MANUAL

SCAL, SCCL, SEpL AIR COOLED CONDENSERS SCAG, SCCG, SEpG AIR COOLED DRY COOLERS

Please maintain the instructions for the whole product life cycle!

Author: 3.1.2005 / SKA Revision: 21.5.2012/SBR Alfa Laval Vantaa Oy Ansatie 3, FI- 01740 Vantaa, Finland Tel. +358 9 89441, fax +358 9 8944 318 www.fincoil.fi; www.alfalaval.com Subject to changes without prior notice. Original instruction

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TABLE OF CONTENT

TABLE OF CONTENT ...................................................................................................................................................... 1 1 PRODUCT SPECIFICATION .................................................................................................................................. 2

GENERAL ..................................................................................................................................................................... 2 1.2 TECHNICAL DATA ............................................................................................................................................... 2 1.3 IDENTIFICATION OF............................................................................................................................................ 2 PRODUCT ..................................................................................................................................................................... 2 1.4 ENERGY EFFICIENCY CLASSIFICATION ........................................................................................................ 2

NOTE ! ...................................................................................................................................................... 2 1.5 PRODUCT SAFETY ............................................................................................................................................... 3 1.6 TERMS USED IN THE MANUAL ........................................................................................................................ 3

2 TRANSPORT AND STORAGE .............................................................................................................................. 4 2.1 PACKING, CONTENTS AND HANDLING OF PACKAGE ................................................................................ 4 2.2 STORAGE ............................................................................................................................................................... 4 2.3 TURNING AND LIFTING THE UNIT .................................................................................................................. 5 2.4 DISCHARGE AND RECYCLING OF PACKING MATERIALS ......................................................................... 6

3 INSTALLATION INSTRUCTIONS ........................................................................................................................ 7 3.1 PLACING ................................................................................................................................................................ 7

Placing of a unit with horizontal air flow ....................................................................................................... 7 Placing of a unit with vertical air flow .......................................................................................................... 8

3.2 INSTALLATION REMARKS ................................................................................................................................ 9 3.3 SET-UP FOR INSTALLATION ............................................................................................................................. 9 3.4 TUBE CONNECTIONS .......................................................................................................................................... 9

Condensers ............................................................................................................................................... 9 Dry coolers .............................................................................................................................................. 10

3.5 FANS AND FAN CONNECTIONS ...................................................................................................................... 10 3.6 FANS´ POWER VALUES .................................................................................................................................... 11 3.7 OPTIONS ............................................................................................................................................................... 11

Water spraying system (D) ..................................................................................................................... 11 Stepwise (SC) and stepless (SVC) fan speed control ............................................................................ 12 Vibration dampers (T) ............................................................................................................................. 12

3.8. CHECKINGS BEFORE START-UP ................................................................................................................... 12 4 SERVICE INSTRUCTIONS .................................................................................................................................. 13

4.1 SERVICE INSPECTION ....................................................................................................................................... 13 4.2 HEAT TRANSFER SECTION .............................................................................................................................. 13 4.3 HEAT TRANSFER SECTION .............................................................................................................................. 14 4.4 REPLACING THE FAN BLADE ......................................................................................................................... 15 4.5 REPLACING THE FAN MOTOR ........................................................................................................................ 15

5 DISCARDS AND RECYCLING ............................................................................................................................ 16 5.1 RECOVERY OF REFRIGERANTS ..................................................................................................................... 16 5.2 DEMOLISHING THE UNIT ................................................................................................................................. 16 5.3 MATERIAL RECYCLING AND DISCHARGING ............................................................................................. 16

6 ADDITIONAL REMARKS .................................................................................................................................... 16 7 TROUBLESHOOTING .......................................................................................................................................... 17 8 ELECTRICAL SAFETY CHECKLIST ................................................................................................................. 19

8.1 LOCKOUT AND TAGOUT ................................................................................................................................. 19 8.2 DIAGNOSING A PROBLEM WHERE POWER IS REQUIRED ....................................................................... 19 8.3 TOOLS AND EQUIPMENT (PPE) ....................................................................................................................... 19

Verify with a testing device .................................................................................................................................... 19 Lockout/Tagout ....................................................................................................................................................... 19

9 LIFTING INSTRUCTIONS ................................................................................................................................... 20 DECLARATION OF CONFORMITY…………………………………………………………………………………………………………..21

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1 PRODUCT SPECIFICATION

GENERAL

SCAL, SCCL, SEpL air cooled condensers and SCAG, SCCG, SEpG dry coolers are designed for outdoor use in commercial and industrial refrigeration plants using refrigerants and solutions, which do not corrode copper

To avoid outer corrosion on heat transfer section always make sure that material of fins and heat transfer tubes is suitable for ambient conditions. The air may not include any particles, which together with condensing water or any other solvent might form corrosive combinations on fins or heat transfer tubes. The manual also concerns E-models (E= non-standard model). In these cases please always check from the delivery documents, in which way the difference has to be taken into notice in installation, service and use.

