H-IM-68

March 2000

Part No. 25001301

Replaces H-IM-44

Direct Drive
Fluid Coolers
Installation and
Maintenance Data

Table of Contents
Inspection
System Warranty
Installation ......................................... 2
Rigging Instructions ........................... 3
Internal Volume and Weight .............. 4

Mixing Glycol and Water

Glycol Sludge Prevention
Fluid Circulating Pump .................................. 8
Start-up
Space and Location Requirements .......... 9-10

Electrical Wiring ............................ 4-6

Typical Piping
In-Warranty Return Material Procedure........11

System Installation
Piping Installation
Glycol Charge ................................... 7

Replacement Parts ...................................... 12

Inspection
Responsibility should be assigned to a dependable
individual at the job site to receive material. Each shipment
should be carefully checked against the bill of lading. The
shipping receipt should not be signed until all items listed on
the bill of lading have been accounted for.
Check carefully for concealed damage. Any shortage or
damages should be reported to the delivering carrier.

Damaged material becomes the delivering carrier's

responsibility, and should not be returned to the manufacturer
unless prior approval is given to do so. When uncrating, care
should be taken to prevent damage. Heavy equipment should
be left on units shipping base until it has been moved to the
final location.

System Warranty
This equipment is designed to operate properly and
produce rated capacity when installed in accordance with
accepted industry standards. Failure to meet the following
conditions may result in voiding of the system warranty:

a.

Voltage for 208/230 motors not less than

195 volts or more than 253 volts.

b.

All other voltages must not exceed +/- 10%

of nameplate ratings.

c.

Phase imbalance not to exceed 2%.

1.

System piping must be installed following industry

standards for good piping practices.

2.

System must be thoroughly leak checked before initial

charging.

4.

All controls and safety switch circuits properly

connected per wiring diagram.

3.

Power supply to system must meet the following

conditions:

5.

Factory installed wiring must not be changed

without written factory approval.

Installation
NOTE:

Installation and maintenance to be performed only by

qualified personnel who are familiar with local codes
and regulations, and experienced with this type of
equipment.

CAUTION:

Sharp edges and coil surfaces are a potential

injury hazard. Avoid contact with them.

Unit Location
Units are designed for outdoor application and may be
mounted on a roof or concrete slab (ground level installation).
Roof mounted units should be installed level on steel channels
or an I-beam frame to support the unit above the roof. Use of
vibration pads or isolators is recommended. The roof must be
strong enough to support the weight of the unit. Concrete slabs
used for unit mounting should be installed level and be properly
supported to prevent settling. A one-piece concrete slab with
footings extending below the frost line is recommended.

The dry cooler should be located far enough away from

any wall or other obstruction to provide sufficient clearance for
air entrance. Do not attach ductwork to the coil inlet or fan
outlet. Care should be taken to avoid air recirculation conditions
that can be caused by sight screening, walls, etc. Also keep
unit fan discharge away from any building air intakes. See
page 10 for space and location requirements.

Sound Vibration
Units should be installed away from occupied spaces and
above or outside of utility areas, corridors and auxiliary spaces
to reduce the transmission of sound and vibration to occupied
spaces. The refrigerant piping should be flexible enough to
prevent the transmission of noise and vibration from the unit
into the building. If the refrigerant lines are to be suspended
from the structure of the building, isolation hangers should be
used to prevent the transmission of vibration. Where piping
passes through a wall, it is advisable to pack fiberglass and
sealing compound around the lines to minimize vibration and
retain flexibility in the lines.

The unit needs to be secured in its final location. Holes

are provided in the base runner for this purpose.

WARNING: There may be more than one source of

electrical current in this unit. Do not
service before disconnecting all power
supplies.

Heatcraft Inc. 2000.

Figure 1. Rigging Instructions.

Vertical airflow type units should be located no closer

than the width of the unit from a wall or other obstruction. It
two or more units are to be positioned in the same area, a

similar distance should be maintained between adjacent units.

Sufficient free area should be left around and below unit to
avoid air restriction to coil.

Table 1. Fluid Cooler Internal Volume and Weight

Fluid
Cooler
Fan Configuration
1x2
1x2
1x2
1x3
1x3
1x4
1x4
1x5
1x5
1x6
2
2
2
2
2
2
2
2
2
2

