Alfalaval Blue bn User manual

ORIGINAL INSTRUCTIONS

Alfa Laval Blue BC/BN/BX

Instruction manual

•Product description

•Product labels

•Unpacking & lifting

• Installation

• Maintenance

•Spare parts

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

Index

1. Important information

1.1 Disclaimer...................................................................................................................................3

1.2 Intended use...............................................................................................................................3

1.3 Where to nd product information ..............................................................................................3

2. Product description

2.1 Introduction.................................................................................................................................4

2.2 Finned coil..................................................................................................................................4

2.3 Construction ...............................................................................................................................4

2.4 Fans ...........................................................................................................................................4

2.5 Optional features........................................................................................................................4

2.6 Code description ........................................................................................................................5

3. Product labels...........................................................................................................................5

4. Unpacking and lifting

4.1 Packing.......................................................................................................................................9

4.2 Shipping dimensions ..................................................................................................................9

4.3 Unpacking ................................................................................................................................10

4.4 Feet mounting for vertical airow .............................................................................................11

4.5 Wind braces for 1200 mm feet .................................................................................................12

4.6 Lifting from above.....................................................................................................................14

5. Installation

5.1 Mounting dimensions B*M 800s horizontal airow...................................................................15

5.2 Mounting dimensions B*M 800s vertical airow.......................................................................16

5.3 Mounting dimensions B*M 800 horizontal airow.....................................................................17

5.4 Mounting dimensions B*M 800 vertical airow.........................................................................18

5.5 Mounting dimensions B*M 900-100 horizontal airow .............................................................19

5.6 Mounting dimensions B*M 900-1000 vertical airow................................................................20

5.7 Mounting dimensions B*D 800 horizontal airow.....................................................................21

5.8 Mounting dimensions B*D 800 vertical airow .........................................................................22

5.9 Mounting dimensions B*M 900-1000 horizontal airow ...........................................................23

5.10 Mounting dimensions B*M 900-1000 vertical airow................................................................24

5.11 Concrete mounting base ..........................................................................................................25

5.12 Vibration dampers ....................................................................................................................25

5.13 Expansion joints .......................................................................................................................26

5.14 Switchboard..............................................................................................................................26

5.15 Switch on/o󰀨 (option SW).........................................................................................................27

5.16 Master controller (options CBMx and ECCBx).........................................................................27

5.17 Positioning................................................................................................................................28

5.18 Electrical connections...............................................................................................................29

6. Operation

6.1 Start up procedure....................................................................................................................29

6.2 Shutdown/dismounting.............................................................................................................29

7. Maintenance

7.1 Fan replacement ......................................................................................................................30

7.2 End covers ...............................................................................................................................30

8. Spare parts..............................................................................................................................31

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

1 Important information

1.1 Disclaimer

This Instruction Manual applies to all Alfa Laval Blue BC condensers, BN ammonia condensers

and BX gas coolers, and is supplied in combination with the Alfa Laval product manual AHE00049.

Both manuals must be carefully examined and instructions should be followed up at all times. Alfa

Laval does not accept liability for any damage resulting from non-compliance to the instructions as

given in the manuals and order-related documents. If there are any inconsistencies between the

manual and the technical construction file, the manual prevails unless explicitly specified.

1.2 Intended use

Air cooled condensers and gas coolers are partly completed machinery according to Machine

Directive 2006/42/EC and intended for incorporation in cooling systems. Declarations of

Incorporation are available on www.alfalaval.com. Heat exchanger units may not be put into opera-

tion until the conformity of the complete machine or cooling system has been declared according to

the following standards and directives:

• Pressure Equipment Directive 2014/68/EU

• Machine Directive 2006/42/EC

• Low Voltage Directive 2014/35/EU

• Electrical Equipment of Machines IEC 60204-1

• Electro Magnetic Compatibility 2014/30/EU

• Any applicable local or national legislation

1.3 Where to find product information

Detailed technical data for individual product models are available in order related documents, on

the product sticker and in product data sheets. Comprehensive technical information for all Alfa

Laval air heat exchanger products is available on-line on www.alfalaval.com. This includes:

• Product manuals

• Instruction manuals

• Product leaflets & brochures

• Product data sheets (selection software)

• Dimensional drawings

• Electrical wiring diagrams

• Certificates

Alfa Laval offers world-wide service and support in over 55 countries. In case of any questions

or uncertainty please contact your local Alfa Laval representative. Contact addresses are available

at www.alfalaval.com.

Blue BXBlue BNBlue BC

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

2 Product description

2.1 Introduction

The Blue series is a wide range of heavy-duty air cooled condensers and CO2gas coolers for

refrigeration and air conditioning applications. Blue products are available for both horizontal and

ver tical air direction, either in single (M) or dual (D) coil execution.

