating the Equipment ......................................... page 27o Shutdown................................................................. page 28o Starting the Condensers .......................................... page 28o Shutdown................................................................. page 28
• MAINTENANCEo Periodic Preventive Controls ..................................... page 29o Cleaning the Equipment ........................................... page 29o Tools and Accessories for Maintenance ................... page 30o Troubleshooting ....................................................... page 30o Replacement of Motors ............................................ page 31o Spare parts .............................................................. page 32
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.
THE TECHNICAL INFORMATION SUPPLIED AND OTHER MINOR CHANGES CAN BE MODIFY WITHOUT NOTIFICATION
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To the User
TO THE USER
Dear user
This instructions’ manual is intended to be your permanent guide for the different situations you may encounterwhen using this equipment.
Alfa Laval recommends you to study it carefully, and mainly, to make it available for the personnel whonormally 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 tocontact 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 usermisinterpret the instructions of this manual.
System Warranty
This equipment is designed to operate properly and produce rated capacity when installed in accordance withaccepted industry standards. Failure to meet the following conditions may result in voiding of the systemwarranty:
1. System piping must be installed following industry standards for good piping practices.
2. Inert gas must be charged into piping during welding.
3. System must be thoroughly leak checked and evacuated before initial charging.
4. The electrical connections must comply with the following conditions:
a. All voltages must not exceed ±5% of nameplate ratings. Frequency 50-60 Hz.
b. Current absorption per phase imbalance not to exceed 2%.
5. Factory installed wiring must not be changed without written Alfa Laval’s approval.
NOTE !
FREEZING RISKA standard dry cooler cannot be fully drained simply by opening the drainfitting orifices. Anyhow add the anti-cooling mix as further explained.
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Safety
The hazardous operations and other important information are emphasized in this section.The warnings are highlighted by means of special signs.
Always read this manual before using the equipment!
ATTENTION! Indicate that special procedures must be followed to avoid seriousinjures to people.
BE CAREFUL! Indicate that special procedures should be followed to avoid seriousdamages to the equipment.
NOTE! Indicate important information to simplify the operations or to makethem more understandable.
Warning signs: In this page all the warning signs of this manual aresummarized.
General precaution sign
Moving load danger sign
Moving part danger sign
Electrical danger sign
Important information
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Safety
Pay attention to the following instructions to avoid serious injuresto people and / or damages to the equipment.
Operation for the transportation of the equipment
Lifting forks should be placed under appropriate areas of the wooden shipping skid for properhandling; damage may result if the forks come in direct contact with the equipment.
Lifting Operation
ATTENTION!Before lifting the equipment
1. Attach the belts or hooks, only to the providedelements the equipment is equipped with.
2. Be sure that the belts or the slings with hookswill lift the equipment in a balanced way.
Installation and maintenance operations
ATTENTION!Before performing any maintenance operation, the powersupply from the general board should be switched off, andthe safety switch should be in the OFF position to avoidaccidents.
ATTENTION!For no reason, a person should walk or step over theequipment, since besides the damage, it can generate anaccident or a risky situation.
ATTENTION!Whenever Fans maintenance task should be carry out,be sure they are not running and the security switch is inthe OFF position.When the operation is completed, place back thecorresponding protection.
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General Description
General
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.
Equipment description
Innovative heat exchanger gives excellent heat transfer withminimized refrigerant charge, thanks to the new fins corrugation,developed by Alfa Laval, combined with advance cross fin tubesfor BC line; smooth tube for BD line.In the standard execution, heat exchanger manufactured fromcopper tubes and aluminium fins with spacing is 2.1 mm.
Casework made with galvanized steel sheets painted. Newdesign frame provides high rigidity also for heavy applications.