x
x
x
x
x
x
x
x
x
x

2
2
2
3
3
4
4
5
5
6

Number
of
Fans
2
2
2
3
3
4
4
5
5
6

Number
of
Rows
2
3
4
3
4
3
4
3
4
4

Internal
Volume
Gallons
6.7
9.2
11.8
13.0
16.7
16.7
21.7
20.4
26.6
31.6

Approximate
Net Weight
(Lbs.)
1540
1590
1600
2360
2420
3150
2190
3510
3990
4790

2
2
2
3
3
4
4
5
5
6

2
3
4
3
4
3
4
3
4
4

13.5
18.5
23.5
25.9
33.4
33.3
43.3
40.7
53.1
63.1

1540
1620
1760
2420
2480
3230
3510
4040
4390
5270

Electrical Wiring
The electrical installation should be in accordance with
National Electrical Code, local codes and regulations. Proper
overcurrent protection should be provided for the fan motors.
Wiring diagrams shown are only basic and do not show fuses,
disconnect switches, etc., which must be provided in the field.
All standard motors have internal inherent overload
protectors. Therefore, contactors can be used instead of
starters requiring thermal protectors, eliminating the problem
of furnishing the proper heating elements.
All dry coolers or units are furnished with either singlephase or three-phase fan motors which are identified by the
unit dataplate.

Electrical leads from each motor terminate at the unit

junction box. Field connections must be made from these leads
through a contactor, fuse and disconnect in accordance with
local, state and national codes.
Three-phase motors must be connected to three-phase
power of voltage to agree with motor and unit dataplate.
The motors are wired into a common junction box. The
motors must be checked for proper rotation. Be sure to check
that motor voltage and control connection agree with electric
services furnished.

Diagram 1. Typical Fluid Cooler Wiring Diagram Without Fan Cycle Controls.

Single Row of Fans

Double Row of Fans

Diagram 2. Typical Fluid Cooler Wiring Diagram With Standard Fan Cycle Controls.

Single Row of Fans

Double Row of Fans

System Installation
NOTE: All installation and maintenance are to be performed
only by qualified personnel who are familiar with local codes
and regulations, and experienced with this type of
equipment. CAUTION: Sharp edges and coil surfaces are
a potential injury hazard. Avoid contact with them.

General
1.

2.

Structure supporting unit must be designed to support both

the unit and the fluid. Table 2 provides weight of fluid per
gallon. Tables 3 and 4 provide unit weight and volume
data. Provide suitable flashing of the roof, if this is a roof
installation. For ground level mounting, a concrete pad is
recommended. Mounting holes permit the unit to be bolted
down to withstand wind pressures. Provide adequate clearance for unobstructed air flow to coils. See page 2 for
Space and Location requirements.
Level mounting is necessary to assure proper fluid distri-

of the mixture. Any refill should be controlled so as to maintain the proper glycol-to-water ratio.
Table 3 shows pressure drops for various pipe sizes at
flow rates commonly used with a typical dry cooler. These
pipe sizes are not necessarily always correct for the run from
the condenser to the dry cooler. Proper pipe size will depend
on available pump head. This can be determined by subtracting from the total available pump head at design flow, the condenser pressure drop and the dry cooler pressure drop. Allow
some safety factor for last minute pipe fittings added to the
system and for eventual fouling of the system.
a.

Glycol piping requires no insulation except when fluid temperature will be below ambient dewpoint temperatures.
Dry coolers normally produce about 70 or higher fluid
temperatures.

b.

Vents are required at all high points in the piping to bleed

air when filling the system. If fluid coolers are at high
points, vent valves should be installed at each fluid cooler.

c.

It is recommended that gate valves be installed on both

sides of the pump to prevent loss of fluid in the event the
pump should require repair or replacement. Shut-off
valves are also recommended at water cooled condens-

Table 2. Fluid Weight Per Gallon

Percent Glycol
0 (Water)
10
20
30
40
50

Pounds Per Gallon

8.345
8.395
8.495
8.604
8.712
8.804

bution through the coil as well as flooded suction for the

pump.
3.

Water piping must comply with local codes. Correct pipe

sizing will help reduce pumping power and operating costs.

4.

In case of doubt, consult the manufacturer for the dry

cooler fluid pressure drop at the specific conditions on
your job.

5.

Provide sufficient valves and unions to permit easy access to parts subject to wear and possible repair or replacement.

6.

After fluid piping is completed, all joints should be leak

tested.

7.

Where city water makeup is required, follow local codes,

making certain that disconnecting provisions are provided.

8.

Table 3. Pressure Loss in Feet of Water

Flow
GPM
15
20
25
25
30
35
40
40
45
60
60
80
100
150
200
250
300
300
350
400

Pipe
Size
Steel
1
1
1
1 1/4
1 1/4
1 1/4

1 1/2
1 1/2

2
2
2 1/2
2 1/2
3
3
3 1/2
4
4
4

Type "L"
O.D.
Copper
1 1/8
1 1/8
1 1/8
1 3/8
1 3/8
1 3/8
1 3/8
1 5/8
1 5/8
1 5/8
2 1/8
2 1/8
2 5/8
2 5/8
3 1/8
3 1/8
3 5/8
4 1/8
4 1/8
4 1/8

Schedule 40 Steel
Head Ft./100 Ft.
Equiv. Length
17.6
30.2

11.5
16.3
21.8

13.0
16.5

7.9
13.7
8.5
18.6
10.7
16.5
11.1
5.9
7.9
10.2

Copper Tube Head

Head Ft./100 Ft.
Equiv. Length
15.0
23.1
34.6
12.6
17.4
23.0
26.3
12.9
15.7
26.3
7.0
12.0
6.1
12.9
9.1
13.7
9.2
4.9
6.5
8.2

ers in case the condensing unit is to be moved or requires

maintenance involving the coolant system.

