Trenton TFM Installation Manual

Page 1
PRODUCT DATA &
01/16/11
INSTALLATION
ONE TO FOUR FAN MODELS
ELECTRICAL POWER: 208-230/1/60, 208-230/3/60, 460/1/60, 460/3/60, 575/1/60, 575/3/60
TFM-LINE FLUID COOLERS
Bulletin T60-TFM-PDI
1090825
CONTENTS
Page
Nomenclature............................................. 2
Features & Options.................................... 2
Fluid Cooler Selection................................ 3
Typical Applications.................................... 4
Physical/Mechanical Data (All Models)...... 5
Standard Motors
Electrical Data............................................ 5
Low Ambient Operation.............................. 6
EC Motors
About EC Motors........................................ 9
Electrical Data............................................ 9
Wiring Diagram........................................... 10
EC Motor Application Data......................... 11 - 12
Page
Header Sizes (All Models).................. 13
Dimensional Data (All Models)........... 14 - 15
Installation........................................... 16 - 18
Hydronic System Components........... 18 - 19
Pump Package System Parameters... 20
Generic Service Parts......................... 21
Warranty.............................................. 23
Project Information.............................. 23
“As Built” Service Parts List................. BACK
For the latest product updates and further information, visit www.trentonrefrigeration.com
Page 2
Brand Name:
T60-TFL-PDI
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01/16/11
T = Trenton
Product Name
FM = Medium Sized Fluid Cooler
Fans Wide
1 = Inline (Double wide not available)
Fans Deep
Motor
A = 1075 RPM, 3/4 HP Motor E = ECM Motor
Coil Rows Deep
2, 3, or 4
Coil Fins Per Inch
08 = 8 fpi 10 = 10 fpi 12 = 12 fpi
NOMENCLATURE
T FM 1 3 A - 4 08 V - T5 A - XXXX
Optional Sufx
Does Not Affect Design
Design Version
Voltage
S2 = 208-230/1/60 T3 = 208-230/3/60 S4 = 460/1/60 T4 = 460/3/60 S5 = 575/1/60 T5 = 575/3/60
Application
V = Vertical Air Discharge H = Horizontal Air Discharge
STANDARD FEATURES INCLUDE
Heavy-gauge galvanized steel cabinet construction
Energy efcient PSC and 3 phase fan motors with internal overload protection
Quietswept wing” fan blade for quiet operation and optimal efciency
Heavy duty 24” legs
OPTIONAL FEATURES
Fan Cycling – Ambient thermostat / fan row with contactors
Fan Cycling – Aquastat thermostat fan cycling control / outlet uid temperature
Individual fan motor fusing
Non-fused disconnect
Horizontal air discharge conguration
All fan sections individually bafed with clean-out panels.
Zinc plated huck bolts
Control circuit voltage – 230 V
Variable Speed EC Motor which provides optimum efciency and sound levels (see pg. 9-12 for details)
Extended leg kits (36” or 48”) with cross bracing for extra rigidity
Optional n materials
Optional coil coating
Voltages available for 60Hz or 50Hz
Page 3
FLUID COOLER SELECTION
SAMPLE
T60-TFL-PDI
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01/16/11
TFM 60Hz
Previously, the selection of a uid cooler involved using charts, correction factors and hand calculations to determine the capacity and make the selection.
We have simplied the selection process. Our engineering department has created a computer program. This provides exibility and streamlines the selection process
TEMPERATURE LIMITATIONS
Fluid Coolers are suitable for leaving air temperatures up to a maximum of 130°F (54°C). Fluid temperature up to an average of 150°F (66°C ) may be used at ambient temperatures up to 90°F (32°C ). Entering uid conditions should not exceed 200°F (93°C ).
PARAMETERS FOR SELECTION OF A FLUID COOLER
Fluid Type: □ Water □ Ethylene Glycol / Water □ Propylene Glycol / Water
Elevation: ___________ Feet Above Sea Level
Fluid Concentration: ___________%Water ___________%Glycol
Air Inlet (ambient temp.) __________ ºF
Three of the four following parameters must be specied:
1. Required Capacity __________ Btu/h 2. Fluid Inlet Temperature __________ ºF
3. Fluid Flow Rate __________ GPM 4. Fluid Outlet Temperature __________ ºF
Other Items To Specify:
1. Voltage (S2 = 208-230/1/60 S4 = 460/1/60 S5 = 575/1/60 T3 = 208-230/3/60 T4 = 460/3/60 T5 = 575/3/60) ______Specify S2,S4, S5,T3,T4 or T5
2. Please Specify (Check Box) Options Required:
Control Voltage 240V (Standard) Variable Speed EC Motor Control Voltage 120V  Extended leg kits 36” Control Voltage 24V Extended leg kits 48” Fan Cycling Ambient Thermostat  Gold Coat Fin Fan Cycling Aquastat Thermostat  Copper Fin Fan Cycling Control by Others Heresite Coating Non-fused disconnect 50 Hz Horizontal air discharge conguration
Customer Info: Name: ______________________ Telephone Number: _____________________ Fax: ______________________ Email: ______________________
Fax or email completed sheet to your sales representative.
