Alfalaval Alfa-V ACV Series User manual

ORIGINAL INSTRUCTIONS
AHE00052EN 1904
Alfa Laval Alfa-V ACV/ANV/VXD
Instruction manual
• Product description
• Product labels
• Transport & lifting
• Installation
• Maintenance
• Spare parts

AHE00052EN 1904
2
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 General information and application...........................................................................................4
2.2 Standard conguration ...............................................................................................................4
2.3 Options.......................................................................................................................................4
2.4 Code description ........................................................................................................................5
3. Product labels...........................................................................................................................5
4. Unpacking and lifting
4.1 Unit delivered by standard truck.................................................................................................9
4.2 Unit delivered in a container.......................................................................................................9
4.3 Lifting from above.....................................................................................................................10
5. Installation
5.1 Container skid removal (if present) ..........................................................................................12
5.2 Mounting dimensions ...............................................................................................................13
5.3 Feet dimensions detail .............................................................................................................13
5.4 Concrete mounting base ..........................................................................................................13
5.5 Expansion joints .......................................................................................................................13
5.6 Vibration dampers ....................................................................................................................14
5.7 Installation layout guideline ......................................................................................................15
5.8 Electrical connections...............................................................................................................16
6. Operation
6.1 Start-up procedure ...................................................................................................................17
6.2 Shutdown .................................................................................................................................17
7. Maintenance
7.1 Fan replacement ......................................................................................................................17
7.2 Stepping on the unit .................................................................................................................18
8. Spare parts..............................................................................................................................19

AHE00052EN 1904
3
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 Alfa-V industrial condensers and gas coolers and
is supplied in combination with the Alfa Laval Air Cooled Condenser and Gas Coolers 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.
1.2 Intended use
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. The units may not be put into operation 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 label 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.
Alfa-V ACV
Alfa-V ANV
Alfa-V VXD

AHE00052EN 1904
4
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 General information and application
The Alfa Laval Alfa-V series is a wide range of heavy duty dual fan row V-type condensers and gas
coolers for air conditioning and refrigeration applications. Alfa-V air-cooled condensers and gas
coolers provide high capacities at a modest footprint.
• Refrigerants: all halocarbon (ACV), ammonia (ANV) or CO2 (VXD)
• Capacity range ACV: 115 up to 1850 kW (Tair 25 °C, Tcond 40 °C, Tsubcool < 3K, Tsuperheating 25 K)
• Capacity range ANV: 97 up to 1890 kW (Tair 25 °C, Tcond 40 °C, Tsubcool < 3K, Tsuperheating 25 K)
• Capacity range VXD: 160 up to 1000 kW (air temp. 35 °C, CO2at 90 bar, gas temperature in/out 120/38 °C)
• Design pressure: 33 bar (ACV), 30 bar (ANV) or 120 bar (VXD).
• Each heat exchanger is leak tested with dry air and finally supplied with a nitrogen pre-charge.
2.2 Standard configuration
• Finned coil:
- Depending on the application, condensers are fitted with cross-fin copper (ACV) or smooth
stainless steel tubing (ANV). Gas cooler fitted with K65 copper tubes.
- Standard fin spacing 2.1 mm, available with two Alu-fin types: Turbo fins for maximized capac-
ity, Industrial fins for long lasting performance.
- Separate connections allow independent operation of both coils.
• Fans:
-2 to 9 fan pairs (2 to 6 for VXD), available in three fan diameters (ø 800 mm, ø 910 mm &
ø 1000 mm) and different noise levels. ErP compliant motors with dynamically and statically
balanced external rotor, protection class IP 54 according to DIN 40050 and integrated thermo
contacts to provide reliable protection against thermal overload. AC power supplies 400/50/3,
400/60/3 and 460/60/3. EC power supply 380-480/50-60/3. AC/EC Fan motors manufactured in
accordance with VDE 530/12.84
• Casing, supports and frame made of corrosion resistant galvanized steel (class C4-H).
Separated fan sections and removable fan rings.
• Frame construction provides high rigidity for protection against vibration and thermal expansion.
• Stickers indicate fan direction and refrigerant in/out.
2.3 Options
• Non-standard fin spacing (up to 3.2 mm)
• Sub-cooling circuit (SC) - ACV/ANV only
• Stainless steel header tubes for on-site welding connections. -VXD only
• Coil corrosion protection:
- Epoxy coated aluminium fins (EP)
- F-coat (FC)
- Blygold treatment (BY)
- Seawater resistant aluminium AlMg (SWR)
• Coil protection grid (GR)
• Spray water device kit (KW)
• Casing coated RAL 9002
• Container skid (SK)
• Vibration dampers (VD)
• Expansion tank (ET)
• Special fan motors:
- Protection class IP55
- High-temperature motors

