Introduction
General Description
The COLDZONE "Fluid Cooler" system is (U.L. File #SA2285, Vol. 1 Section 3) designed primarily for fast food requirements and installations where only a small quantity of water cooled refrigerated fixtures are to be remote, i.e.; soft-serve freezers for ice cream and frozen yogurt and water cooled condensing units. This will allow heat dissipation on the roof for the high heat producing condensing units, thus eliminating water consumption and reducing indoor air conditioning requirements at a very nominal cost. Totally pre-piped, pre-wired, and weatherized for fast, low cost rigging and installation on rooftop, it is only necessary to provide main power lines to the control panel. In addition, the unit has been carefully designed for easy installation, providing ready access for service and maintenance of all major components.
Closed-Loop Glycol Fluid Cooler
A closed-loop glycol fluid cooling system is installed with the anticipation that it will provide many years of trouble-free operation with minimum maintenance. Usually, the length of service life realized from a particular fluid cooler is directly proportional to the care with which the original installation was performed. Cleanliness is absolutely mandatory when installing the system. All tubing, valves, and fittings must be carefully inspected to ensure cleanliness. The correct electrical supply must be provided to the fluid cooler control panel. The voltage at the pump and fan motor terminals should be checked during start-up and unit operation under full load to ensure a tolerance of plus or minus 10% of the nameplate rating.
Closed-Coupled Centrifugal Pump
A closed-coupled centrifugal pump is precision built for liquid transfer and recirculation of glycol fluid from water-cooled condenser to rooftop heat exchanger. The pump is equipped with a drip-proof motor with shielded ball bearings, thermal protector, sintered iron and BUNA N mechanical seal, and type 303 stainless steel shaft. The discharge port of the pump can be rotated in 90° increments to accommodate various applications.
Heat Exchanger
A heat exchanger is installed in the fluid cooler system to reject heat on the roof to provide a 10°F differential. Each coil is made with aluminum fins bonded upon copper tubing. A shroud is incorporated in the construction of the condenser to provide controlled airflow over the cooling surface.
Fan Motor
Each fluid cooler package is equipped with at least one fan motor to reject heat. Fan motors capable of operating for years with trouble-free maintenance are permanently lubricated with inherent overload protection to prevent locked rotor or overheating.
Glycol Fluid
ColdZone provides 100% propylene glycol; field mixing is required. A 50% propylene glycol and water solution is recommended for cooling media. In geographical areas where the outside temperature may reach -20°F or below, contact the ColdZone Service Department. ColdZone provides 100% propylene glycol; field mixing is required.
Fluid Manifolds
Two fluid manifolds are provided with shut-off valves and by-pass valves. Emergency water supply should be piped through manifolds. Emergency water discharge should be piped to a floor drain.
Control Panel
Each system is provided with a pre-wired, weather-proof control panel for single-point power connection with a main-fused disconnect.
Electrical Characteristics
Each "Fluid Cooler" is equipped for 208/230 volts, 1 phase, 60 hertz power supply.
Standard Components
Each "Fluid Cooler" consists of a closed-coupled centrifugal pump, heat exchanger with heavy-duty fan motor, oversized reservoir, control panel with main-fused disconnect, and two fluid manifolds. The "Fluid Cooler" package system is tested and assembled under strict quality assurance procedures. Each unit is tested for leaks prior to shipment.
Typical Fluid Cooler System Diagram
A diagram illustrates the typical fluid cooler system. It shows a reservoir connected to a heat exchanger, which is linked to a pump. A pressure by-pass valve is present. The system is labeled as an "OUTDOOR REMOTE FLUID COOLER UNIT". Fluid is supplied to and returned from "SOFT-SERVE MACHINE No. 1" and "SOFT-SERVE MACHINE No. 2" via a "MANIFOLD SYSTEM". This system includes shut-off valves (type indicated) and by-pass valves. A check valve and hand valve are shown in the city water input line, designated as "EMERGENCY WATER SUPPLY", which connects to the manifold system. An air purge valve is located on the heat exchanger. A note indicates that the "NUMBER OF SOFT SERVE MACHINES MAY VARY."
Diagram Size and Weight
A diagram shows the "COLDZONE FLUID COOLER" with dimensions labeled L, W, and H. It indicates a "FUSED DISCONNECT BY COLDZONE" and an "AUTOMATIC AIR PURGE VALVE". The front of the unit is marked. A note specifies that a "36" MINIMUM SPACE REQUIRED ON ALL FOUR SIDES OF FLUID COOLER FOR VENTILATION AND SERVICABILITY."
