ALNOR CHDW Duct Cooler Heater User Manual

USER MANUAL

Duct cooler-heater

CHDW

ver. 1223

www.alnor.com.pl

1. Overview and intended use

The CHDW duct cooler/heater has a casing made of galvanised steel insulated with 25 mm thick rubber matting. Inside the casing is a 6-row heat exchanger with an integrated condensate drip tray. The heat exchanger is supplied with 30% ethylene glycol/water mix as the heating/cooling medium. The casing is closed with a system of blanking plugs that match the product version, allowing the heat exchanger to be inspected, removed and cleaned. The heat exchanger coil and stub pipes are made from copper; the heat exchanger fins are made from aluminium. The heat exchanger tubes have a standard metric size of M18x1mm which is compatible with standard hydraulic unions and fittings. The tubes can also be terminated with ½” male thread unions. The stub pipes have the diameter specified for the duct cooler/heater size to minimise pressure drop in the hydraulic system. The duct cooler/heater has EPDM gaskets for the stub pipes.

2. Designation

• CHDW-160 – DUCT COOLER/HEATER – 160mm DIA. PORT
• CHDW-200 – DUCT COOLER/HEATER – 200mm DIA. PORT
• CHDW-G-200 – DUCT COOLER/HEATER W/FILTER, FOR GLYCOL GAHE, 200mm DIA. PORT
• CHDW-G-250 – DUCT COOLER/HEATER W/FILTER, FOR GLYCOL GAHE, 250mm DIA. PORT

3. Technical specifications

3.1 Overall dimensions

Type|

FUNCTION

| FILTER| ØD
[mm]| H
[mm]| L
[mm]| G
[mm]| h
[mm]| i
[mm]| Ød
[mm]
---|---|---|---|---|---|---|---|---|---
CHDW-160|

–

| | 160| 364| 560| 429| 182| 131|

M18x1

CHDW-200|

–

| | 200| 414| 660| 429| 207| 150|

M18x1

CHDW-G-200|

Glycol GAHE

| | 200| 364| 560| 429| 182| 150|

M18x1

CHDW-G-250|

Glycol GAHE

| | 250| 414| 660| 429| 207| 175|

M18x1

For the CHDW duct cooler/heaters, the maximum operating medium temperature is +80°C and the maximum operating pressure is 1 Mpa (10 bar). See the technical data sheet in the product technical catalogue for the specification parameters of the CHDW duct cooler/heater. Use a low-freezing point heating/cooling medium. Otherwise there is a risk of the medium freezing in the duct cooler/heater at indoor temperatures below 0°C. To protect the CHDW duct cooler/heater from freezing, a suitable defrosting system provided with a thermostat control must be used. Do not stop the hot water circulation through the CHDW heat exchanger which passes fresh cold air at a temperature below 0°C. Otherwise, empty the hydraulic end of the cooler/ heater.

3.2 Filters

The CHDW-G cooler/heater is a version provided with a 46mm thick ISO Coarse 70% (G4) air filter on the air intake unit end. Note that adding more filters to the system may increase the pressure drop throughout the ventilation system. It is recommended to replace the filter every 3 months.

3.3 Heating/cooling medium

30% ethylene glycol and water should be used as the heating/cooling medium. Water without an antifreeze can also be used as the medium, but this may affect the operating performance and frost protection must be absolutely considered.

3.4 Operating performance

• maximum airflow temperature of the heat exchanger: 60°C (instantaneous);

• ambient air temperature: +5°C to +40°C;
  – maximum relative humidity: 90%;

• maximum operating pressure of the medium: 1.0 MPa (10bar);

• maximum temperature of the medium: 80°C;

• heat exchanger type: six-row

3.5 Heat exchanger operating orientation

The cooler/heater features a six-row water/glycol heat exchanger core with M18x1 stub pipes that can accept ½” pipe unions. To ensure optimum performance of the heat exchanger, the medium supply should be connected counter-current to the air flow, as illustrated below.

RH version

– DIRECTION OF AIRFLOW
– DIRECTION OF MEDIUM FLOW

LH version

– DIRECTION OF AIRFLOW
– DIRECTION OF MEDIUM FLOW

4. Reversing the cooler/heater, heat exchanger removal, and filter

replacement

To reverse the cooler/heater sides, replace the filter or remove the heat exchanger, follow the procedure below.

