Alfalaval PCJ User manual

Polar Cat Junior AIR COOLERS
Polar Cat Junior G LIQUID CIRCULATED AIR
COOLERS
PCL HEAT RECOVERING CONDENSERS
MANUAL
A. INSTALLATION INSTRUCTIONS
B. SERVICE INSTRUCTIONS
C. DECLARATION OF CONFORMITY
Alfa Laval Vantaa Oy
Ansatie 3, FI-01740 Vantaa, Finland
Tel. [phone], fax [phone]
www.fincoil.fi; www.alfalaval.com 02.05.2005/18.4.2008/7.2.2012

1
A. INSTALLATION INSTRUCTIONS
1. GENERAL
Polar Cat Junior air coolers are suitable for small cold and subzero rooms or cabinets using
refrigerants and liquids, which do not corrode copper.
The Manual also concerns E-model, where applicable (E=non-standard model). In these cases you
always have to check from delivery documents, in which way the difference has to be taken into
notice in installation, service and use.
Wall mounting is possible with a drip tray A (without electric defrost) as accessory. The drip tray is
attached on the air cooler, drip water connection is placed on the drip tray and the original hole is
plugged. The model equipped with electric defrost (SSA) is ready-fitted at factory.
Ceiling mounting Wall mounting with drip tray
PCJ as accessory
PCJ A / SSA
PCL PCL (AK)
Fig 1.
PCL, using the same construction, is a condenser suitable for indoor spaces and for roofed
outdoor spaces. Wall mounting is possible by using a fitting support (AK).

2. TRANSPORT AND STORAGE
Polar Cat Junior air coolers are delivered in individual carton packages. When the air coolers are
stored one upon the other, please note the light construction of the packing (max. 4 packings on
each other).
Products may not be stored in humid outdoor spaces.
3. PLACING
Polar Cat Junior air coolers shall be mounted so that their air flow is not obstructed and there is
nothing to prevent the air flow in front of the equipment.
In models equipped with electric defrost space is needed for changing the defrost theaters of the coil
block (fig. 2).
Fig. 2.
4. TUBE CONNECTIONS, ELECTRIC CONNECTIONS
PCJ air cooler PCJ, G-model PCL condenser
Fig. 3.
A = Through holes for refrigerant tubes and electric wires
B = Drip water connection
C = Liquid in
D = Liquid out
E = Gas in

5. FANS
The fan unit of PCJ air coolers and PCL condensers consists of motor bracket, shaded-pole motor,
fan blade of aluminium and fan guard of plastic.
6. MOTORS
The motors are totally enclosed, impedance protected shaded-pole motors, suitable for voltage of
1/230 V and working temperatures between + 40...- 30 °C. The minimum starting temperature is -25
°C. The motors are parallel connected to a common junction box.
Motors´ connecting diagram
Fig. 4.
7. CONNECTIONS OF MODELS WITH ELECTRIC DEFROST
SS - models without thermostats
PCJ and PCL, sizes 1 and 2: motors and electric defrost heaters connected to the same junction box.
PCJ and PCL, sizes 4 and 3: motors and electric defrost heaters connected to separate junction
boxes.
Fig. 5.

SS - models with thermostats
The defrost system is controlled by a clock (L).
The defrost time set in the clock shall be shorter than the defrost period.
Closing of defrost clock points regulates the contactor (K 1), which stops the compressor and the
fans and switches on the defrost heaters (R).
The defrost break thermostat (S1) switches off the defrost process at + 14 °C by regulating the
contactor (K2), which starts the compressor and turns off the defrost heaters (R).
The fans´ starter thermostat (S2) starts the fans at -4 °C. This prevents water drops being driven
with the air flow.
NOTE!
The thermostat set values are fixed, i.e. the fans´ starter thermostat cannot be used, if the
evaporating temperature is higher than appr. –10 °C. The electric defrost system can also be
delivered without thermostats.
L =Clock
K1 = Contactor
K2 = Contactor
S1 = Defrost break thermostat
S2 = Fan’s starter thermostat
R = Defrost heaters
M = Fan
= Compressor control
Fig. 6. Evaporating period
8. CHECKINGS
The equipment has been pressure-tested at factory.
All soldering in the coil block is made by hard solder (FOSCO 710/DIN8513/LAg2P).
•Check suitability of the electric network.
•Check the electric installations.

