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Service Manual

1. FLUID INLET The fluid inlet nozzle must be at the end adjacent to the refrigerant connections to assure refrigerant superheat for proper operation of the thermostatic expansion valve Locate the unit allowing adequate room to remove the heads should service ever be necessary The unit should be within 2 degrees of level and bolted or welded in place Fluid side piping should be done in accordance with local codes Remove plastic plugs that are placed in the pipe couplings on the shell and install steel pipe plugs A high quality Teflon based pipe dope is recommended for sealing fluid side pipe threads CAUTION Use care removing these plastic plugs as there are tubes very close to the outside of the shell Poking a screwdriver or an awl through the plug could damage a tube The same is true if you need to re tap one of the couplings threading the tap in too deeply will damage tubes possibly causing a leak Dry Expansion Evaporators 10 A filter or strainer must be installed on the evaporator fluid inlet if you have silt particles or other foreign debris in your fluid This debris can accumulate in or block fluid flow through the tubes and will result in excessive pressure drop with localized areas of high fluid velocity You also risk freezing the unit since pockets of stagnant fluid will accumulate in the unit Filters and strainers must be maintained on a regular basis Upstream filters are recommended for any u
2. Reinsulate all affected areas WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable 16 Dry Expansion Evaporators Evaporator Gasket Replacement Procedure for Grooved Heads Tubesheets 1 Ensure that all refrigerant has been recovered and that the vessel has been isolated There is no need to drain the barrel Carefully remove insulation to expose bolt heads Cut carefully and mark position of insulation so that it can be reused Cut or un sweat liquid and suction lines as necessary for removal of heads Measure line sizes and get slip couplings Put witness marks at 12 o clock on the tubesheet and on the head to ensure proper alignment during reassembly Support head and remove all but two bolts carefully remove the final two bolts but be careful that head does not slip down or swing out Janine HEADS ARE VERY HEAVY HANDLE WITH EXTREME CARE 5 Once head is secured where you can safely work on it peel off old gasket Scrape the remaining adhesive from the head be careful not to scratch or gouge head Remaining adhesive can be removed using a solvent cleaner On TX25s and smaller only use solvent Clean tubesheet with brake cleaner Clean gasket with solvent until the surface is shiny black allow all surfaces to dry Verify that you have the correct gaskets Cut out any unused gasket dividers cut along the lines of the webs and
3. Service Manual Commercial refrigeration solutions Literature Code ERCO0632EN 1510 Original manual Standard Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice The manual is only intended as a guide and is not intended to replace professional training or experience Safety IM POM ANT Informatio is aici OE RO EE OE ege RR Ee ES 5 Warning Ee EE 5 Safety Precautions eene AN NL EN n BA Ao ie ee AN Re AS AK Ke ed Re Rek N HY 6 Dry Expansion Evaporators Evaporator Installation Recommendations ss 7 Fluid Quality and Ee 9 d eines Kugeler 9 SUCTION Line Guideline EE EO 10 S ldering Brazing Guidelines ss SABS ENE PES ei GENE DEE EIN EE De GE DER REDE IN Geb ERG iere IR be ae Ee 10 Welding Repair e E 11 Evaporator Cleaning Inondation siese ads Re eN di es n ae NG NEG ee ien ew be Su ee 11 OEREN A EE N EE EE N 11 eed OE ER EE OR OE N RA OE 11 SEdiIMEN i eass EE OE RE ET EE N N 12 Flow Switches amp Fluid Velios be ee Ee ee Ne EE DE OER BEDR Ee ME ee 12 Evaporator Refrigerant Loss sesse sesse ees EE EE Ee EE EE EE EE Ee ERG EE Re ER EEE NEE EEN 12 Evaporator Tube Leak Test Procedure ss 12 Field Evaporator Gasket Leak Test Procedure ss 13 Evaporator Gasket Layouts Examples iese es ses oe AKA es Du ko ees de de ewe de ER De GEN ki 14 Evaporator Gasket Cutting Procedur
4. taken not to circulate fluids in excess of the maximum allowable refrigerant temperature through the shell side of the evaporator since the corresponding refrigerant pressures may exceed the tube side working pressure Consult the nameplate to determine the maximum working pressure Under such conditions gasket blowout can occur along with tubesheet and head distortion Also abnormal thermal expansion and contraction of the different materials used in the evaporator can also cause similar gasket blowout or damage to the tubes tubesheets and or heads Other causes of gasket leaks include excessive bolt load due to over tightening which may crush the gasket and create excessive bow in the tube sheet or head Evaporator Tube Leak Test Procedure If you suspect you have a leaking tube or tubes in an evaporator you need to verify it Electronic leak detectors can be used to sense the presence of a leak but you need to pinpoint the leaks exact location To do this you can use the procedure below 1 Shut off the system and ensure the recovery of all refrigerant Ensure the vessel has been isolated from the rest of the system Remove evaporator heads see evaporator gasket replacement procedure Shut off fluid to evaporator drain fluid side of vessel close the valves and go to step 4 If there are no valves you will have to split the flanges and install blank flanges 4 Pressurize the shell with nitrogen to 150 PSIG NOTE YOU
5. the inside diameter of the gasket so there is no overhang on the groove Apply a thin 0 010 to 0 015 uniform coat of adhesive in the groove of the head and one side of the gasket Carefully place the gasket into the groove start from the outside at the top and bottom and work towards the center then the partitions on the side Once the gasket is in place run a small flat blade screwdriver between the wall of the groove and the gasket to make sure that the gasket is seated in the groove If the gasket is not fully seated it will probably leak Allow adhesive to cure at least one full hour Guide the head into place and align the witness mark on the head with the witness mark on the tubesheet this is Critical and the head must remain aligned and fully supported until all bolts are completely tightened Be careful not to disturb gasket Tighten bolts until gasket is just touching the tubesheet all the way around Torque bolts in a crisscross pattern to step 1 then step 2 and step 3 if applicable see chart Torque once more to the final value once more CAUTION DO NOT TIGHTEN BOLTS ANY FURTHER Re braze all connections Charge evaporator to 150 PSIG with nitrogen and check for leaks using a leak reactant such If a gasket leak is found torque the bolts 10 ft Ibs higher and recheck Evacuate to 1500 microns break the vacuum with nitrogen and evacuate to 500 microns You can now recharge and start the evaporator Reinsulate you can use the left
6. MUST VERIFY THAT EVERY PART OF THE SYSTEM EXPOSED TO PRESSURE IS RATED TO SAFELY HANDLE THAT PRESSURE INCLUDING THE EVAPORATOR PIPING VALVES BLANK FLANGES RELIEF VALVES AIR BLEEDS ETC Start by leak checking the tube to tubesheet joints by spraying or brushing a leak detecting soap solution on the tubesheet Let the bubbles that form when applying pop and then look for a thick white froth around the outside diameter of each tube this indicates a leak After an hour verify that you still have 150 PSIG reapply soap recheck if no leaks are found go to step 5 5 There are three methods for checking leaks inside of the tubes All of these should be done while the pressure applied in step 4 is still on the shell a For this method you will need a bubbler This is easily made by drilling a hole in an appropriate size rubber plug insert a tube through the hole and insert the other end into a clear glass jar half filled with water Plug the tubes at one end with rubber plugs and insert the bubbler into each tube at the other end individually and observe the jar for bubbles for 20 30 seconds on each tube A leaking tube will produce bubbles in the jar This is the simplest method 12 Dry Expansion Evaporators b Plug the tubes at one end with rubber plugs and form bubbles at the other end using a leak reactant Watch for bubbles that rapidly expand and pop It is best to leave the unit open for several hours since any remaining refri
7. N A 1 2 20 brass nuts HP with 1 2 20 brass nuts 15 65 N A HP with 1 2 20 steel nuts CALL FACTORY CALL FACTORY CALL FACTORY ELT TNT SWT with 1 4 20 nuts 8 N A ELT SWT with 5 16 18 nuts 15 N A KHX with 5 167 24 nuts 15 N A HSE units 150 horsepower and larger SST units 126 horsepower and larger and all AMC use the head bolt torque table All torque values are shown in foot pounds Always tighten the bolts in a crisscross sequence l1 g Torgue Pi 7 i SK 1st Pattern 15 sr N es 14 Torque Sequence p 11 20 S 2 a Ze 8 aot 6 5 15 14 7 D 2 e X 8 5 16 9 13 16 1 I Stay Bolt 4 13 4 O 3 18 3 Torque First l 12 9 12 4 20 N 7 14 40 11 17 Os 82 3 019 _ 20 A 15 16 3rd 4th amp 5th 10 6 11 2nd N Torque Sequence 18 26 Condensers Condenser Head Bolt Torgue Bolt Diameter 1 nae 2 Torque Step 3 4 amp 5 9 16 HEX 3 4 HEX 15 16 HEX 1 1 8 HEX 2 3 8 All torque values are shown in foot pounds Always tighten the bolts in a crisscross sequence Sample torque sequence for SST HSE CA and MSE units Use crisscross pattern for all bolt configurations For tube in tube units see the tube in tube gasket replacement section Tube In Tube Condenser Gasket Replacement Procedure 1 Before starting work ensure that you have the correct gaskets This can be done by comparing the current gasket with the new
8. a zinc plate in the field remember to order the appropriate endplate and stud set Check with your local sales representative or contact the factory for more details With regular maintenance of the epoxy coating on the tubesheet your shell and tube marine condenser should give you many many years of fine service 24 Condensers Marine Seasonal Maintenance 1 At the end of the fishing season every six months or whenever the condenser would stagnate for over 36 hours fluid should be drained from the condensers Stagnant fluid left in a heat exchanger for long periods of time can cause deoxidization of the fluid greatly increasing the level of corrosion in any given heat exchanger 2 Every six months or at the end of the fishing season the tubesheets should be brushed clean A gasket should be added to give protection for the upcoming season s activities 3 Water plates should be put back on the condenser and torqued to 25 ft lb on each bolt Follow torqueing sequence shown in the diagram Sea Water Marine Condenser Materials of Construction Tubes 90 10 CuNi Stainless Steel Header Naval Brass Stainless Steel Epoxy Coated Carbon Steel Shell Carbon Steel Stainless Steel Tube Sheet 90 10 CuNi Stainless Steel Epoxy Coated Carbon Steel Tube Supports Carbon Steel Stainless Steel Sea Water and Marine Water Velocity Ranges 90 10 Copper Nickel Shallow i 7 0 ft s 90 10 Copper Nickel Deep Water 10 0 ft s Stainless Steel 10