1.2 TECHNICAL DATA Please see the product leaflet at http://www.fincoil.fi for technical data, product designation, performance data, lifting/fixing points of fan motors, weights, internal volumes, position of connections.

1.3 IDENTIFICATION OF PRODUCT Please check the identification data on the product nameplate! This nameplate is located at the end with inlet connections. The product nameplate includes contact information of the manufacturer, product designation, number of order acknowledgement, technical data of fan motor, operating/test pressure, min/max operating temperature, internal volume, weight, month/year of manufacture and CE marking.

1.4 ENERGY EFFICIENCY CLASSIFICATION At the cooler end there is a label showing the energy efficiency class of the product according to Eurovent certification. Class Energy consumption Energy Ratio R

A Extremely low R> 110

B Very low 70< R <110

C Low 45< R <70

D Medium 30< R <45 E High R< 30

R=Nominal Capacity / Total input power of fan motors

Fig. 1.1: Picture on the above shows placement of product sign, picture on the right the product sign contents

NOTE ! Please follow these instructions to guarantee safe and correct installation, service and use of condensers (SCAL, SCCL, SEpL) and dry coolers (SCAG, SCCG, SEpG). Persons, who are responsible for installing, using or servicing condensers and dry coolers, must be familiar with the installation and service instructions. Please do not change or repair the unit without the manufacturer´s permission and instructions! The neglect to follow the instructions may result in warranty expiration.

Fig. 1.2: Energy efficiency class label

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1.5 PRODUCT SAFETY Each fan is equipped with a lockable safety switch and with fan guard (except central units with safety switch as an option). The wire spacing in the fan guard and the safety distance of the blade correspond to the safety standard concerning persons over 14 years. The safety guards are protections from contact only; please do not stand on them!

It is not allowed to climb on the coolers. If necessary, e.g. due to service operations, to climb on the unit, the fans have to be electrically isolated and reliably locked into off-position.

The units must always be installed in a place with no entrance of outsiders.

Please be very careful with lifting and transferring the units packed in an upright position. DANGER OF FALLING, see item 2 TRANSPORT AND STORAGE.

Before lifting please check from the transport documents or from the product nameplate the unit weight and make sure that the lifting device, crane or truck are appropriate.

The electric connections may be performed by an authorized electrician only.

Before starting the installation/service please always read through item 8 SAFETY CHECKLIST OF ELECTRICAL INSTALLATIONS.

Before starting the service operation make sure that the electrical supply is reliably isolated; use lock-out/tag-out system!

Before starting the service always check by voltmeter that the unit is electrically isolated and shut off.

Before switching on the unit always make sure that everyone is on a safe distance from the unit.

The refrigerant recovery of the SCAL, SCCL/SEpL units may be performed by an authorized contractor only.

The electric motors may be scrapped by an authorized contractor only.

1.6 TERMS USED IN THE MANUAL Warning and note

Models according to air flow direction:

WARNING ! Includes information, the negligence of which might result in accident or fatality.

NOTE ! Includes information, the negligence of which might cause damage to unit, environment, assembly or service.

Models with vertical air flow, fans in one or two rows (see fig. 1.3 on the right)

Models with horizontal air flow, fans in one or two rows (see fig. 1.3 on the right)

Fig. 1.3 Models according to air flow direction

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2 TRANSPORT AND STORAGE

2.1 PACKING, CONTENTS AND HANDLING OF PACKAGE Solar range air cooled condensers and dry coolers are transported in an upright or horizontal position on a wooden flat.

Both in upright and horizontal transport position the unit with vertical air flow is from its legs fixed into the wooden flat, legs installed in transport position. Lifting /turning lug, turning leg and horizontal leg support are delivered loose in the same package. Lifting/turning lug and turning leg are included in the package of the models packed in an upright position only.

The unit with horizontal air flow, packed in an upright position, is fixed into the wooden flat from a mounting rail. The lifting lug is delivered loose in the same package.

When lifting the package by forklift truck, please use the lifting point where the lengthwise centre of gravity is between the forklifts, in the middle. When lifting a long unit, please use as wide lifting position as possible.

2.2 STORAGE The products may not be stored in humid outdoor spaces, where water may condensate in their fan motors or in the tubing of heat transfer section. The motor bearings may be damaged by the humidity. Long standing humidity in the tubing of heat transfer section can cause formic acid corrosion . The units shall be stored in dry spaces with even temperature. During long term storage the fan motors must be driven for at least 30 minutes once a month.

