AIR LIQUID COOLERS AND CONDENSERS

BCD (BCDT, BCDS, BCDL, BCDQ, BCDR) and BDD (BDDT, BDDS, BDDL, BDDQ, BDDR MODELS)

INSTRUCTIONS MANUAL
IM100527-GB EN 2006-01
 Table of contents

GENERAL
o To the user ............................................ page 2
o Warranty ....................................................... page 2
o Safety .................................................... page 3
o Equipment Description..... ............................. page 5
o Reception ................................................. page 14
o Storage ................................................. page 14
o Unpacking ......................................................... page 15 1

PROVISIONS FOR MOUNTING

o Layout .................................................. page 16
o Bases .............................................................. page 17 EN

MOUNTING
o Anti-vibration Dampers ............................................. page 18
o Lifting Tables ............................................................ page 18
o Vertical Installation ................................................... page 19
o Horizontal Installation ............................................... page 19
o Piping Connections: Condensers ............................. page 22
o Piping Connections: Dry Coolers ............................. page 22
o Mounting (Optional) .................................................. page 24
o Electric Installation .................................................. page 25

OPERATION
o Starting the Dry Coolers ........................................... page 27
o Operating the Equipment ......................................... page 27
o Shutdown ................................................................. page 28
o Starting the Condensers .......................................... page 28
o Shutdown ................................................................. page 28

MAINTENANCE
o Periodic Preventive Controls ..................................... page 29
o Cleaning the Equipment ........................................... page 29
o Tools and Accessories for Maintenance ................... page 30
o Troubleshooting ....................................................... page 30
o Replacement of Motors ............................................ page 31
o 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
 To the User

TO THE USER

Dear user

This instructions manual is intended to be your permanent guide for the different situations you may encounter
when using this equipment.

Alfa Laval recommends you to study it carefully, and mainly, to make it available for the personnel who
normally install, operate and maintain the equipment.
2 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, dont hesitate to
contact the closest Alfa Lavals representative. We can offer you our help wherever you may be located.
EN
NOTE !

Alfa Laval wont become responsible for any equipment failure if the user
misinterpret the instructions of this manual.

System Warranty

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

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 Lavals approval.

NOTE !

FREEZING RISK
A standard dry cooler cannot be fully drained simply by opening the drain
fitting orifices. Anyhow add the anti-cooling mix as further explained.
 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!

L
ATTENTION! Indicate that special procedures must be followed to avoid serious
injures to people.

BE CAREFUL! Indicate that special procedures should be followed to avoid serious 3

damages to the equipment.

NOTE! Indicate important information to simplify the operations or to make

them more understandable. EN

Warning signs: In this page all the warning signs of this manual are
summarized.

General precaution sign

Moving load danger sign

Moving part danger sign

Electrical danger sign

L Important information
 Safety

Pay attention to the following instructions to avoid serious injures

to 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 proper
handling; damage may result if the forks come in direct contact with the equipment.

EN

Lifting Operation

ATTENTION!
Before lifting the equipment
1. Attach the belts or hooks, only to the provided
elements the equipment is equipped with.
2. Be sure that the belts or the slings with hooks
will lift the equipment in a balanced way.

Installation and maintenance operations

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

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

ATTENTION!
Whenever Fans maintenance task should be carry out,
be sure they are not running and the security switch is in
the OFF position.
When the operation is completed, place back the
corresponding protection.
 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 with 5

minimized refrigerant charge, thanks to the new fins corrugation,
developed by Alfa Laval, combined with advance cross fin tubes
for BC line; smooth tube for BD line.
In the standard execution, heat exchanger manufactured from
copper tubes and aluminium fins with spacing is 2.1 mm. EN
Casework made with galvanized steel sheets painted. New
design frame provides high rigidity also for heavy applications.

