Alfalaval AlfaBlue Junior DG User manual

ORIGINAL INSTRUCTIONS
AHE00061EN 1904
Alfa Laval AlfaBlue Junior DG
Instruction manual
• Product description
• Product labels
• Unpacking & lifting
• Installation
• Maintenance
• Spare parts

AHE00061EN 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 Packing.......................................................................................................................................7
4.2 Shipping dimensions ..................................................................................................................7
4.3 Feet mounting for vertical airow ...............................................................................................8
4.4 Lifting from above.......................................................................................................................9
5. Installation
5.1 Mounting dimensions ...............................................................................................................10
5.2 Concrete mounting base ..........................................................................................................14
5.3 Vibration dampers ....................................................................................................................14
5.4 Expansion joints .......................................................................................................................14
5.5 Switch on/o󰀨 (option SW).........................................................................................................15
5.6 Switchboard fan speed control (option FT) ..............................................................................15
5.7 Installation layout guideline ......................................................................................................16
5.8 Electrical connections...............................................................................................................17
6. Operation
6.1 Start-up procedure ...................................................................................................................17
6.2 Shutdown .................................................................................................................................17
7. Maintenance
7.1 Fan replacement ......................................................................................................................18
7.2 End covers ...............................................................................................................................18
8. Spare parts..............................................................................................................................19

AHE00061EN 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 AlfaBlue Junior DG dry coolers and is supplied in
combination with the Alfa Laval Air Cooled Liquid Coolers Product Manual AHE00050. Both manu-
als 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
Liquid 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.
AlfaBlue Junior DG

AHE00061EN 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
AlfaBlue Junior DG is a competitive dry cooler line that offers excellent performance, allowing easy
installation on site and an outstanding integration with other components. High efficient fan motors
combine excellent sound characteristics and low energy consumption. AlfaBlue Junior dry coolers
are often used for cooling down condenser water in air-conditioning and refrigeration installations.
In the processing industry, dry coolers are suitable for closed circuit cooling of various process
liquids.
•Suitable for all liquids that do not corrode copper.
•Capacity range: 45 up to 233 kW (water, EN1048).
2.2 Standard configuration
Finned coil:
Innovative coil design manufactured from 8 mm Cu tubes and aluminium turbo fins. Standard fin
spacing 2.1 mm. Liquid connections externally threaded. Each heat exchanger is leak tested with
dry air. Higher design/test pressures on request.
Model Design pressure Test pressure
AlfaBlue Junior DG 10 bar 15 bar
Construction:
Patented coil frame design allowing thermal expansion and offering protection against vibration.
Corrosion resistant casing material, powder coated RAL9002. Separated fan sections.
Fans:
High efficiency AC or EC fans and low power consumption. Available in two fan diameters (500
& 630 mm), different power supplies (230/50-60/1, 400/50/3, 480/60/3) and four noise levels.
Protection class IP 54 according to DIN 40050.
AC motors are fitted with integrated thermo contacts to provide reliable protection against thermal
overload (terminals in the box).
2.3 Options
•Switch on/off (SW)
•Connection box for electrical power connection (CB)
•Fan speed control 230/1 and 400/3 (FT)
•Coil options:
- Epoxy coated fins (EP)
- Seawater resistant aluminium alloy fins (SWR)
- Copper fins (CU)
- F-coat treatment (FC)
- Industrial fins (IF)
- Fin spacing 2.5 mm (other fin spacings on request)
•Vibration dampers (VD)
•End covers (CV)
•Mounting feet kit for vertical airflow
•Aluminium flanges (FL)