A table provides specifications for various ColdZone Fluid Cooler models:
| COLOZONE MODEL NO. | NUMBER OF FANS | HEAT OF REJECTION (BTU) | TOTAL FLUID VOLUME (SAL) | FLUID FLOW (SPM) | CONNECTIONS (O. D.) HOT FLUID (INLET) | CONNECTIONS (O. D.) COLD FLUID (OUTLET) | DIMENSIONS (INCH) L | DIMENSIONS (INCH) V | DIMENSIONS (INCH) H | TOTAL SYS. AMPS (230VOLT/ 1PH/60HZ) | SHIPPING WEIGHT (LBS.) | DRY WEIGHT (LBS.) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| FC-3A | 1 | 30,000 | 4 | 4 | 1 1/8 | 1 1/8 | 43.5 | 48 | 43 | 9.7 | 625 | 400 |
| FC-5A | 2 | 50,000 | 5 | 8 | 1 1/8 | 1 1/8 | 73 | 48 | 43 | 13.9 | 750 | 470 |
| FC-7A | 2 | 70,000 | 8 | 12 | 1 1/8 | 1 1/8 | 73 | 48 | 43 | 16.2 | 850 | 570 |
| FC-9A | 2 | 90,000 | 10 | 16 | 1 3/8 | 1 3/8 | 73 | 48 | 43 | 16.2 | 950 | 670 |
| FC-11A | 2 | 110,000 | 12 | 18 | 1 5/8 | 1 5/8 | 73 | 48 | 43 | 17.7 | 1050 | 770 |
| FC-15A | 3 | 150,000 | 14 | 22 | 1 5/8 | 1 5/8 | 103 | 48 | 43 | 21.9 | 1350 | 1000 |
ColdZone reserves the right to make changes in design and construction at any time without notice. Maximum line run is 65' horizontally and 30' vertically. For longer line runs, consult the factory.
Diagram Rigging Detail
A diagram illustrates the rigging detail for the fluid cooler unit. It shows the unit suspended by a "LIFTING CABLE" attached to a "SPREADER". Notes provide instructions: "1. DO NOT DROP THIS UNIT WHEN UNLOADING. 2. RIGGING INSTRUCTIONS BY GENERAL CONTRACTOR."
Installation
Receipt and Inspection of Equipment
Inspect the Fluid Cooler unit and all accessories shipped with it for any damage or shortages. Any damage or shortages should be reported immediately to the delivering carrier. Damaged material becomes the delivering carrier's responsibility and it should not be returned to the manufacturer without prior approval from the service manager and a return material authorization number.
Lifting Instructions
Careful consideration of lifting procedures should be made before the unit is lifted by any means. Cables or other load-bearing devices must not be allowed to press against piping or electrical conduit. The base of the unit is designed to carry the lifting load. Lifting loads should be distributed evenly around the base to avoid twisting. When lifting by crane, use the provided lifting space in the lower portion of the base frame as attachment points for lifting cables. Prevent lifting cables from contacting the unit with a spreader or similar device.
Location and Ventilation
The Fluid Cooler must be located in an area allowing easy access for installation and service of electrical lines, refrigeration piping, and accessory equipment. The unit must be level to ensure proper lubrication. A minimum of 3 feet clearance must be provided on all sides of the unit.
Installation Area
Page 4 illustrates the overall dimension and installation requirements.
Roof Rail Requirements
The total weight of the complete unit is shown on Page 4. Installation should comply with local code requirements. ColdZone recommends placing the unit directly upon two (2) 4" x 4" redwood rails. For light roof construction, vibration isolation pads can be used underneath the supporting frame.
Pitch Pocket
A 6" x 9" pitch pocket must be provided for electrical and glycol lines. After lines are installed, backfill the opening with pitch to prevent water leakage into the building.
Electrical
To ensure proper operation and reduce the possibility of electrical power interruption, observe the following precautions:
- All electrical work must be done in accordance with the National Electrical Code and existing local codes.
- The power supply must match the data plate of the motors.
- An adequate power supply must be provided.
- Voltage fluctuations in excess of plus or minus 10% should be corrected.
Before starting a Fluid Cooler, check that all breakers and motor protective devices are in place and that all wiring is secure. A complete wiring diagram for trouble-shooting is included.
Glycol Piping
WARNING: PRIME PUMP BEFORE STARTING UNIT
- Piping: Connect red return and blue supply lines to manifold sets at machines. Piping must be adequately supported with hangers that can withstand the combined weight of tubing and fluid.
- Leak Testing: After both glycol lines are connected, the entire system must be leak tested. Particular care should be given to parts that will be inaccessible later.
