LU-VE AlfaSolar S User manual

AlfaSolar S/SR™ Air Cooled Liquid Coolers
Instruction manual
ORIGINAL INSTRUCTIONS
No. 9460157273-04

Contents
1 How to contact Alfa LU-VE......................................................................... 4
2 General information..................................................................................... 5
2.1 System warranty and disclaimer........................................................................................................ 5
3 Safety............................................................................................................. 6
3.1 Terms used in this manual................................................................................................................. 6
3.2 Warning symbols................................................................................................................................ 6
3.3 Prohibition symbols.............................................................................................................................7
3.4 Mandatory action symbols..................................................................................................................8
3.5 Operator qualification symbols........................................................................................................... 9
3.6 Residual risks..................................................................................................................................... 9
3.7 Additional remarks............................................................................................................................ 14
4 Electrical safety checklist......................................................................... 15
4.1 Lockout and tagout...........................................................................................................................15
4.2 Diagnosing a problem where power is required.............................................................................. 16
4.3 Tools and equipment (PPE)............................................................................................................. 17
5 General description....................................................................................18
5.1 Equipment description...................................................................................................................... 18
5.2 Technical data...................................................................................................................................19
5.3 Identification of product.................................................................................................................... 20
6 Transport and storage............................................................................... 25
6.1 Lifting package..................................................................................................................................25
6.2 Unloading unit from standard truck.................................................................................................. 26
6.2.1 Unloading horizontal unit from container (Container on ground level)............................... 27
6.2.2 Unloading horizontal units from container (Container on wheels)...................................... 27
6.2.3 Unloading vertical units from container (Container on ground level)..................................28
6.2.4 Unloading vertical units from container (Container on wheels).......................................... 29
6.3 Packing............................................................................................................................................. 30
6.4 Turning and lifting unit......................................................................................................................33
6.5 Storage..............................................................................................................................................40
7 Installation instructions............................................................................. 41
7.1 Installation checklist..........................................................................................................................41
7.2 Tightening torques............................................................................................................................ 42
7.3 Positioning.........................................................................................................................................42
7.3.1 Individual units.................................................................................................................... 42
7.3.2 Multiple units....................................................................................................................... 45
© Alfa LU-VE, Rev-04 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

7.4 Setup for installation......................................................................................................................... 45
7.5 Liquid cooler tube connections.........................................................................................................47
7.6 Grounding......................................................................................................................................... 48
7.7 Fans and fan connections................................................................................................................ 48
7.8 Fans' power values...........................................................................................................................53
7.9 Options for AlfaSolar S/SR™ models...............................................................................................53
7.9.1 Water spraying system....................................................................................................... 53
7.9.2 Connection box options of EC-fans....................................................................................55
7.9.3 Painting............................................................................................................................... 56
7.9.4 High mounting legs.............................................................................................................56
7.9.5 Vibration dampers............................................................................................................... 58
7.9.6 Expansion joints..................................................................................................................59
7.10 Options for AlfaSolar SR™ models................................................................................................ 60
7.10.1 Connection options for IEC-fans.......................................................................................60
7.10.2 Counter flanges.................................................................................................................63
7.10.3 Vibration monitor device for fans......................................................................................63
7.10.4 Air streamer...................................................................................................................... 63
7.10.5 Handrails and ladders.......................................................................................................64
7.10.6 Expansion tank................................................................................................................. 65
7.11 Checks before start-up................................................................................................................... 66
8 Operation.....................................................................................................68
8.1 Startup...............................................................................................................................................68
8.2 Shutdown.......................................................................................................................................... 68
9 Service instructions................................................................................... 70
9.1 Service inspection.............................................................................................................................70
9.2 Stepping on unit............................................................................................................................... 72
9.3 Filling liquid cooler with fluid............................................................................................................ 73
9.4 Draining liquid cooler........................................................................................................................74
9.5 Changing liquid to another liquid......................................................................................................74
9.6 Coil cleaning..................................................................................................................................... 74
9.7 Fans.................................................................................................................................................. 77
9.8 Acceptable fan vibration level for single operating fan.................................................................... 77
9.9 EC-fans: Replacing fan package......................................................................................................78
9.10 IEC-fans: Replacing fan impeller....................................................................................................80
9.11 IEC-fans: Replacing fan motor....................................................................................................... 83
10 Discharge and recycling..........................................................................85
10.1 Discharge and recycling of packing materials................................................................................85
10.2 Recovery of fluid.............................................................................................................................85
10.3 Demolishing unit............................................................................................................................. 85
10.4 Material recycling and discharging................................................................................................. 86
11 Troubleshooting........................................................................................87
12 Spare parts................................................................................................90
© Alfa LU-VE, Rev-04 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