Extra copies of this form available on page 22
Page 4
TYPICAL APPLICATIONS
p
y
p
T60-TFL-PDI
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01/16/11
TFM 60Hz
Data Center / Computer Rooms
Fluid Coolers are suitable for use with Computer Room Air Conditioning (CRAC) Units. (see Illustration below)
Dry Type Fluid Coolers are particularly suitable for ap­plications where long pipe runs of refrigerant piping to an air cooled condenser are not practical. Cooling Tower maintenance and winter operation issues are eliminated. Piping can be easily installed and low ambient control can be used using water regulating valves. Fluid cooler can be easily connected to city water for emergency use.
The glycol loop is sometimes connected to a “Free-Cool­ing” Economizer Coil within the CRAC unit, which allows for partial free-cooling when the glycol loop temperature is below the CRAC units return air temperature.
Dual Pump Pkg c/w
ansion Tank
Ex
Dry Fluid Cooler
Industrial Glycol /Water Cooling Systems
Water pollution issues and water conservation have become critical in recent years. The “Once-Only” use of water for industrial process cooling has been wasteful and often unnecessary. By using a dry type Fluid Cooler, glycol/water for industrial process cooling applications can be cooled to within 10°F (6°C) of the ambient dry bulb temperature. The water is continuously re-circulated and remains in a closed system so reducing the problem of corrosion normally encountered in non re-circulated systems.
Considerable savings can be affected by using a Dry Type Fluid Cooler. Many industrial applications have seen water consumption being reduced by millions of gal­lons and reduced maintenance costs to a fraction of that experienced prior to the use of a closed non re-circulated system. (see illustration below)
Dual Pump Pkg c/w
ansion Tank
Ex
Dry Fluid Cooler
Computer Room Air
Conditioner( CRAC)U nit
Glycol /
Water
Cooled
Cond.
Computer Room AC
(CRAC)
Unit
Secondary
Heat
Exchanger
Remote Radiators for Diesel and Gas Engines
A remote radiator is usually required with the larger style of diesel engine. The Fluid Cooler is suitable for this type of application. Designed to give the customer trouble free operation, the multiple fan arrangement reduces the pos­sibility of down time. Units are completely pre-assembled and require only piping and electrical connections. (see illustration to the right)
Glycol/Water
Cooled
Cooling
S
stem
Process
Heat
Load
Glycol/Water
Cooled
Chiller
E V A P
C O N D
Cooler
Glycol/Water
Cooled
Cooling
System
Dual Pump Pkg c/w
Dry Fluid Cooler
Expansion Tank
Remote
Radiator
for
Engine
Diesel Engine
for
Page 5
TFM
T60-TFL-PDI
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01/16/11
PHYSICAL / MECHANICAL DATA
60Hz
1075 RPM (A) ECM (E)
MODEL
NO.
TFM 11*-310 10 1 x 1 6870 TFM 11*-312 12 1 x 1 6640 TFM 11*-410 10 1 x 1 6620 TFM 11*-412 12 1 x 1 6400 TFM 12*-208 8 1 x 2 14800 TFM 12*-210 10 1 x 2 14400 TFM 12*-212 12 1 x 2 13900 TFM 12*-308 8 1 x 2 14200 TFM 12*-310 10 1 x 2 13700 TFM 12*-312 12 1 x 2 13300 TFM 12*-408 8 1 x 2 13700 TFM 12*-410 10 1 x 2 13200 TFM 12*-412 12 1 x 2 12800 TFM 13*-308 8 1 x 3 21300 TFM 13*-310 10 1 x 3 20600 TFM 13*-312 12 1 x 3 19900 TFM 13*-408 8 1 x 3 20500 TFM 13*-410 10 1 x 3 19900 TFM 13*-412 12 1 x 3 19200 TFM 14*-308 8 1 x 4 28400 TFM 14*-310 10 1 x 4 27500 TFM 14*-312 12 1 x 4 26600 TFM 14*-408 8 1 x 4 27400 TFM 14*-410 10 1 x 4 26500 TFM 14*-412 12 1 x 4 25600
NOTES:
* Insert voltage code (see Nomenclature, page 2) (1) For 50 HZ fan data, use 60 Hz CFM (m3/h) x 0.83 (2) Sound level pressure at 30 ft (10m) (3) Not including headers.
FPI
FAN
AIR FLOW
(1)
CONFIG.
RATE
CFM (m3/h) dBA CFM (m3/h) dBA US (LITRES) LBS. (kg.)