AHE00061EN 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.
2.4 Code description
DG S(E) 50 2 .1 B D H/V BO * - AL 2.1 CU *
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 AlfaBlue Junior dry cooler
2 Sound level/fan code (S=standard, L=low, Q=quiet, R=residential, E=EC fan motor)
3 Fan diameter (50=500, 63=630 mm)
4 Number of fans (1 to 6)
5 Version number
6 Tube rows code (A, B, C)
7 No. of phases (S=1, D=3)
8 Units are suitable for both horizontal and vertical airflow
(mounting feet kit required for vertical airflow setup).
9 Packing (BO=box, CR=crate)
10 Options
11 Fin material (AL=aluminium, IF=industrial fins, SWR=AlMg, CU=Copper,
EP=epoxy coated aluminium, FC=F-coat)
12 Fin spacing (2.1, 2.5 mm)
13 Tube material (CU=copper)
14 Options
3 Product labels
①②
⑤
③
⑨③④
⑦
⑧
⑥⑩
Spare part
item no
9460088799
2. Fan motor
Fan motor item number.
1. Electrical warning
Electrically powered component. Switch off
power supply before any maintenance or instal-
lation activity.
3. Fan direction
Sticker indicates fan rotation direction.
4. Eurovent
Sticker is applied when the product is included in
the Eurovent Certify All program.

AHE00061EN 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.
5. Product label
Model Refer to paragraph "Code
description"
Item ID
Serial no.
Communicated 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.
6. Product label - coil
Model Refer to paragraph "Code
description"
Item ID
Serial no.
Communicate these 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. *********
DG******************
***************
Item ID *************
Serial no. *************
Sn
Material CU
PED Category Art. 4.3
Max DN 33
Fluid Group 2
Coil Ts +110/-60 °C
Ps 10 bar
Pt 15 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. ********
DG********************
*********************
Item ID **************
Serial no. ***************
Unit Net Weight 86 Kg ±5%
Sn
Motorfan data
Vn 3~400V-480V
f 50/60Hz
WARNING
READ INSTRUCTION MANUAL BEFORE INSTALLATION AND
MAINTENANCE TO AVOID INJURIES OR DAMAGE
Country of origin Italy
EXAMPLE
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
7. & 8. In/Out
Liquid connections inlet and outlet.
9. Moving parts
Warning: moving parts.
Switch off power supply before any mainte-
nance or installation activities.
10. 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 off.

AHE00061EN 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.
4 Unpacking and lifting
Always follow guidelines and instructions as given in the air cooled liquid coolers product manual
AHE00050.
4.1 Packing
All units are packaged and shipped in horizontal airflow position. AlfaBlue Junior 501/502 units are
mounted on a wooden pallet and covered with a sturdy cardboard box. All other models are mount-
ed on a wooden pallet, wrapped with plastic foil and covered with an open crate.
4.2 Shipping dimensions
model Standard
packing
type
Standard packing Including fan speed control switchboard
Length
cm
Width
cm
Height
cm
Volume
m3
Weight
kg
Length
cm
Width
cm
Height
cm
Volume
m3
Weight
kg
501 box 120 61 97 0,7 67 125 61 95 0,7 75
502 box 210 61 97 1,2 121 224 70 101 1,6 134
503 crate 311 70 100 2,2 208 311 70 100 2,2 226
504 crate 402 70 102 2,9 282 412 58 100 2,4 296
631 crate 177 91 135 2,2 122 177 87 127 2,0 130
632 crate 277 91 135 3,4 198 259 91 141 3,3 212
633 crate 377 91 135 4,6 296 377 91 135 4,6 310
634 crate 477 91 135 5,9 376 577 91 137 7,2 390
635 crate 577 91 135 7,1 477 559 91 141 7,2 491
636 crate 677 91 137 8,4 554 678 91 141 8,7 577
Handling can take place with use of a forklift.
Heat exchangers can be stacked during storage.
(max. 2 units).
501
502
503
504
63* max. 1

AHE00061EN 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.
All units are packed and shipped in horizontal
airflow position. For setup with vertical airflow,
the mounting feet (kit) must be mounted prior
to installation. For this purpose the unit must be
lifted and tilted 90° onto supports. Use supports
for each mounting foot position. The supports
must span the full casing width to avoid damage
to the finned coil.
Loosen fixing bolts and remove all mounting pro-
files. For DG 630 models also remove the lifting
lugs positioned on the opposite casing side.
Replace all mounting profiles with the sup-
plied mounting feet. Mounting feet should be
fitted on both sides of the casing at all vacant
mounting feet and lifting lug positions.
With all mounting feet in place, the unit is
ready for further positioning and installation.
4.3 Feet mounting for vertical airflow