If the above mentioned storage conditions cannot be guaranteed, a continuous low voltage must be lead into the motors to keep their surface temperature higher than the air dew point temperature.

In humid conditions, where the unit will not keep dry, some “white rust” can exist on the zink surface.

The units shall be stored fixed on their packing flats.

Do not keep the units stored on inclined or uneven plane.

Fig. 2.1 On the left: the unit packed in an upside position On the right: the unit packed in horizontal position

NOTE !

Be very careful when handling high units. Never place them on inclined or uneven plane due to DANGER OF FALLING!

Please check that the unit is tied tightly enough to prevent moving during transport. Take care that the unit is not damaged through binding.

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2.3 TURNING AND LIFTING THE UNIT

Before starting the lifting please make sure that:

• manual is included • necessary advance control has been made • lifting device has been checked and is functioning well • driver has the permission for lifting • ground under the unit has enough bearing capacity • machine/device is correctly erected and horizontally installed • support legs are in supporting position • lifting capacity of the device is sufficient • operators know, how to use the lifting device according to operation and safety instructions • there are no electric or other cables near to the lifting place • working area of the lifting device is sufficient and safe • there are no obstacles or risks on the working area

How to turn a unit with vertical air flow, packed in an upright position, into operating position:

• Fix the lifting /turning lugs (included in the delivery) into the fixing points on unit sides. Make sure that the lugs are tightly fixed!

• Hang the unit by crane from the lifting/turning lugs so that the lifting chain is tightening but the unit still stands on ground.

• Remove the unit from the transport flat. • Lift up the unit ca 0,5 m from the ground. Install the turning legs (included in the delivery) so that

the leg is ca 0,5 m outwards from the lower side of the unit. Fix the turning leg by screws into the side of the fan plate and of the unit leg being in transport position (see Fig 2.2). While fixing the legs, support the unit so that it does not swing or fall down.

• Put down the unit carefully so that the unit turns around the turning leg, to the direction of the centre of gravity. The crane is driven into the turning position and slowly put down into horizontal position.

• Remove the lifting/turning (for horizontal model) from the unit. • Remove the turning legs. • Hang the unit using the lifting points of the model with vertical air flow. Install the legs of the

vertical model into right installation height.

NOTE ! The unit may be lifted by an experienced operator only, who is familiar with the regulations and safety instructions concerning liftings.

WARNING! Do not stay under the unit being hanged!

NOTE !

The unit may be lifted by using the designed lifting points only.

For lifting and turning a model with horizontal air flow only appropriate lifting/turning lugs may be used (fig. 2.2.1).

For liftingf a model with vertical air flow only the lifting lugs designed for this purpose may be used (Fig. 2.2.4).

When lifting the unit, all lifting points in the direction of lifting shall be used.

The allowed angles for lifting device may not be exceeded.

When lifting long units, a lifting beam shall be used.

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2.4 DISCHARGE AND RECYCLING OF PACKING MATERIALS

Non-standard models (E) and copper coil (CC): check the unit weight from the product nameplate!

All packing materials are suitable either for recycling or for energy recovery.

NOTE ! The minimum length of a lifting chain, when no lifting channel is used = distance of lifting points.

max. 60o max. 60o

1. 3. 2.

4. 5. A

Figure 2.2.1…2.2.5 Turning and lifting of the unit

Table 2.1 : Distance between lifting points. It is recommended to use a lifting channel.

Distance Distance DistanceSCAL between Unit SCAL between Unit SCAL between Unit SCAG lifting points weight SCAG lifting points weight SCAG lifting points weight

A [mm] kg A [mm] kg A [mm] kg111 1400 240 152 4200 1300 253 6300 2770112 1400 260 153 5400 1600 261 7200 2730113 1800 320 221 3600 920 262 7200 2970121 2800 480 222 3600 990 263 8400 3320122 2800 520 223 4200 1110 264 7200 3200123 3600 640 231 1800 1370 265 7200 3430131 1400 720 232 1800 1490 266 8400 3590132 1400 780 233 2100 1670 267 8400 3860133 1800 960 241 3600 1830 271 5400 3190141 2800 960 242 3600 1980 272 5400 3460142 2800 1040 243 4200 2220 273 5400 3730143 3600 1280 251 5400 2280 274 5400 4000151 4200 1200 252 5400 2470 - - -

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3 INSTALLATION INSTRUCTIONS

3.1 PLACING Air cooled condensers and dry coolers should be situated so that there is no obstruction to air flow and that no hot air recirculation will occur. When choosing the installation site, please note, that the air flow from the units should be away from wind blowing against it. This concerns especially the models with horizontal air flow and with low rpm fans. When necessary, please use fairings. In dimensioning, the actual site temperature in the sun should be noticed. Please also note the effect of snow for the installation level of the unit. Placing of a unit with horizontal air flow