These units BCD and BDD are available in five noise levels fanmotor, (S) standard, (L) low, (Q) quiet, (R) residential and the new(T) high performance fan:
Code Alfablue Condenser DualExample: BCDQ 906 A D Model BCD Blue Condenser DualNoise level T =high performance fan S=standard L=low Q=quite R=residential Fan diameter 80=800mm, 90=910mm, 100=1000mmNumber of fan 2, 3, 4, 5, 6 Coil size A, B, C,Motor connections D=delta Y=starMotor type T=three phase S=single phase
CODIFICATION WAY:
Code Alfablue Dry Cooler DualExample:BDDQ 1003 A YModel BDD Blue Dry Cooler DualNoise level T =high performance fan S=standard L=low Q=quite R=residential Fan diameter 80=800mm, 90=910mm, 100=1000mmNumber of fan 2, 3, 4, 5, 6 Coil size A, B, C, DMotor connections D=delta Y=starMotor type T=three phase S=single phase
CODIFICATION WAY
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General Description
BCD-BDD Models 800mm Fan diameter Vertical Installation
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General description
BCD-BDD Models 800mm Fan diameter Horizontal Installation (Std. 500mm, opt. 850mm)
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General Description
BCD-BDD Models 800mm Fan diameterHorizontal Installation (adjustable feet height)
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General description
BCD-BDD Models 900mm Fan diameter Vertical installation
BCD/BDD Models 900mm Fan diameter Horizontal Installation (Std. 500mm, opt. 850mm)
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General Description
BCD-BDD Models 900mm Fan diameter Horizontal Installation (adjustable feetheight)
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General Description
BCD-BDD Models 1000mm Fan diameter Horizontal Installation (Std. 500mm, opt. 850mm)
BCD-BDD Models 1000mm Fan diameter Vertical Installation
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General Description
BCD/BDD Models 1000mm Fan diameter Horizontal Installation (adjustable feetheight)
NOTE !If adjustable feet are used, the minimum chose height has to be enough topermit the necessary air volume inlet in relation of the used fans.In case of doubts contact Alfa Laval.
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General Description
DIMENSIONS, WEIGHT AND CONNECTIONS’ TABLE
HEIGHT WIDTH DEPTH
mm mm mm... 802 A 2290 (V) 3955 900 (V) 600 2x3" 2x3" 2x54 2x42 4 2... 802 B 2290 (V) 3955 900 (V) 680 2x3" 2x3" 2x54 2x42 4 2... 802 C 2290 (V) 3955 900 (V) 760 2x3" 2x3" 2x54 2x42 4 2... 802 D 2290 (V) 3955 900 (V) 840 2x3" 2x3" 4 2... 803 A 2290 (V) 5705 900 (V) 820 2x3" 2x3" 2x54 2x42 6 2... 803 B 2290 (V) 5705 900 (V) 940 2x3" 2x3" 2x60 2x54 6 2... 803 C 2290 (V) 5705 900 (V) 1060 2x3" 2x3" 2x60 2x54 6 2... 803 D 2290 (V) 5705 900 (V) 1180 2x3" 2x3" 6 2... 804 A 2290 (V) 7455 900 (V) 1040 2x4" 2x4" 2x60 2x54 8 3... 804 B 2290 (V) 7455 900 (V) 1200 2x4" 2x4" 2x76 2x60 8 3... 804 C 2290 (V) 7455 900 (V) 1360 2x4" 2x4" 2x76 2x60 8 3... 804 D 2290 (V) 7455 900 (V) 1520 2x4" 2x4" 8 3... 805 A 2290 (V) 9205 900 (V) 1260 2x4" 2x4" 2x76 2x60 10 4... 805 B 2290 (V) 9205 900 (V) 1460 2x4" 2x4" 2x76 2x60 10 4... 