AHE00061EN 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.
Total amount of lifting points (identical for both horizontal and vertical airflow models)
1 fan: 4 2 fans: 4 3 fans: 4 4 fans: 6
5 fans: 8 6 fans: 8
30° max 30° max
side view
AlfaBlue Junior heat exchangers can be lifted
from above. For models with 2 or more fans the
use of a hoisting beam is required. DG63 mod-
els are supplied with lifting lugs. For DG50 mod-
els eye bolts must be fitted on all lifting points.
Attach belts or hooks to the lifting point. Respect
the allowable chain angles. The load on the lift-
ing chains shall be equally distributed on all the
lifting points.
For all heat exchanger models it is mandato-
ry to use all indicated lifting positions during
any lifting operation.
4.4 Lifting from above
M8 eye bolts to be
fitted on DG50 models
(not provided)

AHE00061EN 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.
5 Installation
Always follow guidelines and instructions as given in the liquid coolers
product manual AHE00050.
5.1 Mounting dimensions
Drawings showing all required mounting and refrigerant connection dimen-
sions are available for download on www.alfalaval.com.
Mounting dimensions model 50 - Horizontal airflow
860
900 ±5
1165 ±10
1760
1800 ±5
2065 ±10
2660
2700 ±5
2965 ±10
3865 ±10
1800
3600 ±5
1760
40
20
Ø14
FRONT VIEW
826 ±5
420
470
Side view (all models)Mounting profile
Dimensional drawings

AHE00061EN 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.
Mounting dimensions model 50 - Vertical airflow
890 ±10
420
854
899
45
60
Ø16
TOP VIEW
Side view (all models) Mounting profile
1165 ±10
860
920 ±5
3865 ±10
1760
1800
3620 ±5
2065 ±10
1760
1820 ±5
2965 ±10
2660
2720 ±5

AHE00061EN 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.
Mounting dimensions model 63 - Horizontal airflow
5265 ±10
2000 1000 1960
5000 ±10
3265 ±10
2960
3000 ±5
19602000
4000 ±10
4265 ±10
960
1000 ±5
1265 ±10
1960
2000 ±5
2265 ±10
6265 ±10
2000 2000 1960
6000 ±10
700
750
1036 ±5
40
24
Ø14
FRONT VIEW
Side view (all models)Mounting profile

AHE00061EN 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.
Mounting dimensions model 63 - Vertical airflow
45
60
Ø16
TOP VIEW
Side view (all models)Mounting profile
1204 ±10
500
1057
1102
1265 ±10
960
1020 ±5
1960
2020 ±5
2265 ±10
2960
3020 ±5
3265 ±10
2000 1960
4020 ± 10
4265 ± 10
5265 ±10
2000 1000
5020 ±10
1960
6265 ±10
2000 2000 1960
6020 ±10

AHE00061EN 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.
5.2 Concrete mounting base
To avoid oxidation of the equipment feet, it is recommended to mount the heat exchanger on con-
crete mounting bases. Base dimensions as indicated.
78
M 10
128
3
30
110
9
Natural rubber, hardness 60° Sha.
5.3 Vibration dampers
For active and passive isolation of vibrations and
reducing noise transmission, Alfa Laval strongly
recommends the installation of vibration damp-
ers. 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
M10 screws.
Model Total nr. of
vibration dampers
501, 502, 503
631, 632, 633 4
504, 634 6
635, 636 8
45 mm
60 mm
min. 145 mm min. 160 mm
min. 100 mm
Vertical airflow
5.4 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.
min. 140 mm
min. 100 mm
Horizontal airflow
model 50: min. 570 mm
model 63: min. 850 mm
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.

