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Installation & Maintenance


Manual for

Air Cooled Fluid Cooler


(Remote Radiator)

Model - FCW
Model - FCH
Model - FCS
DG Capacity 100-2000 KVA & Above

Making people lives better by unleashing the power of Cummins

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INDEX
CONTENTS

Page No.

1.

General .....................................................................................

2.

Unloading .................................................................................

3.

General Layout Arrangement ..................................................

4.

Location of Air Cooled Fluid Cooler in Primary Circuit .......

5.

Mounting ..................................................................................

6.

Power Supply Requirement ....................................................

7.

Expansion/Dearating Tank ......................................................

8.

Water Piping & Connection .....................................................

9.

Valves & Fittings ......................................................................

10.

Cleaning of the Treatment .....................................................

11.

Coolant Treatment ...................................................................

12.

System Filling and Purging .....................................................

13

Installation Guidelines for Secondary Circuit .......................

14

Maintenance Instruction .........................................................

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1. General
1.1 A well planned installation is essential to achieve maximum efficiency, ease of maintenance,
and extended service life from the Air-cooled Fluid Coolers (Remote Radiators)
1.2 The study of this installation manual is essential to achieve proper results and better
efficiency of Remote Radiators. This manual contains many helpful suggestions and
recommendation for proper piping, system filling & wiring etc. This manual gives a clear cut
view as to how to install the Air cooled fluid cooler successfully & easily without any trouble.
1.3 If necessary please feel free to consult ICL engineers on the following :(a)
Installation layout drawings
(b)
Proper filling of the system
(c)
Purging of air from the system.
1.4 Fig. 1, 2, 3, gives the dimensional details of various Air cooled fluid coolers.

2. Unloading
2.1 ICL recommends that experienced riggers should handle the Air cooled fluid cooler when it is
to be unloaded from its carrier and moved to the site for installation. Be sure, the equipment
to be used for unloading the cooler should be capable of handling the weight of the fluid
cooler. A crane of adequate capacity is required to lift the fluid cooler. Fig. 4 illustrates the
typical lifting arrangement of Air cooled fluid cooler.
2.2 Table 1 lists the various Air cooled fluid cooler models with their approximate shipping
weights along with their approximate floor loading. (These weights do not include the weight
of any auxiliary equipment.) This table gives you a clear idea to select the capacity of crane
during unloading.
2.3 The Unloading of cooler at site is not in the International Coil Ltd scope of supply. So ICL can't
be held responsible for the damage caused during unloading. Unloading should be done very
carefully & with all precautions.
2.4 ICL cannot be held responsible for damage caused in transit. In case of any damage during
transportation claims should be made to the carrier within the allowable time limits.
2.5 When slings are used, use heavy pipe or solid bars inserted through the holes in the mounting
skids. Use spreader bars to prevent damage to the cooler while lifting.
2.6 While moving the Air cooled fluid cooler or raising it, be sure slings or jacks are not attached
to the piping, o r apply stress to the fluid cooler coils or headers. Never raise the fluid cooler
from one corner, be sure it is always raised evenly.

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3. General Layout Arrangement


3.1 In Primary Circuit the Air Cooled Fluid cooler is connected director to the engine & general
layout of the same is shown below.
EXPANSION TANK
TO BE LOCATED AT THE HIGHEST POINT

SIGHT GLASS

" VENT LINE

MAKE -UP LINE

AIR COOLED FLUID COOLER


(REMOTA RADIATOR)
AIR

OUT

GAUGES (TYP.)

AIR

AIR

ISOLATING VALVES (TYP.)


MAIN
GENERATOR
SUPPLY LINE

IN

FLEXIBLE JOINT (TYP.)

