LU-VE ALFA User manual

AHE00049 2002
9460163200-02
1
Air cooled condensers & gas coolers
Product manual
• Health & safety
• Transportation & storage
• Installation
• Commissioning
• Operation
• Maintenance
• Troubleshooting
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ORIGINAL INSTRUCTIONS
EN
EN

AHE00049 2002
2
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.
ORIGINAL INSTRUCTIONS
Index
1 Important information
1.1 Disclaimer.............................................................................................................................. 3
1.2 Intended use.......................................................................................................................... 3
  ......................................................................................... 3
1.4 Warning symbols................................................................................................................... 3
2 General
2.1 Operating principle ................................................................................................................ 4
2.2 Safety .................................................................................................................................... 4
2.3 Transport and storage ........................................................................................................... 4
2.4 Checks at delivery................................................................................................................. 5
2.5 Return of unused heat exchangers ....................................................................................... 5
2.6 Guarantee ............................................................................................................................. 5
2.7 Damaged heat exchangers ................................................................................................... 5
3 Installation & Operation
3.1 Location................................................................................................................................. 5
3.2 Lifting..................................................................................................................................... 6
3.3 Mounting................................................................................................................................ 6
3.4 Pipework and connections .................................................................................................... 6
3.5 Electrical connections............................................................................................................ 6
3.6 Power failure ......................................................................................................................... 6
3.7 Fan motors ............................................................................................................................ 6
3.8 Sound level............................................................................................................................ 6
3.9 Commissioning...................................................................................................................... 7
3.10 Disposal................................................................................................................................. 7
4 Maintenance
4.1 General.................................................................................................................................. 7
4.2 Cleaning ................................................................................................................................ 7
4.3 Casing ................................................................................................................................... 7
4.4 Coil ........................................................................................................................................ 7
4.5 Fans ...................................................................................................................................... 7
4.6 Shut down periods................................................................................................................. 8
5 Residual risks...................................................................................................................... 8
6 Troubleshooting .................................................................................................................. 8
EN

AHE00049 2002
3
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 Important information
1.1 Disclaimer
This Product Manual applies to all Alfa LU-VE air cooled condenser and gas cooler products and
is supplied in combination with a product line specific Instruction Manual. 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.
1.2 Intended use
Air cooled condensers and gas coolers are partly completed machinery according to Machine
Directive 2006/42/EC, intended for incorporation in cooling systems and for outdoor installa-
tion. Declarations of Incorporation are available on alfa.luvegroup.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 EN 60204-1: 2006
• 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
LU-VE air heat exchanger products is available on-line on alfa.luvegroup.com.
This includes:
• Product manuals
• Instruction manuals
• Product leaflets & brochures
• Product data sheets (selection software)
• Dimensional drawings
• Electrical wiring diagrams
• Certificates
Alfa LU-VE offers world-wide service and support. In case of any questions or uncertainty please
contact your local Alfa LU-VE representative.
Contact addresses are available at alfa.luvegroup.com.
1.4 Warning symbols
The following warning symbols are used in Alfa LU-VE product & instruction manuals.
General warning. Risk of malfunc-
tioning and/or damage. Hot surfaces. Danger of burns. Wear adequate protection.
Moving parts. Danger of injuries.
Do not operate without protection
guard mounted.
Sharp surface. Danger of cutting
injuries. Wear adequate protection.
Overhead load. Never stand or
walk below the load. Mandatory prescription. Follow instructions as provided.
Forklift trucks or other logistic vehi-
cles. Stay clear of working space. Risk of injuries. Wear head protection.
alfa.luvegroup.com
EN