805 C 2290 (V) 9205 900 (V) 1660 2x4" 2x4" 2x76 2x60 10 4... 805 D 2290 (V) 9205 900 (V) 1860 2x4" 2x4" 10 4... 806 A 2290 (V) 10955 900 (V) 1480 2x4" 2x4" 2x76 2x60 12 4... 806 B 2290 (V) 10955 900 (V) 1720 2x4" 2x4" 2x76 2x60 12 4... 806 C 2290 (V) 10955 900 (V) 1960 2x4" 2x4" 2x76 2x60 12 4... 806 D 2290 (V) 10955 900 (V) 2200 2x4" 2x4" 12 4... 902 A 2290 (V) 4655 900 (V) 790 2x3" 2x3" 2x54 2x42 4 2... 902 B 2290 (V) 4655 900 (V) 880 2x3" 2x3" 2x60 2x54 4 2... 902 C 2290 (V) 4655 900 (V) 970 2x3" 2x3" 2x60 2x54 4 2... 902 D 2290 (V) 4655 900 (V) 1060 2x3" 2x3" 4 2... 903 A 2290 (V) 6755 900 (V) 1020 2x4" 2x4" 2x60 2x54 6 2... 903 B 2290 (V) 6755 900 (V) 1160 2x4" 2x4" 2x60 2x54 6 2... 903 C 2290 (V) 6755 900 (V) 1300 2x4" 2x4" 2x76 2x60 6 2... 903 D 2290 (V) 6755 900 (V) 1440 2x4" 2x4" 6 2... 904 A 2290 (V) 8855 900 (V) 1250 2x4" 2x4" 2x76 2x60 8 3... 904 B 2290 (V) 8855 900 (V) 1440 2x4" 2x4" 2x76 2x60 8 3... 904 C 2290 (V) 8855 900 (V) 1630 2x4" 2x4" 2x76 2x60 8 3... 904 D 2290 (V) 8855 900 (V) 1820 2x4" 2x4" 8 3... 905 A 2290 (V) 10955 900 (V) 1480 2x4" 2x4" 2x76 2x60 10 4... 905 B 2290 (V) 10955 900 (V) 1720 2x4" 2x4" 2x76 2x60 10 4... 905 C 2290 (V) 10955 900 (V) 1960 2x4" 2x4" 2x76 2x60 10 4... 905 D 2290 (V) 10955 900 (V) 2200 2x4" 2x4" 10 4
... 1002 A 2290 (V) 4655 900 (V) 790 2x3" 2x3" 2x54 2x42 4 2
... 1002 B 2290 (V) 4655 900 (V) 880 2x3" 2x3" 2x60 2x54 4 2
... 1002 C 2290 (V) 4655 900 (V) 970 2x3" 2x3" 2x60 2x54 4 2
... 1002 D 2290 (V) 4655 900 (V) 1060 2x3" 2x3" 4 2
... 1003 A 2290 (V) 6755 900 (V) 1020 2x4" 2x4" 2x60 2x54 6 2
... 1003 B 2290 (V) 6755 900 (V) 1160 2x4" 2x4" 2x60 2x54 6 2
... 1003 C 2290 (V) 6755 900 (V) 1300 2x4" 2x4" 2x76 2x60 6 2
... 1003 D 2290 (V) 6755 900 (V) 1440 2x4" 2x4" 6 2
... 1004 A 2290 (V) 8855 900 (V) 1250 2x4" 2x4" 2x76 2x60 8 3
... 1004 B 2290 (V) 8855 900 (V) 1440 2x4" 2x4" 2x76 2x60 8 3
... 1004 C 2290 (V) 8855 900 (V) 1630 2x4" 2x4" 2x76 2x60 8 3
... 1004 D 2290 (V) 8855 900 (V) 1820 2x4" 2x4" 8 3
... 1005 A 2290 (V) 10955 900 (V) 1480 2x4" 2x4" 2x76 2x60 10 4
... 1005 B 2290 (V) 10955 900 (V) 1720 2x4" 2x4" 2x76 2x60 10 4
... 1005 C 2290 (V) 10955 900 (V) 1960 2x4" 2x4" 2x76 2x60 10 4
... 1005 D 2290 (V) 10955 900 (V) 2200 2x4" 2x4" 10 4
BCD
S/BD
DS,
BC
DL/
BDD
L, B
CD
Q/B
DD
Q,
BCD
R/B
DD
R
N° N°
BCD
S/BD
DS,
BC
DL/
BDD
L, B
CD
Q/B
DD
Q, B
CD
R/B
DD
R B
CD
T/BD
DT,
BC
DS/
BDD
S, B
CD
L/BD
DL,
BC
DQ
/BD
DQ
, BC
DR
/BD
DR
Outlet Inlet OutletKg
Condenser and Dry Cooler Dual
Model Code
Dim ension Weight Dry Cooler Condenser Fans Feet
Inlet
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General Description
RECEPTION
The equipment is received in pallets with the following dimensions:
Carefully inspect all equipment upon arrival to detect any shock marks or damage of the nyloncoverage over the pallet that could cause damage to the equipment.In case of damage during transportation, the transportation company and AL (or one of its agents)must be informed immediately by note/reservation written on the document of the delivery.Then, the customer should complete a written report including pictures concerning each relevantdamage.