9. amp 01 Control Setting Notes Every year many evaporators are needlessly frozen Freeze ups can be prevented with properly installed and adjusted controls that are protected from tampering The two most important controls are the low pressure cut out and the flow switch both of which should be set up to shut off the compressor should they be tripped They can be either manual or automatic reset The low pressure cut out should be set to trip at a pressure corresponding to the refrigerant saturation temperature slightly above the freezing point of the fluid being circulated through the evaporator For example a system using R 22 and straight water should be set at 58 59 PSI This pressure corresponds to 32 33 F You can go to lower settings to minimize nuisance trips but this does risk freezing the unit up The flow switch should be adjusted so that it will trip not only when fluid flow stops completely but when it drops off significantly A freezestat can be used however with the compact high performance TX line of evaporators there is a much smaller volume of fluid in the evaporator and for the example above the freezestat must be set at 39 F The best protection is still the low pressure and flow switches Always verify settings with a calibrated set of gauges through several cycles Remember to account for glide with blends such as R 407C amp R 409A If using gauge pressure which most refrigerant gauge sets do be sure to corre
10. be used if desired CAUTION Do not use a heavy sealing compound or anything that sets hard Install as follows see Note for 8 5 8 and 9 3 4 OD units 1 Make sure the gasket is mounted correctly on the level indicator Hold head up and float end then point towards the flange Start inserting the float into the flange Swing head down and in at same time wiggle slightly to check against binding a BO ND When all the way in check to be sure float is free by rotating head slightly each way Indicator pointer swings with float The alarm makes no sound but a slight jar can be felt when the float swings to the upper and lower stops 6 Keep the indicator head snug against the gasket and rotate it to right side up NOTE The upper lug holding the dial or switch is rounded the bottom one is square 7 Install screws finger tight then tighten screws in a crisscross pattern to a final torque of 10 12 ft lbs There should be an equal clearance space between the indicator body and the flange face when the required torque is reached NOTE The 8 5 8 and 9 3 4 OD indicators should be started differently or the float rod may be bent Hold the unit with the stem horizontal and parallel to the tank with the head to the right of the flange upper stop will keep the float from dropping Swing the head from right to left and in Check float travel with head about two inches out from the flange then rotate to right side up and ins
11. corner followed by a nine digit serial number You can weld on these as necessary It is your responsibility to use proper procedures and a qualified welder You accept full liability for any of these repairs and any resulting damage will void any remaining warranty UM amp U These are medium and larger units identified by a steel tag welded to the unit UM units have a UM symbol in the upper left corner of the tag and says MFR SER No followed by a six character serial number with the first being an letter and the remaining five being numbers across the top U units have a U symbol in the upper left corner and say MFR SER amp NAT L BD NO followed by a six digit number across the top Any welding done on either of these units must be done by an ASME certified welder that holds an R stamp following proper procedures An R 1 form must be completed Welding by an unauthorized welder or removal of the steel tag voids the warranty and the vessel s certification with the National Board Any damage caused by unauthorized welding will void the warranty Evaporator Cleaning Information Evaporators can build up deposits on the tubes baffles and sediment inside the evaporator This can lead to a complete or partial blockage which often results in freeze ups and dramatically reduced performance It is crucial to maintain fluid quality and keep scale and sediment from accumulating in the unit Below are guidelines on how to keep the uni
12. gasket to ensure the correct number of bolt holes and pass configurations Make sure that the fluid supply to the condenser is shut off ELT SWT and TNT Units Remove all of the nuts from the U bolts remove the cross bars and the endplates Take note which side gasket came off each side since they are different NOTE Some fluid will drain from the unit after the removal of the endplates 4 KHX Disconnect the front head Removing as much of the piping as possible as this will make the removal and replacement of head easier Remove the nuts and bolts and then remove endplates Take note of which gasket came off each side since they are different Peel off old gasket NOTE Some fluid will drain from the unit after the removal of the endplates 5 If the factory applied epoxy shows any signs of damage corrosion or pitting on either the tubesheet or inside of the head it should be touched up or recoated Follow the epoxy application instructions for more details 6 ELT SWT and TNT Place gaskets into end plates ensure that the gaskets are installed on the correct side put end plate against tubesheet and slide cross bars over U bolts and hand tighten nuts 7 KHX Pass bolts through end plates and gaskets and guide endplate into place Ensure that gaskets are installed on the correct side Only hand tighten the nuts 8 ELT SWT and TNT Run down all nuts by hand and torque to step 1 and then step 2 Move from the center bolts to the o
13. joints In some cases it will be necessary to install a vibration isolator in the refrigerant inlet line to insulate the condenser from compressor vibration a discharge muffler is advisable when the condenser is very close to the compressor Use a nitrogen flood to prevent the formation of oxidation on the inside of the copper lines and steel fittings while brazing This is done by filling the unit with nitrogen and setting the regulator as 2 4 PSIG and letting it flow while you are brazing There must be an opening to prevent pressure from building up inside the unit Install a relief valve in the fitting provided Verify the rating on the valve is not higher than the maximum allowable working pressure MAWP specified on our tag A quality sealant such as Loctite 554 or equivalent should be used to seal the relief valve and any other pipe thread joints on the refrigerant side of the unit Pressure test all of the refrigerant connections by pressurizing the condenser to 150 PSIG and applying a leak reactant Evacuate the condenser Fluid side piping should be done in accordance with local codes Size the piping to ensure that the fluid side velocity does not exceed the published maximum velocities see Fluid Quality amp Velocity table Pipe the fluid side using unions this enables easier removal of the heads if the unit needs to be cleaned in the future Dielectric unions should be installed if galvanic corrosion is a concern The fluid regulating v
14. line Connect the 3 8 hose to the vacuum pump and the two 1 4 lines to the system 3 Whenever possible remove the cores from the 1 4 SAE fittings that you are connecting your hoses to If you have done this you should also remove the core depressors from your hoses The fewer restrictions there are in the path that the vacuum will be pulled through the faster the vacuum will come down If the 1 4 fitting is not installed on an isolation valve temporary access fittings are available that allow the cores to be removed and reinstalled after evacuation is complete 4 Low temperatures make it harder to pull a vacuum Water boils at 101 F at 27 95 of vacuum but at 53 F you must pull the vacuum down to 29 53 or 10 000 microns and at 1 F water boils at 29 88 or 1 000 microns Isolating an evaporator and raising the temperature will make the evacuation go much faster This can be done by draining the unit and letting it warm up or by running warm fluid through it 5 If you are evacuating the compressor crankcase make sure that the crankcase heater is on Change compressor oil as needed Replace dryer or cores anytime you open a system 7 You can expect to pull 1 less of a vacuum per 1000 of elevation above sea level 35 Accessories Dehydration 1 4 5 If the failure was in a evaporator blow the tubes out with nitrogen or compressed air when the repair is done the tubes are internally enhanced or rifled
15. over adhesive for this WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate 17 Dry Expansion Evaporators Evaporator Torque Chart 1 g Torque P 3 NS 1st Pattern 15 al 14 Torque Sequence pA 11 20 N q q 2 ae oe 10 8 aT 6 5 8 16 13 3 9 16 13 l Stay Bolt 4 13 4 O 3 18 3 Torque First l j 9 12 8 9 12 Av 47 29 e 14 Mo IT OS ME n 10 P E 10 15 16 Pi 3rd 4th amp Sth 16 2nd Torque Sequence 18 Torque Sequence There are numerous bolt patterns used on our evaporators Illustrated above is the torque sequence of a 20 bolt head If the unit that you are working on does not match use the written instructions below 1 Start at a top bolt or 12 o clock and torque bolt Move 180 degrees to a bottom bolt or 6 o clock and torque bolt Move 90 degrees to a bolt at 9 o clock and torque bolt Move 180 degrees to a bolt at 3 o clock and torque bolt a fF ON Go back to the top and move clockwise one bolt and start the sequence over Continue using the steps outlined above using the torque steps listed in the chart 18 Dry Expansion Evaporators Evaporator Head Torque information Torque Step 1 Torque Step 2 Torque Steps 3 4 amp 5 5 10 3 1
16. the suction line into the suction fitting using a nitrogen flood and a flame barrier to protect the insulation from scorching and the head gasket from excessive heat See suction line guidelines Connect the expansion valve and hot gas bypass valve equalizer line s if used This can be done by brazing the line directly to a hole punched in the suction line or using the connection that we install on the steel suction fitting This should only be done after all brazing is done If you are going to do this you will need to thread a 1 4 NPT to 1 4 SAE adapter into the coupling welded to the steel suction fitting If the adapter does not thread in easily the coupling should be cleaned out with a 1 4 NPT tap and all shavings should be removed We recommend using a high quality sealant such as Loctite 554 on the pipe threads Be sure to remove any Schrader pins from the 1 4 SAE fitting unless the equalization line connector is fitted with a depressor Attach the expansion valve bulb or equivalent to the suction line Follow the equipment manufacturer s instructions for more details suction line dryer can be installed at this time and is very helpful after a compressor burnout We do recommend that the core be removed after 24 hours if the sight glass indicates no moisture and if an acid test shows that the oil condition is satisfactory Leaving the core in can cause problems later if the pressure drop across the dryer gets too hig
