Alfalaval Optigo CC Series User manual

Optigo CC
Instruction manual
ORIGINAL INSTRUCTIONS
AHE00047EN

Contents
1 Important information..............................................................................3
1.1 Disclaimer..................................................................................................................................... 3
1.2 Intended use................................................................................................................................. 3
1.3 Where to find product information................................................................................................3
2 Product description................................................................................. 4
2.1 General information and application.............................................................................................4
2.2 Standard configuration..................................................................................................................4
2.3 Options..........................................................................................................................................5
2.4 Code description...........................................................................................................................5
3 Product labels.......................................................................................... 7
4 Unpacking and lifting............................................................................ 10
4.1 Unpacking................................................................................................................................... 10
4.2 Lifting...........................................................................................................................................12
5 Installation...............................................................................................15
5.1 Mounting dimensions..................................................................................................................15
5.2 Mounting bracket........................................................................................................................ 17
5.3 Technical spaces........................................................................................................................ 18
5.4 Refrigerant connections..............................................................................................................19
5.5 Hotgas connection (optional)......................................................................................................19
5.6 Drain line.....................................................................................................................................20
5.7 Electrical connections................................................................................................................. 21
5.7.1 Electrical connections 1-phase AC fan motors.............................................................22
5.7.2 Electrical connections 3-phase AC fan motors.............................................................23
5.7.3 Electrical connections 1-4 EC fan motors 1-phase (2-speed, CC250 only).................. 24
5.7.4 Electrical connection for 1-4 EC fan motors 1-phase with 0-10V speed regulation..... 25
5.7.5 Electrical connection for 1-4 EC fan motor 3-phase with 0-10V speed regulation...... 27
5.7.6 Electrical connection for electric defrost CC400 & CC500........................................... 28
5.7.7 Electrical connection for electric defrost CC250 & CC350........................................... 29
5.7.8 Electric defrost capacities............................................................................................. 29
6 Maintenance............................................................................................33
6.1 Fan replacement.........................................................................................................................33
6.2 Driptray........................................................................................................................................33
6.3 Side covers................................................................................................................................. 34
6.4 Coil heater elements replacement..............................................................................................34
6.5 Driptray heater elements replacement....................................................................................... 35
7 Spare parts............................................................................................. 37

1 Important information
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB. Alfa Laval reserves the right
to change specification without prior notification.
1.1 Disclaimer
This Instruction Manual applies to all Alfa Laval Optigo CC air cooler products and is supplied in
combination with the Alfa Laval Air Cooler Product Manual AHE00042. 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
Air 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
Optigo CC
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.
AHE00047EN 3Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

2 Product description
2.1 General information and application
Optigo CC are commercial single discharge unit coolers for general application in small to medium-sized
cooling, freezing and working rooms. Coolers are available in draw-through (CC) and blow-through design
(CCB). A wide range of models make them especially suitable for refrigerated working, processing and
storage rooms. Dedicated ranges for HFO/HFC refrigerants (E), brine (W) and CO2 (X). A selection of
Optigo CC coolers is available from stock.
• Refrigerants: HFO/HFC DX (E), CO2 DX (X) and brine (W)
• Room temperatures: +10 to -30 °C
• Capacity (SC2): 1 up to 55 kW (SC2)
• Air volumes: 770 up to 30000 m3/h
Model Refrigerant Design pressure Test pressure
CC(B) E HFO/HFC 40 bar 57 bar
CC X CO2 80 bar 114 bar
CC(B) W Brine 10 bar 14.3 bar
2.2 Standard configuration
• Internally grooved Cu tubes and aluminium fins, smooth tubing for brine applications and dedicated
thicker tubes for CO2 application. Tube pitch is staggered. All HFO/HFC DX models fitted with a T-
connection to improve the refrigerant distribution and for hotgas defrost in coil.
• Optigo CC coolers are available with 1 to 4 fans fitted with AC or EC fan motors in two fan speed
executions (noise levels) H/L. Fan diameters 250, 300, 350, 400 or 500 mm drawing or blowing through
the coil. Integrated thermo contacts (Clixon) standard for 3-phase AC motors. All single phase motors
protected by an integrated internal overload switch. Electronically integrated overload protection for EC
fan motors.
• All casing parts made of durable sheet metal, epoxy coated RAL 9002. Top plate corrosion resistant
Magnelis®.
• All models fitted with hinged side panels and aluminium driptray. Driptray is adjustable for perfect
leveling. Removable internal driptray for inspection and cleaning.
• Hinged side panels and driptray, drain(s) 1½" BSP external
• Fitted with schräder valve on the suction connection for testing purposes.
• Sufficient room for fitting the expansion valve inside.
• Stickers indicate fan direction and refrigerant in/out.
• Optigo CC251-403 models are delivered in wood-reinforced cardboard boxes, CC404-504 and CCB
models in wooden crates. All packings suitable for safe stacking.
AHE00047EN 4Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