IN

RETURN LINE

General Layout of Air Cooled Fluid Cooler (Remote Radiator)


In Primary Circuit of Engine without LTA Circuit
EXPANSION TANK
TO BE LOCATED AT THE HIGHEST POINT

SIGHT GLASS

" VENT LINE


AIR COOLED FLUID COOLER
(REMOTA RADIATOR)
AIR

MAKE-UP LINE

OUT

GAUGES (TYP.)
LT IN
AIR

LT OUT

MAIN
GENERATOR

AIR

IN

IN

ISOLATING VALVES (TYP.)

FLEXIBLE JOINT (TYP.)

HT OUT

General Layout of Air Cooled Fluid Cooler (Remote Radiator)


In Primary Circuit of Engine with LTA Circuit (2PZL)

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4. Location of Air Cooled Fluid Cooler in Primary Circuit.


4.1 The proper location of Air cooled Fluid Cooler is very essential for the successful and efficient
running of Air cooled fluid cooler. In this the cooling media is the ambient air. Therefore in
order to obtain maximum efficiency from the cooler it is necessary to get fresh air in its
surrounding. The air to be sucked in should not have any external hot medium such as
engine exhaust, furnace exhaust etc. Moreover there should be not restriction at the fan
outlet (from where the hot air is going out) such as ceiling or any shed, because this can result
into short cycling of hot air resulting in increase in water temperature.
4.2 Care should be taken while installing the Air cooled fluid cooler in Primary circuit. The
distance and height of cooler from Genset is governed by the restriction imposed by piping
and coolant head above the crank center line. If the cooler is to be connected in Primary
circuit then the maximum vertical distance form the engine top should not exceed 5 m and
maximum horizontal distance of 10 m from the engine. Any relaxation in above limits, please
contact ICL /Cummins India Ltd.
4.3 Piping size should be designed in such a way that the external restriction of piping and
radiator is within limits. The maximum pressure drop allowed in LTA & HT circuit is 4 PSI & 5
PSI respectively. The recommended pipeline diameter is given in table below the fig no. 2 & 3
Note : Make sure that the proper ventilation for the DG room is provided to take care of
heat dissipated from the engine body.

5. Mountings
5.1 No special masonry support is necessary except to keep the Air cooled fluid cooler on a leveled
surface. Normally 6"/8" foundation should be made to place the cooler. Moreover the cooler
itself is mounted on a heavy structured steel base. It is preferable to elevate the Air cooled
fluid cooler as additional protection from drainage, for easy installation and to minimize the
chances of dist/dirt getting attracted from the ground. Pillars or mounting structure of
approx. Im height is a usual practice in such instance.
5.2 In case of roof installations check your building specifications for the permissible floor
loading as mentioned above.
5.3 Secure the Air cooled fluid cooler with bolts through the mounting bolts in the base. Bolts are
of 15mm diameter to allow for production tolerances. The bolts are of M.S. with 1 thread
and its type is M-16.

6. Power Supply Requirement


6.1 The Air cooled fluid cooler is factory wired up to the electrical junction box which is located at
the back of Air cooled fluid cooler. The wiring form the electrical junction box to starter is to be
done in accordance with national and local electric codes,
6.2 It is important to use proper size of wire to bring the electrical power to Air cooled fluid cooler.
The voltage drop in feeder line should not be more than 3% MCB/MPCB are recommended to
use for the protection of fan motors under any overloading or short-circuiting. Cable to be
used from the junction box to the panel is generally 4 core Aluminium cable of size 10mm 2.

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6.3 There must be a remote fused disconnect switch installed for the Air cooled fluid cooler main
power supply and no other load should be connected to this switch.
6.4 All the motors used in Air cooled fluid cooler are of 3 phase/415 volt/50 Hz. Motors are totally
enclosed fan cooled motors with class F insulation & class b temperature limits.
6.5 When line voltages are not exactly the same on all phases, unbalanced current will flow in the
stator winding. A small voltage unbalance can increase the temperature rise & current, at
operating speed. by 6 to 10 times the voltage unbalance.