17. 0 ft s Shell amp Tube Condenser Gasket Replacement Procedure 1 Before starting work ensure that you have the correct gaskets In most cases this can be done by comparing the gaskets that you have on hand with the illustration in the appropriate catalog Make sure that the fluid supply to the condenser is shut off If the unit is equipped with a drain plug in either of the heads remove it to drain the unit and piping NOTE Some fluid will remain in the unit below the level of the drain plug To remove the remaining fluid on units with no drain plugs you will have to remove the rear head to completely drain the unit To do this remove the nuts and pull the bottom of the head away from the vessel Use extreme care not to scratch the gasket surface as this will cause leaks after assembly 4 Disconnect the piping from the front head Removing as much piping as possible will make removal and replacement of the head easier Remove the nuts and follow the instructions in step three if the head does not come off by hand NOTE Some of the studs may back out when you try to remove the nuts simply note which hole it came from and put it back in the same one during reassembly CAUTION The fluid regulating valve should always be installed on the fluid inlet to prevent water hammer 5 The gaskets will remain on the unit NOTE The position of the gasket and if possible take a photograph Use a plastic scrapper to separate the gasket from the tu
18. 6 Allen 5 16 Allen 9 16 Hex 3 4 Hex 7 8 Hex 15 16 Hex 1 1 16 Hex 1 1 8 Hex 1 1 4 Hex 2 3 8 All torque values are expressed in foot pounds Units designed for low temperature operation 20 F and below will use B7 or B7M bolts These bolts have larger heads 19 Condensers Condenser Installation Guidelines There are many steps in installing a fluid cooled condenser Following the proper procedures will ensure a long trouble free service life for the condenser Below is an outline of steps that should be followed These steps are recommendations only and not a substitute for proper training and experience 1 Inspect the condenser Any damage should be reported to the shipping company immediately This is your responsibility As with any shipping damage it is advisable to take a picture of any damage Install the condenser using our universal brackets or factory installed brackets Condensers should always be securely mounted Refrigerant lines should be sized and routed to meet system capacity requirements pressure drop requirements and proper refrigerant velocity to ensure no oil return to the compressor Chapter 1 Halocarbon Refrigeration Systems in the ASHRAE Refrigeration Handbook provides an excellent guide for refrigeration piping practice Pipe up the refrigerant side of the condenser use a solder with 45 or higher silver content and the proper flux for copper to steel
19. WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable Liquid Level Indicator Maintenance Location To enable a liquid level indicator installation units require a special dedicated factory installed flange Liquid level indicators are available for 8 5 8 OD and larger horizontal receivers only Normal location is on the side centered between the liquid inlet and outlet connections Other mounting locations can be provided but this must be specified at time of order NOTE At least six inches are required between centers of adjacent units and also between a unit and the liquid outlet pickup tube Indicators can be mounted in the center of either end provided the respective inlet or outlet fitting is moved to at least 1 5 tank diameters from that end A sketch must accompany orders indicating the custom location if required 31 Accessories Description Liquid Level Indicator model part numbers vary depending on vessel OD and operating pressure The dial reads the percent of pumpdown capacity of the receiver When the pointer indicates 100 the receiver is 80 full of liquid Pounds of refrigerant can be determined by taking the indicated percentage of the specified pumpdown capacity of the receiver be aware that some tables show pump down capacity at 90 Example RBV3865 with R 22 dial indicates 75 full and RBV3865 pumpdown capacit
20. alve should be carefully sized and must be installed on the inlet side to prevent water hammer which can cause damaging vibrations and shorten the life of the condenser A high quality Teflon based pipe dope is recommended for all fluid connections If you have fluid leaks at the gaskets ensure all of the bolts are tight as these can come loose during shipping Follow torque settings in the condenser head bolt torque tables When you have started the unit you should verify that there is adequate fluid flow for proper operation and that the fluid flow rate does not exceed the values published in our catalog for your particular model The surest way to verify proper flow rate is to use a flow meter If a clamp on flow meter is not available for startup testing or some type of flow meter cannot be permanently installed in the water line you can use the fluid pressure drop across the condenser as an indication of flow rate Make sure that you are not sending any abrasives such as sand or silt through the unit this is particularly a concern when you are using river water or in shallow water marine applications Install or maintain a filter or strainer if debris or sediment is a problem Also ensure that you are not entraining air or gas in the fluid inlet at the pickup point this will cause cavitation which will lead to premature failure and void the warranty If you have followed the above mentioned guidelines the condenser makes a rattling noise when y
21. and will hold large amounts of fluid and oil Anytime spent removing fluids from the tubes before replacing the heads will result in a significant reduction in evacuation time The condenser is more difficult to dehydrate if it has been flooded It is usually worth the time and effort cut the copper tubing coming from the refrigerant outlet to drain the unit To speed this up you can blow nitrogen or compressed air through the safety fitting on the top Repair the liquid line later with a coupling Once you have removed the bulk of fluid from the system and you have it all sealed up you can start pulling vacuum It is strongly recommend using a cold trap A cold trap is a vessel that goes between the vessel or system being evacuated and the vacuum pump It holds dry ice and has a chamber which the air being removed passes through This causes the moisture to condense inside it thus preventing the moisture from reaching the vacuum pump and contaminating the oil This speeds the process by eliminating oil changes and allowing the pump to run overnight unattended Although you may have reached a good vacuum you may still have moisture trapped in parts of the system such as suction oil traps You will have to use dryers to remove the last traces of moisture It is a good idea to install an oversized liquid line dryer and a suction line drier with replaceable cores to speed up the dehydration process Use cores with a high fluid capacity Remember to remove th
22. anifold Pressure all circuits to 150 PSIG with nitrogen or carbon dioxide Using a leak reactant brush or spray a liberal amount over the entire outside of the gasket and check for indications of a leak If no leaks are found and you are working on a single circuit unit you are done If you are working on a multi circuit unit move onto the next step If a leak is found move onto step 5 On multi circuit units you can now check for cross circuit leaks Pressurize the first circuit to 150 PSIG Place a hose over the flare fitting on the second circuit two circuits and place the other end into a small jar of water Watch the jar for bubbles for five minutes If you are working on a two circuit model reverse the connections i e pressurize circuit 2 and check circuit 1 If a gasket has been blown out by higher pressure in circuit 2 pressurizing only circuit 1 may push the gasket back into place sufficiently to conceal the leak If a leak of this nature is found re torqueing the bolts will not fix the problem the gasket must be removed and replaced On three and four circuit units you must pressurize each circuit and check adjacent circuits In other words on a four circuit unit you would pressurize circuit 1 and check 2 Pressurize circuit 2 and check circuits 1 amp 3 Pressurize circuit 3 and check circuits 2 amp 4 Do this until each circuit has been pressurized If no leaks are found you may put the unit back into service If you do f
23. be has been expanded or split due to freezing If this is the case it will be necessary to flatten a portion of the protruding tube and apply a C clamp with bar plates place on each side of the tube so additional pressure may be applied Cut out this Tube portion of tube Step drill for removal of copper tube 4 All chips debris or tube particles must be removed from the tube hole following the removal of the leaking tubes The grooves in the tube holes must also be carefully cleaned without damaging or scratching the tubesheet hole surfaces Drill for removing 5 8 OD copper tubing Drill for removing 3 4 OD copper tubing di 1 Approx Ra ME 1 Approx 638 OD Grind clearance back of cutting edge Grind clearance back of cutting edge 29 Tube Repair mid Wal RE RS y 1 5 12 5 gt m E LE 0 375 0 750 T N NS A 1 32 R Drive rod for removing 3 8 OD evaporator copper tubing not to scale Drive rod for removing 3 4 OD condenser copper tubing not to scale Tube OD Tube Wall Thickness For other tube OD and thicknesses please consult the factory Tube Installation 1 Inspect groove thoroughly to assure that they are clean and free of foreign material 2 Insert a new tube until it is flush with both tube sheets If the tube is slightly longer than the unit make one end flush with the tube sheet The other end will have to be cut off after the rolling op
24. besheet Work your way around the gasket pulling it off a little at a time Be very careful not to scratch the gasket surface on the tubesheet as this will create leaks after reinstallation 6 If the factory applied epoxy shows any signs of damage corrosion or pitting on either the tubesheet or inside of the head it should be touched up or recoated Follow the epoxy application instructions for more details 7 Clean the gasket surfaces the heads and the tubesheet to ensure that there are no particulates or scratches on any surface Any scratches will have to be repaired before reassembling the unit 25 Condensers 8 Install the new gaskets over the studs Push them on by hand a little bit at a time CAUTION NEVER FORCE THEM ON WITH A HAMMER OR TOOL 9 Install the head and torque nuts in a crisscross pattern to values shown in the illustration 10 Re pipe the front head and turn fluid back on Check for leaks after the fluid pressure has been on for at least 10 minutes If a leak is found re torque in the same crisscross pattern 5ft llbs higher WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate Condenser Endplate Torque Torque Step 1 Torque Step 2 Torque Step 3 4 amp 5 SST HSE CA MST and MSE with 15 30