AHE00052EN 1904
5
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
• Electrical options:
- Switch on/off (SW)
- EC Motors wired to a common terminal box (CBP= parallel config. CBM= master/slave config.)
- Switchboard IP55 (B)
- AC Fan step control cabinet (BS/BST)
- EC fan speed control cabinet (ICM)
- Basic EC switchboard panel (ECCB)
2.4 Code description
ACV S(E) 90 4 .1 - B D SK * - AL 2.1 CU *
1 2 3 4 5 6 7 8 9 10 11 12 13
1 Alfa Laval Alfa-V (ACV= halocarbon condenser, ANV=ammonia condenser, VXD=gas cooler)
2 Sound level/fan code (T=turbo, S-standard, L=low, Q=quiet, R=residential, E=EC fan motor)
3 Fan diameter (80=800, 90=910, 100=1000 mm)
4 Number of fan pairs (2 to 9 for ACV and ANV, 2 to 6 for VXD)
5 Alfa-V series II
6 Tube rows code (A, B, C, D for ANV and ACV. B, C for VXD)
7 Fan motor connection (D=delta, Y=star)
8 Number of circuits (blank for ACV/ANV)
8 Packing (SK=container skid)
9 Electrical options
10 Fin material (AL=aluminium, IF=industrial fins, SWR=AlMg, EP=epoxy coated aluminium,
FC=F-coat, BY=Blygold)
11 Fin spacing (2.1, 2.3, 2.5, 3.0 and 3.2 mm)
12 Tube material (CU=copper, SS=stainless steel, K65= K65 copper)
13 Options
3 Product labels
10
10
7
13
3
6
11
4
12 12
11
10 10
9
2
1
14
5 15
68
16
1 & 2. 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.
HANDLE
WITH CARE
!
PLEASE PAY ATTENTION
TO THE FORKS!
WITH
HANDLE
CARE

AHE00052EN 1904
6
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
3. Product label
Model Refer to paragraph
"Code description"
Item ID
Serial no.
Communicate these
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
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. ************
ACV******************************
***********************************
Item ID **************
Serial no. **************
Unit Net Weight 2368 Kg ±5%
Sn
Motorfan data
Vn 3~400V
f 50Hz
Country of origin Italy
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. ************
ACV************************
******************************
Item ID **************
Serial no. **************
Sn
Material CU
PED Category I
Volume
Max DN 103
Fluid Group 2
Coil Ts +125/-60 °C
Ps 33 bar
Pt 47 bar
Test Date 04-2019
EXAMPLE
4. Product label - coil
Model Refer to paragraph
"Code description"
Item ID
Serial no.
Communicate these
when ordering spare
parts as they identify
the unit
Material Tube material
PED Category According to PED
Max DN Maximum diameter
of the distributor tube
Fluid Group According to PED
Coil Ts Range of operating
temperatures for the
coil
Ps Design pressure
Pt Test pressure
Test date Date on which the
coil has been pres-
sure tested in the
factory

AHE00052EN 1904
7
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
5. Fan direction
Sticker indicates fan rotation direction
10. Lifting lug
Use all marked lifing lugs when lifting from
above.
6. Electrical warning
Electrically powered component. Switch off
power supply before any maintenance or instal-
lation activity.
Spare part
item no
9460088799
8. Fan motor
Fan motor item number.
11. & 12. In/Out
Refrigerant connections inlet and outlet.
9. Grounding
It is mandatory to ground the unit. 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.
13. Eurovent
Sticker is applied when the product is included
in the Eurovent Certify All program.
7. Moving parts
Warning: moving parts.
Switch off power supply before any mainte-
nance or installation activity.
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
IN
OUT

AHE00052EN 1904
8
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
14. Forklift
When present, this sticker indicates the location
where to place the forks.
FORKLIFT
15. Master
This sticker is present only if the unit is equipped
with option code CBM, and indicates the master
(no sticker on the slaves).
MASTER
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
16. 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.