7. Expansion / Derating Tank


7.1 A suitable Expansion tank / Duration tank will be supplied along with the Air cooled fluid
cooler. The tank should be located at the highest point of the entire cooling system. Due
to the requirement of positive pressure at water pump inlet the expansion tank is usually
installed in cold water line i.e. the outlet of cooler and near to the engine pump suction line.
The diameter of a pipe which connects the expansion tank to pipeline should be 1" (NB).

8. Water Piping & Connections


8.1 The most important factor in the piping layout of ACFC is the size of pipe. The exact size of
pipe is essential so as to get the proper flow rate of water and moreover for achieving the pr.
drop within the prescribed limits. It is always advisable to use MS pipe of Schedule 20. It is
recommended to use flexible joints in the pipeline close to the D.D. set.
8.2 It is characteristic of most heat transfer fluid systems at high temperature, to have a tendency
to leak at connections, unless these connection are very tight. Flanged connections are
recommended but should be used sparingly to minimize potential leaks. In larger size pipe.
welded connections should be used wherever practical. Careful layout and use of curved
sections of pipe can minimize the welded or flanged connections required. Flanges of the 150
pound class, with proper gasket, are usually adequate for most systems. Spiral wound
asbestos or stainless steel gaskets are good. Gas lock short fiber, precut and cured asbestos
gaskets have also proved satisfactory and are generally more economical. It is recommended
that high temperature bolts, ASME, SA 193 Grade B6 or better which do not yield, be used
with ASME, SA grade 2 or 2H outs, for all flanged joints.

9. Valves & Fittings


9.1 Butterfly Valves are recommended in the pipe line for isolating the engine so that the entire
system does not have to be drained during any maintenance in the DG Set or Air Cooled fluid
coolers

10. Cleaning of the system


10.1It is always recommended that all the pipe length, fittings, valves & accessories should
be properly flushed/cleaned before being connected to the engine and Air cooled fluid
cooler. Also make sure that there are no traces of welding slag, dust and any foreign
particles inside the pipeline. These particles must be removed otherwise they will be
carried by the heat transfer fluid into the system and the DG Set causing faulty
operation or failure of the major equipment.

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11.

Coolant Treatment

11.1

To avoid scaling & corrosion in the cooling closed circuit, the first filling and make up water
shall be of convenient quality. It is always recommended to provide good quality water/
coolant
Water Quality
First fitting and make up water quality shall be as follow :

Hardness as CACO3

< 170 ppm

PH

< 5.0 to 9.0

Chlorides

< 40 ppm

TDS

< 400 ppm

Sulphates

< 100 ppm

11.2

It is suggested that coolant is premixed prior to filling in the ratio of 1 : 15

11.3

Ensure that the coolant treatment is as per the recommendation.


Units / It.

: Above 0.6

PH

: 8.5 10 (Pink colour)

12.

System Filling & Purging

12.1

After the cooler is installed, the next comes the system filling of the Air cooled fluid cooler.

12.2

Filling of the entire system has to be done from the expansion tank.

12.3

Ensure that all Valves in the pipeline including the Purging Valves provided in the cooler
should remain open.

12.4

Continue filling the coolant/water through expansion tank until a proper flow of water
comes out from the Purging Valves.

12.5

Close the Purging Valves & continue filling of water till 3/4th of expansion tank is filled.
(a) The next most important procedure is the Purging of the cooler. Purging is done through
the purge valves provided at the top of the header of the cooler. Purging has to be done till
the complete air trapped in the system is taken out until a proper flow is seen from the
Purge Valves. If the purging is not done properly there may be a chances of rise in cooling
water temperature.

12.6

After the Purging is done start the engine and make sure that positive pressure is developed
on the gauges. Run the system for some time without load. Shout down the engine & check
the level of water/ coolant in the expansion tank and fill the coolant deficit in the tank
before putting the Genset on load.

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13.

