Polar Cat UNIT AIR COOLERS Polar Cat G LIQUID CIRCULATED AIR COOLERS
MANUAL
A. INSTALLATION INSTRUCTIONS B. SERVICE INSTRUCTIONS C. DECLARATION OF CONFORMITY Alfa Laval Vantaa Oy Ansatie 3, FI-01740 Vantaa, Finland Tel. +358-9-894 41, fax +358-9-894 4318 www.fincoil.fi; www.alfalaval.com SKA 02.05.2005/18.4.2008/7.2.2012
A. INSTALLATION INSTRUCTIONS 1. GENERAL Polar Cat unit air coolers are suitable for cold and subzero rooms in refrigeration plants using refrigerants and liquids, which do not corrode copper.
The Manual also concerns E-model, where applicable (E = non-standard model). In these cases you always have to check from delivery documents, in which way the difference has to be taken into notice in installation, service and use.
2. TRANSPORT AND STORAGE Polar Cat unit air coolers, sizes 101, 102 and 104, are delivered in carton package. All other sizes are packed in board crates.
During transport the products are fixed with their roof supporting trails into transport pallet (fig. 1), (excl. sizes 101, 102 and 104). When products are stored one upon the other, please note the ”light-construction” of the packing (i.e. max. 4 packages on each other).
Products may not be stored in humid outdoor spaces.
3. LIFTING Before lifting the equipment, please, turn the packing very carefully from transport position into lifting position and remove the crate (sizes 103, 105, 106 and 107) and the cover plate (sizes 108…116,) (fig. 1 and 2).
Use the bottom plate of the packing when lifting the equipment (fig. 3 and 4).
Fig. 1 Fig. 2 Fig. 3 Fig. 4
4. PLACING Polar Cat unit air coolers and liquid coolers shall be mounted so that their air flow is not obstructed and there is nothing to prevent it in front of them (fig. 5).
Fig. 5 It is recommended to leave space at both ends and under the air coolers for service and cleaning.
In models equipped with electric defrost space is needed for changing the defrost rods of heat transfer section (fig. 6).
Fig. 6
5. PLEASE NOTE AT INSTALLATION • Before fastening the equipment check at site possible transport damages, especially those in heat
transfer section. The supplier is not responsible for the costs caused by broken equipment as a result of faulty handling or transport.
• Check the endurance of fixing point constructions before installation. • Air coolers and liquid coolers are installed in such a way that the tubes of heat transfer section
are in horizontal position. • Trouble free operation of liquid coolers demand good air venting in the system. • As to drip tray outlet note that the tray must be opened and removed for cleaning and changing
the defrost heater. • All soldering in heat transfer section is made by hard solder (FOSCO 710/DIN8513/LAg2P).
6. TUBE CONNECTIONS EVAPORATOR G-MODEL (liquid circulated)
7. ELECTRIC CONNECTIONS Location of junction boxes (fig. 8)
• Polar Cat, sizes 101, 102 and 104: motors´ junction box at the opposite end of air cooler as tube connections (2).
• Polar Cat, sizes 103, 105…116: junction boxes in the middle of fans (1). • Junction box for electric defrost (SS) at the opposite end as tube connections (3). Fig. 8
8. FANS Polar Cat, sizes 101, 102 and 104 are equipped with 1-phase shaded-pole motors. The fans are wired into the junction box on the cooler end.
Polar Cat, sizes 103, 105…113 are equipped with 1- or 3-phase external rotor motors.
Polar Cat, sizes 114…116, have 3-phase external rotor motors.
Polar Cat 101, 102 and 104: connection diagram (1-phase shaded pole motor)
Power supply: 1/230 V, 50 Hz Fan: diam. 254, 1400 rpm
A = liquid tube connection B = suction tube connection C = drip water connection D = liquid in E = liquid out F = venting screw G = drain screw
Polar Cat 103, 105…113 (1-phase fan units) Power supply: 1/230 V, 50 Hz Fan: Diam. 350 1400 rpm model EBM Diam. 450 1400 rpm model ZIEHL
Thermal protectors not connected Thermal protectors connected
The fans are equipped with an internal thermal protector (TW or TK), which can be connected to control the contactor. Polar Cat 103, 105…116, connection diagrams (fan units, 3-phase) Power supply: 3/400 V, 50 Hz Fan: diam. 350 EBM 4-pole 1400 rpm Y connection
(Do not use D-connection, which causes motor burning!)
diam. 450 Ziehl 4-pole 1400/1150 rpm D/Y connection diam. 500 Nicotra 4-pole 1400/1150 rpm D/Y connection diam. 350 Ziehl 6-pole 900/700 rpm D/Y connection diam. 450 Ziehl 6-pole 900/700 rpm D/Y connection diam. 500 Nicotra 6-pole 900/700 rpm D/Y connection Power supply 3/440 V, 60 Hz: fan speed ca 1.2x the fan speed used with 3/400 V, 50 Hz network. Power supply: 3/230 V, 50 Hz Fan: diam. 350 EBM 4-pole 1400 rpm D connection diam. 450 Ziehl 4-pole 1400/1150 rpm D/Y connection diam. 500 Ziehl 4-pole 1400/1150 rpm D/Y connection diam. 450 Ziehl 4-pole 700 rpm Y connection diam. 500 Nicotra 4-pole 700 rpm Y connection
The fan speed can be regulated by changing the voltage (in 50 Hz network).