2.3 Options
• Electric defrost
For cold rooms with room temperatures below 4 °C and where frost build-up is likely, the application
of a defrosting system is advised. Electric defrost for Optigo CC consists of stainless steel heater
elements. The defrost elements are connected to separate terminals in the terminal box. Available
defrost systems are:
• Electric defrost in coil (standard E1, heavy E2)
• Electric defrost in driptray (HD)
• Hotgas defrost in driptray (HG)
• Electric defrost in driptray & hotgas in coil
• Driptray insulation 12 mm + cladding (IS)
• Shut-up sock (S)
• Airsock adapter ring (SR). Available for CC400 and CC500 draw-through models only.
• Coil protection
• Pre-coated aluminium fins (EP)
• Cataphoresis treatment (CA)
• Stainless steel casing and frame (SSC)
• Fan ring heater (FRH)
• Re-heating coil (RH)
• Switch on/off (SW)
• Fan motors wired to connection box (CB)
2.4 Code description
CC B E H E 50 1 .2 A S 230V BO SS E EP - 7.0 CU IS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
AHE00047EN 5Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

1. Commercial unit cooler
2. Air direction (default=draw through, B=blow through)
3. Refrigerant system (E= HFO/HFC DX, X=CO2 DX, W=brine)
4. Fan speed (H=high speed, L=low speed)
5. Fan motor type (blank=AC, E=EC)
6. Fan diameter (25=250, 30=300, 35=350, 40=400, 50=500 mm)
7. Number of fans (1 to 4)
8. CC version
9. Tube rows code (A, B, C)
10.No. of phases (S= 1, T=3)
11.Motor voltage
12.Packing (BO=box, CR=crate)
13.Casing material (PC=powder coated, SS= stainless steel)
14.Defrost system (A=air defrost, E=electric defrost, HG=hotgas, HG+E= hotgas + electric defrost in
driptray)
15.Fin material (AL=aluminium, EP=epoxy coated aluminium, CA=cataphoresis)
16.Fin spacing (4, 5.5, 7, 10, 12 mm)
17.Tube material (CU=copper)
18.Options
AHE00047EN 6Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

3 Product labels
⑧
③
②
①
⑨
⑩
⑧
⑥⑦
⑤
④
1. Product label
WARNING
READ INSTRUCTION MANUAL BEFORE
INSTALLATIONS OPERATIONS AND MAINTENANCE
TO AVOID INJURIES OR DAMAGE
Country of origin Italy
Manufactu rer: Manuf. Date:
AIR HEX ALONTE S.R.L. - Italy 04 / 2019
Model: O.A. 1100186
CCEH502.2BD 400V CR PCE
CA 5.5 CU
Item ID: 3289208322
Serial no. AP 2003621
Unit Net Weight: 190 Kg ±5%
Sn
Motorfan data:
Vn: 3~400V
f: 50 H z
EXAMPLE
Model Refer to 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
2. Product label - coil
WARNING
READ INSTRUCTION MANUAL BEFORE
INSTALLATIONS OPERATIONS AND MAINTENANCE
TO AVOID INJURIES OR DAMAGE
Manufactu rer: Manuf. date:
AIR HEX ALONTE S.R.L. - Italy 04 / 2019
Model: O.A. 1100186
CCEH502.2BD 400V CR PCE
CA 5.5 CU
Item ID: 3289208322
Serial no. AP 2003621
Sn
Coil PED data: I
Max DN: 38 mm
Fluid G roup 2
Coil Ts: +125/-60 °C
Ps: 40 bar
Pt: 57 bar
Test Date: 04-2019
EXAMPLE
Model Refer to Code description
AHE00047EN 7Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

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 temperatures for the coil
Ps Design pressure
Pt Test pressure
Test date Date on which the coil has been pressure tested
in the factory
3. Nitrogen precharge warning
Units are delivered from the manufacturer with an overpressure. Check pressure on the Schrader
valve. With unpressurised unit: imme- diate report to manufacturer and note on the bill of delivery.
4. In
5. Out
Refrigerant connections inlet and outlet.
6. Fan motor
Fan motor item number
7. Electrical warning
Electrically powered component. Switch off power supply before any maintenance or installation
activity.
8. Fan direction
Sticker indicates fan rotation direction.
9. Moving parts
AHE00047EN 8Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

Warning: moving parts.
Switch off power supply before any maintenance or installation activities.
10.Eurovent
Sticker is applied when the product is included in the Eurovent Certify All program.
AHE00047EN 9Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