STORAGE
If the equipment has to be stored before its installation (one or more months) it is convenient to takethe following precautions:
1.- Leave the equipment in its packing.
2.- Store it indoors, in a room with adequate conditions, temperature (15 to 25 º C) andhumidity ( 50 to 70 % ).
3.- In an environment without corrosive liquids or vapours.
PACKAGING FOR BCD / BDD MODELS
Length Width Height
2 404 97cm 244cm3 579 97cm 244cm4 754 97cm 244cm5 929 97cm 244cm6 1104 97cm 244cm2 474 97cm 244cm3 684 97cm 244cm4 894 97cm 244cm5 1104 97cm 244cm2 474 97cm 244cm3 684 97cm 244cm4 894 97cm 244cm5 1104 97cm 244cm
Packing Dimensions
800
900
1000
Fan
diam
eter
N° o
f fan
s co
uple
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(This operation should be done at the mounting site)
General decription
UNPACKING
Take off the wrapping cover leaving the equipment on the pallet.
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Provisions for Mounting
Layout
The following aspects should be considered before mounting:
a) Verify the structure supporting capacity regarding the weight of the equipment.
b) Avoid the installation in closed locations.
c) When walls are present, followthe distances recommended byAlfa Laval.
d) Special care should be taking in following the minimum distances recommended,particularly in cases for installations with two or more units, either horizontal or vertical,in areas with strong winds.
YES
GRID
GRID
n° UNITS
NO NO
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Provisions for Mounting
Bases
For horizontal equipment:
To avoid the oxidation of the equipment’s legs, it is recommended to lean them on concrete bases of about 4inches (10 cms.) high (one base for each leg).The basement should be oversized in relation to the plate on the foot
For vertical equipment:
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Mounting
Vibration isolators
For active and passive isolation of vibrations andreducing noise transmission, Alfa Laval strictlyrecommends the installation of anti-vibration dampers.
MATERIALIsolator: Natural rubber.Frame: Galvanized steel, with yellow Zinc treatment.
Install the anti-vibration attachment between theequipment and the base. (For Horizontal mounting)
WEIGHT AND VERTICALLIFTING EYEBOLTS’ TABLE
Models Code Num. of
legsQty. of
isolators,,,802 4 2,,,803 4 2,,,804 6 3,,,805 8 4,,,806 8 4,,,902 4 2,,,903 4 2,,,904 6 3,,,905 8 4
,,,1002 4 2,,,1003 4 2,,,1004 6 3,,,1005 8 4
Vibrations' IsolatorEach Kit contain 2 units
BC
DS/
BD
DS,
BC
DL/
BD
DL,
B
CD
Q/B
DD
Q, B
CD
R/B
DD
R,
BC
DT/
BD
DT
Models Code Ømm Qty. Weight,,,802 30 4,,,803 30 4,,,804 30 4,,,805 30 8,,,806 30 8,,,902 30 4,,,903 30 4,,,904 30 4,,,905 30 8
,,,1002 30 4,,,1003 30 4,,,1004 30 4,,,1005 30 8
BC
DS/
BD
DS,
BC
DL/
BD
DL,
B
CD
Q/B
DD
Q, B
CD
R/B
DD
R,
BC
DT/
BD
DT
See
page
13
Eyebolts
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Mounting
See first «Unpacking» in page 15.See first “Provisions for mounting” in pages 16 and 17.