25. commended Water Ouality for Copper pH 7 5 gt X lt 9 0 SO 2 100 HCO37 SO4 7 gt 1 0 Total Hardness AS as Cl lt 50 POLE 2 0 NH3 lt 0 5 Free Chlorine ADS Fes lt 0 5 Mn lt 0 05 CO lt 50 H2S e GU Temperature lt 150 65 Oxygen Content amp 01 Frozen Condensers We receive many calls regarding condensers that have been frozen This commonly occurs when a large amount of refrigerant is lost out of a condenser quickly The most frequent cause is the relief valve opening due to excessive head pressure This is caused by overcharging high fluid temperature or the sudden shutdown of fluid flow to the condenser Other causes are mistakenly removing refrigerant from an idle unit or accidental breakage of a liquid line Pumps should be on circuits that will not be shut off while the compressor is running and lines should be protected from accidental damage Freeze ups are also caused by not completely draining a condenser that is exposed to low ambient air temperatures The only way to be certain that a unit is completely drained is to loosen the nuts holding the heads on and pulling the head and gasket away from the tubesheet Simply removing a drain plug does not ensure that all of the fluid will be drained from the unit Units that have been frozen are not covered under warranty Welding Repair Notes If the unit is still under warranty please consult with the factory before performing any repair work Any wor
26. ct the pressure setting for the local atmospheric pressure Dry Expansion Evaporators Suction Line Guideline Suction line sizing This is very important If suction line diameter is too small you will see excessive pressure drops which can cause a reduction in performance and inadeduate compressor cooling Too large of a diameter can reduce velocities enough that the oil will not remain entrained with the refrigerant and can cause oil to build up in the evaporator and suction line Ensure that the velocity is kept under the recommended limit shown in Chapter 1 of the ASHRAE Refrigeration handbook at the normal design conditions Keep the suction line as short and straight as possible and use as few elbows as possible use long radius elbows where space permits This will minimize pressure drop and enhance performance NOTE Suction lines should always be insulated Oil traps P traps are made up with copper elbows and ells to help keep the oil mixed with the refrigerant as it travels to the compressor Traps may not be necessary when the compressor is mounted below or level with the evaporator unless you do not have pumpdown control In that case you should have an inverted trap to prevent oil from draining into the compressor during the off cycle Simply pitching the suction line towards the compressor should be adequate when the compressor and evaporator are mounted at the same level A P trap should be installed at the base of any suctio
27. d the manual before using WARNING Indicates that special procedures must be followed to avoid serious personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the pressure vessel NOTE Indicates important information to simplify or clarify procedures Warning signs General warning IN Safety Pay special attention to the instructions below so that severe personal injury and or damange to the valve are avoided Safety Precautions Installation Always read the technical data thoroughly Never touch the the pipeline when processing hot liquids Never dismantle under pressure Never dismantle when it is hot Operation Never dismantle under pressure Never dismantle when it is hot Always read the technical data thoroughly Never touch when processing hot liquids Always rinse well with clean water after the cleaning Maintenance Always read the technical data thoroughly Never service when it is hot Never service under pressure Dry Expansion Evaporators Evaporator Installation Recommendations There are many steps involved in installing a new evaporator Following proper procedures will help ensure a long trouble free service life for the evaporator This document is an outline of steps that should be followed however they are not a substitute for proper training or experience Te Inspect the evaporator Any da
28. duced or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise or for any purpose without the expressed permission of Alfa Laval Corporate AB Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law including the seeking of criminal prosecution
29. due to a freeze up you must work it down before installing the plug This can be done using a large line up punch Drive the Tubesheet tapered punch into the tube using light hammer taps until the punch bottoms in the hole Work the punch around the inside of the tube and remove it Ei Tube 3 Select a plug of the proper size and material If you ee e Blister are not sure which the correct size is contact the plug supplier Plugs can be ordered in one or two pieces either design will work To ensure the best fit measure the inside diameter ID of the tube after cleaning If you are making your own plugs measure Tubesheet the ID of the tube to be plugged The plug should Grooves be 3 inches long and taper 0 010 per inch The ID you measured will be the diameter in the center of the plug add 0 015 this will be the size of the large end subtract 0 015 and this will be the size of the small end In other words if your tube ID is 0 570 the plug will run from 0 555 to 0 585 The material must be compatible with the tube being plugged Copper and cupronickel tubes should be plugged with brass carbon steel with carbon steel plugs and stainless steel with stainless steel plugs 4 When you have the plug ready you must clean the hole This can be done using Virginia 10e solvent or acetone Thoroughly clean the inside of the hole and the plug allow the solvent to evaporate Taper Pin 5 When installin
30. e cores from the suction line dryer once the clean up is complete or you may have performance problems due to high pressure drop across the drier later Also replace the liquid line dryer Change compressor oil prior to starting the system back up The system should be run for 24 hours and then checked with an acid test kit Change oil and cores until oil shows no residual acid Replace the sight glass if the moisture indicating element has been saturated with fluid CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate 36 Decommissioning and Disposal Decommissioning and Disposal At the end of any vessel s service life it must be decommissioned and disposed in accordance to local laws and legislations The decommissioning of any heat exchanger pressure vessel or other equipment must be performed only by qualified personnel who will operate in accordance with local environment legislation laws All fluid must be drained from the equipment before disconnecting any of the pipes Use the Evacuation Procedure and Dehydration sections shown in this service manual for more information IN WARNING Ensure that the vessel and system show zero gauge pressure before disconnecting any bolts or fittings After draining all of the fluids some residual parts could remain inside the vessel or equipment depending on the type of fluids utilized over the lifespan o
31. e ss ER EE ER EE ER E EEN 15 Evaporator Gasket Replacement Procedure ss ee ee EE Re Gee AE Re Ge Ge EG Ge ee nnee 16 Evaporator Gasket Replacement Procedure for Grooved Heads Tubesheets 0s0000002 17 Evaporator Torque Gath issciiessscesdesiesscveadevenseavesarvendevenssevsesesenssesscveesestevasduesestessstenssissssbsesseassaues 18 Evaporator Head Torque information ses 19 Condensers Condenser Installation Guidelines N EKEN KA RR KA AR ai ae EKKE diam 20 SESSION elle ARE EE RO EA EE OR N N 21 Fluid Quality de lee ER KA SE HD 21 Frozen EES at ee EEN eeh OR OE EE EE EE N 22 Welding Repair Notes ss RR EES Rg N ee be EK EDE ee EA ED ees Ge Ke GE Dei N De Ee Ne be DE N ee 22 Condenser Cleaning Information ee ee ss 23 Soft deposits EE rttr EEAEEEAEEEAEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EE EEE EEE EEEEEEEEEEEEEEEEEEEE 23 EE Een EE a 23 d lte el 23 Heid ROIS lee EE 23 Condenser Tube Leak Test Procedure cccceeeeeeessecneeeeeeeeeensenaaeeeeeeenseenenseeeaeeeeeseeseeseeeees 23 Marine Shell amp Tube Seasonal Maintenance PDrocedure KANNER AEN ee ee ee Re GE RR ee GR Re ee ee 24 Sacrificial ZINC ele 24 Marine Seasonal Maintenance sise 25 Shell amp Tube Condenser Gasket Replacement Procedure ss 25 Condenser Endplate Torque sise 26 Condenser Head Bolt Tordue iese EER RES ENE BEKER REGEER GR EER ENEE AR SERE GEE GEE ARE GER GE Ke el EER BEER GEE ESE EEN EER NE 27 Tube In Tube Condenser Gasket Replacem
32. ent Procedure 27 Tube Repair Tube Plugdind Procedure esse sesse eke seke ee se ee ee Ee ENE oe Ne bede Ee eN ee SR eie bee DE eke END ee ie 28 Tube Replacements issie sis see ER Ge SE ee Ee Ge Re Ge Ee Ri we ie seels Ee GEE RE GEN Ge ee 29 Diet e EE 29 T belnstallatioi OR EE EE EE EE EE EE N 30 Accessories Sight Glass Replacement Procedure sessies KERKE RE eN EKEN EK ES EN dNK kak Ke ke ee NA GEK EKKE EKS ese Ni 31 Liquid Level Indicator Maintenance see 31 LOCATION EE ER OR A EE N 31 IR Ne el 32 oe e sandal geass pads eee een ete ba a age ee AE 32 a Ge OR EA OE N RE ER OE 32 G n ral SHSCIICATIONS AE OE OO RE N AR 33 Liquid Level Indicator Alarm Maintenance siennes 33 gl ele EE 33 Description RR RA R 33 G n ral SpeEllCcatonS iss ies eeh dE SAAR ee Ede Se EA Ek Ee EG De ER dace Been Geek D EN eek se ad Liquid Level Indicator Gasket Replacement Procedure 34 EVACUATION Procedure is ie N Ee ee ee ve dee Pe ae D EE GER N Ee ee E De Ene ee 35 lede RE ed RE ati EE EE ON EG 35 EVECUSTION TDS GR SR EO N 35 RRC RE 36 Decommissioning and Disposal Decommissioning and Disposal ee 37 Frequently Asked Questions Frequently Asked QueSTIONS c cccececeeeeeeceneeseeeeeeeeeeeeaeenesseeeeeeseeseaeaussseeeeeeeseeaaggssseeseessensoanenses 38 Safety Unsafe practices and other important information are emphasized in this manual Warnings are emphasized by means of special signs Important Information Always rea
33. ent can cause a loss of performance and freeze ups When sediment builds up it restricts fluid flow through the tube bundle The way to prevent this is to install a strainer or filter the inlet of the evaporator If the fluid is exposed to airborne particulates heavy rust or any other source of sediment you must clean the screen or filter as needed to ensure full fluid flow through the barrel Blocked filters increase the risk of fouling and can dramatically reduce the performance and service life of the unit due to the lower velocity of the fluid To remove accumulated sediment back flush the unit by reversing the fluid flow through the unit To improve the results of this procedure inject low pressure air 25 50 PSIG through a nozzle into the 3 4 NPTF coupling on the flange that the fluid is being pumped through this will help agitate the sediment Flow Switches amp Fluid Velocity It is crucial that a flow switch is installed on the evaporator fluid outlet and inspected for function on a regular basis It is also important that fluid velocity through the evaporator remains below 5 ft s as higher velocities can result in tube failure If you are unsure of the velocity please contact the factory or use the ProSuite software to calculate the velocity of the fluid flow by providing the GPM Evaporator Refrigerant Loss Refrigerant loss can occur in a number of different ways and can be caused by several different issues Care must be