1 How to contact Alfa LU-VE
Manufacturer: Fincoil LU-VE Oy
Ansatie 3, FI-01740 Vantaa, Finland
Tel switchboard [phone], Fax switchboard [phone]
Manufacturer representative in
Russia:
LU-VE Moscow
ul. Sovetskaya 73, Microdistrict Bolshevo, Korolev, Moscow region,
Russian Federation, 141060
Tel switchboard: [phone] - Fax switchboard: [phone]
alfa.luvegroup.com
Visit alfa.luvegroup.com to get detailed contact information.
Newest manual use link or QR-code: http://alair.techmanuals.info/en/lc/solar/index.html.
© Alfa LU-VE, Rev-04 4Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

2.1 System warranty and disclaimer
2 General information
This instruction manual introduces you to the different situations you may encounter when using this
equipment.
Read through this manual carefully, and ensure that it is available for the personnel installing, operating and
maintaining the equipment.
If you encounter a problem not reviewed in this manual, contact the closest Alfa LU-VE representative.
Air cooled liquid coolers may be used to cool various process liquids. For this application, the liquid flows
through the tubes. This liquid is cooled by the ambient air that is forced through the coil. Depending on the
application, air cooled liquid coolers are often referred to as 'radiators' or 'dry coolers'.
2.1 System warranty and disclaimer
This equipment is designed to operate properly and produce rated capacity when installed in accordance
with accepted industry standards. Failure to meet the following conditions may result in voiding of the system
warranty:
• System piping must be installed following industry standards for good piping practices.
• Inert gas must be charged into piping during welding.
• System must be thoroughly leak-checked and evacuated before initial charging.
• As standard, the electrical connections must comply with the following conditions:
• Voltages must not exceed ±5 % of nameplate ratings. The frequency is 50-60 Hz.
• Factory installed wiring must not be changed without written approval from Alfa LU-VE
Caution: Follow these instructions to guarantee safe and correct installation, service and use of
AlfaSolar S/SR™ series. Do not change or repair the unit without the manufacturer´s permission and
instructions. The neglect to follow the instructions may result in warranty expiration.
Disclaimer
This Instruction Manual applies to all AlfaSolar S/SR™ air cooled liquid coolers and is supplied in combination
with the Air Cooled Liquid Coolers Product Manual AHE00050. Both manuals must be carefully examined and
instructions should be followed up at all times. Alfa LU-VE does not accept liability for any damage resulting
from non-compliance to the instructions as given in the manuals and order-related documents.
© Alfa LU-VE, Rev-04 5Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.1 Terms used in this manual
3 Safety
3.1 Terms used in this manual
Note: Always read this manual before using the equipment.
Note types
WARNING: Describes a potentially dangerous situation that may result in personal damage or
fatal injury.
Caution: Describes a situation that may result in damage to unit, environment, assembly or
service.
Note: Gives the user a piece of information of particular importance.
3.2 Warning symbols
The following warning symbols are used in this instruction manual.
General warning. Risk of malfunctioning and/or damage.
Overhead load. Never stand or walk below the load.
Forklift trucks or other logistic vehicles. Stay clear of working space.
Moving parts. Danger of injuries. Do not operate without protection guard mounted.
Hot surfaces. Danger of burns. Wear adequate protection.
© Alfa LU-VE, Rev-04 6Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.3 Prohibition symbols
Automatic start-up.
Electric parts. Switch off power before any handling or maintenance activities.
Sharp surface. Danger of cutting injuries. Wear adequate protection.
Crushing of hands. Hands and fingers can be crushed, pulled in or otherwise injured.
3.3 Prohibition symbols
No stepping on surface
Do not extinguish with water
Do not attempt to extinguish with water. Disconnect all voltages sources in the control panel.
No open flame. Fire, open ignition source and smoking prohibited
Keep ignition sources away. Do not allow ignition sources to develop.
Do not lift with hook / No lift point
Moving parts can crush and cut you. Do not operate with the guard removed.
Forklifting not allowed
© Alfa LU-VE, Rev-04 7Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.4 Mandatory action symbols
3.4 Mandatory action symbols
Wear eye protection
Use eye protection: Protective cover, protective glasses or face protection.
Connect earth terminal to the ground
Risk of injuries. Wear protective gloves.
Wear protective clothing
Personal protective clothing must be suitable for the working fluid used. It must have good
insulation properties.
Disconnect before carrying out maintenance or repair
Inactivate the electrical system and secure it against switching on accidentally before starting
installation, maintenance or repairs.
Check guard
Before starting the machine, check that the guards of the fans are correctly fixed.
Risk of injuries. Wear safety footwear.
Risk of injuries. Wear head protection.
Wear ear protection
© Alfa LU-VE, Rev-04 8Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.5 Operator qualification symbols
3.5 Operator qualification symbols
Unskilled worker, an operator without specific skills that is capable of performing simple tasks
on qualified technicians' instructions.
Lifting and moving equipment operator, a qualified operator capable of using the lifting
and moving equipment for the materials and machine (while scrupulously following the