1. Use Phillips a screwdriver to remove the screws of the casing cover which displays the logo.

Removing the casing cover facilitates air filter replacement and service access to the heat exchanger.

2. The next step is to remove the heat exchanger cover screws.

The heat exchanger can be removed together with its cover. This access allows cleaning the heat exchanger easily and verifying that the drip tray drain is not clogged.

3. The cooler/heater casing can be oriented liberally as required by the installation conditions.

4. Reassemble the casing by following this procedure in the reverse order.

Caution!
If the cooler/heater casing orientation is changed during reinstallation of the heat exchanger integrated with the drip tray, the drain port of the drip tray must point downward. For the CHDW-G, the extra filter must be installed at the air inlet end of the cooler/heater, respecting the counter-current flow of the air and liquid medium, see Section 3.5 “Heat exchanger operating orientation”.

5. Packing

• The cooler/heaters are factory packed in cardboard boxes for protection against damage by impact.
• When unpacking, verify that none of the cooler/heater components has been damaged during transport and that the cooler/heater is complete.

6. Transport

• The cooler/heater needs to be transported using normal modes and respecting general safety regulations;
• unload using suitable lifting equipment;
• protect the load against impact while unloading;
• it is recommended to handle the cooler/heater using a forklift.

7. Storage

• The cooler/heater should be stored in a dry, sheltered room, away from dust, with a maximum relative humidity of 70% and at a temperature of +20°C;
• keep the ambient temperature between 0°C and +30°C.

8. Safety

• Use the product as intended.
• Do not modify the product in any way or alter its construction as it may result in malfunctions.
• Make sure that the product is securely attached to the ventilation system to ensure safe operation.
• Prevent the cooler/heater ports from loads imposed by the connected ventilation system.
• Wear protective clothing when servicing the product.
• Watch out for the risk of cutting by the edges of the cooler/heater casing edges and the heat exchanger structural parts during servicing and maintenance.

9. Installation

• Qualified and trained personnel only may connect the cooler/heater to the ventilation system.
• Install the cooler/heater securely to prevent tilting during its operation.
• Prevent the cooler/heater ports from loads imposed by the connected ventilation system.
• Tighten the union nuts of the hydraulic system connections to the stub pipes using two wrenches where one backs up the flats on the stub pipes to prevent their twisting by the applied torque.
• It is recommended to connect the cooler/heater stub pipes to the hot water system using flexible connectors.
• Install the cooler/heater in an orientation which provides a counter-current flow of the liquid medium to the air flow for optimum performance.
• It is recommended to install stop valves on the cooler/heater stub pipes for easier removal of the heat exchanger for cleaning or replacement.
• The liquid medium piping connected to the heat exchanger must be thermally insulated.
• All mounting brackets used for the cooler/heater shall be installed isolated from the heat from the cooler/heater.
• Provide good service access to the cooler/heater cover for inspection and cleaning of the heat exchanger.

10. Operation

The CHDW duct cooler/heater should be used under the conditions for which it is designed. It is critical to ensure optimum quality of air feeding the heat exchanger. The air shall be clean of particulates, oil, and high CO2 levels. Too much dirt entrained in the air supply may result in clogging the heat exchanger. The air supply temperature must be limited to 60°C (instantaneous). If the temperature is too high, the heat exchanger can fail. Ensure that the liquid medium system for the heat exchanger is in optimum condition. If it is made of galvanised steel piping, internal electrochemical corrosion is possible. This requires periodic inspections of the system. During the shutdown of the duct cooler/heater for winter at air temperatures below 0°C, the water charge in the heat exchanger may freeze. This requires emptying the heat exchanger for winterising.

11. Maintenance

The CHDW duct cooler/heater is recommended to be cleaned at least once a year or more often, depending on the operating conditions. If dust accumulates on the heat exchanger, clean it by blowing with compressed air. If the heat exchanger is clogged, wash it clean under running hot water. Disconnect the cooler/heater from the systems before cleaning. The heat exchanger can be removed from the casing, refer to Section 4.