• Blue BC condensers for all HFO and HFC refrigerants.

• Blue BN condensers for ammonia systems.

• Blue BX gas coolers for CO2refrigerant systems.

2.2 Finned coil

Innovative coil design manufactured from Cu tubes (K65 for BX) and corrugated aluminium turbo

fins for maximized capacity or industrial power fins for long lasting performance. Fin spacings 2.1

up to 3.2 mm. Separate connections in the D series provide the opportunity for independent opera-

tion of both condenser coils. Each heat exchanger is leak tested with dry air and finally supplied

with a nitrogen pre-charge. Higher design/test pressures on request.

Model Design pressure Test pressure

Blue BC 33 bar 47 bar

Blue BCP 33 bar 47 bar

Blue BCH 45 bar 65 bar

Blue BN 30 bar 45 bar

Blue BX 120 bar 172 bar

2.3 Construction

Frame construction provides high rigidity for protection against vibration and thermal expansion.

Casing and framework of corrosion resistant pre-galvanized sheet steel, epoxy powder coated white

RAL 9002. Separated fan sections.

2.4 Fans

High efficiency AC or EC fan motors, available in 3 fan diameters (800, 910 & 1000 mm) and sev-

eral noise levels, power supply 400/50/3. Motors with external rotor, protection class IP 54 accord-

ing to DIN 40050. Integrated thermo contacts provide reliable protection against thermal overload.

2.5 Optional features

• Mounting feet for vertical airflow (500 mm, 850 mm and 1200 mm)

• Coil options:

Epoxy pre-painted aluminium fins (EP), seawater resistant aluminium alloy fins (SWR),

copper fins (CU), blygold treatment (BY), E-coat (ED) or F-coat treatment (FC).

• Vibration dampers (VD)

• Sub-cooling circuit (SC, only for BC and BN)

• Spray water device (KW)

• Stainless steel header tubes for on-site welding connections (BX only, on request)

• Electrical options:

- Switch on/off (SW)

- AC Motors wired to a common terminal box (CB)

- Basic Switchboard for AC fans (BS)

- Basic Switchboard for AC fans+ Fan step control (BST)

- EC Motors wired to a common terminal box (CBP)

- EC Motors wired to a common terminal box + master controller + temperature probe (CBPMT)

- Basic Switchboard for EC fans (ECCB)

- Basic switchboard for EC fans+ master controller (ECCBM)

- Basic switchboard for EC fans+ master controller+ temperature probe (ECCBMT)

- EC fan speed control cabinet (ICM)

- EC fan speed control cabinet + temperature probe (ICMT)

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

2.6 Code description

B C M P - S E 80 2 L A D * CR Feet - AL 2.1 CU *

1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 15 16

1 Alfa Laval Blue

2 Family: C= Condenser, N= Ammonia Condenser, X= Gas Cooler

3 Number of fan rows: M=1, D=2

4 Dedicated series: blank= default, P= propane (R290) condenser, H= R410A

5 Sound level/fan code: T=turbo, S-standard, L=low, Q=quiet, R=residential

6 EC fan: blank= AC fan, E= EC fan

7 Fan diameter (80=800 mm, 90=910, 100=1000 mm)

8 Short coil module; blank= default, s= short coil module

9 Number of fans per row: 1 to 6

10 Tube rows code (A, B, C, D, E)

11 Fan motor connection (D=delta, Y=star)

12 Number of circuits (only for BX)

13 Packing: P=pallet, PP= pallet with protection for headers and coil, CR=crate

14 Feet=Mounting feet supplied mounted (type of feet according to airflow selected)

blank=Mounting feet supplied loose

15 Electrical options

16 Fin material/coating: Al=aluminium, IF=industrial fins, SWR=seawater resistant fins,

EP=epoxy coated alu, FC= F-coat, BY=Blygold, ED= E-coat

17 Fin spacing (2.1, 2.3, 2.5, 3.0 and 3.2 mm)

18 Tube material (BC: CU=copper, BN: SS=stainless steel, BX: K65=copper K65)

19 Options

⑦

②

③

⑤

④

①

⑧

⑥

⑩

⑨⑨

⑫

⑬

⑪

⑭

⑭⑭

⑮⑮

3 Product labels

1. Lifting point

Use all marked lifing points when lifting from

above. Lifting points available for both horizontal

and vertical airflow setup.

5.307

ATTENZIONE!

CIRCUITO FRIGORIFERO PRECARICATO CON AZOTO

WARNING!