11670 11280 11250 10870 25150 24470 23620 24130 23280 22600 23280 22430 21750 36190 35000 33810 34830 33810 32620 48250 46720 45190 46550 45020 43490
SOUND
LEVEL
51 6180
51 5980 51 5960 51 5760 53 13320 53 12960 53 12510 53 12780 53 12330 53 11970 53 12330 53 11880 53 11520 54 19170 54 18540 54 17910 54 18450 54 17910 54 17280 55 25560 55 24750 55 23940 55 24660 55 23850 55 23040
APPROX. DRY
(3)
SHIPPING
WEIGHT
AIR FLOW
(2)
RATE
(1)
10500 10160 10130
9790 22630 22020 21250 21710 20950 20340 20950 20180 19570 32570 31500 30430 31350 30430 29360 43430 42050 40670 41900 40520 39140
SOUND
LEVEL
50 1.9 7.2 245 111 50 1.9 7.2 250 114 50 2.5 9.5 265 120 50 2.5 9.5 270 123 52 2.4 9.1 410 186 52 2.4 9.1 415 189 52 2.4 9.1 420 191 52 3.6 13.6 450 205 52 3.6 13.6 455 207 52 3.6 13.6 460 209 52 4.8 18.2 480 218 52 4.8 18.2 490 223 52 4.8 18.2 500 227 53 5.4 20.4 630 286 53 5.4 20.4 640 291 53 5.4 20.4 650 295 53 7.2 27.3 680 309 53 7.2 27.3 695 316 53 7.2 27.3 710 323 54 7.1 26.9 810 368 54 7.1 26.9 825 375 54 7.1 26.9 840 382 54 9.5 36.0 880 400 54 9.5 36.0 900 409 54 9.5 36.0 920 418
(2)
INTERNAL
VOLUME
ELECTRICAL DATA
1075 RPM MODELS - SINGLE PHASE
NO. OF
FAN
MOTORS
1 3.6 4.5 15.0 790 1.7 2.1 15 810 1.4 1.8 15.0 830
2 7.2 8.1 15.0 1580 3.4 3.8 15 1620 2.8 3.2 15.0 1660
3 10.8 15.1 20.0 2370 5.1 5.5 15 2430 4.2 4.6 15.0 2490
4 14.4 15.3 20.0 3160 6.8 7.2 15 3240 5.6 6.0 15.0 3320
NO. OF
FAN
MOTORS
1 2.3 2.9 15.0 720 1.2 1.4 15 720 0.9 1.1 15.0 720
2 4.6 5.2 15.0 1440 2.3 2.6 15 1440 1.8 2.0 15.0 1440
3 6.9 7.5 15.0 2160 3.5 3.7 15 2160 2.7 2.9 15.0 2160
4 9.2 9.8 15.0 2880 4.6 4.9 15 2880 3.6 3.8 15.0 2880
TOTAL
TOTAL
208-230/1/60 460/1/60 575/1/60
FLA
MCA MOP WATTS
TOTAL
FLA
MCA MOP WATTS
TOTAL
FLA
1075 RPM MODELS - THREE PHASE
208-230/3/60 460/3/60 575/3/60
FLA
MCA MOP WATTS
TOTAL
FLA
MCA MOP WATTS
TOTAL
FLA
MCA MOP WATTS
MCA MOP WATTS
Page 6
TFM
T60-TFL-PDI
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01/16/11
LOW AMBIENT OPERATION
60Hz
Fan Cycling Control
When a remote air cooled Fluid Cooler is installed out­doors, it will be subjected to varying temperatures. Within many areas, winter to summer annual temperature swings can be as high as 120°F (48.9°C) or so. This will have a major impact on the performance of the Fluid Cooler. As the ambient temperature drops, the Fluid Cooler capacity increases due to a wider temperature difference between ambient air and entering uid temperature. As this hap­pens, the leaving uid temperature drops as well. Cycling of the Fluid Cooler fans helps control the leaving uid temperature. With this approach to solving low ambi­ent problems, fans are taken off-line one at a time. It is not recommended that multiple fan Fluid Coolers cycle more than two (2) fans per step. The reason for this is that the uid temperature will change drastically as several fans are taken off-line at the same time. This could result in excessive tube stress within the unit, due to rapid expan­sion and contraction of the coil which could lead to need­less tube failure.
Fan Cycling Control Schedule
Fans closest to the inlet header should be set to run when­ever the uid circulating pump is running.
Substantial fan motor power savings can be realized as well using this method.
For low ambient conditions, optional
Aquastats (Fluid Temperature Controllers) are used to cycle fans
on and off as required to maintain constant leaving glycol/water temperature as per the schedules below.
Page 7
TFM
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01/16/11
WIRING DIAGRAM
AMBIENT FAN CYCLING
1075 RPM
60Hz
Page 8
TFM
T60-TFL-PDI
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01/16/11
WIRING DIAGRAM
AQUASTAT FAN CYCLING
1075 RPM
60Hz
Page 9
TFM
T60-TFL-PDI
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01/16/11
ABOUT EC MOTORS
EC MOTORS
60Hz
Fluid coolers utilizing electrically commutated motor (EC motor) technology offer many benets; Improved Efciency, Reduced Sound Levels, Speed Control, Simplicity and Reliability
Efciency
The speed control function of an EC motor allows the condenser to run at optimized energy levels at differ­ent operating conditions. Up to 75% in energy sav­ings can be realized when comparing the EC motor speed control method to a conventional fan cycling method.
