Installing, starting up, and servicing
equipment can be hazardous due to system
pressures, electrical components and equipment
location (roofs, elevated structures, etc.). Only
trained, qualified installers and service
mechanics should install, start up, and service
this equipment.
When working on the equipment, observe
precautions in the literature and on the tags,
stickers, and labels attached to the equipment.
Follow all safety codes. Wear safety glasses
and work gloves. Keep quenching cloths and fire
extinguisher nearby when brazing. Use care in
handling, rigging, and setting bulky equipment.
WARNING
Before installation, always check to be sure
main power to systems is OFF. Electrical
shock can cause personal injury or death.
INTRODUCTION
Air Cooled condensers series CCR, CMR, CLR,
CLW, CLX, CNR, CNW, CNX, CVR, CVW,
CVX, CCD, CQD, CLD, CMD, CH8, CL8,
CHD and CID are designed for refrigerant
condensing of refrigeration and air conditioning
systems. They can be manufactured for single or
multiple circuits, for single or multiple
compressors.
Fluid coolers series FCD, FLD, FID, FMD,
FNV, FVD, FVV and FND are designed to cool
glycol, oil or any other fluid that is not corrosive
to copper and will not let the leaving air
temperature exceed 140°F (60°C).
Heat recovery units HCD and HMD are designed
to recover heat from refrigeration system in
warehouse or shipping area.
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HANDLING
CAUTION : Do not use forklift truck to
handle units. Use only chains with hooks and
spread bars to lift units.
When a unit is shipped on its side, two or three
hangers are installed. Use them to unload the
unit from truck.
A lift truck can be used with the wood base in
that position only to lower the unit on the
ground.
Two others hangers, four, six or eight legs
(depending on the unit) and the required
hardware are supplied attached to the cabinet.
Lifting method 1 :
•Install all the legs on the same side as
hangers.
• Gently lower the unit on those legs.
• Install hangers on opposite side.
• Raise the other side and install other legs.
• Install chains and spread bars to raise the
unit to its final position.
Lifting method 2 :
• Gently lower the unit on a flat surface.
• Install hangers on opposite side.
• Install chains and spread bars to raise the
unit.
• Lift the unit and install all the legs.
• Lift the unit to it’s final position.
See fig # 1 for more details. If the unit as been
ordered with extended legs, see fig. #2 for field
assembly. Also refer to table #1, #2 for unit
weight.
INSTALLATION
STEP #1 INSPECTION:
If the unit is suspected of having been damaged
in transit, immediately notify the carrier and file
a claim with that carrier. The refrigeration coil
section(s) of the unit should display a pressurised
nitrogen gas holding charge. Unit should then be
pressurised to 350 psi with dry nitrogen gas and
leak-checked prior to rigging; this to insure no
coil damage has occurred after the unit left the
factory. Bolts & nuts may have become loose in
transit, as well as electrical components. Please
make sure that everything is tight prior to startup.
STEP #2 LOCATION:
Condensers and fluid coolers are installed on the
roof or ground level. If a unit is installed on the
ground it must be fenced to prevent possible
damage. Heat recovery units are installed inside
at the ceiling level. Check loading capacity of the
roof, the ceiling or the floor before installation.
The unit is intended to be installed in an
atmosphere containing only neutral water
vapour, natural precipitation and air. Use in any
other atmosphere must be checked for
compatibility with metals, materials and coating
used in manufacturing of this equipment.
Unit positioning as well as firmness and perfect
levelness of mounting base supports are
important: Good installation practices are well
known and are to be followed. Air flow paths on
all sides as well as coil inlet and fan discharge
areas are not to be restricted. Unit positioning
that may result in air recirculation as well as
prevailing wind impedance is to be avoided.
If a unit is to be placed close to a wall the
minimum distance should be 24 inches for single
row of fans and 48 inches for double row of fans.
If units are to be placed side by side, the
minimum distances should be 48 inches for
single row of fans and 96 inches for a double
row of fans. The chosen location must be
convenient and allow safe accessibility for
maintenance.
STEP #3 WIRING:
NOTE: A wiring diagram is provided with the
unit, it is located on the inner face of the
electrical box access door.
All wiring must be done in accordance with
national and local codes. Check the nameplate
with the current characteristics to be used for
wiring unit. Internal wiring connections of the
fan motors, optional controls and contactors have
been completed at the factory. Once wired, make
sure the unit has been grounded. Disconnect
switch at the unit must be provided by others.
On air cooled condensers with flooding valve,
one fan (single width unit) or one pair of fans
(double width unit) must operate when
compressor is operating to avoid internal damage
to the condenser coil.
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STEP #4 PIPING:
probably occur.
CAUTION: The unit has not been designed to
carry the weight of any extended piping or
valves. The piping must be well supported
otherwise tube breaking at the coil will most
All refrigerant or fluid system components must
be installed in accordance with applicable local
and national codes and in accordance with good
engineering practice required for proper
operation.
Use top quality refrigeration tubing that is
internally free of dirt, humidity or other
contaminants. Unsealed tubing should not be
used. Long radius elbows are recommended.
Dry nitrogen must be swept through the lines
while joints are brazed to avoid oxidation and
carbon deposits.
IMPORTANT: The use of a calibrated
pressure gage and regulator must always be
used with nitrogen gas cylinders.