> B

B

> B/2

B

> B/2

> 2 x B

B B

> B

> B/2

B B

> B/2

Fig.3.1 Placing of a unit with horizontal air flow

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Effect of wind direction

Placing of a unit with vertical air flow

Two units with fans in one row ( B = 1630 mm ) can be installed side by side (please note the minimum distances shown in fig. 3.3). The leg height should be checked – when necessary, the units should be installed on a platform. If the wall is lower than the unit, the minimum distance between the unit and the wall is 0.5 x the minimum distance with a higher wall. If the units are surrounded by 3 or 4 walls, the minimum distances are longer and should be checked according to amount of units and their air flow. In exceptional cases please contact the product supplier/manufacturer!

A

> A / 4 B> B / 2

A

B > A / 4> B / 2

B> B

Fig. 3.3 Fans in one row, the wall higher than the unit height

Fig. 3.4 Fans in two rows, the wall higher than the unit height

> 2 x B

B >B

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1:100

3.2 INSTALLATION REMARKS • Before installation please check at site possible transport damages, especially those in heat transfer

section. The supplier is not responsible for costs caused by equipment broken as result of faulty handling.

• Check the bearing capacity of fixing points and support structures before installation (see the unit weights in product leaflets!).

• To ensure optimum oil circulation of the condensers, and air venting and drainage of the dry coolers, the tubes of the heat transfer section should be in horizontal position.

• Trouble-free operation of the dry coolers provides good air venting of the units. Use the venting screws on the headers for air venting of the heat transfer section. Please always follow the instructions of the refrigerant supplier!

• Water circulated dry coolers shall be drained, when the ambient temperature is < 0 °C. Standard dry coolers are not gravity drained. It is recommended to use frost-proof refrigerants in installations, where the ambient temperature can be lower than 0 °C.

• Please always follow the instructions of the refrigerant supplier in installation, in performing the pressure test, in taking into use, operation and service.

• All soldering of the heat transfer section is made by hard solder (FOSCO 710/DIN8513/LAg2P).

3.3 SET-UP FOR INSTALLATION The models with horizontal air flow can be installed directly to the installation site. Just remove the lifting lugs after lifting.

When mounting a unit with vertical air flow, the legs are installed in correct height. If the unit is installed directly on a plane surface should the height of the legs from the surface to the lower edge of the unit be ca 620 mm (see figure!). Please also install the legs´ horizontal supports (see fig. 3, 5). When the unit is installed on a basement, the legs can be installed in steady middle position (ca 420 mm), without any horizontal support (fig. 3.6).

3.4 TUBE CONNECTIONS The external tubes shall be installed in a way that their weight, vibration or heat expansion will not strain the tubes of the heat transfer section. Condensers

~620

~420

Horizontal support for legs

Fig. 3.5 Installation with legs directly Fig. 3.6 Installation on basement

The transmission of compressor noise and vibration to the condenser can be eliminated by sufficient vibration dampers. Take care of correct charging and oil separation in the plant!

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1 2

3

1 2

3

In multicircuited condensers the number of passes is given from left to right (vertical air flow), or from up to down (horizontal air flow).

Dry coolers

3.5 FANS AND FAN CONNECTIONS The fans are direct driven axial fans. The fan motors are 3-phase squirrel-cage motors built to the IEC standards, designed for outdoor use and provided with condensing water outlets, shaft seals and self-lubricating bearings. The motors are suitable for 220...240 V/380...420 V 50Hz electric network. Their protection class, except for condensing water outlet, is IP54. The motors are prewired to the safety switches (IP65). Please ask the condenser/dry cooler manufacturer about the technical data of the fan motors!

NOTE ! Electric connections may be performed by an authorized electrician only.

Figure 3.9 Model with vertical air flow Figure 3.10 Model with horizontal air flow

Discharge

Venting Fluid in

Fluid out

Discharge

Venting

Fluid out

Fluid in

Bro

wn

Coated w ithblack plastictube

Bla

ck

Blu

e

Yel

low

-gre

en

Bro

wn

Coated w ithblack plastictube

Bla

ck

Blu

e

Yel

low

-gre

en

Coated w ithblack plastictube

Bla

ck

Blu

e

Yel

low

-gre

en

Electric network 220...240V ∆-connection

Electric network 380...420V Y-connection

Safety switch

Motor junction box

Fig. 3.11: Fans´ electrical connections: motor junction box and safety switch

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NOTE ! The water tubing may be broken due to freezing water. The tubing shall always be drained after use by opening end plug (no. 7).

3.6 FANS´ POWER VALUES The product nameplate indicates the power values at +20º C and –30º C. For defining the set values of the overload protector, the power value at other temperatures might be required. It can be nearly linearly calculated by using above mentioned points. For example, the power value corresponding to -10° C can be calculated by multiplying the power value corresponding to +20° C (from product nameplate) by coefficient (k) given in the diagram at –10° C.