34. eration 3 Insert the tube roller until it reaches the stop With firm pressure roll expand the tube into the Tubesheet tubesheet When starting to roll the tube it is necessary to hold the other end of the tube to keep it from turning Use extreme caution not to over roll the tube It is better to under roll and re roll again after testing than to over roll and have to replace the tube again Repeat the procedure on the other end CAUTION Ensure that the rolls and the tube roller are well oiled CAUTION Rollers must not roll the q last 1 8 before the inside surface of the tubesheet Tube Rolling Tool 4 After rolling the tube carefully grind the tube end flush with the tubesheets using a disc grinder The tube can also be trimmed flush with an all cutter 5 The tube ends should be cleaned to remove any chips or filings that may have collected Tubes id should then be blown out to remove any additional chips or fillings Rollers 1 8 from back Do not roll 6 Check your tube to tubesheet joints for leaks by following the Evaporator Tube Leak Test Procedure as shown earlier in this section 7 Install the gasket and heads following the Evaporator Gasket Replacement Procedure 30 Accessories Sight Glass Replacement Procedure If a sight glass is leaking or broken it must be replaced Use the following instructions below to ensure a
35. ert the rest of the way 32 Accessories General Specifications Gasket Neoprene flat gasket fits current indicator and alarm adapter on units manufactured after 1972 Part Number GASKE995 See Liquid Level Gasket replacement Procedure for more information Temperature Operating temperature range 30 F to 150 Humidity Exposed portion should be painted for marine applications Tank pressure 28 vacuum O to 500 psi Burst pressure Gasket will unseat at approximately 2 500 psi External pressure Normal atmosphere to 30 000 feet Liquid Level Indicator Alarm Maintenance Model part number INDIC210A Application This indicator alarm with selectable low level point is designed for use in applications where low liquid level protection is desirable It provides a relay circuit that closes at one of five user selectable levels from 10 to 50 This relay circuit can be used to drive a variety of applications from alarms to pumps The indicator alarm also provides a direct visual indication of the liquid level in the tank Description This liquid level indicator alarm features a four bolt brass head that accommodates the direct attachment of the 4 steel junction box Other indicator alarm components are of either stainless steel or aluminum All of these metals are fully compatible with common refrigerants and lubricants The indicator alarm float is magnetically coupled to the indicator ala
36. f the equipment CAUTION The residual chemicals could potentially be corrosive If any chemicals remain the equipment must be rinsed before disposal The disposal of any heat exchanger pressure vessel or associated equipment must be performed by a specialist company who operates in accordance to all local environmental legislation laws Heat exchangers and receivers are gt 98 metal After full decommissioning of the equipment the metal can be recycled The remaining material is polymeric based gaskets and plastic baffles Units which have an external insulation layer if provided by Alfa Laval Standard is elastomeric polyurethane Original packaging material consists of wood and or cardboard boxes All Alfa Laval materials are compliant with the Reach and Rohs regulations Please contact Alfa Laval Standard if further details are required 37 Freguently Asked Ouestions Frequently Asked Questions Below are some frequently asked questions If the content doesn t answer the questions that you have please contact Alfa Laval Standard for assistance Can shell and tube heat exchangers be installed in a vertical orientation No units will not work in a vertical orientation If floor space is a limitation we recommend using a shell and coil tube in tube or brazed plate heat exchanger contact Alfa Laval Standard for selection assistance or refer to our product catalog website Can connect to the threaded IDS connection
37. g the plugs follow the manufacturer s instructions CAUTION DO NOT DRIVE THE PLUG ANY FURTHER THAN NECESSARY TO SEAL THE PLUG EXCESSIVE FORCE CAN CAUSE LEAKS IN ADJACENT TUBES 6 Apply pressure and check for leaks 7 Cut off the excess plug only if it will interfere with the installation of the head 28 Tube Repair Tube Replacement If the unit is still under warranty please contact Alfa Laval Standard before performing any repairs Unauthorized repairs will void any remaining warranty If the number of plugged tubes exceeds 10 of the total tubes in any of the passes the tubes can be replaced All tubes must be replaced with the same tube as the originally fitted Extreme caution should be used so that no damage will occur to the tube sheet holes when drilling out the tube Damage to the tubesheet holes will result in future leaks Tube Removal 1 To remove any tubes drill the tube out at both ends until the two grooves in the tube sheet are visible or within 1 16 of the back face of the tube CAUTION Do not drill the tube entirely out of the tube sheet since this will allow the tube to drop out of line with the tube hole 2 After the tube ends are drilled out use a step drive rod to drive the tube If the tube does not start readily moving from one end try the opposite end as the tube may be distorted 3 After starting the tube should come through the tube sheet easily unless the tu
38. gerant laden oil will give false indications as the refrigerant boils c Plug both ends of the tubes and let the unit sit for at least 12 hours leaking tubes will pop one of the plugs out If leaks are found and the unit is still under warranty contact Alfa Laval Standard before performing any repairs Unauthorized repairs will void any remaining warranty You must also take corrective action to eliminate the conditions that caused the failure Bulges or blisters on the inside of tubes are caused by ice that formed when the suction pressure drops below the freezing point of the fluid WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate Field Evaporator Gasket Leak Test Procedure If you suspect that you have leaking evaporator gaskets this must be verified by testing the unit The steps to check for cross circuit or external gasket leaks are listed below 1 Shut off the system and ensure the recovery of all refrigerant The liquid and suction lines must be sealed to isolate the evaporator The liquid line solenoids will not seal the liquid lines Close the suction valves at the compressor Install 1 4 SAE fittings without cores into the 1 4 pipe thread couplings on the suction fittings This allows you to use your gauge m
39. h Once the entire system has been leak checked you can evacuate it charge it and adjust all settings and controls WARNING Do not exceed the shell side or tube side design working pressures and temperatures stamped into the nameplate Never remove the nameplate from the shell WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate DX Evaporator Materials of Construction Default Material Alternative 1 Alternative 2 Tubes Copper Carbon Steel Stainless Steel Header Carbon Steel Stainless Steel Shell Carbon Steel Stainless Steel Tube Sheet Carbon Steel Stainless Steel Baffles Carbon Steel Stainless Steel Plastic Dry Expansion Evaporators Fluid Quality and Velocity Poor fluid quality can foul a unit to a point where there is a significant reduction in performance or drastically reduced service life Corrosive water can attack and destroy the baffles inside a unit this can cause an 80 90 reduction in performance Highly corrosive water can also attack the copper tubes creating cross fluid to refrigerant leaks We recommend that you take a sample of the fluid to be run through the unit and have a local laboratory run the Langelier and Ryznar indexes These are simple tests which will give you an idea of the conditi
40. inations such as sand mud and dirt there can be marine life which can end up in the tubes die and cause highly corrosive by products There are numerous chemicals from processing plants present in rivers that feed into the sea Each of these contaminants has its own effect on condensers Sand will cause erosion of the tubes and tubesheets This causes what is known as under deposit corrosion High sulfur content can cause rapid deterioration because sulfur is highly corrosive to copper Phosphorous compounds in sea water can cause embrittlement by combining with the nickel in cupronickel and forming nickel phosphides Finally free electric current which is a common characteristic of many boats can cause condenser deterioration To help mitigate these issues Alfa Laval Standard has added an epoxy coat to the cupronickel tubesheets giving tubesheet surfaces and tube joints protection against chemical attack and sand but correct operating conditions are still required to ensure a long service life Sacrificial Zinc Anodes A sacrificial zinc plate which used to be included on all standard MS units is no longer necessary due to advancements in Alfa Laval Standard manufacturing process Optional zinc plates can be added between the rear gasket and the endplate or zinc plug inserts are available from the factory NOTE Some units with zinc plates require a different rear endplate and set of studs than units without zinc plates If you are adding
41. ind a leak see step 5 If you cannot find a hose and a jar you can form a soap bubble on the opening of the fittings and see if it grows and pops If it is not leaking the bubble will collapse or it will not grow Be careful not to get excessive amount of soap in the fitting NOTE Refrigerant laden oil can give a false leak indication as the unit warms and the refrigerant begins to boil out of the oil and expand If the unit is used you may want to let it sit for 24 hours or until the residual refrigerant boils off If no leaks are found you may put the unit back into service If you are confident that you have a leak see step 5 If you verify a leak you should re torque the bolts to the correct torque and retest If this does not stop the leak you can raise the torque by 10 foot pounds and retest If you still have a leak you must replace the gaskets Contact Alfa Laval Standard for gaskets and the appropriate procedure Only gaskets supplied by Alfa Laval Standard should be used since other materials may not be compatible with all refrigerants and oils CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate 13 Dry Expansion Evaporators Evaporator Gasket Layouts Examples Gasket A Single Circuit Dual Pass OO Front Rear Gasket C Dual Circuit Dual Pass DO Front Rear Gasket E Quad Circuit Dual Pass wD D Front Rear Gasket G Sing
42. ise head pressure if it leaks past valves 2 After you have verified there are no leaks vent the nitrogen and evacuate to 5000 microns Use a micron gauge a gauge manifold is not accurate enough 3 If using an older single stage vacuum pump that can only achieve 10 000 microns break the vacuum with nitrogen pressurize to 50 PSIG and vent NOTE This step is not required with modern vacuum pumps that can achieve better than 500 microns 4 Evacuate to the level specified by the system manufacturer If this information is not available evacuate to 500 microns Isolate the unit and micron gauge Note the initial reading and observe the gauge for 20 minutes The reading should not rise more than 50 microns on a new system and 100 microns on a used system in that time Any decay above that level is an indication of non condensable fluids still in the system or a leak Once the system holds to no more than 600 microns for 20 minutes break the vacuum with refrigerant Remove the vacuum pump The system is now ready for charging Evacuation Tips 1 Use a large enough vacuum pump 1 CFM per 7 tons is a rule of thumb Always start with fresh oil in the vacuum pump Keep open containers of oil tightly capped since it is very hygroscopic Change the oil as soon as it shows signs of moisture in it Keep the gas ballast valve open until the vacuum is down to 29 of vacuum or 25 000 microns and then close 2 Use a gauge manifold with a 3 8 vacuum