1
9. ADDITIONAL REMARKS
NOTE!
Venting/draining valve of Polar Cat Junior G standard units are not adapted for refrigerant based on
potassium formiate; DANGER OF LEAKAGE!
When using a refrigerant, which is based on potassium formiate, it has to be checked from the
documents if the heat transfer section’s piping system and the venting/draining valves are adapted
for the refrigerant.
Instructions from refrigerant supplier have to be followed at installation, pressure test, use as well as
in maintenance.
NOTE!
Applicability of the material of fins and heat transfer tubes to ambient conditions shall always be
checked to avoid external corrosion.
In the air there should be no particles, which - together with water or other solvent condensing on
the surface of the heat transfer section - might form corrosive combinations. These combinations
can corrode the fins and tubes of the heat transfer section.

2
B. SERVICE INSTRUCTIONS
Trouble free operation of Polar Cat Junior air coolers and PCL condensers requires regular service.
WARNING: Before starting service operations make sure that the circuit is reliably switched off.
In service please check:
•Outward condition of the equipment
•Fixing of the equipment and of fans
•Fan function
•Defrost system
•Cleanness of the coil block
•Drainage
1. COIL BLOCK AND DRIP TRAY
The coil block needs regular cleaning, if the air cooler is in use in dirty conditions or if the running
conditions require special cleanness.
For cleaning the coil block open the fan plate, which the fan units are fixed on, very carefully
(NOTE! The fan plate may not be hung on the jumpers only).
The coil block can be vacuum-cleaned or washed (please do not use any strong alkaline detergents
or acids!). Recommendable detergent is e.g. ENVIRO-COIL.
It is easy to clean the drip tray construction (PCJ) after opening the fan plate.
2. FANS
Polar Cat Junior air coolers and PCL condensers have 1-phase shaded-pole motors, fan blade diam.
178 mm.
Should the fan make any rattling or scratchy noise, stop it immediately and check its fixing points. If
necessary, replace the motor.

3. REPLACING A DAMAGED ELECTRIC COMPONENT
Please note, that an authorized person may only replace the damaged electric component.
WARNING:
Before changing the damaged component make sure that the circuit is reliably switched off!
A new motor, defrost heater or thermostat:
•Open the fan plate
•Open the cover plate of the junction box
•Release the cables of the damaged component
•Replace the damaged component
•Connect the new component
•Check the earthing
•Close the cover plate of the junction box
•Close the fan plate
•Make a test-run
Fig. 7

Declaration by the manufacturer of the component
incorporated to the machinery (Directive 2006/42/EC, Annex II,
sub.B)
ALFA LAVAL VANTAA OY
Ansatie 3, FI-01740 Vantaa, Finland
herewith declares that the component
PC, PCD, PBD, PCJ, FMP, FSS, FKS, FTPE air cooler
PCG, PCDG, PBDG, PCJG, FMPG liquid cooler
which is not able to function independently is intended to be incorporated into machinery or to be assembled
with other machinery to constitute machinery covered by Directive 2006/42/EC and changes related to it and
with national implementing legislation meant machinery.
By designing of the component the following directives have been applied:
2006/42/EC, 2004/108/EC, 97/23/EC
and the following harmonized standards have been applied:
ISO-EN 12100:2010, SFS-EN ISO 13857, SFS-EN 60204-1,
SFS-EN 61000-6-1, SFS-EN 61000-6-3, SFS-EN 61000-6-4
and furthermore declares that is not allowed to put the machinery into service until the machinery into which it
is to be incorporated or of which it is to be a component has been found and declared to be in conformity with
the provisions of Directive 2006/42/EC and with national implementing legislation including the machinery
referred to in this declaration.
Vantaa, February 7, 2012
Silja Beierschoder
Quality Manager