3.7 OPTIONS

Water spraying system (D) The water spraying system helps to even out the short loading peaks in summer time.

For the unit with fans in one row one water spray tubing will be installed. The units with fans in two rows will be equipped with two water spray tubings.

The loose tubing together with assembly instructions will be delivered with the unit.

Please assemble the tubing in numerical order and at the place shown in the figure below. Carefully tighten the joints and make sure that all nozzles are in the same direction. Turn the tubing to get the nozzle angle to correspond the fan speed. Check the right nozzle angle in the table at right!

Lock the tubing at its place. The water flow is 0,5 l / min for one nozzle, pressure 3 bar.

1 Reduction joint 5 End tube 2 Water nozzle 6 Distance tube 3 T-connector 7 Plug + connector 4 Double nipple 8 Clamp/ drill screw

NOTE ! The nozzles may be blocked up by limey water, which can also form an isolating layer on the surface of the heat transfer section. Wrong pH-value of water may damage the heat transfer section. The pH-value shall vary between 7...8.

1,2

k

1,0

-20 -10 10-30 20 400 °C 30

Fig. 3.12 : Motor power value depending on temperature

α α

α

α

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Table 3.1 Cable lenghts

SCAL SCAG

Cable MCMK,

[m]

SCAL SCAG

Cable MCMK,

[m]

SCAL SCAG

Cable MCMK,

[m]

111 4 221 19 221 9112 4 222 19 222 9113 4 223 20 223 10121 8 231 33 231 16122 8 232 33 232 16123 9 233 36 233 18131 14 241 53 241 26132 14 242 53 242 26133 17 243 57 243 28141 22 251 74 251 36142 22 252 74 252 36143 25 253 81 253 40151 30 261 98 261 48152 30 262 98 262 48153 36 263 107 263 54 - - 264 98 264 48 - - 265 98 265 48 - - 266 107 266 54 - - 267 107 267 54 - - 271 127 271 63 - - 272 127 272 63 - - 273 127 273 63 - - 274 127 274 63

The cable lenghts of models [m]

Fan size ø900 mm Fan size ø1200 mmStepwise (SC) and stepless (SVC) fan speed control SVC fan speed control has been pre-configured and test run at the factory including test-run of the fans and inspection of the regulator. See the leaflets of Alfa Laval Vantaa´s Step Control (SC) and SVC! The necessary documentation for the control system is included in the delivery (within the terminal box). The cables corresponding to the EMC standard have been connected to the unit end. Please see the normative cable lengths in the table 3.1! The lengths might be different when using special equipment or special cables.

Vibration dampers (T) The suitability of the elastic vibration dampers, supplied by Alfa Laval Vantaa, has been ensured.

• Check the load weight to be damped and make sure that just the right dampers for this load are available. Pay attention to the weight distribution of the damping rubber!

• The vibration dampers are meant for vertical

compression load. Check that the ground and the basement of the unit to be damped are horizontal.

• When damping group of units, shall both the driving unit and the unit to be operated be placed on a similar rigid basement.

• Please check the ambient conditions at site:

o Temperatures –35...+65°C

o Organic solvents are injurious

o Oils might damage the damper´s rubber parts

• When connecting eg. tubes to the unit to be damped, always use flexible connections to guarantee trouble-free vibration damping, to prevent transmission of vibration to the tubes and vibration stress on the tubing.

• After installation please check the correct deflection of the dampers from the table 3.2.

• Take care that there is margin around the unit to be damped. • Please ask the manufacturer for further instructions, when necessary.

3.8. CHECKINGS BEFORE START-UP The heat transfer section has been pressure-tested and the electric safety of the unit has been measured at the factory. The electric safety checking includes steady-state and insulation resistance measurement of the protecting cable. An introduction inspection has to be done before taking the unit into use, including both sensory and visual checking and measurements. The customer has to make all measurements and tests (including grounding resistance measurement) which are required in the operating country. Check visually:

• Make sure that all components are in good condition, without any damage. • Make sure that the unit is firmly in position.

Vibration damper Deflection [mm]

xx percentage from mm

34 LV 10/_ _ 7,5...8 75...80% from 10 mm 34 LV 16/_ _ 12...12,8 75...80% from 16 mm 34 LV 24/_ _ 18...19,2 75...80% from 24 mm 34 LV 40/_ _ 30...32 75...80% from 40 mm

Table 3.2 Allowed deflection of the vibration damper

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• Check the fixing of mechanical parts. • Check the suitability of the electric network. • Check the electrical connections. • After electric installation, check that the fans rotate properly and that the air flow direction is correct. • When the fans are running please check that there is no unusual noise or vibration in the unit. • Make sure that there are all necessary connection diagrams, signs and warning stickers are included.