43. k performed without the approval of Alfa Laval Standard will void any remaining warranty If a weld repair is necessary on a condenser you must determine what type of unit it is since different rules apply You must also determine whether or not the part that you need to repair is a code part Most condenser fluid plates are not code items and you may weld on them as necessary The exception to this would be a UM or U condenser that has a tube side rating on the steel tag such as our HP line of condensers Heads on these units are code parts UL These are smaller units and can be identified by an adhesive label that says built in the upper right corner followed by a nine digit serial number You can weld on these as necessary It is your responsibility to use proper procedures and a qualified welder You accept all liability for these repairs and work causing damage to the unit will void any warranty UM amp U These are medium and larger units identified by a steel tag welded to the unit The UM units have a UM symbol in the upper left corner of the tag and says MFR SER NO followed by a six character serial number with the first being a letter and the remaining five being numbers The U units have a U symbol in the upper left corner and say MFR SER amp NAI L BD NO followed by a six digit number across the top Any welding done on either of these units must be done by an ASME certified welder that holds an R stamp following prope
44. l joints You must use a solder with no less than 45 silver content and the corresponding flux Copper to copper joint Solder with no less than 15 silver content is recommended Solders with a lower silver content can be used if necessary but are not recommended Nitrogen flood The system should be flooded with nitrogen when soldering to prevent the formation of oxidation on the inside of the copper tubing being brazed This is done by filling the system with nitrogen and then setting the regulator at 2 4 pounds and letting it flow while you are brazing There should be an opening large enough to prevent pressure from building up in the system Wipe the joints clean with a flame barrier once brazing is complete Always pressure test with nitrogen when brazing is completed 150 PSIG is recommended for testing WARNING Ensure all of the systems components and relief valves are rated for at least that pressure Test all joints with a leak detection fluid 10 Dry Expansion Evaporators Welding Repair Notes If the unit is still under warranty please consult with the factory before performing any repair work Any work performed without the approval of Alfa Laval Standard wil void any remaining warranty If a weld repair is necessary on an evaporator you must determine what type of unit it is since different rules apply UL These are smaller units and can be identified by an adhesive label that says built in the upper right hand
45. le Circuit Three Pass OO Front Rear Gasket B Single Circuit Four Pass DO Front Rear Gasket D Dual Circuit Four Pass DO Front Rear Gasket F Single Circuit Four Pass DO Front Rear Gasket H Dual Circuit Three Pass DO Front Rear Dry Expansion Evaporators Evaporator Gasket Cutting Procedure Contact Alfa Laval Standard for the correct gasket or gasket sheet material There are times when you will need to cut a gasket by hand from sheet material The gasket material used at Alfa Laval Standard is compatible with the refrigerants that are approved for the particular evaporator and refrigerant oils and is available in 1 8 3 16 amp 1 4 Follow the procedure below to hand cut a gasket Contact the factory for gaskets for units with grooved heads or tubesheets 1 Cut a disc from suitable material To obtain the dimensions for this disc you can use the old gasket if it is in usable condition If not you will have to measure on the inside of the head move 1 4 from the inside of one bolt hole measure 180 degrees across to the same point on another bolt hole This is your diameter which must be transferred to a sheet do this using a large compass If you do not have a compass you can make one using a ruler yardstick or a straight edge Take a ball point pen and a white paint marker tape them to the yard stick and use this as your compass Center the ball point pen and mark you
46. le you are getting the pattern the lines must be clear before you start cutting Always make sure that you keep the disc centered when patterning Both methods can be done with the head in a vertical position but are much easier to do with the head lying flat and should be done with two people 4 Once you have your pattern cut out the sections of the gasket Follow the directions in step 2 The difference being when you come to the corners be very careful one slip and you will have to start over NOTE Always cut away from the corners 15 Dry Expansion Evaporators Evaporator Gasket Replacement Procedure Te Ensure that all refrigerant has been recovered and that the vessel has been isolated There is no need to drain the barrel Carefully remove any insulation to expose bolt heads Cut carefully and mark position of insulation so that it can be reused Cut or un sweat liquid and suction lines as necessary for removal of heads Measure line sizes and get slip couplings Put witness marks at 12 o clock on the tubesheet and on the head to ensure proper alignment during reassembly Support head and remove all but two bolts carefully remove final two bolts be careful that head does not slip down or swing out WARNING HEADS ARE VERY HEAVY HANDLE WITH EXTREME CARE Once head is secured where you can safely work on it peel off the old gasket Scrape the remaining gasket material and adhesive from the head be careful not
47. lug the tubes at one end with rubber plugs and form bubbles at the other end using a leak detecting solution Watch for bubbles that rapidly expand and pop c Plug both ends of the tubes and let the unit sit for a minimum of 12 hours the leaking tube will pop out one of the plugs 4 If leaks are found you must repair replace or plug leaking tubes You must also take corrective action to eliminate the conditions that caused the failure Large leaks coming from inside of a tube can be an indication that the unit was frozen This can be caused by low ambient temperature or the loss or removal of gas from the unit which lowers the refrigerant pressure below the freezing point which freezes the fluid and ruptures the tube from the inside out WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate Marine Shell amp Tube Seasonal Maintenance Procedure It is important to remember that a sea water environment is hostile and unpredictable Waters found in Houston Harbor are not the same as those found in the Pacific Northwest The presence of salt will accelerate the rate of deterioration of a heat exchanger Cupronickel is used primarily to protect against that possibility Sea water is not simply salt water There are also particulate contam
48. mage should be reported to the shipping company immediately This is your responsibility As with any shipping damage it is advisable to take a picture of any damage Use the lifting lug s to position the barrel to avoid damaging the insulation Addition layers or thicker insulation should be used if the unit will be exposed to temperatures in excess of 95 F and 70 relative humidity or when the leaving fluid temperature is 32 F or lower If the unit is installed where the ambient temperature can drop below the freezing point of the shell side fluid a heat tape sufficient to keep the shell side fluid from freezing must be installed under the barrel insulation Stock evaporators are normally equipped with shell side fluid nozzles on the right hand side when viewed from the refrigerant connection end Right hand units can be converted to left hand units by removing and switching heads see Evaporator Gasket Replacement Procedure section for more details Top mounted fluid nozzle evaporators must be ordered from the factory CAUTION Do not install the evaporator rolled over on its side or upside down The evaporator will not function properly if it is rolled over 90 on its side or 180 upside down with the suction nozzles below the liquid nozzles See diagram below for more details FLUID OUTLET REFRIGERANT SUCTION y Y a REFRIGERANT eA g og LIGUID 9 9 Q 9
49. n line with a vertical rise In long runs a P trap should be installed for every 20 feet of vertical rise and every 30 feet of horizontal run Suction accumulators P traps will not prevent large amounts of oil or liquid refrigerant from slugging the compressor Systems that are prone to liquid damage such as commercial and low temperature systems should use a suction accumulator This will prevent flood back slugging and enhance oil return The accumulator should be installed at the same level as the compressor Suction line heat exchangers These use the suction gas to sub cool the liquid refrigerant boil off any liquid in the suction line and add superheat This increases system performance and adds a measure of protection for the compressor For further information refer to the ASHRAE Refrigeration Volume Chapter 1 Soldering Brazing Guidelines Only air conditioning and refrigeration tubing that is plugged and dehydrated should be used for piping the system Always use a torch tip that is large enough to bring the metal being soldered up to the appropriate temperature quickly to prevent overheating the work piece Whenever possible the component being soldered should be disassembled This is especially important on ball valves as the seats in these valves are prone to damage from overheating and most are easily disassembled and reassembled Always clean both pieces being brazed with a sand paper or a wire brush Copper to stee
50. ndicator gasket surfaces with a solvent such as Virginia 10e Also clean the gasket until it has a shiny black appearance Allow all surfaces to dry Place the gasket on the indicator and work it back into place Seat the indicator gasket in the groove machined into the flange Torque the bolts to 30 inch lbs in a crisscross pattern and then tighten the bolts to 60 inch lbs Pressurize the receiver with nitrogen and test with a leak reactant If you see a leak identify if it is coming through a scratch in the casting or the gasket If the leak is caused by damage to the indicator replace the indicator If the gasket is the source of the leak ensure all of the bolts are tight and if necessary tighten to 65 inch lbs and retest CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate 34 Accessories Evacuation Procedure Any time you install a new refrigeration component or open a system you must properly evacuate it The following steps will help to insure that the system is dry and free from non condensable fluids If the system has been flooded due to a freeze up of a evaporator or condenser follow the dehydration instructions Evacuation 1 Pressure test all connections by pressurizing with nitrogen to 150 PSIG and using leak reactant NOTE Remember when testing with nitrogen that it is a non condensable and will accumulate in the condenser and ra