ELECTRICAL DATA
ECM 1075 RPM MODELS - SINGLE PHASE
Sound
As EC motor speeds vary for different operating conditions they also offer reduced sound levels when compared to conventional motor running full speed. Sound levels are reduced on cooler days and in evenings.
Simplicity and Reliability
The installation and control of EC motors is very simple compared to other methods of speed control used on conventional AC motors. Lower running op­erating temperatures and smooth transitional speed changes make EC motors durable and reliable.
NO. OF
FAN
MOTORS
1 6.3 7.9 15 560
2 12.6 14.2 15 1120
3 18.9 20.5 25 1680
4 25.2 26.8 30 2240
TOTAL
208-230/1/60
FLA
MCA MOP WATTS
Page 10
TFM
T60-TFL-PDI
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01/16/11
WIRING DIAGRAM
MODELS WITH EC MOTORS
EC MOTORS
60Hz
Page 11
TFM
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01/16/11
EC MOTOR APPLICATION
EC MOTORS
60Hz
Motors With Built-in Variable Speed –
Optional “E” Fan/motor Code
Units with an E (in nomenclature) motor designation use an EC (electronically commutated) motor / fan combina­tion to provide variable speed fan motor control. ECM fan/ motor combinations use DC motors with integral AC to DC conversion allowing direct connection to AC mains with the energy saving and control benets of a DC motor. Ideally the motors on the uid cooler should all be EC and simul­taneously slow down /speed up together. This provides for maximum energy savings. However some applications may exist where just the last fan or pair of fans (ones closest to header) is solely EC motors. (The remaining conventional type motors are then cycled off by fan cycling temperature controls).
Important Warnings:
!
(Please read before handling motors)
1. When connecting the unit to the power supply, dangerous voltages occur. Due to motor capacitor discharge time, do not open the motor within 5 minutes after disconnection of all phases.
2. With a Control voltage fed in or a set speed value being saved, the motor will restart automatically after a power failure.
3. Dangerous external voltages can be present at the motor terminals even when the unit is turned off.
4. The Electronics housing can get hot.
5. The cycling on and off of EC motors should be controlled by the DC control voltage (i.e. 0V DC will turn motor off). Excessive cycling of the motor by line voltage contactors may cause stress on the motors and reduce the motor life.
Speed adjustment Characteristics
The EC motor varies its speed linearly based on a 1-10V input signal. At 10 VDC, the motor runs at full speed. At 0 to approx. 1 VDC, the motor turns off. A chart of the speed control curve is shown below. The motor can be controlled at any speed below its nominal RPM.
Full RPM
RPM
1
Control voltage [V dc]
Control Signal
The input control signal can be supplied by an external control signal or from a factory installed proportional tem­perature control. Units with factory installed proportional temperature controls require no installation wiring and are adjusted with initial factory settings. These may require further adjustments to suit local eld conditions.
External Control Signal (Supplied by others)
Contact control manufacturer for setup of external control­ler to provide a 0-10 VDC control signal. Wire the control signal to terminal board in unit control box. Refer to the uid cooler EC wiring diagram for typical external signal control wiring.
10
Page 12
TFM
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EC MOTOR APPLICATION (cont’d)
EC MOTORS
60Hz
A350P Proportional Temperature Control (Factory Installed) Units equipped with factory installed A350 controls use a proportional plus integral temperature controller to vary and maintain the motor speed at the desired uid outlet temperatures. The controller has two main user adjustable features:
• Temperature Set point
• Throttling range
Leave the minimum Output setting at 0% and Jumpers should be set for Direct Acting (do not re-adjust)
Module
User Adjust
Setpoint
Potentiometer
User Adjust
Throttli ng Range
Pote ntiom eter
0%
Min i m um
Output
Potentiomet er
LED Indicator
(Percent of Output)
THROT RANGE
OUTPU
Conn ector
MIN
T
3 4 2 1
N
O
Integration DIP Switch
Direct
Acting
Throttling range
The throttling range potentiometer controls how far the system uid temperature deviates from the control set point to generate a 100% output signal from the control and is adjustable from 2oF to 30oF range. The throttling range determines how quickly the motor will reach full speed when detecting a change in uid temperature. For example, if the set point is 90oF and the throttling range is 10oF when the system temperature drops below 90oF, the fans will be off. When the system temperature reaches 100oF (90 + 10) the fans will be at maximum full speed. To make the fans ramp more slowly the throttling range should be increased. To maximize sound reduction and energy efciency and to provide for the most stable con­trol, it is recommended this setting be left at 10oF.
Reverse acting or direct acting mode of operation
The reverse acting/direct acting jumper is used to en­sure the controller responds correctly to the desired uid temperature. In Direct Acting (DA) mode, the motor speed increases as the temperature rises above desired set point. For proper uid cooler operation, this jumper MUST be in Direct Acting (DA) mode. Failure to ensure J1 jumper is in direct acting mode will cause the system to trip on high uid temperatures.