Measurements on function:

Steady-state measurement of the protecting cables (measurement is done, when the unit is in power-off condition. Earth potentials´ continuity resistance measurement is done between conductive part and nearest point which is connected on the main earth potential); there is no exact limit value for the measurement, thus the measured value shall be compared with the value estimated on basis of across diameter and length of the cable.

• Measurement of non-standard resistance (measurement is done, when the unit is in power-off condition, in order to resolve that all the live parts (phases) are sufficiently insulated against earth potential). - Make the unit dead. - Make sure that there is not any live equipment connected to the electric circuit. - Ensure that the unit is disconnected and dead. - Make sure that the switches of risers are closed and the fuses are placed. - If needed, loosen N-PE connection or neutral connector. - Perform the measurement. If the result is not acceptable, find out the reason. - Make the unit working again in reverse order.

4 SERVICE INSTRUCTIONS

4.1 SERVICE INSPECTION Trouble-free operation of Solar range condensers and dry coolers provides regular service to check

• visual condition of the units and fans, once a month • fixing of the units, fans, fan motors and fan guards, once a month • cleanness and visual condition of the heat transfer section, once a month • When the condenser/dry cooler capacity is stepwise controlled by changing the number of fans, the

running order of fans must be changed periodically. • correct deflection of vibration dampers, each year (when needed, replace the vibration dampers by

new ones supplied by Alfa Laval Vantaa Oy)

4.2 HEAT TRANSFER SECTION The heat transfer section needs regular service if the unit is operated in dirty conditions. The dust gathered on fins can be vacuum-cleaned (industrial vacuum-cleaner) on air inlet side, or the fins can be washed with water, preferably against the air flow. Washing can be done by running water, without using pressure. Water must be directed onto the heat transfer section, against the air flow direction inside the unit. The water jet may not be too strong, and it must be directed perpendicularly to the fins´ side to prevent them bending or damaging Do not use any strong alkaline detergents/solvents and acids, or dangerous, inflammable or environmentally dangerous detergents! The pH value of the washing water must be between

NOTE ! The electrical connections may be performed by an authorized electrician only.

WARNING ! Before starting the service operations make sure that the unit is electrically isolated and dead.

Figure 4.1 Allowed angle of low pressure cleaning water jet against the coil material

14

7…8.

4.3 HEAT TRANSFER SECTION Please always check the motors, when performing service operations! Should the fan make any unusual noise, please stop it immediately, and check the fixing of the fan and fan motor. When necessary, replace the motor by a new spare part motor supplied by Alfa Laval Vantaa.

NOTE ! During stand-stills the fans must be operated for 3…4 hours at least once a month.

WARNING ! Before washing the heat transfer section, read the Material Safety Data Sheet of the detergent and follow the manufacturer´s instructions! When vacum-cleaning and washing, use protection glasses, safety gloves, safety shoes and other personal protection!

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4.4 REPLACING THE FAN BLADE

• Remove the fan guard by unscrewing the fixing screws. • Remove the fan blade by unscrewing the locking screw. • Pull out the fan blade with an extractor. • Clean and lubricate the shaft. • Place the new blade into the shaft (do not forget the wedge!). • Do not knock the blade into the shaft, the motor bearings easily damage. • Stroke at the shaft end HI-TEMP 343 RTV silicone rubber sealing spray,

according to the instructions. • Place a washer at the shaft end, on the silicone rubber sealing. Lock the blade hub

by a fixing screw into the motor axle by using torque strong enough. When tightening the fixing screw, some sealing compound presses out through the washer edge and hole. This shows that enough silicone rubber sealing spray has been used.

• Silicone rubber sealing spray prevents the water running along the joint between the blade hub and the motor shaft into the motor.

• Place the fan guard. • After installation make a test-run for the fan and check the fan visually.

4.5 REPLACING THE FAN MOTOR

• Switch off the current from the safety switch and close the switch. (Lockout and Tagout) • Remove the fan guard (2). • Remove the fan blade (see item 4.4 REPLACING THE FAN BLADE). • Open the junction box and make sure that the motor is dead . • Remove the electric cable. • Unscrew four fixing screws of the fan motors . • Lift up the fan motor. • Install the new fan motor in reverse order. • Install the fan blade (see item 4.4 REPLACING THE

FAN BLADE). • Check the minimum blade point gap: for fan Ø914 it is

3 mm, and for fan Ø1240 the minimum point gap is 5 mm.

• Place the fan guard. • After installation make a test-run for the fan to check

correct rotation direction and its function in general. • Please always use spare part motors supplied by Alfa

Laval Vantaa to guarantee their applicability to operating conditions.