These units BCD and BDD are available in five noise levels fan
motor, (S) standard, (L) low, (Q) quiet, (R) residential and the new
(T) high performance fan:

CODIFICATION WAY:
Code Alfablue Condenser Dual
Example: BCDQ 906 A D
Model BCD Blue Condenser Dual
Noise level T =high performance fan S=standard L=low Q=quite R=residential
Fan diameter 80=800mm, 90=910mm, 100=1000mm
Number of fan 2, 3, 4, 5, 6
Coil size A, B, C,
Motor connections D=delta Y=star
Motor type T=three phase S=single phase

CODIFICATION WAY
Code Alfablue Dry Cooler Dual
Example:BDDQ 1003 A Y
Model BDD Blue Dry Cooler Dual
Noise level T =high performance fan S=standard L=low Q=quite R=residential
Fan diameter 80=800mm, 90=910mm, 100=1000mm
Number of fan 2, 3, 4, 5, 6
Coil size A, B, C, D
Motor connections D=delta Y=star
Motor type T=three phase S=single phase
 General Description

BCD-BDD Models 800mm Fan diameter Vertical Installation

EN
 General description

BCD-BDD Models 800mm Fan diameter Horizontal Installation (Std. 500mm, opt. 850mm)

EN
 General Description

BCD-BDD Models 800mm Fan diameterHorizontal Installation (adjustable feet height)

EN
 General description

BCD-BDD Models 900mm Fan diameter Vertical installation

EN

BCD/BDD Models 900mm Fan diameter Horizontal Installation (Std. 500mm, opt. 850mm)
 General Description

BCD-BDD Models 900mm Fan diameter Horizontal Installation (adjustable feet

height)

10

EN
 General Description

BCD-BDD Models 1000mm Fan diameter Vertical Installation

11

EN

BCD-BDD Models 1000mm Fan diameter Horizontal Installation (Std. 500mm, opt. 850mm)
 General Description

BCD/BDD Models 1000mm Fan diameter Horizontal Installation (adjustable feet

height)

12

EN

NOTE !
If adjustable feet are used, the minimum chose height has to be enough to
permit the necessary air volume inlet in relation of the used fans.
In case of doubts contact Alfa Laval.
 General Description

DIMENSIONS, WEIGHT AND CONNECTIONS TABLE

Condenser and Dry Cooler Dual
Dim ension Weight Dry Cooler Condenser Fans Feet

Model Code HEIGHT WIDTH DEPTH

Kg Inlet Outlet Inlet Outlet N N
mm mm mm
... 802 A 2290 (V) 3955 900 (V) 600 2x3" 2x3" 2x54 2x42 4 2
BCDS/BDDS, BCDL/BDDL, BCDQ/BDDQ, BCDR/BDDR

... 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
13
... 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 EN
... 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
BCDT/BDDT, BCDS/BDDS, BCDL/BDDL,

... 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
BCDQ/BDDQ, BCDR/BDDR

... 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
BCDS/BDDS, BCDL/BDDL, BCDQ/BDDQ,

... 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
BCDR/BDDR

... 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
 General Description

RECEPTION

The equipment is received in pallets with the following dimensions:

PACKAGING FOR BCD / BDD MODELS

N of fans couple

Pa cking Dim e nsions

Fan diameter

14
Le ngth W idth He ight

EN 2 404 97cm 244cm

3 579 97cm 244cm
800 4 754 97cm 244cm
5 929 97cm 244cm
6 1104 97cm 244cm
2 474 97cm 244cm
3 684 97cm 244cm
900
4 894 97cm 244cm
5 1104 97cm 244cm
2 474 97cm 244cm
3 684 97cm 244cm
1000
4 894 97cm 244cm
5 1104 97cm 244cm

Carefully inspect all equipment upon arrival to detect any shock marks or damage of the nylon
coverage 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 relevant
damage.

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

1.- Leave the equipment in its packing.

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

3.- In an environment without corrosive liquids or vapours.

 General decription

UNPACKING
(This operation should be done at the mounting site)

Take off the wrapping cover leaving the equipment on the pallet.

15

EN
 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.

16 c) When walls are present, follow

the distances recommended by
Alfa Laval.
GRID

EN

n UNITS

YES

GRID

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.

NO NO
 Provisions for Mounting

Bases

For horizontal equipment:

To avoid the oxidation of the equipments legs, it is recommended to lean them on concrete bases of about 4
inches (10 cms.) high (one base for each leg).
The basement should be oversized in relation to the plate on the foot

17

EN

For vertical equipment:

 Mounting

Vibration isolators

For active and passive isolation of vibrations and

reducing noise transmission, Alfa Laval strictly
recommends the installation of anti-vibration dampers.