AHE00061EN 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.
5.5 Switch on/off (option SW)
If switch on/off (SW) is selected, the default positioning is for horizontal airflow installation.
The cover design is such that it can be used both for horizontal and vertical airflow installation.
To adjust the switch positioning to the actual positioning on site: unscrew the cover fixing screws,
turn it as shown and replace fixing screws.
5.6 Switchboard fan speed control (option FT)
If fan speed control (FT) is selected, the default positioning of the switchboard is for vertical airflow
installation. For application with horizontal airflow, unscrew switchboard and remount in position as
indicated below. The cover plate should always be positioned horizontally to protect the electrical
components.
2xM6
Cover plate
Cover plate
Correct
switchboard position
horizontal airflow
Correct
switchboard position
vertical airflow
Default
switchboard position
at delivery
Incorrect
switchboard position
horizontal airflow

AHE00061EN 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.
5.7 Installation layout guideline
Ensure installation is such thet 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 the liquid.
• As a rule of thumb the (unrestricted) air-inlet surface area should at least equal the coil surface
of the unit(s).
• Recirculation of heated air is to be avoided at all times.
C
C
C
Wind Wind
>C
C
>2C
> C/2
> C
C
> C/2
>C
2 units next to each other
Obstacle
Obstacle
CC
H (> B-C)
C
B
>4C
Obstacle
C
H > B
B
<4C

AHE00061EN 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.
• Close the liquid-in valve and open the liquid-out valve.
• Open unit vent plug and then fill the unit while venting.
• When all air has been discharged from the liquid circuit, close unit vent plug.
• Start liquid pump.
• Open system inlet valve slowly until the appropriate liquid flow is reached.
• Verify there are no leaks in the liquid circuit and connections.
• Switch on fan power supply.
• Start the fans and verify fan direction.
• After some operating time, check the absence of air in the liquid circuit (vent if needed) and
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 liquid supply and switch off electrical power supply.
• Make sure neither liquid nor power supply can be resumed accidentally or unexpectedly.
• Close liquid-in and liquid out valves.
• Install a proper hose at the drain valves. Open venting and draining valves. Attention: fluid may
be hot.
• Make sure all drained liquid will be collected in a suitable vessel.
• Compressed air helps to drain in less time. Compressed air shall be oil free.
5.8 Electrical connections
The following data determine which connection diagram is to be selected
and respected for electrical installation:
• Heat exchanger model indication
• Fan motor type
• Electrical options
Electrical connection diagrams are available for download on www.alfala-
val.com. When in doubt always contact your local Alfa Laval representa-
tive for assistance. Electrical connections
Contact Alfa Laval to determine optimal unit spacing for specific conditions on site. Special care
should be taken in particular circumstances such as:
• When the installation site is exposed to strong winds.
• When walls or other obstructions with different configuration than the ones shown in the previ-
ous pictures are present on site.
• When severe environmental influences are likely to affect to the unit.

AHE00061EN 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.
4x
7 Maintenance
Ensure complete electrical isolation before performing any maintenance activity and always follow
guidelines and instructions as given in the air cooled liquid coolers product manual AHE00050.
7.1 Fan replacement
Always disconnect power supply before perform-
ing any maintenance activities on fans and fan
motors. Disconnect fan cabling.
Unscrew fixing bolts and remove old fan.
Mount new fan in identical position.
Remount fasteners. Use an anti-corrosion com-
pound when remounting the fixing bolts.
Restore electric connection.
Check the correct fan rotation.
7.2 End covers
End covers can be removed for inspection,
cleaning and maintenance purposes. To remove
end covers, loosen fixing bolts.

AHE00061EN 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.
Alfa Laval Anytime
Spare parts for AlfaBlue Junior
①End cover - bends side
②End cover - connection side
③Mounting profiles (horizontal airflow)
④Mounting feet (vertical airflow)
⑤Fan
⑥Vibration damper
⑦Switch on/off
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.
8 Spare parts
②
①
③
⑥
⑤
⑦
④

www.alfalaval.com