All units are supplied with supports for vertical installation but, if requested, kits with supports andscrews for horizontal mounting can be provided.
For both cases the procedures are as follows:
Vertical Installation
1. Lift the equipment removing the pallet. 2. Place it on top of the bases andfix it with anchor bolts.
Vertical lifting eyebolt(See tables on page 18)
Horizontal Installation
1. Lift the equipment as is done forvertical mounting.
2. Lean it on an trestle.
3. Remove the lifting eyeboltand the vertical supporting leg.
Lifting eyebolt
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Appoggiare sulla struttura portante, non sul pacco alettato!
Mounting
4. Fix the horizontal legs to the equipment with screws.
Let it sit on the load-bearing frame andnot on the coil!
Lift the unit and secureits legs
Move the eyebolt andmake sure that it istightened beforelifting the unit
5. Lift the equipment placing the hooks as is shown in the figures, according to the differentmodels. Then fix the equipment to the bases with anchor bolts.
Use a rocker arm tolift the unit
Use a rocker armto lift the unit
The min. lifting anglebetween the belts and theunit must be 60°
Use a rocker armto lift the unit
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Mounting
PIPING CONNECTIONS
Coolers:
The equipment are delivered with the following connections:
• BSP threaded, male, in this case the installer should insert a double joint fordisassembling.
• PN 16 DIN Flanged
Tools and accessories for lifting
• Open end or combination wrenches kit, (sizes from 10 to 20 millimeters).
• Ø 12 mm Steel slings.
• Lifting system with capacity according to weight table, page 13.
• Lifting devices:
o UPN 10 Steel section, length 2 to 3 meters (2 and 4 Fans).
o UPN 12 Steel section, length 3 to 6 meters (3 and 5 Fans).
The water hammer is a pick of pressure of short duration that canappear during the starting or the shutdown of a system, making theliquids to move through a pipe like a wave at the speed of the sound.This effect can produce considerable damages to the equipment.
Important
a) The pipe’s sizes should be in accordance with the IN and OUTconnection’s diameter of the coil.
b) To avoid the water hammer effect, regulating valves (preferably) shouldbe installed at the input and output of the external circuit of theequipment. It should be mounted as close as possible to the equipment,so the normal maintenance could be carried out without draining thehydraulic installation.
c) To verify the operation, thermometers at the input and output of theequipment should also be installed..
d) All the threads should be covered with TEFLON to ensure tightness.
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Mounting
Steps to follow:
1. The external piping to the equipment should be ready and made by the customer.
2. Remove the covering panel before making the connections (condenser).
3. Once the piping has been installed, and before connecting to the equipment, the cleaning of thepipes should be carried out with a compressed air sweeping (condenser) or with water (drycooler), in order to avoid dirt and welding residuals.
4. Check the alignment of the piping with the input and output ends of the equipment.
Do NOT bend theconnections!
Align the piping with theequipment’s connection.
Ensure a min. slope of 1% in the liquid line,between the discharge and liquid receiver.
Condensers:
The equipment is delivered with the following connections:• BW Type Cooper tube connection for welding.
The following diagram shows the recommended installation:
Antivibrationdampers
Dry coolers:
Antivibrationdampers
KEYPiping temperature probe
Ball valve
Conveyed drain
Spring safety valve
Antivibration joint
Butterfly valve
Basket filter
Piping temp. meter
Piping gauge
3-way valve with modulatingelec. or magnetic servo control
Condenser
Dry cooler
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Mounting
Important
a) Size the pipes to minimize the pressure drop and to obtain the coolant speedvalues to assure the oil drifting.
b) In the delivery line, between the compressor and the condenser, install an antivibration device to reduce the noise and vibration transmission along the line.
c) Be sure that the line for liquid should have a minimum gradient of 1%, betweenthe liquid discharge and the receiver.