Diagram Rail and Curb Detail
A diagram shows "RAIL REQUIREMENT" and "CURB DETAIL". The rail requirement diagram illustrates the unit's front view, indicating dimensions and the placement of two 4"x4" redwood rails (64" long). It shows a "CURB OPENING FOR ELECTRICAL & PIPE LINES" and the location of the "FUSED DISCONNECT" and "CONTROL PANEL".
The curb detail diagram shows a side view of the unit mounted on a "FINISHED ROOF" via a curb. It highlights the "CONTROL BOX", "FUSED DISCONNECT BY COLDZONE", and a "CURB OPENING FOR ELECT. AND PIPE LINES".
Notes for rail requirement:
- 1. RAILS TO BE INSTALLED LEVEL.
- 2. PROVIDE SHEETMETAL HAT SECTION WITH WATER TIGHT SOLDERED JOINTS.
- 3. BACK FILL CURB OPENING WITH HOT PITCH AFTER INSTALLATION.
Diagram Wiring Diagram
A "CONTROL PANEL WIRING DIAGRAM" is provided for a 208/230/60/1 power supply. It shows the connection from a "FUSED DISCONNECT" through "15A FUSES" and a "GRD LUG" to the "FLUID COOLER CONTROL PANEL". The diagram details internal wiring, including terminal blocks (TB1-1, TB1-2), capacitors (CF1, CF2, CF3), a transformer (XFMR), and a pump motor (PM). It uses color codes (BLK, YEL, R, BRN) and component identifiers (FCTC, CAP). Lines are distinguished as "FACTORY WIRING" and "FIELD WIRING".
Key notes include:
- 1. USE COPPER CONDUCTORS ONLY.
- 2. UNIT MUST BE GROUNDED.
- 3. FOR MOTOR AMPS SEE RATING STICKER ON OUTSIDE OF UNIT.
The legend defines terms such as TERMINAL BLOCK, TERMINAL NUMBERS, CAPACITOR, WIRE NUMBERS, FAN CYCLE, TEMPERATURE CONTROL, TRANSFORMER, and PUMP MOTOR.
Start-Up Procedure
After installation is complete, follow these steps for start-up:
- Ensure city water inlet/outlet valves on the manifold are closed. Inlet and outlet valves to the fluid cooler and for each soft serve machine must be open.
- Fill the fluid cooler at the reservoir's top. DO NOT START PUMP. Remove the cap from the automatic air vent and manually depress the shader valve while filling to purge air. Once air is purged, the pump can be primed by opening the bleed valve on the impeller housing. The reservoir should be 3/4 full.
- Start the pump.
- Close all inlet and outlet valves to individual soft serve machines, except the one farthest away. Start up this machine. Once operating properly, shut it off and close its manifold valves. Move to the next machine, open its manifold valves, and start it up. Check fluid level in the Fluid Cooler. Repeat for all machines. Finally, open all individual soft serve machine inlet and outlet valves. Note: Isolating and starting up one machine at a time speeds up air purging.
- Check fluid level in the Fluid Cooler.
- Check amperage and voltage draw on the pump motor to ensure it is not overloaded. Compare to the data plate.
- Check fan for proper vertical air flow.
Mechanical Seal
Pumps are equipped with a precision mechanical seal, installed and checked at the factory. No adjustment should be needed at installation. Running the pump without a glycol solution will result in rapid seal failure.
After extended service, the seal may need replacement if it leaks, indicated by dripping liquid from the motor shaft area.
CAUTION: The precision lapped faces on the mechanical seal are easily damaged. Handle replacement seals carefully and read instructions before attempting replacement. Running the pump dry will cause permanent damage to the mechanical seal.
ColdZone provides 100% propylene glycol; field mixing is required.
Maintenance
Inspect the unit regularly for loose bolts and connections, rust, corrosion, and dirty or clogged heat transfer surfaces (cooling coils). Check all lines for leaks and deformation.
Heat Transfer Surface
Remove dirt and dust by brushing fins and tubes and blowing loose dirt with an air hose. If the surface is greasy, remove the motor and brush or spray fins and tubes with a mild alkaline solution or nonflammable de-greasing fluid. Rinse with hot water and dry thoroughly.
Electric Motor
Pump and fan electric motors are designed for years of operation with minimal maintenance. Periodically clean dirt accumulations from open-type motors, especially around vent openings, preferably by vacuuming (avoid embedding dirt in windings). Check running amps and voltage. Fan and pump motors have sealed ball bearings; re-lubrication is not normally required.
Repairs or Replacement of Parts
When ordering replacement parts or inquiring about service, have the model number and serial numbers handy. Any reference to the motor must include its serial and model numbers.