To minimise hydraulic shock line breakage
possibilities, valving and controls must be
designed to eliminate any rapid introduction of
hot gas into cold piping. Most especially if the
piping contains liquid refrigerant or is at a much
lower pressure than the hot discharge gas, which
can be the case of double-wide condensers that
feature one-half operation during winter. Plans
should be for utilising either a slow-shifting
three-way/four-way valve, or not completely
lowering to suction pressure the condenser coil
side that deactivates during winter. Most often, a
combination of both of these options works well
in geographic areas that encounter lower than
freezing seasonal outdoor temperatures.
Air-cooled condensers must be provided with
inverted “P” trap with a purge connection. A
separate sub cooling circuit may be necessary if
liquid line must rise to level higher than the unit.
Vibration in the discharge or liquid line must be
corrected immediately to avoid piping and/or
header breakage and refrigerant loss.
Generally, horizontal-piping runs should grade
slightly downwards in the direction of the flow.
Liquid line piping must be arranged so that it is
free draining from the condenser to the receiver.
It is best to pipe liquid lines so that there is an
immediate drop, at least 2 or 3 feet, at the
condenser outlet, before headering or running
horizontally.
STEP #5 LEAK TESTING:
Leak testing and evacuation must be done in
accordance with local and national codes.
Once all refrigerant connections are made, leak
test all joints before charging the system with
refrigerant. After leak testing, all moisture and
non-condensable gas must be evacuated from the
system. Attach high vacuum line pump and gage
on both high and low pressure sides of the
system. A minimum vacuum level of 100
microns is required to effectively remove
moisture.
Be sure all valves such as compressor, hot gas,
receiver, and liquid solenoid valves are open.
Break the vacuum in the system with the
refrigerant to be used. Always charge the
refrigerant into the system through a new 16 cu.
in drier (field supplied) in the charging manifold
line.
OPERATION
The notice below depicts the label that is affixed
to the control box cover.
WARNING
ONE FAN (SINGLE WIDTH UNIT) OR ONE
PAIR OF FANS (DOUBLE WIDTH UNIT)
OPERATE SIMULTANEOUSLY TO AVOID
Not complying to this condition can cause
uneven rapid expansion and contraction of the
condenser core tubing contributing to condenser
tubes failures. Violation of this condition will
void the warranty of the misused unit.
For a refrigeration system to function properly,
the condensing pressure and temperature must be
maintained within certain limits.
To prevent excessively low head pressure during
winter operation, two basic control methods are
used, refrigerant side control and air side control.
Warranty Condition
AND THE COMPRESSOR MUST
DAMAGE TO THE CONDENSER COIL.
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1) A) Refrigerant-side control is accomplished
by modulating the amount of active
condensing surface available for condensing
by flooding the coil with liquid refrigerant.
This method requires a receiver and a larger
charge of refrigerant. See fig. #3.
B) Refrigerant-side control by doing the
one-half condenser operation. The
condenser is initially resigned with two
equal sections, each accommodating 50% of
the load during normal operation.
During winter an ambient controlled flow
divider valve blocks off one section of the
condenser and pumps down the inactive
section in the suction. This saves the
flooding overcharge and sometimes allows
the shutdown of the fans on the inactive
condenser side. Fig. #4
2) Airside control is accomplished by cycling
fans in response to condensing pressure or
outdoors-ambient temperature. To reduce
stress on the condenser coil, one fan or one
pair of fans must operate when a condenser
is operating. Speed control on the constant
operating fan may be used to reduce motor
cycling and stabilise the operating pressure.
See table 3 to 6 for more information.
For low ambient operation this method must be
combined with refrigerant side control.
FAN MOTORS:
Check the fan blade clearances within the
venturies, as well as check for proper rotation.
Fan motors operating at higher elevations will
draw lower than rated amp as well as draw less
effective air volume across the coil surface. This
is due to the reduced density of the higher
altitude air, which results in higher compressor,
and higher discharge pressure along with
reduced unit capacity. Please consult factory if
you suspect this situation.
The fan motors are permanently lubricated for
service free operation. The motor may restart on
automatic thermal protection. Motors are readily
serviced by removing fan guards and fans. If a
motor is inoperative or it cycles on thermal
protection, check supply voltage at the motor
leads. Fan motors may cycle on thermal
protection if the coil is blocked.
Units equipped with axial fans, CVR, CVW,
CVX: The entire fan assembly, motor, blade and
ventury need to be replaced if there is a failure of
any kind. With the two speed version, 3
contactors are used per motor. Do not attempt to
manually close one of these contactors; this may
result in motor winding damage.
FAN CYCLING:
Optional temperature or pressure controls are
located in the control box. Air temperature
sensors are located in the air flow and pressure
controls are directly connected to the circuit in a
return bend.
Optional line duty controls are connected
directly to the fan motors. Controls are double
pole single throw, one line remain live on the
motors. Units must be completely disconnected
before servicing.
Optional pilot duty controls are connected to 3
pole motor contactors. If controls or contactors
are defective, they must be replaced.
MAINTENANCE
CLEANING:
After one day of operation, check for any
vibration that might have developed in the unit.
It is recommended that the unit be inspected
occasionally for dirt accumulation. Grease and
dust should be removed from the fans and fan
guards.
Periodical cleaning of finned surfaces can be
done by washing down dust with warm water
spray and a mild detergent. Do not use alkaline
or acidic solution as it will attack the coil
material.
The inner face of the coil may be cleaned by the
access panel on the side of the units or by
removing the fan guards.
Always pressure -clean in reverse of the air flow.