Select wire in accordance wit nameplate data and local

codes.

Glycol Charge
Piping Installation
The piping system should provide maximum leak prevention. Weld or sweat joints should be used where possible
or tightly drawn Teflon tape threaded pipe joints should be made
if needed. The fact that glycol solutions or other heat transfer
fluids will leak where water will not, must be taken into account.
The glycol system should not employ a pressure reducing valve. This is because a slight leak would lead to dilution

The amount of ethylene glycol required depends upon

the following:
a.

The holding volume of the system which includes the holding capacity of the condenser, the holding capacity of the
interconnecting piping (Table 3) and the holding capacity
of the dry cooler (see Table 3).

b.

Percentage of glycol required by volume to provide protection at the design minimum outside temperature (see
Table 2).
7

Table 4. Percentage of Ethylene Glycol to be Added by

Volume.
Percent %
Minimum Outside Design
Temperature F

20% 30% 40% 45% 50%

+15

-3

-14

-23

-38

Mechanical seal type pumps must be used for glycol

systems. Gland type pumps would cause glycol waste and, if
used with a pressure reducing valve, will lead to dilution of the
glycol mixture and eventual freeze-up.

Table 4 is intended to be used as a guide only. Proper precautions need to

be taken to prevent freeze damage during low ambients. Consult glycol vendor recommendations for specific freeze protection for your location.

Pump is selected for piping friction loss plus fluid pressure drop through the dry cooler coil, plus pressure drop
through the heat source. No allowance for vertical lift is made
since in a closed system a counterhead acts on the pump suction.

Mixing Glycol and Water

With glycol solution the pump performance curve will

drift to the right from its design point, due to differences in
circuit design, control valve application, pressure drop calculations, etc. The pump should be selected high on the curve
so as to provide for the "drift". The pump curve should be
"flat" so that the pump will compensate for our inability to exactly predict the final operating system flow condition and to
provide sufficient flow for satisfactory heat transfer and maximum protection against freezing at the far end of the circuit.
The pump motor should have sufficient power for operating
over the entire pump curve to prevent motor overload at reduced voltages. Paralleled pumps can also be used for good
power economy and continuous and automatic standby operation. Properly applied parallel pumps will guard against
system breakdown caused by a simple pump failure. Certain
older systems have nonoperating standby pumps of equal
capacity to the operating unit. We recommend parallel pumps
in continuous operation because they provide practically the
same type of standby, in addition to being completely automatic, at lower initial and operating cost.

Regardless of the strength of the mixture, you MUST

pre-mix the glycol and water prior to adding it to the system.
The chemical reaction between the two will release oxygen,
which is extremely undesirable in a close-loop system.
WARNING: For dry coolers operating without glycol
mixture, adequate freeze protection is
necessary during ambients below 32 F.

Glycol Sludge Prevention

Glycol systems may be subject to sludge formation in
coils, due to one or more of the following causes:
1.

Reaction of the corrosion inhibitor with galvanized piping

(zinc).

2.

Reaction of the glycol with chromate type water additives.

3.

Reaction of the glycol with pipe dope, cutting oils, solder

flux, and other system dirt.

Glycol manufacturers offer a specially inhibited glycol

(formulated for snow melting systems) which does not react
with zinc. This glycol is also suitable for heat transfer systems. Glycol manufacturers also provide inhibitor check services on a regular basis.
Consequently, good glycol system design requires the
following precautions:

Fluid Circulating Pump

1.

No galvanized piping is to be used.

2.

System piping must be thoroughly cleaned and flushed

with a heated trisodium phosphate solution before filling
wit the water/glycol mixture.

3.

No chromate inhibitor treatment must be used.

4.

The glycol manufacturer should provide inhibitor check

service and supply additional inhibitor as required.

Start-up
1.

Prestart:
Connect a pump and hose to the hose bibb away
from the pump and a hose to the hose bibb closest
to the pump. Begin pumping the glycol mixture into
the system at FULL PRESSURE. For the return
hose you should close the hose bibb so that you
get only a small flow of fluid or air. This is
necessary so you will build a head of fluid which will
force the air from the system. Once all the air is out
you will have a steady flow of only fluid. At this joint
you should close off the two hose bibbs and open
the shut off valve. See Diagram 3.

Check for correct dry cooler fan rotation. This can be done
by quickly jogging the fan contactor. Be sure that the fans
run freely. The same check is recommended for pumps.
2.