AHE00052EN 1904
9
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
A
4 Unpacking and lifting
Always follow guidelines and instructions as given in the air cooled condensers & gas coolers prod-
uct manual AHE00049.
Before lifting the unit, check the weight stated on the name plate, located on the inlet connection
side. Verify that the lifting equipment supports the unit weight plus 10%. When forklifts are used,
forks must be longer than 2.5 m for safe lifting and be fully inserted under the unit.
4.1 Unit delivered by standard truck
Alfa-V air heat exchangers can be delivered
either on standard trucks or in containers. The
procedure below applies to the unloading of
units delivered on standard trucks. 9 fan pairs
units are equipped by default with the container
skid and should be unloaded following the pro-
cedure described in paragraph "Unit delivered in
a container" even if they are delivered by stand-
ard truck.
The unit should be unloaded from the side of the
truck with the use of a forklift as shown in the
picture below.
4.2 Unit delivered in a container
In case of container delivery, container skid option is to be selected in order to facilitate the loading
and unloading operations. In case of 9 modules unit, skid is installed by default. Follow the proce-
dure below to unload the unit:
• Remove any obstacle to allow the skid sliding out of the container.
• Ensure the truck is stopped.
• Two forklifts are needed to unload the unit. Forklifts are identified by letter A and B in the follow-
ing steps. In order to pull the unit, fix the chain to forklift A and the hooks in the skid holes as
shown in the picture below.
A
With forklift A, support the unit weight and pull it
slowly out of the container. The unit must remain
on the container floor for at least 1 m.

AHE00052EN 1904
10
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
With forklift B, insert the forks where indicated by
sticker "Forklift" (under the centre of gravity) on
the unit and slightly lift the unit. Remove hooks
and chains and drive away with forklift A.
A
B
B
> 65°
> 65°
DETAIL A
A
90° 90°
Slowly drive forward with the truck until the unit
is completely outside the container.
4.3 Lifting from above
Verify that lifting lugs are safely fixed to the unit
and have no signs of damage. Attach the belts
or hooks only to the lifting lugs as shown in the
drawing on the next page.
Angle of chains as shown for all models.
Load on the lifting chains shall be equally distrib-
uted on all the lifting points. If one chain is not
fully loaded another chain will be extra loaded.
This is not allowed.

AHE00052EN 1904
11
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 MOD
4 FANS
3 MOD
6 FANS
4 MOD
8 FANS
5 MOD
10 FANS
6 MOD
12 FANS
7 MOD
14 FANS 8 MOD
16 FANS
9 MOD
18 FANS

AHE00052EN 1904
12
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
5 Installation
Always follow guidelines and instructions as given in the condenser & gas cooler product manual
AHE00049.
5.1 Container skid removal (if present)
Container skid option is selected in order to facilitate loading and unloading operations. 5 fan pair
units container skids have two additional feet which can be recognized because above them there
is no coil support, as shown in the picture.
Container skid (included the additional feet, if present) shall be removed before installation.
Container skid components are connected to the unit by means of screws, as highlighted below. To
remove the skid and the additional support feet it is needed to slightly lift the unit.

AHE00052EN 1904
13
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
5.2 Mounting dimensions
Drawings showing all required mounting and refrigerant connection
dimensions are available for download on www.alfalaval.com.
Dimensional drawings
5.3 Feet dimensions detail
Feet dimensions are identical for all models.
Avoid any lateral torque on the feet when fixing the unit to the ground.
External fixing holes can be used only to fix the unit to the ground. It is not allowed to use them
neither when the heat exchanger is mounted on a beam structure nor for vibration dampers.
2280
80
20
160
Vibration damper
fixing hole
160
80
20 Fixing hole
5.4 Concrete mounting base
To avoid oxidation of the equipment feet, it
is strongly recommended to mount the heat
exchanger on concrete mounting bases. One
base for each foot. Base minimum dimensions
are 100 mm height and 260 mm width.
5.5 Expansion joints
Alfa Laval recommends the installation of expan-
sion joints on both inlet and outlet connections.
Expansion joints are elastic elements which, if
properly installed, absorb the thermal expan-
sions of the tubing. Expansion joints are also
helpful in order to reduce vibrations in the piping.