PRECHARGED REFRIGERANT CIRCUIT WITH NITROGEN

ACHTUNG!

VERLADTER KÄLTEMITTELKREISLAUF MIT STICKSTOFF

ATTENTION!

CIRCUIT FRIGORIFIQUE PRE-CHARGE AVEC AZOTE

BHИМАНИЕ!

СИСТЕМА ЗАПРАВЛНА АЗОТОМ

2. Nitrogen precharge warning

Units are delivered from the manufacturer

with an overpressure. Check pressure on

the Schrader valve. With unpressurised unit:

Immediate report to manufacturer and note on

bill of delivery.

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

6. Product label

Model Code description

Item ID

Serial no.

To be communicated when

ordering spare parts as

they identify the unit.

O.A. Order acknowledgement

number

Unit Net Weight Check before any lifting

operation to ensure that

proper lifting tools are

used.

7. Product label - coil

Model Code description

Item ID

Serial no.

To be communicated when

ordering spare parts as

they identify the unit.

Max DN Maximum diameter of the

distributor tube

Fluid Group According to PED

Coil Ts Range of operating tem-

peratures for the coil

Ps Design pressure

Pt Test pressure

Test date Date on which the coil has

been pressure tested in

the factory

WARNING

READ INSTRUCTION MANUAL BEFORE INSTALLATION AND

MAINTENANCE TO AVOID INJURIES OR DAMAGE

Manufacturer Manuf. Date

AIR HEX ALONTE S.R.L. - Italy 04 / 2019

Model O.A. 388857/30

BCDT1003CD P

AL 2.1 CU

Item ID 3289094889

Serial no. AA 2352038

Material CU

PED Category I

Volume

Max DN 76

Fluid Group 2

Coil Ts +125/-60 °C

Ps 33 bar

Pt 47 bar

Test Date 04-2019

EXAMPLE

WARNING

READ INSTRUCTION MANUAL BEFORE INSTALLATION AND

MAINTENANCE TO AVOID INJURIES OR DAMAGE

Manufacturer Manuf. Date

AIR HEX ALONTE S.R.L. - Italy 04 / 2019

Model O.A. 388857/30

BCDT1003CD P

AL 2.1 CU

Item ID 3289094889

Serial no. AA 2352038

Unit Net Weight 1267 Kg ±5%

Motorfan data

Vn 3~400V

f 50Hz

WARNING

READ INSTRUCTION MANUAL BEFORE INSTALLATION AND

MAINTENANCE TO AVOID INJURIES OR DAMAGE

Country of origin Italy

EXAMPLE

3. & 4. In/Out

Refrigerant connections inlet and outlet.

OUT

5. Hot surfaces

Warning: danger of burns. Wear adequate pro-

tection. Applied to the INLET header.

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

9. Fan direction

Sticker indicates fan rotation direction.

10. Eurovent

Product included in the Eurovent Certify All pro-

gram (only for units where it is applicable).

IN WINDY CONDITION IS NOT

RECOMMENDED TO LIFT THE UNIT

CHECK THAT ALL ROPES ARE EQUALLY

LOADED. AVOID VIOLENT TUG

ropes with

high tension

CHAIN ANGLE:

HORIZONTAL INSTALLATION

CHAIN ANGLE:

VERTICAL INSTALLATION

≥60°

ALFA LAVAL BLUE 1, 2 AND 3 MODULES:

LIFTING BAR IS NOT NEEDED.

N° 4 EYEBOLTS AT EACH CORNER OF THE UNIT

VALID FOR BOTH SINGLE AND DOUBLE FAN ROW

ALFA LAVAL BLUE 4, 5 AND 6 MODULES:

LIFTING BAR IS COMPULSORY.

N° 4 LIFTING POINTS AT INTERMEDIATE POSITIONS.

VALID FOR BOTH SINGLE AND DOUBLE FAN ROW

11. Lifting instructions

Detailed lifting instructions.

12. & 13. Centre of gravity/Handle with care

When lifting the unit using a forklift, always place

the forks under the center of gravity.

When handling the unit using a forklift, always

take maximum care.

Both stickers are applied on the protective plas-

tic foil covering the units during transportation.

HANDLE

WITH CARE

PLEASE PAY ATTENTION

TO THE FORKS!

WITH

HANDLE

CARE

PARTI INTERNE IN MOVIMENTO A

COMANDO AUTOMATICO.

TOGLIERE TENSIONE PRIMA DI TOCCARE

AUTOMATIC CONTROL MEANS MOVING

INTERNAL PARTS.