AHE00049 2002
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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.
Electrically powered component.
Switch off power supply before any
maintenance or installation activity.
Risk of injuries.
Wear safety footwear.
Risk of injuries.
Wear protective gloves.
2 General
2.1 Operating principle
Alfa LU-VE finned coil air heat exchangers have been designed to achieve an optimized exchange
of thermal energy between air and another medium. The ‘heart’ of our air heat exchangers is the
finned coil, built up from a circuit of interconnected tube serpentines and fins to increase the heat
exchanging surface. Thanks to the combination of key design variables (coil materials, coil geom-
etry, casing design, fan type), air heat exchangers are very versatile products with a great variety of
applications in many industries.
Air cooled condensers are key components in air cooling systems with an evaporating refrigerant
like HFO/HFC, ammonia or CO2. In these systems air cooled condensers are used to condensate
(liquify) the hot, compressed refrigerant gas using relatively cold outside air to cool down the cond-
erser tubes.
CO2gas coolers replace traditional air-cooled condensers in refrigerating systems designed for
the use of carbon dioxide as a single refrigerant. In a gas cooler, hot compressed CO2gas flows
through the cooler tubes and is cooled down by the ambient air that is forced through the coil. The
refrigerant gas is not liquefied in the gas cooler, but later on in the expansion valve. Air cooled gas
coolers operate with considerably higher pressures than air cooled condensers.
2.2 Safety
Ensure that the following guidelines are observed:
• All work on the equipment must be carried out by trained personnel.
• The electrical supply is suitable for the equipment supplied.
• Refrigerant, temperature and pressure must agree with the data on the product label of the rel-
evant heat exchanger.
• As the heat exchanger is supplied indirectly, the producer is not acquainted with its actual appli-
cation.
• The heat exchanger should be installed in conformance with all recognized national standards of
electrical and refrigeration installation practice.
• The supplied heat exchanger is optimized for the refrigerants as stated in the data sheet or
order documents. Please contact Alfa LU-VE before using any other refrigerants. The allowed
maximum pressure (design pressure PS) is noted on the type plate. During production the heat
exchanger was subjected to a strength test exceeding the design pressure PS. However, during
normal use the design pressure PS may not be exceeded.
• Heat exchangers supplied by Alfa LU-VE are normally not equipped with a high-pressure cut
out. The installer is responsible for fitting a high-pressure cut out on the system in which the
heat exchanger is used.
• The heat exchanger shall not be blocked in. If the ambient temperature rises, the pressure could
rise and exceed the design pressure.
• It is not permitted to use the heat exchanger for any purpose other than the one it was designed
for by Alfa LU-VE.
2.3 Transport and storage
During transportation the heat exchanger must be handled with all required care. Any instruction or
warning signs attached to the heat exchanger or the packaging must be followed. Avoid shocks or
continuous vibrations during transport. These may cause damage to the product. If required, con-
sult Alfa LU-VE and disassemble during transport any parts that are likely to be set into vibration.
Air heat exchangers must be adequately fixed on the transport vehicle. If temporary storage of the
heat exchanger is required, the following points should be observed:
• Store the heat exchanger in its packing, in a dry place with sufficient protection against sun and
other environmental influences.
EN

AHE00049 2002
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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.
• Always place air heat exchangers on an even surface.
• Do not stack air heat exchangers unless explicitly indicated this is allowed.
• Storage temperature between -40° C and +50 °C.
• Never open or remove the schrader valves. Overpressure in the coil must be maintained.
Shelf life of air cooled condensers and gas coolers is one year. If longer storage periods occur,
carefully check:
• Proper functioning of the fan motor.
• Mounting feet, lifting lugs and fan fixings for corrosion.
2.4 Checks at delivery
All finned coils are pressure tested with dry air, sealed and supplied with a slight overpressure. Prior
to installation, the leak resistance must be checked with the schrader valve.
2.5 Return of unused heat exchangers
Air heat exchangers that have been delivered in accordance with orders are in principle not return-
able. Heat exchangers can only be returned under certain conditions and following consultation with
Alfa LU-VE. This applies exclusively to unused units. The heat exchangers that are to be returned
should be delivered carriage paid to Alfa LU-VE in the original, undamaged and unwritten factory
packaging. Not returnable are:
• Heat exchangers older than three months from the invoice date.
• Heat exchangers that have already been built in and/or are damaged.
2.6 Guarantee
For our guarantee conditions, we refer to the Terms of Delivery. In general, the warranty period
between Alfa LU-VE and the customer is 24 months from factory invoice date or 12 months of
operation, which ever comes first. Heat exchangers must not be returned or disposed of, other
than in accordance with instructions from Alfa LU-VE. Contact your local Alfa LU-VE representative
before any remedial action is taken on the units, otherwise warranty may be void.
2.7 Damaged heat exchangers
At the moment of delivery, carefully check the units. Any present damage must be reported on the
delivery note with a description of the damage. Damaged heat exchangers, including when the
damage is not externally visible, are to be reported to the shipping agent and Alfa LU-VE within 24
hours.
3 Installation & Operation
The instructions below are complementary to the information in the instruction manual that is sup-
plied with every unit.
3.1 Location
Heat exchangers should be positioned such that the following criteria are met:
• Adequate space must be left on the air inlet side of the heat exchanger. The air discharge side
should be free of restrictions. Hot air recirculation is to be avoided. More detailed instructions as
given in the instruction manual are to be respected.
• If several heat exchangers are set up close to one another, this is to be carried out in such a
way that there is no danger of short circuiting of the air flow.
• The heat exchanger should not be connected to ducting on either the air inlet side or discharge
side, unless the heat exchanger has been specifically designed for such an application.
• Unless explicitly stated in the product documentation, air cooled condensers and gas coolers are
not intended for use in potentially explosive environments.
It is important to remember that the total amount of heat to be dissipated depends on receiving the
full design air volume at the design entry air temperature, which allows this air to be freely dis-
charged after passing through the heat exchanger. Any restrictions may impair the performance of
the heat exchanger. If in doubt, please check with Alfa LU-VE.
EN