• Verify the threaded union tightness of the cooler/heater at least twice a year.
• Check the tightness of the heater exchanger at least twice a year, e.g. by testing with compressed air.
• Check for the correct medium flow through the heat exchanger twice a year, e.g. by temporarily increasing the medium temperature and reading the temperature at the stub pipes of the cooler/heater.
• Do a functional test of the defrosting system (if installed) at least twice a year). To ensure proper performance of the CHDW, inspect the ventilation system for obstructions at least once a year. Clean or replace dirty components as required.

12. Warranty

Alnor Systemy Wentylacji Sp. z o.o., as the manufacturer, provides a 12-month warranty from the date of purchase on the CHDW duct cooler/heater. The manufacturer shall not be liable for:

• unauthorised alteration of the structure of the CHDW duct cooler/heater;
• unauthorised repairs by unqualified personnel in the warranty period;
• non-intended use of the CHDW duct cooler/heater;
• failure to maintain the specified pressure and temperature of the liquid medium and air;
• poor cleaning of the heat exchanger,
• poor installation of the duct cooler/heater.

13. Connections

Installation procedure of the CHDW duct cooler/heater in the ventilation system.
It is recommended to install the CHDW in a horizontal ventilation system, with the CHDW ports oriented horizontally. The condensate drain port must be located at the bottom of the cooler/heater.

13.1 Permitted installation methods:

Condensate drain port shown at the bottom of the cooler/heater

13.2 Prohibited installation methods:

Ports oriented vertically

Condensate drain port shown at the top of the cooler/heater

13.3 Installation

A suspended installation of the cooler/heater requires EQLS suspension brackets and self-drilling sheet metal screws not longer than 19mm, e.g. WGO- KZ-4,2-19-ISO15481. Secure the suspension brackets in the locations shown in the figure below:

1. min 30 [mm]

Screw down the feet at least 60mm clear from the casing edge.

1. min. 60 [mm]

The cooler/heater can alternatively rest on the floor if provided with dedicated vibration-damping feet included with the product.

13.4 Service access

1. min. A [mm]
2. min. B [mm]

|

A [mm]

| B [mm]
---|---|---
CHDW-160
CHDW-G-200| 600|

800

CHDW-200
CHDW-G-250| 700|

900

The figure shows the minimum service access clearances required for filter replacement and heat exchanger cleaning. The filters can be replaced from two access sides, left-hand or right-hand. For the CHDW-G version, blanking plugs are provided to facilitate filter replacement without opening the heat exchanger cover.

14. Filters

CHDW-G-…-FILT-C70 filters

ISO Coarse 70% filter (ISO 16890) (formerly G4)
They are pleated filters with an increased filtering area and low pressure drop.

Part number

| Filter class| Size
[mm]
---|---|---
CHDW-G-200-FILT-C70| ISO Coarse 70%|

504x300x46

CHDW-G-250-FILT-C70

| ISO Coarse 70%|

605x350x46

15. Available combinations

3-way cooling valves:
CHDW-200, CHDW-G-250    Valve, R3015-1P6-B1 (DN15, kvs 1.6 m3/h, dp 8 kPa) Actuator, TR24-SR
CHDW-160, CHDW-G-200    Valve, R3015-1-B1 (DN15, kvs 1 m3/h, dp 7 kPa) Actuator, TR24-SR

3-way heating valves:
CHDW-160, CHDW-G-200    Valve, R3015-P63-B1 (DN15, kvs 0.63 m3/h, dp 9 kPa) Actuator, TR24-SR
CHDW-200, CHDW-G-250    Valve, R3015-1-B1 (DN15, kvs 1 m3/h, dp 10 kPa) Actuator, TR24-SR

6-way cooling/heating valves:
CHDW-160, CHDW-G-200    Valve, R3015-1P3-P63-B2 (DN15, kvs 1.3 / 0.63 m3/h, dp 11 / 9 kPa)    Actuator, LR24A-SR
CHDW-200, CHDW-G-250    Valve, R3015-1-1-B2 (DN15, kvs 1 / 1 m3/h, dp 7 / 10 kPa)                  Actuator, LR24A-SR

ALNOR® ventilation systems
is a legally protected trademark and technical patent. All rights reserved.

References

• Alnor | TSI

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