Filling and Purging the System

The system should be pressure tested before adding glycol.
The system can be tested with air or water, however if the
ambient temperature is at or below freezing the use of air
is recommended. Test pressure should not exceed 60
PSIG.
a.

Roof Mounted Fluid Cooler

To fill the system pour the premixed water and glycol
into the expansion tank. Fill the system until the
expansion tank is half full, then purge the air from
ALL vents. Operate the system for a minute, then
purge ALL vents again, and add glycol as required.
Repeat the purging of all vents after the first hour of
operation and again after several hours of operation.

b.

Ground Mounted Fluid Cooler

The fluid cooler may be lowest point in the system,
consequently the premixed water and glycol will have
to be pumped into the system. Close the shut off valve
and open the two hose bibbs installed in the piping
run on the leaving side of the pump, see piping
diagram.

3.

Flow Adjustment Procedure:

Once the system is completely full of fluid, start the fluid
circulating pump. To assure proper fluid flow, adjust the
shut-off valve for required GPM by checking pump curve
and observing gauge pressure, or by using an in-line flow
meter.

4.

Instruction Envelope:
Keep wiring diagrams, instructions, list of spare parts, in
an envelope within easy reach of the installed dry cooler.

Diagram 3.

Space and Location Requirements

The most important consideration which must be taken
into account when deciding upon the location of air-cooled
equipment is the provision for a supply of ambient air to the
condenser, and removal of heated air from the fluid cooler
area. Where this essential requirement is not adhered to, it
will result in higher head pressures, which cause poor operation
and possible eventual failure of equipment. Units must not be
located in the vicinity of steam, hot air or fume exhausts.

Another consideration which must be taken is that the

unit should be mounted away from noise sensitive spaces
and must have adequate support to avoid vibration and noise
transmission into the building. Units should be mounted over
corridors, utility areas, rest rooms and other auxiliary areas
where high levels of sound are not an important factor. Sound
and structural consultants should be retained for
recommendations.

Walls or Obstructions
The unit should be located so that air may circulate freely
and not be recirculated. For proper air flow and access all
sides of the unit should be a minimum of W away from any
wall or obstruction. It is preferred that this distance be increased
whenever possible. Care should be taken to see that ample

room is left for maintenance work through access doors and

panels. Overhead obstructions are not permitted. When the
unit is in an area where it is enclosed by three walls the unit
must be installed as indicated for units in a pit.

Multiple Units
For units placed side by side, the minimum distance
between units is the width of the largest unit. If units are placed
end to end, the minimum distance between units is 4 feet.

Units in Pits
The top of the unit should be level with the top of the pit,
and side distance increased to 2W.

If the top of the unit is not level with the top of pit, discharge cones or stacks must be used to raise discharge air to
the top of the pit. This is a minimum requirement.

Decorative Fences
Fences must have 50% free area, with 1 foot undercut,
a W minimum clearance, and must not exceed the top of

unit. If these requirements are not met, unit must be installed

as indicated for Units in pits.

* W = Total width of the fluid cooler.

10

Diagram 4. Typical Piping

In-Warranty Return Material Procedure

Material may not be returned except by permission of
authorized factory service personnel of Heatcraft Inc.
Refrigeration Products Division in Stone Mountain, Georgia.
A Return Goods tag will be sent to be included with the
returned material. Enter the required information on the tag in
order to expedite handling at our factories and prompt issuance
of credits. All parts shall be returned to the factory designated
on the Return Goods tag, transportation charges prepaid.

The return of a part does not constitute an order for

replacement. Therefore, a purchase order must be entered
through your nearest Heatcraft Refrigeration Products
representative. The order should include part number, model
number and serial number of the unit involved.
Following our careful inspection of the returned part and if
it is determined that the failure is due to faulty material or
workmanship, credit will be issued on customer's purchase order.

11

Replacement Parts
When writing to the factory for service or replacement parts,
refer to the model number and serial number of the unit as stamped
on the serial plate attached to the unit. If replacement parts are

required, mention the date of installation of the unit and date of

failure, along with an explanation of the malfunctions and a
description of the replacement parts required.

Table 5. Replacement Parts List

Part Description

Fan Motor, 1 1/2 HP, 1140 RPM

Fan Blade, 30"
Fan Guard, 30"

Part Number

208-230/3/60
25301801
22900401
23100301

460/3/60
25301801
22900401
23100301

575/3/60
25302001
22900401
23100301

Contact Customer Service Department for parts to specific fluid cooler models.
Since product improvement is a continuing effort at Heatcraft, we reserve the right to make changes in specifications without notice.

Heatcraft Refrigeration Products

2175 West Park Place Blvd.
Stone Mountain, GA 30087
(770) 939-4450 Fax: (770) 908-5480
www.heatcraftrpd.com
12