MATERIAL
Isolator: Natural rubber.
Frame: Galvanized steel, with yellow Zinc treatment.

18 Install the anti-vibration attachment between the

equipment and the base. (For Horizontal mounting)

EN

WEIGHT AND VERTICAL

Vibrations' Isolator LIFTING EYEBOLTS TABLE
Each Kit contain 2 units
Num. of Qty. of Eyebolts
Models Code legs isolators Models Code mm Qty. Weight
,,,802 4 2 ,,,802 30 4
,,,803 4 2 ,,,803 30 4
BCDQ/BDDQ, BCDR/BDDR,
BCDQ/BDDQ, BCDR/BDDR,

BCDS/BDDS, BCDL/BDDL,
BCDS/BDDS, BCDL/BDDL,

,,,804 6 3 ,,,804 30 4
,,,805 8 4 ,,,805 30 8
,,,806 30 8
BCDT/BDDT
BCDT/BDDT

,,,806 8 4
See page 13

,,,902 4 2 ,,,902 30 4
,,,903 4 2 ,,,903 30 4
,,,904 6 3 ,,,904 30 4
,,,905 8 4 ,,,905 30 8
,,,1002 4 2 ,,,1002 30 4
,,,1003 4 2 ,,,1003 30 4
,,,1004 6 3 ,,,1004 30 4
,,,1005 8 4 ,,,1005 30 8
 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 and
screws for horizontal mounting can be provided.

For both cases the procedures are as follows:

Vertical Installation
19
1. Lift the equipment removing the pallet. 2. Place it on top of the bases and
fix it with anchor bolts.

EN

Vertical lifting eyebolt

(See tables on page 18)

Horizontal Installation

1. Lift the equipment as is done for 3. Remove the lifting eyebolt

vertical mounting. and the vertical supporting leg.
2. Lean it on an trestle.

Lifting eyebolt
 Appoggiare sulla struttura portante, non sul pacco alettato!

Mounting

4. Fix the horizontal legs to the equipment with screws. Lift the unit and secure
its legs

Let it sit on the load-bearing frame and

not on the coil!

20
Move the eyebolt and
make sure that it is
tightened before
lifting the unit
EN

5. Lift the equipment placing the hooks as is shown in the figures, according to the different
models. Then fix the equipment to the bases with anchor bolts.

Use a rocker arm

Use a rocker arm to
to lift the unit
lift the unit

Use a rocker arm

to lift the unit

The min. lifting angle

between the belts and the
unit must be 60
 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 for
disassembling.

PN 16 DIN Flanged
21

Important
EN
a) The pipes sizes should be in accordance with the IN and OUT
connections 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.

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
L liquids to move through a pipe like a wave at the speed of the sound.
This effect can produce considerable damages to the equipment.

Tools and accessories for lifting

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

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).

 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 the
pipes should be carried out with a compressed air sweeping (condenser) or with water (dry
cooler), in order to avoid dirt and welding residuals.

22 4. Check the alignment of the piping with the input and output ends of the equipment.

Do NOT bend the

connections!
EN

Align the piping with the

equipments connection.

Condensers:

The equipment is delivered with the following connections:

BW Type Cooper tube connection for welding.
The following diagram shows the recommended installation:

Ensure a min. slope of 1% in the liquid line,

between the discharge and liquid receiver.

Condenser KEY
Piping temperature probe
Antivibration
dampers Ball valve

Conveyed drain

Spring safety valve

Dry coolers:
Antivibration joint

Butterfly valve

Basket filter

Piping temp. meter

Piping gauge

Dry cooler
3-way valve with modulating
elec. or magnetic servo control
Antivibration
dampers
 Mounting

Important
a) Size the pipes to minimize the pressure drop and to obtain the coolant speed
values to assure the oil drifting.

b) In the delivery line, between the compressor and the condenser, install an anti
vibration 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%, between
the liquid discharge and the receiver.
23

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

Welding the pipes:

An overlapped welding is suggested to weld the
external piping to the equipment, (cooper pipes) , for
L the double purpose of assuring the staunchness and
reducing the breaking risks in the welded area,
generated by inducted vibrations.
If the diameter of the pipes doesnt allow this
solution, special female adapter should be used.
Before making the welding, disassembly the cap-label of the gas valve
and eliminate the preloaded nitrogen completely.
 Mounting (Optional)

Electric Board

24

EN

Single switchboard Single switchboard

Vertical position Vertical position 4-6 couple of fans
1-3 couple of fans Opt. speed control

Single switchboard Single switchboard

Horizontal position Horizontal position 4-6 couple of fans
1-3 couple of fans Opt. speed control

The equipment is delivered from the factory with the electrical board
installed in the final installation position. A different placement requires
different electrical board and manifold cover plate.
 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)

25
Electric board provision

EN

Main power supply

Free cooling remote signal

Remote signal slave mode control

Remote signal speed controller fault

_ Unit
Optional Alfa Laval delivery
Customer Supply
Supply in according to order
 Electric Installation

FUNCTIONAL OUTLINE

MAIN SWITCH ON/OFF

26 Tk Thermistor included in the

stators winding

EN

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

SWITCH ON / OFF

Auxiliary contacts: 2
Rated current: 16 A
Voltage protection: 600 volts
Cable: VDE 7030
Protection class: IP 65

Grounding

Attention: The ground connection is required by law

The ground connection should be made through a cable from the motors frame to the equipment structure,
and from structure to the plant ground.

Attention: Ground resistance should be lower than 3 ohms

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 100C
Connection
o 3 Phase 400 V + - 10% 50 Hz.
o Single phase 230 V + - 10% 50 Hz.
 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 that 27
the 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 as
shown in the label.
EN
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 than
the rated, when the fan(s) are running at rated rpm.

It is important to follow the starting procedure every time you

want to start the equipment.
 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.

28 Follow the start-up procedures whenever the equipment is started up.

TAB. 3
EN Air T. (C) Glycol % (kg/kg)
0 10
-5 20
-10 30
-15 35
-20 40
<-20 50

STARTING THE CONDENSERS See installation diagram on page 22

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 following
procedure 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.

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

Attention!: Before attempting any maintenance operation, make sure that

the power supply is properly disconnected
 Maintenance

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

Periodic preventive controls

Every three months the following controls should be performed:

1. Check the equipment fastening.

29
2. Verify that the electric connection terminal studs are properly tight, to avoid losses and wear due
to sparks.

3. Verify the good condition of the wiring (it should not have cuttings or deterioration signs). EN
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 rated
value when the fan(s) work(s) at rated speed.

6. Check the fan vibration level.

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

Cleaning the equipment

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

ACQUA P max < 1.5/2 Bar

 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 to 2)

o Adjustable wrench (3 opening)

o Oxyacetylene welding equipment / Gasket

30 o Ammeter

o Voltmeter

EN

Troubleshooting:

PROBLEM POSSIBLE CAUSE SOLUTION

Condensation pressure too
high / outlet fluid temperature
too high
Air flow to condenser blocked by
dirt on the coil with fins
Defective fan
Wrong air flow direction through
the coil
Clean the coil with water
and a degreaser or non
corrosive liquid
Replace
Invert the rotating direction
of the fan, switching two of
the three phases

Air temperature too high Contact Alfa Laval

Air temperature too low
Adjust the condenser
Condensation pressure too low Excessive air flow through the
pressure regulation
condenser
Faulty motor Replace
Check the voltage value
Line voltage lower than tolerance
between phases with a
limits
voltmeter
Fans not running
Measure the voltage
Lack of a phase between phases, check the
power supply line
Overloaded motor Check with an Ammeter
Fan break Blockage or shocked Replace
 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 the
OFF position.

2. Then, open the electric motor derivation box, disconnect and remove the electric wires.
31
3. Place the new fan motor and install it.

4 Place the protection grid.

5. Make the electric connection. EN

6. Check the correct rotating direction.

Panel

Fan grid
 Spare Parts

CODE DESCRIPTION
A COIL
B FAN COWL
C COVER PLATE CONNECTIONS SIDE
D COVER PLATE BENDS SIDE
E SUPPORT LEG
32 F FAN

EN

See Spare Parts section on RCPL