AHE00052EN 1904
14
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
5.6 Vibration dampers
For active and passive isolation of vibrations and reducing noise transmission, Alfa Laval strongly
recommends the installation of vibration dampers. Installation of vibration dampers must be carried
out before positioning the unit. Vibration dampers are to be positioned between the unit feet and the
mounting base with the supplied M16 screw.
Fan pairs Vibration dampers
2 4
3 4
4 6
5 8
6 8
7 8
8 10
9 12
4
51,5
168
150
M 16
132
168
12,5
Isolating material natural rubber,
hardness 60° Sha.
Picture shows an installation example using
threaded bar, nut, grower washer, washer and
locknut (not supplied).
This way vibration dampers can be used to
make the cooler level adjusting the locknut. This
is particularly useful with long units or irregular
basement.

AHE00052EN 1904
15
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
5.7 Installation layout guideline
Ensure installation is such that the following conditions are met:
• Place the unit outdoor, so that it can be monitored and controlled from all sides at all times.
• Ensure that sufficient space is available for maintenance.
• Verify the structures supporting capacity regarding the weight of the unit(s), including refrigerant.
Floor mounted
Single unit
Two or more units
The unit spacings shown above are default values. If the unit(s) is (are) lifted from the ground, dis-
tances might be reduced. The 1000 mm shown above refer to the unit base and not necessarily to
the ground. In case of doubt, to determine optimal unit spacing for specific conditions on site please
contact your Alfa Laval representative for advise.
L/2 L/2
< 1000 < 1000
L/2
< 1000
L L/2
< 1000
L
L

AHE00052EN 1904
16
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
Platform for two to six units
Number of fan pairs
2, 3 4, 5, 6 7, 8, 9
H ≥ (N-1)/2 (N-1)/1.2 N-1
d ≥ L/2 L/2 L/2
h ≤ (N-1)/2 (N-1)/1.2 N-1
N= number of units on the platform.
All three conditions (H, d, h) shall be met. Contact Alfa Laval in case a different lay out is required.
Special care should be taken in particular installations such as:
• When installation site is subjected to strong winds.
• When walls with different configuration or heights than the ones shown in the previous pictures
are present.
• When more than 6 units are installed on a platform.
• When severe environmental loads (e.g. earthquakes) are likely to affect the unit.
In these cases contact your local Alfa Laval representative for support.
5.8 Electrical connections
The following data determine which connection diagram is to be selected and respected for electri-
cal installation:
• Heat exchanger model indication
• Fan motor type
• Electrical options
Electrical connection diagrams are available for download on
www.alfalaval.com. When in doubt always contact your local Alfa Laval
representative for assistance.
h
L
h
d
d
H
Electrical connections

AHE00052EN 1904
17
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 Operation
6.1 Start-up procedure
The following procedure is to be respected at every system start-up.
• Verify there are no leaks in the refrigerant circuit and connections.
• Switch on fan power supply.
• Start the fans and verify fan direction.
• After some operating time, verify that current absorbtion does not exceed the value as given in
the technical specifications.
6.2 Shutdown
If the unit requires emptying for maintenance, system shutdown or dismounting, proceed as follows:
• Stop refrigerant supply and switch off electrical power supply.
• Make sure neither refrigerant nor power supply can be resumed accidentally or unexpectedly.
• Drain all liquid refrigerant into a suitable vessel.
• Evacuate the coil to remove any remaining refrigerant gas.
7 Maintenance
Ensure complete electrical isolation before performing any maintenance activity and always follow
guidelines and instructions as given in the condenser and gas cooler product manual AHE00049.
7.1 Fan replacement
• Open the connection box. Disconnect fan cabling.
• Unscrew fixing bolts and remove old fan.
• Mount new fan assembly in identical position. Remount fasteners. Use an anti-corrosion coating
like Geomet or comparable when remounting using new fixing bolts.
• Restore the electric connections (water trap as shown).
• Check for correct fan direction.

AHE00052EN 1904
18
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
7.2 Stepping on the unit
If for maintenance purposes it is required to step on the on the unit, always wear safety shoes. It is
not allowed to step on the unit while it is working. Proper protection against falling shall be arranged
with railings and safely fixed ladders. If the units do not have railings a safety device that prevents
falling shall be used. Never step on the fan grids and on the liquid connections. It is not allowed to
step outside the areas highlighted in the example below.
= Walkable areas

AHE00052EN 1904
19
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change specification without prior notification.
8 Spare parts
Spare parts for Alfa-V
①Fan
②Switch on/off
③Switchboard
④Vibration damper
⑤Protection grids (available on request)
Spare parts can be selected and ordered in the online eBusiness tool
Alfa Laval Anytime. If required please contact your local Alfa Laval
representative for assistance.
Alfa Laval Anytime
②
③
④
⑤
①

www.alfalaval.com