SWITCH OFF POWER BEFORE TOUCHING

SCHALTUNG AUF AUTOMATIK, INTERNE

BAUTEILE IN BETRIEB. VOR ARBEITSBEGINN

SPANNUNG UNTERBRECHEN

ÉLÉMENTS INTERNES A DÉMARRAGE

AUTOMATIQUE. COUPER L’ALIMENTATION

ÉLECTRIQUE AVANT INTERVENTION

Cod. 69100175

8. Moving parts

Warning: moving parts.

Switch off power supply before any mainte-

nance or installation activities.

14. Do not walk

Don’t walk on the headers or on the fan cowls

15. Sharp surfaces

Warning: danger of cutting injuries. Wear ade-

quate protection.

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

Stickers on this page are not represented in the stickers overview illustration.

CB1

Connection box indentifier

Connection box power. One for each fan row.

Only for units featuring the corresponding option.

Signal box identifier

Connection box for EC fans signal. Only for units

featuring the corresponding option.

Master Controller identifier

Only for units featuring the corresponding option.

Switchboard identifier

Only for units featuring the corresponding option

(ICM/ECCB).

Q1.1

Switch ON/OFF identifier

Only for units featuring the corresponding option

(ICM/ECCB).

Spare part

item no

9460088799

Fan motor

Fan motor item number.

Electrical warning

Electrically powered component. Switch off

power supply before any maintenance or instal-

lation operation.

Grounding

Whenever electrical components supplied by

Alfa Laval have this sticker, is mandatory to

ground them. The yellow/green grounding wire

must be left longer than the others, to ensure

that it is the last one to be detached from the

terminals in the event of the cable being pulled

off. Grounding is designed for the electrical

equipment supplied with the unit and is not to be

intended as protection from external sources.

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

4 Unpacking and lifting

Always follow guidelines and instructions as given in the product manual for Alfa Laval air cooled

condensers & gas coolers AHE00049.

4.1 Packing

By default, all units are shipped in horizontal airflow position. If vertical airflow is selected, mounting

feet come loose. Units are mounted on a wooden pallet, wrapped with plastic foil. As an optional,

open crate (single fan row models) or protection for headers and coil (dual fan row models) can

be selected. Blue for vertical airflow can be ordered with mounted feet. These units are shipped in

mounting position with a pallet for on-site handling.

4.2 Shipping dimensions

Dimensions in the table refer to basic units without any option, shipped in horizontal airflow position

with the different packing options available.

Model

Pallet packing

(with and without protections)

Width (m) Height (m) Length (m)

B*M 801s 0.97 1.69 2.25

B*M 802s 0.97 1.69 3.65

B*M 803s 0.97 1.69 5.05

B*M 804s 0.97 1.69 6.45

B*M 805s 0.97 1.69 7.85

B*M 801 1.10 1.71 2.55

B*M 802 1.10 1.71 4.30

B*M 803 1.10 1.71 6.05

B*M 804 1.10 1.71 7.78

B*M 805 1.10 1.71 9.53

B*M 901-1001 1.10 1.71 2.90

B*M 902-1002 1.10 1.71 5.00

B*M 903-1003 1.10 1.71 7.10

B*M 904-1004 1.10 1.71 9.18

B*D 802 1.10 2.52 4.3

B*D 803 1.10 2.52 6.05

B*D 804 1.10 2.52 7.78

B*D 805 1.10 2.52 9.53

B*D 806 1.10 2.52 11.28

B*D 902-1002 1.10 2.52 5

B*D 903-1003 1.10 2.52 7.1

B*D 904-1004 1.10 2.52 9.18

B*D 905-1005 1.10 2.52 11.28

Model

Crate packing

(only for single fan row models)

Width (m) Height (m) Length (m)

B*M 801s 1.09 1.75 2.29

B*M 802s 1.09 1.75 3.69

B*M 803s 1.09 1.75 5.09

B*M 804s 1.09 1.75 6.49

B*M 805s 1.09 1.75 7.89

B*M 801 1.09 1.75 2.64

B*M 802 1.09 1.75 4.39

B*M 803 1.09 1.75 6.14

B*M 804 1.09 1.75 7.89

B*M 805 1.09 1.75 9.64

B*M 901-1001 1.09 1.75 2.99

B*M 902-1002 1.09 1.75 5.09

B*M 903-1003 1.09 1.75 7.19

B*M 904-1004 1.09 1.75 9.29

9460173341-02

Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.

Alfa Laval reserves the right to change specification without prior notification.

4.3 Unpacking

The unit is shipped on a pallet, handling can take place with use of a forklift. Remove cover crate or

wooden protections on headers and coil (if present).

Unscrew from pallet.

The unit is now ready to be lifted into mounting

position. During this procedure the operator must

never stand nor walk below the suspended load.

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