Operation Mo de
Jumper Posi tions
Fluid Temperature Set point
The uid temperature set point potentiometer is adjustable from -30oF to 130oF. Note: Very low set points may cause the fan motors to run full speed continually even if the uid cooler is properly sized. The fans will turn off if the uid temperature falls below the desired set point.
Minimum Output
The minimum output potentiometer controls the minimum signal sent to the motor and is factory set at 0%. It is ad­justable between 0 and 60% of the output range. If this is adjusted to 50%, the motors will not start running until 5V is applied to the motor. The motor will start running at 50% of full speed. To maximize sound reduction and energy savings and to provide the most stable control, it is recom­mended this setting be left at 0%.
Integration constant
The integration constant switch provides ability to change controller from a proportional only control to a propor­tional plus integral control. To provide the most responsive system and to maintain a stable uid temperature, it is recommended the integration setting be left on “fast” with the Mode switch set to OFF (Proportional AND Integral activated)
FAST (on)
3 4
2
1
O
N
MEDIUM (off)
SLOW (off)
OFF (set for PROPORTIONAL / INTEGRAL MODE)
Page 13
HEADER SIZES
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TFM 60Hz
GPM (fps)
0 - 10 (0.0 - 3.9) 1 1/8 (29) PLAIN or MPT
11 - 20 (2.8 - 5.1) 1 3/8 (35) PLAIN or MPT
21 - 30 (3.8 - 5.4) 1 5/8 (41) PLAIN or MPT
31 - 50 (3.2 - 5.2) 2 1/8 (54) PLAIN, MPT or FLANGED
51 - 80 (3.4 - 5.4) 2 5/8 (67) PLAIN or MPT
81 - 150 (3.8 - 7.1) 3 1/8 (79) PLAIN, MPT or FLANGED
SIZE
In. (mm)
2
(50.8)
3
(76.2)
HEADER SIZE O.D.
inches (mm)
OPTIONAL FACTORY SUPPLIED FLANGES
FITTING
Flanged
Flanged
FLANGE
DIA.
In. (mm)
6
(152.4)
7 1/2
(190.5)6 (152.4)
CONNECTIONS
AVAILABLE
BOLT
CIRCLE In. (mm)
4 3/4
(120.7)
HOLES -
In. (mm)
QTY @
4 @
3/4 (19)
4 @
3/4 (19)
OPTIONAL FLANGED CONNECTIONS
BOLT HOLE LOCATION
(150 lbs. working shock pressure)
6” & 7 1/2”
Dia. Flanges
Page 14
DIMENSIONAL DATA
T60-TFL-PDI
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01/16/11
TFM 60Hz
Page 15
DIMENSIONAL DATA
T60-TFL-PDI
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01/16/11
TFM 60Hz
LEG FOOTPRINT
Page 16
INSTALLATION
T60-TFL-PDI
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01/16/11
TFM 60Hz
! !
WARNING
ADEQUATE PRECAUTIONS MUST BE TAKEN, AFTER FIELD LEAK TESTING TO INSURE REMOVAL OF
WATER IN TUBES. IT IS RECOMMENDED THAT AN INHIBITED GYLCOL SOLUTION BE USED TO FLUSH
THE COMPLETE COIL. FAILURE TO TAKE PRECAUTIONS CAN RESULT IN FROZEN TUBES SHOULD THE
UNIT BE SUBJECTED TO LOW AMBIENT CONDITIONS BEFORE PLACED IN OPERATION.
INSPECTION
A thorough inspection of the equipment, including all component parts and accessories, should be made immediately upon delivery. Any damage caused in transit, or missing parts, should be reported to the carrier at once. The consignee is responsible for making any claim for losses or damage. Electrical characteristics should also be checked at this time to ensure that they are correct.
LOCATION
Before handling and placing the unit into position a review of the most suitable location must be made. This uid cooler is designed for outdoor installation. A number of factors must be taken into consideration when selecting a location. Most important is the
provision for a supply of ambient air to the uid cooler, and removal of heated air from the uid cooler area. Higher uid temperatures, decreased performance, and the possibility of equipment failure may result from inadequate air supply.
Other considerations include:
1. Customer requests
2. Loading capacity of the roof or oor.
3. Distance to suitable electrical supply.
4. Accessibility for maintenance.
5. Local building codes.
6. Adjacent buildings relative to noise levels.
WALLS OR OBSTRUCTIONS All sides of the unit must be a minimum of 4 feet
(1.25 m) away from any wall or obstruction. Overhead obstructions are not permitted. If enclosed by three walls, the uid cooler must be installed as indicated for units in a pit.
4 ft
(1.25 m)
min
UNITS IN PITS
The top of the uid cooler must be level with, or above the top of the pit. In addition, a minimum of 8 feet (2.5 m) is required between the unit and the pit walls.