D connection Y connection
”TW” and “TK” markings mean thermal protectors in fan motors. If thermal protectors are used, they are connected to control the fan’s contactor. 9. FANS´ POWER VALUES
The type shield indicates power values at temperatures of +20 °C and –30 °C. For defining the set value of overload protector the power value at other temperatures might be required. It can be linearly calculated by using the above mentioned points. E.g. the power value corresponding to –20 °C can be calculated by multiplying the power value corresponding to –30 °C (from the type shield) by the factor k from this diagram, at –20 °C.
L1 L2 L3 L1 L3L2
EBM
Ziehl Nicotra
10. DEFROST The Polar Cat air coolers can be equipped with electric defrost. SS = electric defrosting in coil and drip tray SS0 = low capacity electric defrost in coil and tray SP = electric defrost for fan openings NOTE! The defrost periods shall be adjusted so that the coil block will not be frozen in. The defrost capacities of models SS, SS0 and SP Polar Cat SS total SS0 total SP
Connections of the models with electric defrost - Max. defrost period is 45 minutes. - The defrost heaters of the coil block and drip tray are pre-wired to the junction box. - The connection diagram of the electric defrost will be enclosed in the packing.
Defrost heater symbols used in the connection diagram
11. CHECKINGS The equipment has been pressure-tested at factory.
• Make sure that the equipment is firmly attached at installation site. • Check the attachment points of mechanical parts. • Check suitability of the power supply. • Check the electric installations. • After electric installations check that the fans run properly and that their rotating direction is
correct.
Pair of electric heaters Electric defrost for fan opening Heater element in drip tray Contact plug series
12. ADDITIONAL REMARKS NOTE! Venting/draining valve of Polar Cat G standard units are not adapted for refrigerant based on potassium formiate; DANGER OF LEAKAGE! When using a refrigerant, which is based on potassium formiate, it has to be checked from the documents if the heat transfer section’s piping system and the venting/draining valves are adapted for the refrigerant. Instructions from refrigerant supplier have to be followed at installation, pressure test, use as well as in maintenance NOTE! Applicability of the material of fins and heat transfer tubes to ambient conditions shall always be checked to avoid external corrosion. In the air there should be no particles, which - together with water or other solvent condensing on the surface of the heat transfer section - might form corrosive combinations. These combinations can corrode the fins and tubes of the heat transfer section
B. SERVICE INSTRUCTIONS
1. GENERAL Trouble free operation of Polar Cat air coolers and liquid coolers requires weekly service. WARNING: Before starting service operations make sure that the circuit is reliably switched off!
In the weekly service please check: • Outward condition of the equipment • Fixing of the equipment and its fans • Defrost system • Cleanness of heat transfer section • Drainage
2. HEAT TRANSFER SECTION AND DRIP TRAY Heat transfer section needs regular service, if it is in use in dirty conditions or if running conditions require special cleanness. Heat transfer section can be washed by a pressure washer. The washer’s water jet may not bee too strong and must be directed perpendicularly to the fin side not to make the fins bend. No strong alkaline detergents or acids may be used. Recommendable detergent is e.g. ENVIRO-COIL. After opening the hinged drip tray the heat transfer section can be washed on both sides. Whole fan box can be cleaned and disinfected, if necessary. Drip tray is removable, which facilitates washing in a separate washing room.
Opening and removing the drip tray • Remove the drip tray outlet. • Support lugs on outlet tube connection side of drip tray form the hinge, when their fixing screws are opened enough (do not unscrew them!). • Loosen the coach screws on pressure side of drip tray to open it. Do not let the drip tray open automatically, because the support lug or drip tray edge can be damaged. • Loosen the drip tray by removing the coach screws of support lugs. NOTE! If a SS-model is in question, disconnect the plug of drip tray’s defrost heater cable before loosening the drip tray.
3. FANS Polar Cat 101, 102 and 104: 1-phase shaded-pole motors, fan blade diam. 254 mm Polar Cat 103, 105…116: 1- or 3-phase external rotor motors, diam. 350, 450 and 500 mm Should the fans make any rattling or scratchy noise, stop them immediately to check their fixing. If necessary, replace the motor or the whole fan. NOTE! During stand-stills the fans must be allowed to run for 3...4 hours at least once a month.