manufacturer’s instructions) in compliance with the laws in force in the nation of use.
Electrician, an authorized electrician capable of making electric connections.
Manufacturer’s technician, a qualified technician provided by the manufacturer to conduct
operations of complex nature in particular situations or whenever agreed with the user. This
person may master mechanical and/or electrician and/or hardware and/or software skills as
required.
3.6 Residual risks
WARNING:
Lift and transport the units packed in an upright position very carefully.
Handle high units very carefully. Never place them on an inclined or uneven plane.
Danger of falling. See section Transport and storage on page 25.
WARNING:
To avoid the falling of a wooden box (optional for Solar SR™):
• Stack max 3 units on top of the other.
• Place the packages in line.
Always store the packages on a level surface.
See Figure 10: Wooden box available only for AlfaSolar SR™ on page 32.
© Alfa LU-VE, Rev-04 9Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.6 Residual risks
WARNING:
Before lifting the unit, check its weight from the transport documents or from
the product nameplate and make sure that the lifting device, crane or truck is
appropriate.
1. Only use lifting equipment that is equipped with appropriate labels.
2. Ensure that the belts or slings with hooks used for lifting keep the equipment
balanced.
3. Do not lift the unit with a crane before removing the pallet from under the unit.
Do not stand under the unit when it is hanging.
WARNING:
Always install the units in a place with no entrance for outsiders.
WARNING:
Do not walk or step over unprotected heat transfer section, since besides being
damaged it can generate an accident or a risky situation.
WARNING:
If you must step on the unit for maintenance purposes, always wear safety shoes.
Use proper safety devices that prevent falling.
Do not step over SM/SRM™ units.
WARNING:
Before switching on the unit, always ensure that everyone is at a safe distance from
the unit.
WARNING:
Risk of slipping or falling down.
© Alfa LU-VE, Rev-04 10 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.6 Residual risks
WARNING:
Each fan is equipped with a fan guard and a lockable service switch. The wire
spacing in the fan guard and the safety distance of the blade correspond to the
European safety standard. The safety guards are protections from contact only.
Do not remove the safety guard before the fan is shut down. The rotating impeller
may catch in your clothes, cut you or pull you in.
WARNING:
Breaks in pressure pipes or components may cause injuries. Do not exceed the unit
design pressure. Only perform maintenance work on pressurized parts when the unit
is empty.
WARNING:
In operation, the heat transfer section and pipe temperatures exceed 45 °C. Contact
may cause burns. Use hand protection.
Hot air over the unit when the unit is operating. Never work a long time over the unit
when it is operating.
WARNING:
Only an authorized electrician may perform the electric connections.
WARNING:
Before starting the service operation, ensure that the electrical supply is reliably
isolated; use the lockout/tag-out system. Always check with a voltmeter that the unit
is electrically isolated and shut off.
© Alfa LU-VE, Rev-04 11 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.6 Residual risks
WARNING:
Ensure free space in front of the electrical cabinet according to local regulations.
WARNING:
EC-fans: Electrical load (>50 μC) between mains wire and protective earth
connection after switching of the supply when switching multiple devices in parallel.
Electric shock, risk of injury. Ensure that you have sufficient protection against
accidental contact.
Before working on the electrical connection, short the connections to the mains
supply and PE.
EC-fans: Terminals and connections have voltage even in a unit that is shut off.
Electric shock. Wait for five minutes after disconnecting the voltage at all poles before
opening the device.
WARNING:
Fans with Inverter: Terminals and connections have voltage even in a unit that is
shut off.
Electric shock. Wait for 15 minutes after disconnecting the voltage at all poles before
opening the device.
WARNING:
EC-fans: High temperature at the electronics enclosure. Danger of burn injuries.
Ensure that you have sufficient protection against accidental contact.
WARNING:
Cutting and crushing hazard when removing the spare parts from the packaging.
Wear safety shoes, safety helmet and cut-resistant safety gloves.
© Alfa LU-VE, Rev-04 12 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.6 Residual risks
WARNING:
Follow the recommendation of the working fluid supplier (Material Safety Data Sheet)
strictly.
Prevent the accidental release of fluid and adopt the visual and acoustic alarms to
minimize the consequences of insufficient amount of fluid. Plan the installation field
for recovering or disposing of the fluid.
WARNING:
Before washing the heat transfer section, read the Material Safety Data Sheet of the
detergent and follow the manufacturer´s instructions.
When vacuum-cleaning and washing the heat transfer section, use protection
glasses, safety gloves, safety shoes and other personal protection.
WARNING:
Depending on the installation and operating conditions, a sound pressure level
greater than 70 dB(A) may arise. Use appropriate ear protection.
WARNING:
Sharp edges. Use protection glasses, safety gloves, shoes and clothes.
WARNING:
Ensure that the unit is electrically isolated and dead before discarding and
demolishing it.
WARNING:
Do not lift the unit before it is fully empty.
WARNING:
Before moving to the solution, ensure that the unit is in safe condition. See Residual
risks.
© Alfa LU-VE, Rev-04 13 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