WARNING ! Before changing the fan blade make sure that the unit is electrically isolated and that the motor is dead!

NOTE ! The electric motor may be changed by an authorized electrician only. WARNING ! Before changing the fan motor make sure that the unit is electrically isolated and the motor is dead.

Fig. 4.3 Fan unit :safety switch, :fan guard :junction box, : fan´s locking screw and :motor´s fixing screw

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5 DISCARDS AND RECYCLING

5.1 RECOVERY OF REFRIGERANTS

5.2 DEMOLISHING THE UNIT

• Remove the unit from the installation site and transfer it to the place of demolishing. Please follow the instructions for lifting the unit.

• Turn the unit with horizontal air flow into horizontal position by paying attention to the lifting instructions.

• Remove the fans, fan motors and cables. • Remove the fan plate, legs and side plates. • Remove the headers from the heat transfer section by cutting off the connection tubes.

5.3 MATERIAL RECYCLING AND DISCHARGING

• Sheet metals, Fe + Zn – to steel scrap • Heat transfer section, Cu-tube / Al--fin– to mixed copper scrap • Header, Cu – to copper scrap • Fan collar / motor bracket, Fe + Zn – to steel scrap • Fan guard, Fe + Zn to steel scrap • Motors recycling / scrapping (authorized contractor). • Safety switches, cables recycling / scrapping (authorized contractor) • Water jet tubing, Cu – to copper scrap

6 ADDITIONAL REMARKS

NOTE ! The refrigerant recovery of condensers may be performed by an authorized contractor only . The manufacturer´s instructions shall always be followed in handling and recovery of the refrigerants.

NOTE ! In demolishing the unit and in recovery, recycling and discarding of refrigerants, components and materials shall the local, national and international regulations be followed.

WARNING ! Before discarding and demolishing the unit make sure that the unit is electrically isolated and dead.

NOTE ! Venting/draining valve of SCAG, SCCG, SEpG standard dry coolers is not adapted for heat transfer fluids based on potassium formiate; DANGER OF LEAKAGE! When using heat transfer fluids based on potassium formiate please always check from the documentation that the piping system and venting/draining valves of the heat transfer section are adapted for the heat transfer fluid in question. Please follow the instructions of the heat transfer fluid supplier at installation, pressure-testing, starting-up, operation and maintenance.

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7 TROUBLESHOOTING

Trouble Reason What to do Short of capacity Refrigerant flow too low Check the valves/filters!

Leakage in system / coil block Check the connections, brazings in heat transfer

section and the tubing. When there is leakage in the heat transfer section, please take contact with the manufacturer for further repair instructions!

The wrong flow direction in the circuiting

See chapter 3.4 Tube Connection

Air in system Ventilate the system! Fan/fans do not operate. Localize the problem, repair it or change the fan

unit. Heat transfer section blocked up/ dirty

Vacuum-clean/ wash the heat transfer section

Incoming air flow too low Check the minimum distance between the unit and the hinderances (see item 3.1 Location) Make sure that there are no obstacles for the air flow.

Wrong fan rotation direction Wrong phase sequence. Change the connection on motor coupling or from the switch board.

Inlet air too warm Check the location of the units (item 3.1). Shade the unit from the sun! Heat transfer capacity can be increased by water jet system.

Vibration in the unit Broken fan Repair/ change the fan! Damaged vibration dampers Install new vibration dampers, check the correct…

Fan does not start Fan is frozen in the fan collar Remove ice The fuse has blown out Replace the fuse Overload release Check and reset from the overload release switch!

Wrong supply voltage Check that the supply voltage corresponds to the value marked on the motor sign.

Wrong connection Check the connections from the item ”Motor connections” and from the product nameplate.

Break in coil or in control circuit If the switch is in off-position, there will be bumbling noise. Check the slack line switches! Check that the line switches close.

Mechanical failure Check that the fan motor and fan blade rotate freely. Check the bearing and lubrication!

Short circuit in coil Can be indicated by a blown-out fuse. The motor has to be replaced.

One phase in the motor can be broken.

Check the connection!

Fan stops. Voltage break Blown-out fuses

Low voltage Check that the voltage given the product nameplate is followed. Check the connections!

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Trouble Reason What to do Fan starts, then stops Failure in supply voltage Check the loose connections, fuses and control

circuit. Fan does not reach the maximum speed

Wrong fan motor type Ask the supplier about a correct type of fan. Too low voltage at the fan motor terminals because of voltage drop.

Use higher voltage or a starter transformer. Check the connections and the correct cable size.

Broken rotor Check eventual breaks in short-circuiting ring. Generally, a new rotor or motor is needed

Motor takes high amp. Too low voltage Check the size of cables on basis of voltage drop.