51. nit to extend the service life of the unit All new piping must be flushed before being connected to the evaporator A flow switch should be installed in the 3 4 NPTF coupling on the fluid outlet flange or in the outlet pipe immediately after the flange Provisions may be made to install wells in the outlet piping for a freezestat and temperature control sensors if the leaving fluid is being used for compressor control Always use new gaskets on flanges and clean flange sealing surfaces Install the expansion valve or a tee connector if you are using a hot gas bypass valve Sporlan sells a fitting designed for this to into the liquid line fitting Wrap the expansion valve with a flame barrier to protect it while soldering Use a nitrogen flood and wet wrap a rag around the steel liquid fitting to protect the insulation from scorching and the head gasket from excessive heat Solder the sight glass into the liquid line using a nitrogen flood and a flame barrier to protect the element Solder the liquid line solenoid valve in place using a nitrogen flood and a flame barrier to protect the internal components The solenoid valve should be installed in accordance to the manufacturer s specifications Ensure that fluid flow will go in the correct direction through the valve Solder the liquid line dryer in place using a nitrogen flood and flame barrier at both ends Complete high side piping with connection to condenser outlet Solder
52. on of your fluid For further information we recommend that you contact a local water treatment professional Excessive fluid velocity will reduce the service life of an evaporator When you have started the unit you should verify that there is adequate fluid flow for proper operation and that the fluid flow rate does not exceed the values published in our catalog for your particular model The best way to verify proper flow rate is to use a flow meter If a clamp on flow meter is not available for startup testing or some type of flow meter cannot be permanently installed in the fluid line you can use the fluid pressure drop across the evaporator as an indication of flow rate When the unit is first installed it is the best time to check pressure drop since the pressure drop will rise slightly as the unit accumulates the normal amount of fouling which is acceptable and expected Too high of a pressure drop is an indication of excessive fluid flow or velocity through the unit This will cause excessive wear on the tubes and can result in premature tube failure Too low of a pressure drop is an indication of too little fluid flow This will cause poor and erratic system performance Recommended Water Quality for Copper pH 752X290 SO lt 100 HCO37 SO 7 gt 1 0 Total Hardness 45 gt X lt 8 5 Cl lt 50 PO lt 20 NH3 lt 0 5 Free Chlorine lt OS Fes lt 0 5 Mn lt 0 05 CO lt 50 H2S lt E Temperature lt 150 65 Oxygen Content
53. ou start the unit the source of the vibration is probably the fluid side You may need to install vibration dampeners in the fluid piping WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate 20 Condensers Selection Guidelines There are many things to consider when selecting a condenser Criteria such as performance and pumpdown capacity are covered in our condenser catalogs Below are factors that affect longevity Size The use of too small of a condenser will force you to run an excessive amount of fluid through it to maintain head pressure This will cause premature failure though impingement corrosion or cavitation The small amount of money that you may save by buying a smaller condenser will be lost since damage caused by impingement corrosion is not covered under warranty Material Few applications have ideal fluids Tower systems can be treated If you are using city well or river water you cannot economically treat your water and if the fluid quality is poor you can quickly damage a unit We recommend the Langelier and Ryznar indexes to assess your fluid quality These are simple tests that can be done by a local laboratory at a reasonable cost Give them a sample of the fluid that will be run through the unit Thi
54. permanent repair 1 Ensure all remaining refrigerant is recovered and the unit is isolated 2 Unscrew the old sight glass to remove it 3 It is highly recommended to use new sight glass however if you are reusing an old sight glass it must be cleaned Carefully using a wire brush dental pick or tap to clean the threads ensuring to remove all old sealant residues When using a tap do not cut the threads any deeper just use it to clean them Stop any residue from the old sealant reentering the unit as this can cause contamination and damage the system 4 Clean the threads on the inside of the coupling and the sight glass with Loctite 7649 primer Virginia 10e solvent or acetone Clean as many times as necessary to remove all oil and moisture Allow all solvent to evaporate fully before proceeding 5 Apply Loctite 554 thread sealant or equivalent Put 3 4 drops on the first 2 threads in the coupling and a heavy ring around the sight glass covering the first four threads 6 Thread the sight glass into the coupling by hand as far as possible and torque to the value specified in the table Wipe off excess sealant from threads 7 Allow the sealant to cure at least one full hour before putting the unit back into service but please be aware the longer it cures the stronger the bond will be 8 Evacuate properly prior to putting system back into operation NPT Size Torque ft Ibs N A SGO4 SGO6 SG08 SG10 SG11 GLASS193
55. r diameter with the paint marker Two ball point pens can be used if necessary but lines are much harder to see 2 Lay material on flat clean surface a piece of cardboard on a bench or the floor works well Using a utility knife with a new blade make your first cut along the outside diameter mark you have laid out using light pressure Follow along the same line on the second cut the blade will pass through 1 8 thick material 3 16 will take 3 cuts and 1 4 will take 4 cuts Work your way around the disc cutting 1 4 of the diameter at a time CAUTION Don t use a hacksaw to cut the gasket as this can result in contaminate inside the exchanger 3 Once you have a disc you must now lay out the partition webs if you have a gasket in good condition you can lay it on top of your disc and trace the webs with the paint marker If you do not have a usable gasket there are two alternatives to transferring the pattern to the disc a In the first method put a good coat of oil on the head and then holding the gasket very tightly at one edge roll it down over the head and press on the backside of the gasket Peel the gasket back up without allowing it to slip and you will have a pattern to cut along b Inthe second method you again hold the gasket but now you push firmly on the back of the gasket with your thumbs along the inside diameter of the head and on both sides of the partitions In both cases you must make sure that the disc does not slip whi
56. r procedures An R 1 form must be completed Welding by an unauthorized welder or removal of the steel tag voids the warranty and the vessel s certification with the National Board 22 Condensers Condenser Cleaning Information As condensers run deposits accumulate in the tubes inhibiting heat transfer This raises head pressure and utility costs With good fluid condensers can run for years without cleaning however poor quality fluid can build up enough deposits to cause a drop in performance in a very short time Below is information that will help you clean your condenser The importance of controlling fluid quality and proper condenser maintenance cannot be overstated Soft deposits Soft deposits are really biological growth in the form of mud slime and algae resulting from the use of river water or poorly controlled tower water This is best cleaned using a pneumatic tube cleaning gun which forces plugs down the tubes Some have a brush between two rubber plugs and others are specially designed plugs which scrape the tube walls as they travel down the tube Scale Scale is minerals that have been deposited on the inside of the tubes resulting from the use of fluid with high alkalinity These deposits are harder to clean and require special equipment These systems utilize a flexible shaft which rotates a brush as it is fed down the tube they can also simultaneously flush out the tubes with fluid There is a wide
57. rm sender This provides a static seal for no leak reliability and allows the sender to be replaced if necessary without evacuating the tank Each indicator alarm uses highly reliable and accurate three wire voltage divider technology to send the level signal to the level alarm and relay circuitry The voltage divider uses a thick film element in conjunction with a multi fingered contact to ensure accuracy and reliability The connector built into the indicator alarm mates with a standard Packard automotive type rubber sealed connector for easy installation and reliable connections The case and integral crystal of the indicator alarm are made of polycarbonate The case halves are ultrasonically welded together to obtain a hermetic seal 33 Accessories General Specifications Temperature Operating temperature range 4 F to 158 F Working pressure 450 psi Power Rating 5 amps 240 volts AC maximum Voltage Input 110 or 220 volts AC Liquid Level Indicator Gasket Replacement Procedure If you need to replace the liquid level indicator LLI or LLI block off plate gasket follow the procedure outlined below Ty 2 Recover all refrigerant You must ensure that all pressure is removed prior to the removal of the indicator plate Remove the 4 bolts and remove the indicator You will have to work the head around to get the float out It is okay to deflect the rod slightly but do not bend it Clean the flange and i
58. s No the thread on the IDS connections is for testing purposes only piping must only be brazed to these connections Why does the tube side head leak First check the bolt torque on each bolt see the relevant torque charts in the condenser and evaporators sections if the bolts are loose follow the torque pattern and tighten all of the bolts to the recommended specification If the bolts are torqued to the correct specification visually check the condition of the gasket If the unit has not been serviced recently remove head and replace the gasket refer to the gasket replacement sections for more details For marine units that include a zinc plate anode these will erode over time and will require the removal of the head and the replacement of both the zinc anode and gasket refer to the gasket replacement sections for more details For marine units with zinc anode plugs these plugs have weep holes so when enough of the zinc has eroded the seawater will drip through the hole Simply replace the zinc plug anode with a new anode Call Alfa Laval Standard for a genuine replacement part number or refer to the catalog What is the recommended braze material for connecting pipes Use 45 or higher silver content solder and the proper flux for steel to copper joints and 15 for copper to copper Can weld to the shell of the heat exchanger We do not recommend welding to the shell of the heat exchanger as this can damage the internal