3.7 Additional remarks
• The cables may carry voltage even when the unit is powered off.
• The action service switch on/off restarts the machinery/fan. Take appropriate precautions.
• All the main pressure bearing parts of the air heat exchanger (AHE) are designed according to PED
2014/68/EU and Harmonized standards only for internal pressure within the limits of maximum design
pressure (PS) and maximum operation temperature (TS) pointed out in the nameplate (positive pressure).
• The end user is responsible for adopting the suitable safety devices against overpressure and overheating
(i.e. safety valves).
• The stop/emergency stop device is not supplied by the manufacturer, because the total process risk may
increase or a new risk would be introduced by the action of a localized stop/e-stop system.
• S-models without service switches (and without SW or cabinet options): The end user is responsible for
securing the equipment, that is, for switching off the installation/machine where the fan is installed and for
securing it from being switched on again.
• The end user is in charge of the periodic inspection of the safety devices installed on the air heat
exchanger (AHE) according to the national regulations.
3.7 Additional remarks
Caution:
The venting/draining valve of the liquid coolers is not suitable for heat transfer fluids based on
potassium formiate. There is a danger of leakage.
When using heat transfer fluids based on potassium formiate, the piping system and venting/draining
valves of the heat transfer section must be adapted for the heat transfer fluid in question. Always
check this from documentation.
Follow the instructions of the heat transfer fluid supplier at installation, pressure testing, startup,
operation and maintenance.
Caution:
Only a skilled mechanic using proper tools and approach may discharge and assemble the motor.
The mechanic must perform the repair work according to the standard IEC-60079-19. Under the
period of guarantee, always return a faulty motor to the supplier. Do not demolish it.
Always use the spare part motor available from Fincoil LU-VE Oy to guarantee its applicability to the
operating conditions.
© Alfa LU-VE, Rev-04 14 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