MULTIPLE UNITS
A minimum of 8 feet (2.5 m) is required between multiple units placed side by side. If placed end to end, the minimum distance between units is 4 feet (1.25 m).
8 ft
(2.5 m)
min
LOUVERS/FENCES
Louvers/fences must have a minimum of 80% free area and 4 feet (1.25 m) minimum clearance between the unit and louvers/fence. Height of louver/fence must not exceed top of unit.
8 ft
(2.5 m)
min
8 ft
(2.5 m)
min
4 ft
(1.25 m)
min
4 ft
(1.25 m)
min
Page 17
INSTALLATION (cont’d)
T60-TFL-PDI
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01/16/11
TFM 60Hz
LIFTING INSTRUCTIONS
Air cooled uid coolers are large, heavy mechanical equipment and must be handled as such. A fully qualied and properly equipped crew with necessary rigging should be engaged to set the uid cooler into position. Lifting holes have been provided at the corners or along sides for attaching lifting slings. Spreader bars must be used when lifting so that lifting forces are applied vertically. See Fig. 2. Under no circumstances
should the coil headers or return bends be used in lifting or moving the uid cooler.
FIG. 2
FIG. 1
LEG INSTALLATION INSTRUCTIONS
Ensure the unit is placed in a level position (to ensure proper drainage of uid). The legs should be securely anchored to the building structure, sleeper or concrete pad. The weight of the uid cooler alone is not enough to hold in place during a strong wind, the legs must be anchored.
1) Assemble centre leg as shown. Remove two bolts from bottom ange of unit side panels that match the hole pattern on the top anges of both legs. Attach center legs using hardware provided at center divider panel location. Replace bolts that were removed from from side panels to secure leg assembly to bottom anges of unit side panels.
2) Assemble four corner legs to bottom anges on unit side panels and end panels using hardware provided, at matching mounting hole patterns. All legs are the same.
Page 18
TFM
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01/16/11
INSTALLATION (cont’d)
60Hz
ELECTRICAL WIRING
All wiring and connections to the air cooled uid cooler must be made in accordance with the National Electrical Code and all local codes and regulations. Any wiring diagrams shown are basic and do not necessarily include electri­cal components which must be eld supplied. (see pages 7,8,10 for typical wiring diagrams). Refer to the Electrical Specications table on pages 5, 9 for voltage availability and entering service requirements.
SYSTEM START-UP CHECKS
1. Check the electrical characteristics of all components to be sure they agree with the power supply.
2. Check tightness of all fans and motor mounts.
3. Check tightness of all electrical connections.
4. Upon start-up, check fans for correct rotation. Air is drawn through the condenser coil. To change rotation on 3 phase units reverse any two (2) fan motor leads.
5. All system piping must be thoroughly leak checked before a refrigerant charge is introduced.
HYDRONIC SYSTEM COMPONENTS
MAINTENANCE
A semi annual inspection should be carried out by a qualied refrigeration service mechanic. The main power supply must be disconnected.
1. Check electrical components. Tighten any loose connections.
2. Check control capillary tubes and lines for signs of wear due to excessive vibration or rubbing on metal parts. Secure if necessary.
3. Check tightness of all fans and motor mounts. Remove any deposits which could effect fan balance. Note: Fan motors are permanently lubricated and require only visual inspection.
4. Clean the uid cooler coil using a soft brush or by ushing with cool water or coil cleansers available through NRP (National Refrigeration Products Inc.)
5. Update service log information (back page of service manual)
PIPING CONSIDERATIONS
1. All piping must comply with local city and plumbing codes.
2. Correct choice of pipe material, diameter, velocity and friction loss (pressure drop) can result in glycol systems running at peak efciency and performance and hence least cost.
3. Studies have indicated that iron pipes are most susceptible to corrosion, followed by galvanized steel, lead, copper and copper alloys (i.e brass). PVC is generally no-corrosive.
4. Good glycol system design therefore requires that Galvanized Pipe NOT be used and a glycol manufac­ turer provide the appropriate Corrosion Inhibitor.
5. Parallel, Direct and Reverse Return piping (see illustration on page 23) networks are the most common used as they allow the same temperature uid to be available to all loads and heat rejection devices (Fluid Coolers). Actual piping should be determined by a qualied hydronic system designer, based on site and design requirements.
6. Isolation Valves should be provided for easy removal of hydronic system components, for repair, maintenance or replacement.
7. All piping should be leak tested after installation.
8. A pressure reducing valve should not be used in a glycol hydronic system.
PUMPING SYSTEM
Pumps
1. Mechanical seal type pumps must be used for glycol systems.
2. Pumps are selected based on Total System Flow and Total Friction Loss (Highest Pressure Drop) through: a. The Fluid Cooler b. The Load (Chiller, CRAC Unit, etc) c. Supply/Return Glycol Piping, Valves & Fittings The Sum of the above is the “Total Head” or Pressure Drop of the system, typically measured in ft-H2O.