59. s will give you an idea if your fluid is corrosive balanced or scale forming and help you decide if you need to treat your fluid or go to a cupronickel or stainless steel unit Damage to a misapplied unit is not covered under warranty Fresh Water Condenser Materials of Construction Default Material Alternative 1 Alternative 2 Alternative 3 Tubes Copper Carbon Steel Stainless Steel 90 10 CuNi Header Carbon Steel Stainless Steel 90 10 CuNi Naval Brass Shell Carbon Steel Stainless Steel Tube Sheet Carbon Steel Stainless Steel 90 10 CuNi Tube Supports Carbon Steel Stainless Steel Fluid Quality amp Velocity As mentioned in the above section fluid quality can affect the service life of a condenser It is your responsibility to make sure that you are using fluids that are compatible with the condenser If applicable you must select a unit to handle harsh fluid conditions or treat the fluid Again as mentioned above excessive velocity will shorten the service life of a condenser All units also run the increased risk of fouling if the fluid side velocity drops below 1 5 ft s and low velocity in any unit will provide poor performance All unit performance values in our catalog are within these ranges Tube Material Minimum Velocity Maximum Velocity Copper 8 0 ft s 90 10 Copper Nickel Shallow Water 7 0 ft s 90 10 Copper Nickel Deep Water 10 0 ft s Carbon Steel 10 0 ft s Stainless Steel 12 0 ft s 21 Condensers Re
60. structure Welding to any pressure retaining surface will invalidate the ASME rating any weld repair will require retesting and recertification of the vessel by a qualified welder If the unit has weld pads mounted on the shell surface it is possible to weld to these surfaces without needing to retest the vessel if weld pads are required please contact the Alfa Laval Standard before placing any orders Do the units require filtration systems Shell and tube heat exchangers are less susceptible to plugging but it is still required to have a filter installed upstream on both the refrigerant and fluid side Regular inspection and replacement of the filters is highly recommended as part of the regular service program Can swap the front and rear heads Evaporators can be swapped provided the water inlet is close to the refrigerant connections head Condensers please consult the factory 38 How to contact Alfa Laval Contact details for all countries are continually updated on our website Please visit www alfalaval us to access the information directly Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights It is the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied repro
61. t clean and how to clean the unit if it becomes dirty Fluid Quality Fluid quality is a complex issue that is best handled by a professional who specializes in water treatment Poor quality fluid can cause corrosion on the inside of the tubesheets shell and baffles Corrosion on the tubesheets can lead to leaks through the tube joints It can also corrode the shell perforating it in extreme cases When the baffles are attacked they no longer direct the fluid flow and allow it to pass through the unit too quickly resulting in a serious loss of performance Once a unit is this badly damaged it cannot be repaired This damage is not reversible and may require replacement of the unit CAUTION Damage caused by poor fluid quality is not covered under our warranty Poor quality fluid can also lead to tube failure and subsequent system damage Scale Excessive hard scale which forms on the tubes will act as an insulator and inhibit heat transfer reducing performance and increasing utility costs This is caused by hard water with high mineral content Some scale build up is normal and this will helo protect the tubes There are formulated descaling products such as RYDLYME which are not as harsh as using acid When using any descaling product follow the manufacturer s instructions CAUTION Running acid through the system is not recommended and will void the unit s warranty 11 Dry Expansion Evaporators Sediment Sedim
62. the shell side 2 Pressurize the shell side of the vessel with air Place a pressure gauge on the high side of the system and check the pressure it requires a minimum of 150 PSIG The pressure can be raised temporarily with a heat lamp If the unit has already been removed from the system securely plug all fittings and pressurize with nitrogen Once you have reached 150 PSIG start by checking the tube to tubesheet joints by spraying or brushing a leak detecting soap solution on the tubesheet If you have corrosion on the tubesheet clean it before leak checking Where white bubbles form indicates the location of the leak After one hour check to see if the unit has maintained the 150 PSIG pressure reapply the soap and test for leaks if no leaks are found go to step 3 23 Condensers 3 There are three methods for checking leaks inside of the tubes All of these should be done with the 150 PSIG still on the unit a For this method you will need a bubbler This is easily made by drilling a hole in an appropriate size rubber plug insert a tube through the hole and insert the other end into a clear glass jar half filled with water ensure the end of the tube is below the water line in the jar Plug the tubes at one end with rubber plugs and insert the bubbler into each tube at the other end individually and observe the jar for bubbles for 30 seconds on each tube A leaking tube will produce bubbles in the jar This is the simplest method b P
63. to scratch or gouge the head Clean gasket surfaces on the head and tubesheet with a solvent cleaner Clean gasket with solvent until the surface is shiny black allow the gasket to dry After that you ensure that you have the correct gaskets apply a thin 0 010 to 0 015 uniform coat of adhesive to the head and one side only of the gasket Carefully place gasket on head This is best done with two people since the gasket should not be moved once it has been placed Ensure that the gasket s webs are centered on the partitions Allow the adhesive to cure for at least one full hour Cut out unused dividers from the gasket after curing Guide the head into place remember to put couplings on liquid and suction lines Be careful not to disturb gasket Tighten bolts until gasket is just touching the tubesheet all the way around Torque bolts in a crisscross pattern to step 1 then to step 2 and finally to step 3 if applicable see chart Torque to the final value once more CAUTION DO NOT TIGHTEN THE BOLTS ANY FURTHER Re braze all connections use 45 or higher silver content solder and the proper flux for steel to copper joints and 15 for copper to copper Charge evaporator to 150 PSIG with nitrogen and check for leaks using a leak reactant If a gasket leak is found torque the bolts 10 ft lbs higher and recheck Evacuate to 1500 microns break the vacuum with nitrogen and evacuate to 500 microns You can now recharge and start the evaporator
64. uter ones 9 KHX Run down all bolts by hand tightening one bolt at top one bolt at bottom one bolt on right side one bolt on left side Follow same sequence and torque bolts to step 1 and then step 2 A wrench must be used on the nut to ensure accurate torque readings 10 KHX Re pipe front head 11 Turn fluid back on and check for leaks after fluid pressure has been on for at least 10 minutes If a leak is found re torque in the same torque sequence 5 ft lbs higher CAUTION THE FLUID REGULATING VALVE SHOULD ALWAYS BE INSTALLED ON THE INLET SIDE OF A CONDENSER THIS WILL PREVENT VIOLENT WATER HAMMER THAT CAN OCCUR WHEN FLUID VALVES SLAM SHUT UNDER CERTAIN CONDITIONS WARNING Never use air refrigerant mixtures for leak testing Under certain conditions some refrigerant air mixtures become flammable CAUTION During any pressure testing do not exceed the MAWP maximum allowable working pressure displayed on the nameplate 27 Tube Repair Tube Plugging Procedure If the unit is still under warranty please contact Alfa Laval before performing any repairs Unauthorized repairs will void any remaining warranty If you must plug a tube in a heat exchanger follow the steps below to ensure the repair is permanent NOTE NEVER PLUG MORE THAN 10 OF THE TUBES IN ANY ONE REFRIGERANT PASS 1 Remove all scale and excess epoxy A tube cleaning brush on a drill works well for this 2 Ifthe tube has a blister in it
65. variety of brushes and tools available that attach to the shaft to clean both soft and hard deposits Corrosion If you find evidence of corrosion or pitting in the tubes on the tubesheets or fluid plates further investigation is required This can be caused by poor fluid quality or inadequate or excessive velocity The investigation should begin by taking a fluid sample to a local lab and having them run the Langelier and Ryznar indexes If the fluid quality is found to be bad it should be corrected immediately and you should repair the damage to the condenser if possible You should then check the fluid velocity through the unit Check the flow in GPM through the unit and call us so that we can calculate the velocity Acceptable tube side velocities are listed in the Fluid Velocity amp Quality section Acid Cleaning CAUTION DO NOT PERFORM ANY ACID CLEANING If acid cleaning is not done perfectly and fully neutralized it can do severe damage This will also void any remaining warranty Condenser Tube Leak Test Procedure If you suspect that you have a leak in a condenser you need to verify this Electronic leak detectors cannot be used to verify a leak Using an electronic leak detector with heavily chlorinated water will give false indications of a leak 1 Shut off the system turn off fluid to the condenser and remove the fluid plates see condenser gasket replacement procedures Recover the refrigerant from
66. y 80 full is 39 lbs gt 989 Ibs x 0 75 indicator full 29 25 lbs of R 22 Operation Movement of the seamless aluminum float rotates a magnet on the inner side of the solid aluminum alloy head The indicator pointer or switch contacts are on the outer side and are operated by a small magnet which follows the position of the inner magnet There is no connection except the magnetic field between the inside and outside Internal gears and bearings are stainless steel If any external damage is sustained the indicators dial or switch cartridge may be replaced from outside so the refrigerant charge is not disturbed The seal between the mounting flange and the gauge head is a gasket which is suitable for halocarbon refrigerants These units should not be used with any other liquids unless the compatibility of the seal and metals has been checked and approved by Alfa Laval Standard Installation Liquid level indicators are an inexpensive effective means of gauging the refrigerant level in a horizontal receiver However care must be exercised to properly install the unit to prevent leaks and insure its proper operation The receiver must be level especially if the indicator is at one end Check with a level The indicator flange face should be vertical Any projections on the face of the flange caused by shipping or handling must be removed to ensure the gasket seats properly A very light film of refrigerant oil or light grease may

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