Important!Before making the connections, verify the presence of thepreloaded nitrogen for the dry maintenance of the circuit. In themulti- circuit condensers the refrigerating lines go from the LEFTto the RIGHT (horizontal version) or from above to down (verticalversion).
Welding the pipes:An overlapped welding is suggested to weld theexternal piping to the equipment, (cooper pipes) , forthe double purpose of assuring the staunchness andreducing the breaking risks in the welded area,generated by inducted vibrations.If the diameter of the pipes doesn’t allow thissolution, special female adapter should be used.Before making the welding, disassembly the cap-label of the ½ ” gas valveand eliminate the preloaded nitrogen completely.
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Mounting (Optional)
Electric Board
Single switchboardVertical position1-3 couple of fans
Single switchboardVertical position 4-6 couple of fansOpt. speed control
Single switchboardHorizontal position1-3 couple of fans
Single switchboardHorizontal position 4-6 couple of fansOpt. speed control
The equipment is delivered from the factory with the electrical boardinstalled in the final installation position. A different placement requiresdifferent electrical board and manifold cover plate.
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Electric Installation
Electric Installation
The customer should provide the following electrical connections:
Power supply
Three phase : 3 x 400 / 415 Volts – 50 / 60Hz (according to the purchase order)
Single phase : 1 x 220 / 230 Volts - 50 / 60 Hz (according to the purchase order)
Electric board provision
UnitOptional Alfa Laval deliveryCustomer SupplySupply in according to order
_
Main power supply
Free cooling remote signal
Remote signal slave mode control Remote signal speed controller fault
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Electric Installation
FUNCTIONAL OUTLINE
MAIN SWITCH ON/OFF
Tk Thermistor included in thestator’s winding
SWITCH ON / OFF
Auxiliary contacts: 2Rated current: 16 AVoltage protection: 600 voltsCable: VDE 7030Protection class: IP 65
Grounding
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.
Electric fans
The standard 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.
Attention:To carry out safe maintenance operations, an ON / OFF Switch should be installed close to theequipment.
Attention: The ground connection is required by law
Attention: Ground resistance should be lower than 3 ohms
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Operation
STARTING THE DRY COOLERS
I. Before starting, check that all the equipment fastening screws are perfectly tighted.
II. Check that the equipment inlet valve is closed and the outlet valve is fully open.
III. First, open the vent valve and then start the liquid feeding pump.
IV. Open the equipment inlet valve slowly, until reaching the designed flow.
V. When the whole air in the equipment was discharged, close the vent valve. Make sure thatthe whole circuit, including the external piping, is free of air.
VI. Once the equipment is full with liquid, start the fan(s) and check the proper fan rotation asshown in the label.
VII. Verify that there are no leaks in the equipment neither in the circuit.
See page 22
Operating the equipment:
1. Check the liquid inlet and outlet temperatures.
2. Check the fluid flow rate.
3. Check the outlet pressure (condenser).
4. Control that the current load indicated on a current clamp tester is equal or slightly lower thanthe rated, when the fan(s) are running at rated rpm.
It is important to follow the starting procedure every time youwant to start the equipment.
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Operation
Shutdown
If the unit requires emptying for maintenance or system shutdown, proceed as follows:
1. Stop the system and then open the vent located on the highest part of the circuit.2. Open the drain valve (that has to be fitted by the installer) and wait until the system is empty.3. When drainage is completed, ice formation is prevented by adding to the unit the amount of
anti-cooling mix shown in TAB. 3.
STARTING THE CONDENSERS
1. Carry out a vacuum phase by connecting to the coupling for equipment loading.
2. Load the system with refrigerant gas.
3. 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 followingprocedure should be performed:
1. Isolate the equipment.
2. Collect the refrigerant liquid.
3. Disconnect the circuit and flush the equipment with nitrogen.
When not in use, leave the equipment loaded with dry nitrogen.
Air T. (°C) Glycol % (kg/kg)0 10-5 20
-10 30-15 35-20 40
<-20 50
TAB. 3
See installation diagram on page 22
For the correct operation of the equipment, Alfa Laval original spares should be used.