3. This is a closed loop system. A counterhead acts on the pump suction so no allowance is required for vertical lift as in an open loop (i.e Open Cooling Tower) system.
4. Many hydronic system designers are specifying and many end-users are purchasing “Pump Packages”. These Pump Packages come ready for nal pipe and electrical connection, allowing the installer to focus on overall pipe connections.
5. Pumps in Parallel are recommended for standby operation where pump failure may interfere with a critIcal application ( i.e Data Center Cooling - N + 1 Design).
Page 19
HYDRONIC SYSTEM COMPONENTS
Manual Isolation Valves
Chiller Condenser
Common
Options
Common
Options
Common Options:
Closed Loop System
Valves, Sensors & Gauges
T60-TFL-PDI
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01/16/11
(cont’d)
TFM 60Hz
PUMPING SYSTEM (cont’d)
Expansion Tanks
As ambient temperature changes so does uid density. System pressure is maintained within an acceptable range with an Expansion Tank. The expansion tank allows for the expansion and contraction of the glycol due to the temperature change in the closed loop system. Expansion tanks are typically sized based on a percentage of the total system volume.
Air Separators
Air Separators are designed to remove entrained air al­lowing the pumps, valves and heat transfer mediums to operate and transfer energy more efciently.
Other Common Hydronic System Options
Depending on the complexity of the hydronic system other system components and devices may be specied such as
• Flow, Pressure Gauges and /or Switches
• Isolation and other Valves
• Strainers
Selecting Glycol
Inhibited Propylene or Ethylene Glycol Solutions ranging from 30 to 50 % are the most commonly used. 30 % is the minimum amount for inhibitors to be effective. For freeze protection amounts, see the following guide. (Con­sult Glycol supplier for most accurate data)
%
By Volume
30 5 (-15) 9 (-17.7)
40 -10 (-23.3) 5 (-15)
50 -32 (-35.5) -29 (-33.8)
Ethylene Glycol Propylene Glycol
Freeze Point °F (°C)
Typical Hydronic System Heat Rejection Closed Loop
c/w Fluid Coolers
Fluid Cooler(s)
Piped in Parallel
Reverse Return
(shown for illustrative purposes only)
Field Installed - By Others
Other components are needed in the closed loop system to make it functional. Common Option Examples Above :
Expansion Tank
Air Separator
Pump Package
Base Unit Includes:
(1) Pump
(1) Standby Pump
Mounting Frame
Control Panel
(2) Low Pressure Switches
Process – By Others Typically a :
CRAC Unit Condenser
Engine
These items can be supplied, mounted and piped to allow the installer to focus on the overall pipe connections.
or Cooing Coil
Page 20
PUMP PACKAGE
FLUID COOLER PARAMETERS
Altitude Above Sea Level
Entering Fluid
Total Heat of Rejection
Fluid Type
Electrical ____ V / _____ Phase / _____ Hz
Leaving Fluid
Note: Of EFT, LFT, Fluid Flow and THR - 3 of the
Design Ambient Air
Temperature
Tamb = ____ °F
PUMP PACKAGE PARAMETERS
Total System
Fluid Flow
Fluid Type
%
Total System
Drop
Altitude Above Sea Level
Pressure Drop
Exchanger
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TFM 60Hz
SELECTION PARAMETERS
To select a Fluid Cooler the following must be known:
Temperature EFT = ____ °F
(THR) Required ________________ Btu/Hr ( Fluid Cooler Capacity)
Fluid Flow Rate ________ gpm
Ethylene Glycol ______ % or Propylene Glycol ______ %
4 Parameters must be known to make a selection
ASL = _______ ft
(Only if 2,000 ft and above )
At The Fluid Cooler
Temperature LFT = ____ °F
To select a Pump Package the following must be known:
Head
________ ft-H2O
= +
Rate
________ gpm
Electrical ____ V / _____ Phase / _____ Hz
Ethylene Glycol ______ or Propylene Glycol ______ %
Volume ________ Gal
= +
Highest
Fluid Cooler
Pressure
____ ft-H2O
Internal
Volume of
Fluid Cooler
_____ Gal
Highest Evaporator
Unit Heat Exchanger
(i.e Cond. As per
below in Chiller)
____ ft H
Glycol/Water
Cooled
E V A P
Internal Volume of
Evaporator Unit Heat
______ Gal
ASL = _______ ft (Only If 1,000 ft and above)
Pressure Drop of
Supply & Return
+
Glycol Piping +
All Valves &
Fittings
O
2
C O N D
+
_____ ft-H
Internal Volume of
Supply & Return
Glycol Piping + All
Valves & Fittings
_____ Gal
O
2
Page 21
GENERIC SERVICE PARTS
T60-TFL-PDI
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01/16/11
TFM
DESCRIPTION Part No
FAN MOTOR - 208-230-460/1/60 1087070
FAN MOTOR - 575/1/60 1087071
FAN MOTOR - 208-230/3/60 1088054
FAN MOTOR - 460/3/60 1088053
FAN MOTOR - 575/3/60 1087073
MOTOR MOUNT 1086090
FAN BLADE - 26”, 30° 1087188
FAN GUARD 1086091
RAIN SHIELD 1085266
LEGS
24” 1086150
36” 1086151
48” 1086152
ANGLE BRACE (36” & 48” LEGS) * 1086153
CROSS BRACE ** 1086154
* 1 Per Leg On Single Fan Wide ** 2 Per Unit On 1, 2 & 3 Fan Models, 3 Per Unit On 1 X 4 Fan Models (Not Req’d On Double Wide)
60Hz
NOTE: Refer to unit service parts label for optional components not listed on this page.