Installation Guidance for Air Cooled Fluid Cooler (Remote Radiator)


when connected in Secondary Circuit.
This is also one of the method of connecting the Air Cooled Fluid Cooler (Remote Radiator)
to the DG Set. A well planned installation is again essential for the satisfactory performance
of the remote radiator. Below are points which give a clear cut view as to how to install the
remote radiator is secondary circuit.

13.1 General Layout Arrangement


In Secondary Circuit, always note that the remote radiator is to be connected after the Heat
Exchanger. In this the Primary cooling of the DG Set is being done by the heat exchanger of
the engine itself. The heat exchanger is further being cooled by the remote radiator
connected to the heat exchanger through suitable pipe diameters. The general layout
arrangement of remote radiator connected in Secondary circuit is shown in Fig. 5

EXPANSION TANK
TO BE LOCATED AT THE HIGHEST POINT
SIGHT GLASS

MAKE-UP LINE

AIR COOLED FLUID COOLER


(REMOTA RADIATOR)
AIR

OUT

AIR PURGE
SOCKETS

I
AR

MAIN
GENERATOR

HEAT
EXCHANGER

AIR

IN

IN

ISOLATING
VALVES

WATER CIRCULATION
PUMP

Fig. 5

13.2 Accessories required in Secondary Circuit


-

The additional accessories required for the installation of Remote Radiators are :-

The DG Set must be equipped with a in-built Heat Exchanger.

Two nos. of water circulation pump of appropriate capacity are required to be installed.
The selection of motor h.p. depends upon the raw water flow rate and the static head. It
is recommended to install two pumps-one as working and one as stand by pump.

Expansion tank of required capacity to be installed at the suction of raw water pump.
(supplied along with the radiator)

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13.3 Location of Air cooled Fluid Cooler in Secondary Circuit.


The proper location of Air cooled Fluid Cooler is again very essential for the successful and
efficient running. In this the cooling media is the ambient air. Therefore in order to obtain
maximum efficiency from the cooler it is necessary to get fresh air in its surrounding. The
air to be sucked in should not have any external hot medium such as engine exhaust,
furnace exhaust etc. Moreover there should be no restriction at the fan outlet (from where
the hot air is going out) such as ceiling or any shed, because this can result into short
cycling of hot air resulting in increase in water temperature.
There is no distance restriction in location of remote radiator in Secondary Circuit. The
distance criteria which is implemented in case of Primary circuit is eliminated as the remote
radiator can be placed at any distance / height in case of Secondary circuit with a
appropriate water circulation pump.
Appropriate pipeline diameter should be used for connecting the remote radiator with the
heat exchanger of the DG. Set the recommended pipeline diameters are shown below :-

Engine Model Without


LTA Circuit

NTA 495 G
NTA 745 G
NTA 855 G2
KTA 1150
VTA 28 G5
KTA 2300
KTA 3067
KTA 50 G3

Engine Model Without


LTA Circuit

KTA 19 G4
KTA 38 G5
KTA 50 G3
KTA 50 G8
QSK 60 G4

Prime KVA rating

100/125/140
200
285
320 / 380
600 / 625
750
1000
1250

Prime KVA rating

500
1000
1250
1500
2000

Recommended pipe line size


mm (inch) NB

63 (2.5")
63 (2.5")
75 (3")
75 (3")
100 (4")
100 (4")
125(5")
150 (6")

Recommended pipe line size


mm (inch) NB

100
150
150
150
150

(4")
(6")
(6")
(6")
(6")

Note : Make sure that the proper ventilation for the DG room is provided to take care of heat
dissipated form the engine body.

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13.4 Expansion / Dearating Tank


A suitable Expansion tank / Dearation tank will be supplied along with the Air cooled fluid
cooler. The Tank Should be located at the highest point of the entire cooling system. Due to
the requirement of positive pressure at water pump inlet the expansion tank is usually
installed at the suction of raw water pump. The diameter of a pipe which connects the
expansion tank to pipeline should be '" (NB).