Attention!: Before attempting any maintenance operation, make sure thatthe power supply is properly disconnected
Follow the start-up procedures whenever the equipment is started up.
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Periodic preventive controls
Every three months the following controls should be performed:
1. Check the equipment fastening.
2. Verify that the electric connection terminal studs are properly tight, to avoid losses and wear dueto sparks.
3. Verify the good condition of the wiring (it should not have cuttings or deterioration signs).
4. Check the electrical resistance of the ground connection (ohms).
5. Use an ammeter to check that the current absorbed is equal to or slightly lower than the ratedvalue when the fan(s) work(s) at rated speed.
6. Check the fan vibration level.
Cleaning the equipment
To guarantee the thermal efficiency of the equipment, it is necessary to eliminate the dirt deposited inthe coils, on the suction side. A low pressure water jet and/or non aggressive liquids can be used.A cleaning is recommended every three months, but this frequency should be defined according with theenvironment where the equipment is installed.
Maintenance
Attention: Before attempting to make any maintenance, the power supply should be turnedoff from the sectional board. For further security, the operator can also turn the switch ON /OFF to the OFF position to avoid accidents.
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 eachtime.
ACQUA P max < 1.5/2 Bar
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Maintenance
Tools and accessories for maintenance
o Open end or combination wrenches kit (millimeters), (sizes from 10 to 20mm)
o Open end or combination wrench kit (inches), (sizes from ½” to 2”)
o Adjustable wrench (3” opening)
o Oxyacetylene welding equipment / Gasket
o Ammeter
o Voltmeter
Troubleshooting:
PROBLEM POSSIBLE CAUSE SOLUTION
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
Air temperature too high Contact Alfa LavalAir temperature too low Excessive air flow through the condenserFaulty motor Replace
Line voltage lower than tolerance limits
Check the voltage value between phases with a voltmeter
Lack of a phaseMeasure the voltage between phases, check the power supply line
Overloaded motor Check with an AmmeterFan break Blockage or shocked Replace
Condensation pressure too high / outlet fluid temperature too high
Condensation pressure too low Adjust the condenser pressure regulation
Fans not running
EN
31
Maintenance
REPLACEMENT OF MOTORS
Control the correct operation of the electric fans periodically.In the event of electric or mechanical failures, the motor should be replaced as follows:
1. Make sure that the power supply has been switched off, by placing the security switch in theOFF position.
2. Then, open the electric motor derivation box, disconnect and remove the electric wires.
3. Place the new fan motor and install it.
4 Place the protection grid.
5. Make the electric connection.
6. Check the correct rotating direction.
Panel
Fan grid
EN
32
CODE DESCRIPTIONA COILB FAN COWLC COVER PLATE CONNECTIONS SIDED COVER PLATE BENDS SIDEE SUPPORT LEGF FAN
Spare Parts
See Spare Parts section on RCPL
IM100527-GB-IT 2006-01
Montaggio/Mounting Sostituisce/Replace pag.18
Isolatori di vibrazioni Alfa Laval consiglia vivamente l’impiego di antivibrazioni per isolare l’apparecchiatura sia in modo passivo che attivo dalle vibrazioni stesse e per ridurre conseguentemente la trasmissione di eventuali rumori. MATERIALE Isolatore: Gomma naturale 60° ShA. Telaio: Acciaio zincato trattato con zinco giallo. Installare il dispositivo antivibrazioni tra l’apparecchiatura e il basamento. (Per l’installazione orizzontale)
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)
Series Model N° FAN Qty.
Of isolators Kit Code
BDD/BCD (S,L.Q,R,T) 800 2 4x60626031 10999078 BDD/BCD (S,L.Q,R,T) 800 3 4x60626031 10999078 BDD/BCD (S,L.Q,R,T) 800 4 6x60626031 10999079 BDD/BCD (S,L.Q,R,T) 800 5 8x60626031 10999080 BDD/BCD (S,L.Q,R,T) 800 6 8x60626031 10999080 BDD/BCD (S,L.Q,R,T) 900-1000 2 4x60626031 10999078 BDD/BCD (S,L.Q,R,T) 900-1000 3 4x60626030 10999072 BDD/BCD (S,L.Q,R,T) 900-1000 4 6x60626031 10999079 BDD/BCD (S,L.Q,R,T) 900-1000 5 8x60626031 10999080
Questi dispositivi antivibrazioni sono forniti sprovvisti di bulloni e dadi.