Page 22
PARAMETERS FOR SELECTION OF A FLUID COOLER
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01/16/11
Fluid Type: □ Water □ Ethylene Glycol / Water □ Propylene Glycol / Water
Elevation: ___________ Feet Above Sea Level
Fluid Concentration: ___________%Water ___________%Glycol
Air Inlet (ambient temp.) __________ ºF
Three of the four following parameters must be specied:
1. Required Capacity __________ Btu/h 2. Fluid Inlet Temperature __________ ºF
3. Fluid Flow Rate __________ GPM 4. Fluid Outlet Temperature __________ ºF
Other Items To Specify:
1. Voltage (S2 = 208-230/1/60 S4 = 460/1/60 S5 = 575/1/60 T3 = 208-230/3/60 T4 = 460/3/60 T5 = 575/3/60) ______Specify S2,S4, S5,T3,T4 or T5
2. Please Specify (Check Box) Options Required:
Control Voltage 240V (Standard) Variable Speed EC Motor Control Voltage 120V  Extended leg kits 36” Control Voltage 24V Extended leg kits 48” Fan Cycling Ambient Thermostat  Gold Coat Fin Fan Cycling Aquastat Thermostat  Copper Fin Fan Cycling Control by Others Heresite Coating Non-fused disconnect 50 Hz Horizontal air discharge conguration
Customer Info: Name: ______________________ Telephone Number: _____________________ Fax: ______________________ Email: ______________________
Fax or email completed sheet to your sales representative.
Page 23
Finished Goods Warranty
T60-TFL-PDI
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01/16/11
The terms and conditions as described below in the General Warranty Policy cover all products manufactured by National Refrigeration.
GENERAL WARRANTY POLICY
Subject to the terms and conditions hereof, the Company warrants all Products, including Service Parts, manufactured by the Company to be free of defects in material or workmanship, under normal use and application for a period of one (1) year from the original date of installation, or eighteen (18) months from the date of shipment from the Company, whichever occurs rst. Any replacement part(s) so supplied will be warranted for the balance of the product’s original warranty. The part(s) to be replaced must be made available in exchange for the replacement part(s) and reasonable proof of the original installation date of the product must be presented in order to establish the effective date of the warranty, failing which, the ef­fective date will be based upon the date of manufacture plus thirty (30) days. Any labour, material, refrig­erant, transportation, freight or other charges incurred in connection with the performance of this warranty will be the responsibility of the owner at the current rates and prices then in effect. This warranty may be transferred to a subsequent owner of the product.
THIS WARRANTY DOES NOT COVER
(a) Damages caused by accident, abuse, negligence, misuse, riot, re, ood, or Acts of God (b) damages caused by operating the product in a corrosive atmosphere (c) damages caused by any unauthorized alteration or repair of the system affecting the product’s reliability or performance (d) damages caused by improper matching or application of the product or the product’s components (e) damages caused by failing to provide routine and proper maintenance or service to the product (f) expenses incurred for the erecting, disconnecting, or dismantling the product (g) parts used in connection with normal maintenance, such as lters or belts (h) products no longer at the site of the original installation (i) products installed or operated other than in accordance with the printed instructions, with the local installation or building codes and with good trade practices (j) products lost or stolen.
No one is authorized to change this WARRANTY or to create for or on behalf of the Company any other obligation or liability in connection with the Product(s). There is no other representation, warranty or condition in any respect, expressed or implied, made by or binding upon the Company other than the above or as provided by provincial or state law and which cannot be limited or excluded by such law, nor will we be liable in any way for incidental, consequential, or special damages however caused.
The provisions of this additional written warranty are in addition to and not a modication of or subtraction from the statutory warranties and other rights and remedies provided by Federal, Provincial or State laws.
PROJECT INFORMATION
System
Model Number Date of Start-Up
Serial Number Service Contractor
Refrigerant Phone
Electrical Supply Fax
Page 24
“AS BUILT” SERVICE PARTS LIST
01/16/11
Service Parts List
Label
To Be Attached
HERE
NATIONAL REFRIGERATION & AIR CONDITIONING CANADA CORP.
159 Roy Blvd. Brantford Ontario, Canada N3R 7K1 PHONE: (519) 751-0444 800-463-9517 FAX (519) 753-1140
Due to National Refrigeration’s policy of continuous product improvement, we reserve the right to make changes without notice.
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