13.5 Cleaning, Filling & Purging of System


All these procedure have to be done essentially as mentioned earlier in case of Primary
circuit.

14.

Maintenance Instructions

14.1

Safety Consideration
(1) It is recommended to wear helmet before starting the maintenance work so as to avoid
any hazards due to the moving parts.
(2) Before cleaning and routine lubrication of motors all the electrical connections should
be turned off from the main supply.
(3) Recommended to wear gloves while fins cleaning.
The Air cooled fluid cooler has been designed with latest technology for minimum
maintenance. All the material used during the manufacturing of these coolers is of very
high quality and of reputed mark. Though the maintenance involved in the system is very
less, however for periodic inspection and maintenance of the system some of the points are
mentioned below :The external surface of heat transfer coils needs to be cleaned once in a month depending
upon the operating atmospheric conditions. The procedure adopted for cleaning is
described below :

(a)

On Line Cleaning
Any dirt / dust / fluff accumulated on the fins over a period of time can be cleaned by using
a low pressure (50 60 PSIG) compressed air even while the cooler is running. This
compressed air is to be blown towards the coils and the dust / dirt can be seen coming out
from the top of the cooler i.e. from the dampers. The average time for blowing the
compressed air should be around 3 to 10 minutes depending upon the cooler's size.

(b)

Periodic Cleaning
Over a certain period of time (approx. once in 6 months, depending upon the atmospheric
conditions) the Air cooled fluid cooler requires some periodic cleaning from inside also. The
procedure for this is as under.
-

Turn off the system completely


Open the coil protective mesh
Open the man hole provided at the side of Air cooled fluid cooler and enter into it to blow
the compressed air over the coil from inside.
Close the man hole and the protective mesh after the cleaning of coil is over.
Restart the system.
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(c)

Cleaning through water hose pipe


The heat transfer coils can also be cleaned by water hose to flush down the dust / dirt
present between the fins. The procedure for this remains the same as in case of cleaning the
coil through compressed air.

(d)

Motor Lubrication
The bearing of motors should be lubricated / greased in accordance with recommendation
of the motor manufacturer based on the running hours.

(e)

Fan Blade Inspection


The fans are adjustable pitch type and are set in the factory for required air quantity. The
fan tightness should be checked in case any vibration is noted in the system. However as a
preventive measure it is recommended to tighten all the nuts & bolts of fans.

14.2 Trouble Shooting

Symptom
* Engine, temp, shooting up the.
designed range.

* Self closing dampers are not


opened at the top of the fan,
while the fluid cooler is
running.

* Abnormal vibration of the


cooler

Cause

Remedy

* Coils are choked

* Clean the fins of coils.

* Air in the system

* Purge out the air from purging


valves.

* Possibility of short cycling of


air.

* Avoid any hot source emitting


heat near the cooler.

* Fans are rotating in the opposite * The fan should run in the
direction due to change in phase
direction of market arrow at the
fan tube i.e. the air should
come out at the fan outlet.
* Motor is not running

* Check the motor.

* Loosening of fan blades.

* Stop the fans & check all the


nuts & bolts of fan blade
assembly.
* Stop the fans & replace the
bush.

* Loosing of the bush from the


motor shaft.

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AIR
AIR
C

WATER OUT
IN
OUT
WATER IN

SIDE VIEW

FRONT VIEW

Fig - 1

DIMENSIONS FOR ACFC FCS MODEL


(a) Length

(b) Width

(c) Height

(D)

(Motor)

(E)

Engine Capacity
(In KVA)

Model No.

140/125/100 KVA

FCS-015

1450

965

1370

760 1220

200 KVA

FCS-020

1830

1090

1400

285 KVA

FCS-025

2210

1090

1400

Qty.

NOTES :1. ALL DIMENSIONS ARE IN mm.


2. TOLERANCE % P 10 mm.

12
m

(Fan)

Recom. Field
Pipe Size In
mm (Inch) N.B.