These dampers are delivered without bolts and nuts
Schema di montaggio
Mounting scheme
page 2/2
Cod. 60626030
Cod. 60626031
IM100527-GB-IT 2006-01
Montaggio/Mounting Sostituisce/Replace pag.21
CONNESSIONI IDRAULICHE Raffreddatori: Questa apparecchiatura viene fornita con le seguenti connessioni:
� BSP filettato, maschio, in questo caso l’installatore dovrebbe inserire una doppia giuntura per permettere lo smontaggio.
� PN 16 DIN flangiato.
PIPING CONNECTIONS Coolers: The equipment are delivered with the following connections:
� BSP threaded, male, in this case the installer should insert a double joint for disassembling.
� PN 16 DIN Flanged
Importante a) Il dimensionamento delle tubazioni deve rispettare il diametro di attacco IN e OUT della bobina (batteria). b) È possibile evitare l’effetto del colpo di ariete installando delle valvole di regolazione (preferibilmente) all’ingresso e all’uscita del circuito esterno dell’apparecchiatura. Dovrebbe essere montata il più vicino possibile all’apparecchiatura così che le operazioni di manutenzione possano avvenire senza dover svuotare il circuito idraulico. c) Per controllare il funzionamento dell’apparecchiatura si devono installare dei termometri all’ingresso e all’uscita della stessa. d) Rivestire tutte le filettature con del TEFLON per assicurarne la tenuta.
Important a) The pipe’s sizes should be in accordance with the IN and OUT Connection’s diameter of the coil. b) To avoid the water hammer effect, regulating valves (preferably) should be installed at the input and output of the external circuit of the equipment. It should be mounted as close as possible to the equipment, so the normal maintenance could be carried out without draining the hydraulic installation. c) To verify the operation, thermometers at the input and output of the equipment should also be installed.. d) All the threads should be covered with TEFLON to ensure tightness.
Il colpo di ariete è un picco di pressione di breve durata che può manifestarsi durante l’avviamento o lo spegnimento di un impianto e che costringe i liquidi a muoversi nel tubo con un’onda alla velocità del suono. Questo fenomeno può causare notevoli danni all’apparecchiatura.
The water hammer is a pick of pressure of short duration that can appear during the starting or the shutdown of a system, making the liquids to move through a pipe like a wave at the speed of the sound. This effect can produce considerable damages to the equipment.
Coppie di serraggio:
Tightening:
DN PN Tightening
(Nm)
25 10/16 40 40 10/16 50 50 10/16 55 65 10/16 60 80 10/16 60
100 10/16 80 125 10/16 80 150 10/16 80 200 10 80
page 2/2
IM100527-GB-IT 2006-01
Attrezzi e strumenti per il sollevamento
� Kit di chiavi fisse doppie oppure composte (da 10 a 20 mm).
� Catene in acciaio con diametro da 12 mm. � Sistema di sollevamento con capacità in
conformità con la tabella di pagina 13. Barre di sollevamento:
� Barra in acciaio UPN 10 con lunghezza pari a 2-3 metri (2 e 4 ventilatori);
� Barra in acciaio UPN 12 con lunghezza pari a 3-6 metri (3 e 5 ventilatori).
Tools and accessories for lifting
� Open end or combination wrenches kit, (sizes from 10 to 20 millimeters).
� Ø 12 mm Steel slings. � Lifting system with capacity according to
weight table, page 13. Lifting devices:
� UPN 10 Steel section, length 2 to 3 meters (2 and 4 Fans).
� UPN 12 Steel section, length 3 to 6 meters (3 and 5 Fans).
