Dura-Max Box Cooler User manual

HEAT EXCHANGE SYSTEMS
Duramax Marine®is an ISO 9001:2015 Certified Company
Box Cooler
Installation Manual

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Figure!1a.!Transverse!mounted!box!cooler.!
Water!
cover!
Tube!bundle!
Sea!
chest!
Outlet!
slots!
Inlet!slots!
Top!plate!

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Figure!1b.!Refer!to!the!supplied!drawing.!
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Figure!2.!Lifting!of!the!water!cover!and!the!tube!bundle.!
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Figure!3a.!Transverse!mounting.!
!
Figure!3b.!Longitudinal!mounting.!
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Figure!4.!Examples!of!inlet!slots!in!a!hatch!(to!be!used!
as!inspection!opening/man!hole).!
!
!
Figure!5.!Maintain!a!closed!area!between!the!inlet!and!
outlet!slots!of!at!least!25%!of!the!hull!section.!
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Figure!6.!Welding!of!the!mounting!frame.!
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1 Water!cover!
2 Gasket!between!water!cover!and!tube!bundle!
3 Tube!bundle!
4 Gasket!for!mounting!frame!5!
5 Mounting!frame!(welded!in!the!sea!chest)!
6 Bolt!(standard!hexagonal)!
7 Nut!
8 Collar!bolt!
Figure!7.!Exploded!view!of!the!box!cooler!
(top!mounted).!
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!
!
!
!
1 Water!cover!
2 Collar!bolt!
3 Gasket!between!water!cover!and!tube!bundle!
4 Tube!bundle!
5 Gasket!for!mounting!frame!
6 Washer!
7 Nut!
8 Mounting!frame!into!the!top!plate!
9 Top!plate!of!the!sea!chest!
Figure!8a.!Top!mounting!arrangement!with!collar!bolt.!!
!
Figure!8b.!Top!mounting!arrangement,!standard!bolts!
!
!
!
!
!
!
!
!
!
!

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!
Figure9a.!BottomUpull!mounting!arrangement!
with!collar!bolt.!
!
Figure!9b.!BottomUpull!mounting!arrangement!
with!standard!bolts.!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
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!
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Figure!10a.!Mounting!arrangement!with!header!frame!(2),!
flat!cover!(1),!tube!sheet!(3)!and!Allen!head!screw.!
!
Figure!10b.!Mounting!arrangement!with!header!frame,!flat!
cover!and!a!standard!bolt.!
!
Figure!10c.!Lifting!the!tube!bundle!towards!the!header!
frame!in!the!top!plate.!

!!
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Figure!11.!Typical!piping!installation!with!an!expansion!
loop!(3),!an!expansion!joint!(4)!and!service!valves!(5),!
connected!to!the!box!cooler!flanges!(1!and!2).!
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!
Figure!12a.!Order!of!tightening!of!the!collar!bolts.!
!
Figure!12b.!Order!of!tightening!of!the!bolts!of!the!water!
cover!of!a!single!section!box!cooler.!
Start!from!the!center.!
!
Figure!12c.!Order!of!tightening!of!the!bolts!of!the!water!
cover!of!a!double!or!triple!section!box!cooler.!
Start!from!the!(central)!partition.!
!
!
Figure!12d.!Order!of!tightening!of!the!bolts!of!the!water!
covers!and!the!flanges.!
!
!
&?JK0/A?AJ!0:9b</!m%Ln!
,?^/!
+-9\:A!>0//D5!=D->>!W#W!f!7,&O!7"XB!VP!
!
,0/@!"!
,0/@!2!
,0/@!B!
,0/@!C!
O!"2!
2M!
CM!
NM!
WM!
O!"N!
NY!
""Y!
"NM!
2"M!
O!2Y!
"BY!
2BY!
BBY!
CBY!
O!2C!
2YY!
CYY!
MPM!
PCY!
Table!1.!Recommended!tightening!torques!(the!values!are!
base!on!"lightly!lubricated!bolts".!

"B!
W:e: ;DNF!MOM@=HM!
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-L:<A0!:.!=:@@/9!?:A>#!&K/!=:@@/9!?:A>!L?R!U?0K!0K/!
>/-U-0/9!?A!0K/!>/-!=K/>0!-A;!;/T9/J<D-0/!0K/!D:=-D!
/AI?9:AL/A0-D!\-D-A=/5!0K<>!><@@9/>>?AJ!L-9?A/!J9:U0K!
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0K/!\:R!=::D/9!U?0K!-A!?A0/J9-0/;!$+7Q!>1>0/L!.9:L!
+:99:>?:A!o!6-0/9!+:A09:D!`>//!.?J#!"C-a#!
$A!0K-0!=->/!0K/!=:@@/9!-A:;/>!-9/!=D-L@/;!0:!-!.9-L/!0K-0!
?>!.?R/;!0:!0K/!\:R!=::D/9#!4-=K!=:@@/9!-A:;/!?>!@9:I?;/;!
U?0K!-!N!L!=-\D/#!&K/!=-\D/>!-9/!@9:0/=0/;!\1!0<\/>!
`=:A;<?0>a!-A;!D/;!0K9:<JK!0K/!0<\/!>K//0!\1!L/-A>!:.!
=-\D/!JD-A;>!`>//!.?J#!"C\a#!
$A>0-DD!0K/!@:U/9!<A?0!-A;!=:AA/=0!0K/!=-\D/>!-==:9;?AJ!0:!
0K/!?A>0-DD-0?:A!L-A<-D!.9:L!Corrosion!&!WaterUControl!bv!
-A;!:\>/9I/!-DD!9/D/I-A0!?A>09<=0?:A>#!
&K/!/D/=09?=-D!?A>0-DD-0?:A!>K-DD!:AD1!\/!=-99?/;!:<0!\1!
><?0-\D1!b<-D?.?/;5!=-@-\D/!-A;!?A>09<=0/;!/D/=09?=?-A>#!
"#!$#%!/#(%!%0,!($#6,!-#6'!($6!/(%0#6,!+)(%,'P!
%:0/!0K-0!0K/!=:@@/9!-A:;/>!-9/!=-D=<D-0/;!.:9!-!>@/=?.?=!
;91T;:=S?AJ!=1=D/!`/#J#!B!:9!M!1/-9>a#!
Figure!13.!Copper!rods!(anodes)!and!steel!(cathode)!plates!
of!the!ICAF!system!mounted!separately!
in!the!sea!chest!below!the!box!cooler.!
Figure!14a.!Box!cooler!with!integrated!
ICAF!system.!
Figure!14b.!Cable!gland!and!conduit!for!the!cables!of!the!
ICAF!system,!leading!to!the!copper!anodes.!
cable!
gland!

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Note!that!internal!cleaning!requires!that!the!tube!
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When!using!this!type!of!cleaning,!contact!a!competent!
company!that!specialises!in!ultrasonic!or!chemical!
cleaning!and/or!cleaning!agents.!Supply!the!company!
with!full!characteristics!of!used!water,!the!materials!of!
the!box!cooler!and!its!use.!
When!required,!contact!Duramax!Marine®!for!advice.!
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When!using!other!cleaning!methods!contact!a!
competent!company!that!specialises!in!chemical!
cleaning!and/or!cleaning!agents.!Supply!the!
company!with!full!characteristics!of!the!materials!
of!the!box!cooler!and!its!use.!
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