H.P.

Qty.

DIA
(mm)
750

890 1600

900

75 (3")

890 1980

750

75 (3")

63 (2.5")

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F
AIR

B
AIR

OUT

AIR

OUT

WATER
OUT

OUT

AIR

AIR

WATER
IN

IN

IN

E
SIDE VIEW

FRONT VIEW

Fig. - 2

DIMENSIONS FOR ACFC FCW MODEL


(D)

(E)

(F)

(MOTOR)

(FAN)

320/380 KVA

FCW-040

2630

1680

1325

1095 1460 2145

RECOM. FIELD
PIPE SIZE IN
DIA
(mm) mm (INCH) N.B.
900
75 (3")

625/600 KVA

FCW-060

3645

1680

1350

1120 1460 3165

1050

100 (4")

750 KVA

FCW-080

3035

1890

2090

1720 1460 2555

1050

125 (5")

1000 KVA

FCW-100

3135

2030

2495

2125 1460 2655

7.5

1050

150 (6")

1250 KVA

FCW-120

3645

2030

2495

2125 1460 3165

7.5

1200

150 (6")

ENGINE CAPACITY MODEL NO. (A) LENGTH (B) WIDTH (C) HEIGHT

Qty.

(IN KVA)

NOTES :1. ALL DIMENSIONS ARE IN mm.


2. TOLERANCE % P 10 mm.

13
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H.P. Qty.

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F
AIR

B
AIR

OUT

AIR

OUT

WATER
OUT

OUT

AIR

AIR

WATER
IN

IN

IN

E
SIDE VIEW

FRONT VIEW

Fig. - 3

DIMENSIONS FOR ACFC FCW MODEL


(MOTOR)

ENGINE
CAPACITY

MODEL NO.

(A)

(B)

LENGTH WIDTH

(IN KVA)

(D)

(C)

(E)

(FAN)

(F)

HEIGHT

Qty.

H.P. Qty.

RECOM. FIELD
PIPE SIZE IN
INCH (N.B.)

DIA LT
HT
(mm)
1050 50 (2") 100 (4")

500 KVA

FCW - 060 (LT+HT)

3645

1680

1350

1120 1460 3165

1000 KVA

FCW - 100 (LT+HT)

3135

2030

2495

2125 1460 2655

7.5

1050 75 (3") 125 (5")

1250 KVA

FCW - 120 (LT+HT)

3645

2030

2495

2125 1460 3165

7.5

1200 75 (3") 150 (6")

1500 KVA

FCW - 140 (LT+HT)

4155

2030

2520

2150 1460 3670

10

1200 75 (3") 150 (6")

2000 KVA

FCW - 160 (LT+HT)

4660

2030

2520

2150 1460 4180

7.5

1200 100 (4") 150 (6")

NOTES :1. ALL DIMENSIONS ARE IN mm.


2. TOLERANCE % P 10 mm.

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FRONT VIEW

SIDE VIEW
Fig - 4

FOR ACFC FCW & FCS MODEL


FOR ACFC FCW & MODEL
AIR COOLED FLUID COOLER

FLOOR LOADING

FCS MODEL

(KGS./SQ.FT.)

APPROX SHIPPING WEIGHT (IN KG.)

FCS-015

10

300

FCS-020

18

370

FCS-025

20

480

AIR COOLED FLUID COOLER


FCW MODEL

FLOOR LOADING

APPROX SHIPPING WEIGHT (IN KG.)

(KGS./SQ.FT.)

FCW-040

35

900

FCW-060 (LT+HT)

38

1370

FCW-060

38

1400

FCW-080

60

1700

FCW-100 (LT+HT)

65

1950

FCW-100

65

2000

FCW-120

55

2200

FCW-120 (LT+HT)

55

2150

FCW-140 (LT+HT)

55

2550

FCW-160 (LT+HT)

55

2950

15
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ICL