4. REPLACING A DAMAGED MOTOR OR FAN UNIT Note that an authorized person may only replace the electric motor. WARNING: Before changing the fan motor make sure that the circuit is reliably switched off!
Polar Cat 101, 102 and 104 • Open the drip tray (see ”Opening and removing of drip tray”). • Open the cover plate on the side of motors´ junction box (see ”Electric connections”, fig. 8). • Open the cover of motor’s junction box. • Release the cables of the damaged motor from the connection strip. • Open the nut caps of the fan guard and remove it. • Remove the fan blade from motor by unscrewing blade’s fixing nut. • Remove motor-bracket system from fan plate and take it out through fan opening. • Remove the damaged motor from motor bracket and replace it. • Re-installation of the fan in reverse order.
Polar Cat 103, 105…116 (fig. 9)
• Open the fan’s junction box (1) and make sure that the motor has been switched off. • Release the electric cable (2). • Open the fan by unscrewing 4 fixing screws (3). • Re-installation of the fan in reverse order. • After installation test-run the fan, check the rotation direction and other function visually.
Fig. 9
5. CHANGING DEFROST HEATERS Defrost heaters may only be changed by an authorized person. !WARNING: Before changing defrost heaters make sure that the circuit is reliably switched off!
Changing defrost heaters in heat transfer section (fig. 10)
• Open the cover plates at both ends (1). • Open the cover of junction box (2). • Release cables of the damaged heater couple from the connection strip. • Remove the locking plates of heater rods (at the end with return bends (3). • Cut off the cable between heater rod couple (at header end) (4). • Draw out both parts of heater rod couple (at header end). • Check that in new heater rods the locking plates (3) are in place (at the end, where the rods are attached to each other). • Pass the rods simultaneously in place. To facilitate this use a thin tube, into which the cable fits and which slides through the coil in front of the rod. • When the rods are in position, fasten the locking plates at their ends. • Fasten electric wires to their original places. • Close the junction box cover and cover plates at the ends. • During the first defrost period make sure that the defrost system works perfectly.
Changing heater element of drip tray In Polar Cat air coolers a heater element is glued on the bottom of drip tray. • Open the cover plate at the cooler end (with return bends) (1). • Open the junction box cover. • Loosen the heating element cable from connector. • Remove the drip tray from air cooler (see ”Opening and removing of the drip tray”).’ • Remove insulated drip tray by loosening the screws on drip tray sides and ends. • If the heating element has not been changed earlier, a new element can be glued upon the old one. Because the heating element is located in insulated place, the old element will not hinder defrosting. • If the heating element has been changed earlier, remove either both or at least one of the elements. Loosen the old element by drawing from element edge. Be careful not to damage the drip tray! • Before removing the old element loosen the male connector from the cable, slacken off the cable clamp (5) and draw the cable (6) through. • Loosen the heating element’s earth conductor (8) from drip tray. • If the old element remains there, remove its connectors by cutting them off. • Before gluing the new element (7) clean the base (e.g. with ethanol) and let it dry. • Start gluing at the drip tray end and go on lengthwise to another end. Remove first about 10 cm of the cover paper, adjust the element so that the hole of outlet tube connection and the tube connection itself match each other. Press the element head in its place. Continue gluing by drawing off cover paper and carefully pressing the element. Try to avoid air bubbles under the element. • Connect the heating element’s earth conductor to drip tray. • Thread the new element’s cable through drip tray inlet in its place and tighten the cable clamp (5). Cut the cable in the right length and switch on the connector. • Install the insulated drip tray in its place and the whole drip tray unit to the air cooler. Connect the plug to plug socket and check the function of heating element.
Declaration by the manufacturer of the component incorporated to the machinery (Directive 2006/42/EC, Annex II, sub.B)
ALFA LAVAL VANTAA OY Ansatie 3, FI-01740 Vantaa, Finland herewith declares that the component PC, PCD, PBD, PCJ, FMP, FSS, FKS, FTPE air cooler PCG, PCDG, , PBDG, PCJG, FMPG liquid cooler which is not able to function independently is intended to be incorporated into machinery or to be assembled with other machinery to constitute machinery covered by Directive 2006/42/EC and changes related to it and with national implementing legislation meant machinery. By designing of the component the following directives have been applied: 2006/42/EC, 2004/108/EC, 97/23/EC and the following harmonized standards have been applied: EN ISO 12100:2010, SFS-EN ISO 13857, SFS-EN 60204-1, SFS-EN 61000-6-1, SFS-EN 61000-6-3, SFS-EN 61000-6-4 and furthermore declares that is not allowed to put the machinery into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of Directive 2006/42/EC and with national implementing legislation including the machinery referred to in this declaration. Vantaa, February 7, 2012
Silja Beierschoder Quality Manager