4 Unpacking and lifting
Always follow guidelines and instructions as given in the air cooler product manual AHE00042.
Optigo CC air coolers are delivered on a wooden pallet, either covered with a wooden folding box or a
wooden reinforced crate. Handling and positioning can take place manually (smaller models) or with use of
a forklift. When more than one cooler units are delivered in a single shipment, packed air coolers may be
stacked during transportation.
Respect the maximum number of stacked air cooler units.
max. units floor stacking
251-254 : 5
301-403 : 4
404-504 : 2
max. 2
In order to avoid damage to the air cooler or falling of the unit, ensure that the lifting forks fully cover the
support pallet.
A
4.1 Unpacking
Folding box (CC251-403)
Place the unit on the ground. Unscrew the fixings from the top of the box and remove the cover.
AHE00047EN 10 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

Unscrew the fixings from the bottom of the box and remove it. Remove the fixing screws from the lower
support pallet.
Wooden crate (CC404-504 & CCB301-504)
Place the unit on the ground and loosen the fixing materials from the top crate. Remove top crate .
Remove fixing screws to lower support pallet.
AHE00047EN 11 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

4.2 Lifting
CC 250/350 & CCB300/350
Unpacked models 250/300/350 must be turned before mounting.
Manually turn the air cooler into mounting position on a second wooden pallet. Use adequate protective
material to prevent the driptray from damaging. The cooler is now ready to be lifted into mounting position.
CC400/500 & CCB400/550
Unpacked models 400/500 are in mounting postion. Remove driptray (supplied unmounted).
For CC400/500, turn mounting brackets into correct position and secure with supplied fixing materials.
The cooler is now ready to be lifted into mounting position.
AHE00047EN 12 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

Lift the unit into mounting position and secure following instructions given in Installation.
After having fixed the cooler to the ceiling, place driptray on its hinges (CC400/500 only).
Use supplied fixing materials to fasten the driptray.
AHE00047EN 13 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

AHE00047EN 14 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

5 Installation
Always follow guidelines and instructions as given in the air cooler product manual AHE00042.
5.1 Mounting dimensions
Dimensions ± 5 mmcooler model
C H L A B
Shipping
volume m3
Draw-through CC
CC 251 811 423 418 508 - 0.3
CC 252 1319 423 418 1016 - 0.5
CC 253 1827 423 418 1524 - 0.7
CC 254 2335 423 418 2032 1015 0.9
CC 351 811 602 418 508 - 0.4
CC 352 1319 602 418 1016 - 0.7
CC 353 1827 602 418 1524 - 0.9
CC 354 2335 602 418 2032 1015 1.2
CC 401 1046 668 583 600 - 0.7
CC 402 1646 668 583 1200 - 1.1
CC 403 2246 668 583 1800 - 1.5
CC 404 2846 668 583 2400 1200 2.1
CC 501 1297 854 583 850 - 1.3
CC 502 2147 854 583 1700 - 2.1
CC 503 2997 854 583 2550 - 2.9
CC 504 3847 854 583 3400 1700 3.7
Blow-through CCB
CCB 301 811 482 609 508 - 0.5
CCB 302 1319 482 609 1016 - 0.7
CCB 303 1827 482 609 1524 - 1.0
CCB 304 2335 482 609 2032 1016 1.2
CCB 351 1046 606 651 600 - 0.7
CCB 352 1646 606 651 1200 - 1.0
CCB 353 2246 606 651 1800 - 1.5
CCB 354 2846 606 651 2400 1200 1.9
CCB 401 1046 665 651 600 - 0.8
CCB 402 1646 665 651 1200 - 1.2
CCB 403 2246 665 651 1800 - 1.6
AHE00047EN 15 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

CCB 404 2846 665 651 2400 1200 2.0
CCB 501 1297 854 902 850 - 1.7
CCB 502 2147 854 902 1700 - 2.7
CCB 503 2997 854 902 2550 - 3.7
CCB 504 3847 854 902 3400 1700 4.7
AHE00047EN 16 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

Detailed drawings showing all required mounting and refrigerant connection dimensions are available for
download on www.alfalaval.com.
Dimensional drawings
5.2 Mounting bracket
Use extra wide washers (ISO 7093) when mounting the unit to the ceiling.
AHE00047EN 17 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

5.3 Technical spaces
Respect the minimum wall distance on suction side.
AHE00047EN 18 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

Respect the minimum space for defrost heater extraction and replacement.
5.4 Refrigerant connections
Never bend the air cooler refrigerant connection tubes.
5.5 Hotgas connection (optional)
Picture shows the T-connection for refrigerant and hotgas defrost inlet.
AHE00047EN 19 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.

5.6 Drain line
The drain line diameter must be at least the size of the driptray drain diameter and should be laid with an
adequate slope. For room temperatures below 0° C drain line insulation and defrosting are required.
A syphon must be installed on the drain line, outside the cold room.
Tighten drain connection by hand only.
AHE00047EN 20 Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB.
Alfa Laval reserves the right to change this specification without prior notification.