Too low supply voltage Check the supply voltage

Wrong rotation direction Wrong sequence of phases Change the connection on motor coupling or from switchboard..

Fan motor overheating. Motor body or cooling openings may be dirty or blocked-up, therefore hindering proper motor ventilation.

Clean the motor and and ensure trouble-free air circulation.

One motor phase may be open. Check the connection.

Earth fault Identify and repair

Asymmetric supply voltage to motor terminal

Check the cables and connections.

Vibrating fan

Loosen motor fixing Tighten the fixing screws and check the alignment Unbalanced fan blade/Fan blades misaligned

Balance the blade or change it.

Faulty bearings Change the bearings 3-phase motor running as single phase

Check the connections

Too big axial play Check the bearings

Abrasive noise in fan Fan blade is chafing against fan collar.

Check the motor centering and fixing.

Motor ventilator is chafing against the cover.

Repair the fan/cover.

Ventilator hits on insulation. Prevent the touch.

Motor has got loose from its fixing.

Tighten the fixing bolts and rebalance the fan.

Exceptionally heavy noise of running

Air gap not centralized. Check steering turning and bearings.

NOTE ! The motor may be discharged and assembled by a skilled mechanician only by using proper tools and approach. The repair work shall be performed according to the standard IEC-60079-19. Under guarantee period the faulty motor must always be returned to the supplier (do not demolish it!). Please always use the spare part motor supplied by Alfa Laval Vantaa to guarantee its applicability to operating conditions.

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Wear PPE

Use GFCI

Use insulated tools

8 ELECTRICAL SAFETY CHECKLIST All service, maintenance, repair, controls and installation employees must have this list with them at every job and read through it before they start the job. These are the minimum requirements. If you cannot meet these requirements, you cannot start the work

8.1 LOCKOUT AND TAGOUT 1. Notify affected persons of the shut down. 2. Shut down the equipment by the normal process. 3. Disconnect and lock and tag all energy sources. 4. Released any stored energy (capacitors, transformers, etc.). 5. All employees working on the equipment must have their

own personal lock in place tulee olla oma lukitus asetettuna paikoilleen.

6. Prior to servicing equipment a check must be made with a ”proximate voltage sensor” to ensure that the frames or control enclosures of equipment being serviced are not energized.

7. Check that circuit-testing devices are working 8. Verify the absence of electrical current or voltage with a circuit-testing device; use insulated gloves

and an insulated mat. 9. Notify affected persons of the return of electrical power.

8.2 DIAGNOSING A PROBLEM WHERE POWER IS REQUIRED 1. Remove all conductive clothing or accessories. 2. Do not use any conductive equipment or tools. 3. Use insulated tools and safety glasses 4. Do Not work on electrical circuits greater than 600 volts

unless you have received specific training 5. Suspend work or have a shelter during adverse weather

conditions. 6. Use a certified insulated mat to stand on while doing the

testing. 7. Use certified electrical insulated gloves while doing the

testing. 8. After diagnostic work is completed and service work is

required you must complete logout and tagout.

8.3 TOOLS AND EQUIPMENT (PPE) 1. Ensure that electrical equipment you are working on is

grounded. 2. Ensure that electrical power tools are double insulated or

have a ground plug. 3. Use Ground Fault Circuit Interrupters (GFCI). 4. Inspect power tools, insulated hand tools and electrical

cords for damage 5. Damaged tools and cords shall not be used. 6. Do not use conductive equipment e.g. metal ladders.

Verify with a testing device Lockout/Tagout

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9 LIFTING INSTRUCTIONS The Solar dry cooler and condenser units are transported in vertical position as standard. The units for horizontal installation (vertical air flow) must be turned at installation. Two turning supports with locking bolts (see pictures below) are included in the delivery of the Solar units . How to turn the unit:

1. Lift the unit off the ground. 2. Remove the transport pallet. 3. Insert the turning support into the leg profile until it reaches the fitting bolts. Place the turning support

beneath both lifting eyes. 4. Lock the turning support into the leg with a locking bolt.

Turning the unit

Turning supports (remove locking bolts before installation!) Turning supports placed correctly

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LIFTING INSTRUCTIONS Air cooled heat exchangers are fragile products, which makes them extremely sensitive to incorrect handling during transport and positioning. The instructions given must be strictly complied with in order to prevent the heat exchanger from being damaged during the lifting procedure. Lifting operations must at all times be carried by qualified personnel using approved lifting equipment.

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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 SJ, SCA, SCAL, SCCL, SEpL, SX air cooled condenser

SJG, SCAG, SCCG, SEpG, SXG air cooled dry 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: ISO 12100:2010, SFS-EN ISO 13857, SFS-EN 14276-2 + A1, 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, May 21

Silja Beierschoder Quality Manager