Removal of Old Seal
- Disassemble the centrifugal housing from the pump by removing the five hex head cap-screws.
- Unscrew the impeller. A screwdriver slot is provided in the rear end of the motor shaft (remove bearing cap for access). To hold the shaft from turning, insert a large screwdriver blade into the slot. The thread is standard right-hand. Turn the impeller counter-clockwise to remove.
- Grasp the sintered iron seat (Ref. #5) and slip it from the motor shaft.
- Remove the pump body from the motor by removing the four (4) hex head cap-screws.
- Remove the spring seal by pushing from the direction of the pump body mounting flange. Exercise care to avoid damaging the seal cavity area.
Installation of Replacement Seal
- Clean the centrifugal body seal cavity before inserting a new seal.
- Using a clean cloth, wipe the shaft and ensure it is perfectly clean.
- NOTE: If removed, slide the rubber shaft slinger washer on the shaft until it is located about 1/8" from the face of the motor bearing hub.
- Carefully wipe the surface of the sintered iron seat with a clean cloth.
- Wet the rubber portion of the sintered iron seat with a light coating of oil.
- Press the brass cap, bellows, and spring squarely into the cavity in the casing cover. Do not distort the brass cap. Press uniformly around its flange.
- After the seal is in place, ensure it is clean and has not been scratched or cracked.
- Mount the centrifugal body on the motor mounting face. Carefully guide the motor shaft through the seal.
- Apply a light coating of oil on the motor shaft. Slide the seal seat onto the shaft (with the sealing face first). Use a 5/8" I.D. tube or 1/2" drive socket to aid in pushing the rubber portion onto the shaft.
Service Diagnosis
Trouble Shooting Chart
| SYMPTOM | CAUSE | REMEDY |
|---|---|---|
| A. Pump will not prime or retain prime after operating. | 1. Air leak in suction line. 2. Low glycol charge. | 1. Repair or replace suction line. 3. Add glycol. |
| B. Flow rate is low. | 1. Piping is fouled or damaged. 2. Clogged impeller or worn impeller. 3. Discharge line restricted or undersized. 4. Plumbing restrictions. 5. Low glycol charge. 6. Air in system. 7. Low voltage. | 1. Clean or replace damaged piping. 2. Clean or replace impeller. 3. Remove restrictions. 4. Remove restrictions. 5. Add glycol. 6. Purge. 7. Consult ColdZone. |
| Pump runs but no fluid is pumped. | 1. Faulty suction piping. 2. Valves closed. 4. Refrigeration valves closed. | 1. Replace piping. 2. Open valves. 4. Start refrigeration system adjust valves. |
| Liquid drips from point where shaft enters the pump is full of liquid. | 1. Damaged mechanical seal. 2. Temperatures over 210°F liquid are not compatible with seal. | 1. Replace mechanical. 2. Replace seal. |
| Excessive noise while pump in operation. | 1. Pump not secured to firm foundation. 2. Piping not supported to relieve any strain on pump assembly. 3. Restricted suction line. 4. Low glycol charge. 5. By-pass valve requires adjustment. | 1. Secure pump properly. 2. Make necessary adjustments. 3. Clean or correct strainer. 4. Add glycol. 5. Check. |
RAD/sel FC.93 08/93
Standard Warranty
ColdZone warrants, to the original purchaser, each product to be free from defects in material and workmanship if installed and used in compliance with ColdZone preparatory start-up procedure.
The limited warranty is effective for a period of twelve (12) months from the date of start-up and is not to exceed fifteen (15) months from the date of seller's invoice. Under the terms of this warranty, ColdZone will, at the seller's option, repair or replace any part(s) which, when returned in sealed containers, tagged as to serial and model numbers, with transportation charges prepaid to the factory or service location designated by ColdZone, proves to be defective.
ColdZone assumes NO responsibility for incidental or consequential damages, including, but not limited to, refrigerant, labor, taxes, food loss, service charges, lost profits, injury to person(s) or property, travel expenses, acts of God, etc...
This warranty does not apply to equipment that has been damaged in transit, altered, abused, or where ColdZone service and installation requirements are not met. Replaced parts warranty expires on original product warranty expiration.
As each compressor sold by ColdZone is warranted by the compressor manufacturer, replacement during the first year of operation must be made through an authorized wholesaler. ColdZone extends the manufacturer's warranties to its customers.
ColdZone includes a sequentially numbered preparation/start-up procedure in each unit shipped. This preparation/start-up procedure must be completed and returned to "Attn.: Service Manager," via certified mail to activate the limited warranty.
ColdZone neither assumes nor authorizes any person(s) to assume for seller any obligation or warranty other than that which is stated in this warranty.