4.1 Lockout and tagout
4 Electrical safety checklist
All installation, controls, service, repair, and maintenance employees must have this list with them at every job
and read it through before starting the job.
Note: These are the minimum requirements. If you do not meet these requirements, do not start the
work.
4.1 Lockout and tagout
Proceed as follows:
1. Notify affected persons of the shutdown.
2. Shut down the equipment.
3. Disconnect, lock and tag all energy sources.
4. Release any stored energy (capacitors, transformers, etc.).
5. Ensure that all employees working on the equipment have their personal locks in place.
6. Prior to servicing the equipment, ensure with a ”proximate voltage sensor” that the frames or control
enclosures of the equipment are not energized.
7. Check that the circuit-testing devices function.
8. Verify the absence of electrical current or voltage with a circuit-testing device.
Use insulated gloves and an insulated mat.
© Alfa LU-VE, Rev-04 15 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

4.2 Diagnosing a problem where power is required
9. Notify affected persons of the reconnecting of electrical power.
4.2 Diagnosing a problem where power is required
Remove all conductive clothing or accessories.
Use insulated tools and safety glasses.
Do not work on electrical circuits greater than 600 volts, unless you have specific training.
Suspend work or have a shelter during adverse weather conditions.
Use a certified insulated mat to stand on while doing the testing.
Use certified electrical insulated gloves while doing the testing.
© Alfa LU-VE, Rev-04 16 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

4.3 Tools and equipment (PPE)
After completing the diagnostic and maintenance work, you must complete logout and tagout.
4.3 Tools and equipment (PPE)
Ensure that the electrical equipment you are working on is grounded.
Ensure that electrical power tools are double insulated or have a ground plug.
Use Ground Fault Circuit Interrupters (GFCI).
Inspect power tools, insulated hand tools and electrical cords for damage.
Do not use damaged tools and cords.
Do not use conductive equipment, for example, metal ladders.
© Alfa LU-VE, Rev-04 17 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

5.1 Equipment description
5 General description
5.1 Equipment description
AlfaSolar S/SR™ series are designed for outdoor cooling with water, various oil solutions and other working
fluids, which do not corrode copper, aluminum or brazing material (EN ISO 17672 Cup 279).
The SR™ models are specially designed for industrial cooling applications, because they allow higher
customization based on customer needs.
To avoid outer corrosion of the heat transfer section, always ensure that the material of the fins and heat
transfer tubes is suitable for ambient conditions. The air must be clean of any particles, which together with
humidity or any other solvent might form corrosive combinations on fins or heat transfer tubes.
The manual also concerns non-standard SR™ models with different specialties and options like double
circuiting, forced draught fans (FD), higher mounting legs, etc. If your model is non-standard, always check
from the delivery documents how to take the difference into account in installation, use and service.
Code description
© Alfa LU-VE, Rev-04 18 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

5.2 Technical data
For details, see S/SR™ series product-specific documentation.
Note: With Solar S™ models, only limited options are available.
5.2 Technical data
Design basic:
© Alfa LU-VE, Rev-04 19 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.

5.3 Identification of product
Wind load 40 m/s (installed unit)
Earthquake 0.2 g
Altitude <100 M.A.S.L.
Minimum ambient air temperature -40 °C (standard unit)
Note: See project-specific documentation for technical data, product designation, performance data,
lifting/fixing points of fan motors, weights, internal volumes, and position of connections.
5.3 Identification of product
Check the identification data on the product nameplate. The nameplate is located at the same end of the unit
as the inlet connections. The product nameplate includes contact information of the manufacturer, product
designation, number of order acknowledgement, technical data of the fan motor, operating/test pressure, min/
max operating temperature, internal volume, weight, month/year of manufacture and (if required) CE or EAC
marking. CE marking is available for SR™ models on request.
Product labels
Table 1: Product labels
Centre of gravity
When lifting the unit with a forklift, always place the forks under
the centre of gravity.
Product nameplate
Model See Equipment description on page 18
O.A. Order Acknowledgement number
Serial no: Ref Communicate these when ordering spare
parts as they identify the unit
Unit net weight Check weight before any lifting operation to
ensure that proper lifting tools are used
Coil data
Material Tube material
Volume Internal volume
Fluid group According to PED
max DN Maximum diameter of the distributor tube
Coil TS Range of operating temperatures for the
coil
PS Design pressure
PT Test pressure
© Alfa LU-VE, Rev-04 20 Alfa LU-VE is a trademark registered and owned by LU-VE Group.
Alfa LU-VE reserves the right to change specifications without prior notification.