This warranty is valid only after all financial obligations to ColdZone have been paid.
ColdZone is solely responsible for this warranty and makes no other warranty, either expressed or implied. All implied warranties of merchantability and fitness for a particular purpose which exceed ColdZone obligations are hereby disclaimed and excluded from this warranty.
ColdZone must be notified of any claim against this warranty within 120 days of the occurrence, with the stipulation that this notification is not made more than thirty (30) days after the expiration of this warranty. Claims made beyond these time frames will not be honored.
P.O. Box 1030 • Brea, CA 92822-1030 • 221 South Berry Street • Brea, CA 92821 Phone: 714/529-4461 • 800/772-2653 • Fax: 714/529-8503
Propylene Glycol (MSDS)
This section contains the Material Safety Data Sheet (MSDS) for Propylene Glycol Solvent (Industrial Grade).
Identification
Product Name: PROPYLENE GLYCOL SOLVENT (INDUSTRIAL GRADE)
Chemical Name: 1,2-Propanediol
Chemical Family: Glycols and Triols
Formula: CH3CH(OH)CH2OH
Synonyms: 1,2-Dihydroxypropane; Propanediol 1-1,2
Department of Transportation Shipping Name: None
Hazard Classification: None
CAS #: 57-55-6
CAS Name: 1,2-Propanediol
Molecular Weight: 76.10
II. Physical Data
Boiling Point, 760 mm Hg: 187.3°C (369.1°F)
Specific Gravity (H2O = 1): 1.0381 at 20/20°C
Vapor Density (air = 1): 2.62
Percent Volatiles by Volume: Nil
Freezing Point: Sets to glass at -60°C
Vapor Pressure at 20°C: 0.1 mm Hg
Solubility in Water, % by wt.: Complete
Evaporation Rate (Butyl Acetate = 1): 0.005
Appearance and Odor: Water-white liquid; mild odor
III. Ingredients
| MATERIAL | % | TLV | HAZARD |
|---|---|---|---|
| Propylene Glycol Solvent | ~100 | None established | None currently known |
IV. Fire and Explosion Hazard Data
Flash Point: 214°F, Tag Closed Cup ASTM D 56; 225°F, Cleveland Open Cup ASTM D 92
Flammable Limits in Air, % by volume: LOWER 2.6, UPPER 12.5
Extinguishing Media: Use carbon dioxide or dry chemical for small fires, alcohol-type foam or water spray for large fires.
Special Fire Fighting Procedures: None
Unusual Fire and Explosion Hazards: None
EMERGENCY PHONE NUMBER: 504744-3487. This number is available days, nights, weekends, and holidays.
VI. Reactivity Data
Stability: Stable [X]
Conditions to Avoid: None
Incompatibility (materials to avoid): None
Hazardous Combustion or Decomposition Products: Burning can produce carbon monoxide and/or carbon dioxide.
Hazardous Polymerization: Will Not Occur [X]
Conditions to Avoid: None
VII. Spill or Leak Procedures
Steps to be Taken if Material is Released or Spilled: Small spills should be flushed with large quantities of water. Larger spills should be collected for disposal.
Waste Disposal Method: Incinerate in a furnace where permitted under appropriate Federal, State, and local regulations.
VIII. Special Protection Information
Respiratory Protection: None required.
Ventilation: General (mechanical) room ventilation is satisfactory.
Protective Gloves: None required, but rubber gloves are suggested.
Eye Protection: Safety glasses
Other Protective Equipment: Eye bath; safety shower
IX. Special Precautions
Precautions to be Taken in Handling and Storing: Normal precautions common to good manufacturing practice should be followed in handling and storage.
Other Precautions: None
FOR INDUSTRY USE ONLY
V. Health Hazard Data
TLV and Source: None established by ACGIH or OSHA.
Effects of Acute Overexposure:
Swallowing: No evidence of adverse effects from available information.
Skin Absorption: No evidence of adverse effects from available information.
Inhalation: No evidence of adverse effects from available information.
Skin Contact: No evidence of adverse effects from available information.
Eye Contact: No evidence of adverse effects from available information.
Effects of Repeated Overexposure: No evidence of adverse effects from available information.
Other Health Hazards: None currently known.
Emergency and First Aid Procedures:
Swallowing: No harmful effects expected.
Skin: Wash with soap and water.
Inhalation: No emergency care anticipated.
Eyes: Flush with water.
Notes to Physician: Toxicology studies have shown the material to be of very low acute toxicity and a nonirritant. There is no specific antidote. Treatment of overexposure should be directed at the control of symptoms and the clinical condition.
