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GENERAL AIR FLUID

COOLERS AND
FLUID PUMPING STATIONS

INSTALLATION, OPERATION & SERVICE MANUAL

PROVIDING INDUSTRY THE RIGHT CHOICE;


SAVING A NATURAL RESOURCE

INSTALLATION INSTRUCTIONS
A. Initial Inspection
All fan coolers may be shipped either flat, (fans facing up) and skid mounted; or on their side,
(fans facing horizontal) also skid mounted. The mounting legs are off and shipped loose.
Mounting legs are furnished with the hardware required for field installation. See unit
drawing for leg location and mounting information.
When the equipment and accessories are received, they should be immediately inspected for
shortages and damage. If the equipment has been damaged in shipment or shortages are
noticed, immediately notify the carrier and file a claim. If hidden damage to the fluid cooler is
suspected, it is recommended that the coil be pressurized to 15 PSI with air or an inert gas, as
a check prior to rigging and/or final placement. Similarly, the pumping station can be tested
to 80 PSIG maximum.
All pumping stations are shipped with the expansion tank loose to avoid damage in transit.
Refer to unit drawings for proper location. Install the expansion tank using pipe joint
compound. Tighten the packing nuts on the gate valves to avoid leaks at startup.
B. Rigging and moving
The exact method of handling and setting the fluid cooler depends on the available equipment,
the size of the unit, its final location and other variables. It is the riggers or movers
responsibility to determine the specific method of handling each unit. Air Fluid Coolers have
lifting channels at the four corners. Do not lift the cooler underneath the cabinet with a
forklift or other lifting apparatus because damage to coil fins or cabinet will result. Under no
circumstances should the coil headers or return bends be used in lifting or moving the units.
See suggested rigging sketches.
The pumping station should be lifted with a forklift under the steel base. Do not lift by any of
the copper tubing.
C. Location and Installation
General AFC units can be mounted indoors or outdoors. Outdoor installation of the fluid
cooler is preferred, with the pumping station mounted indoors to allow for easy system
monitoring. Locate the fluid cooler, outside of the building or on the roof, as close as possible
to the heat source to minimize piping and pumping requirements and costs.
The fluid cooler must be installed level. Mounting legs should be securely fastened to
supporting steel or concrete pads. When mounting on a roof, install unit such that building
columns or load bearing walls support it. (Refer to unit weight chart)

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APPROXIMATE AIR FLUID COOLER WEIGHT


Model
Empty Weight
Coil Volume
Filled Weight
Number
(Pounds)
(gallons)
(Pounds)(#)
AFCA*AX

150

2.0

167

AFC1*AX

180

2.5

201

AFC2*AX

360

4.9

403

AFC3*AX

540

7.5

605

AFC2*AY

1050

12.8

1162

AFC3*AY

1500

18.0

1657

AFC4*AY

2150

23.3

2353

AFC5*AY

2675

28.5

2924

AFC6*AY

2750

36.0

3064

AFC8*AY

3500

46.6

3907

AFC10*AZ

4400

57.0

4897

AFC12*AZ

5250

67.6

5840

* Varies with voltage rating


# Based on 40% Propylene Glycol at 125 oF.
PUMPING STATION SPECIFICATIONS
Weight (Pounds)
Horsepower
Connection Size
Simplex
Duplex
2

380

525

1 Copper (1 5/8 ODS)

400

570

2 Copper (2 1/8 ODS)

425

620

2 Copper (2 1/8 ODS)

475

695

3 Copper (3 1/8 ODS)

10

575

900

3 Copper (3 1/8 ODS)

15

600

930

3 Copper (3 1/8 ODS)

If the warm exhaust air of the fluid cooler is desired for heat recovery, the unit can be
mounted indoors. Any restriction of airflow will adversely affect the fluid cooler thermal
performance, and potentially damage fan motors.

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NOTE:
ALL INDOOR DUCTING WORK SHOULD BE REVIEWED WITH A
QUALIFIED HVAC CONSULTANT.
D. Piping
All fluid piping practices should be in accordance with local codes. General AFC and FPS
units are constructed using Type L copper piping and supplied with ODS (outside diameter
sweat) connections. Copper field piping is recommended using sweat joints. Other piping
material such as steel, cast iron, brass or plastic can be used. If field piping is galvanized, use
uninhibited glycol. Inhibited glycol and galvanized steel must not be used together due to
incompatibility of zinc with the inhibitors of the glycol/water mixture. Whenever components
made from different materials are piped in a system, use dielectric isolation of the materials to
help prevent galvanic corrosion. All threaded pipe connections must be sealed and any
flanged connections gasketed; use extra sealant or Teflon tape or the glycol/water solution
will leak.
General Fluid Coolers are supplied with inlet/outlet headers as follows:

One through four fan units have a single header. (One inlet & one outlet)

Five fan units have a single header except if the flow rate is 160 GPM and over; they
will have two headers. (Two inlets & two outlets)

Six and eight fan units have two headers.

Ten and 12 fan units have two headers except if the flow rate is over 319 GPM; they
will have four headers. (Four inlets & four outlets)
Correct sizing of pipe is critical to assure smooth operation and keep operating costs to a
minimum. Calculation of total system friction pressure loss determines optimum pipeline size.
For closed-loop systems, do not include static head pressure of system piping, as equal and
opposite forces cancel out upward and downward flow. All elbows, tees, valves and system
component pressure drops must be considered when determining pipeline size. Standard
pump selection at rated flow is based on 100 total dynamic head (approximately 45 PSIG
pressure available).

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HP
FLOW
(GPM)
SIMPLEX
PRESSURE
DROP (PSI)
DUPLEX
PRESSURE
DROP (PSI)

PUMP STATION PRESSURE DROP VS FLOW RATE


2
3
5
10 20 30 35 40 50 60 70 80 90 100 119
.38

.77

1.5

2.0

.84

1.3

1.8

2.4

3.0

3.8

4.6

6.3

.6

1.2

2.4

3.2

1.3

2.1

2.7

3.6

4.7

5.8

7.1

9.8

HP
7
10
15
FLOW
125 150 175 183 200 225 230 250 275 300 325 350
(GPM)
SIMPLEX
1.3 1.8 2.4 2.8 3.1 3.9 4.0 4.7 5.6 6.6 7.8 9.1
PRESSURE
DROP (PSI)
DUPLEX
2.1 2.9 3.8 4.3 4.9 6.1 6.4 7.4 8.9 10 12 14
PRESSURE
DROP (PSI)
Table is based on 40% Propylene Glycol at 90OF.
Proper use of valves (gate type, full port ball type or globe type) is recommended to allow for
isolation of components in the event of maintenance to reduce closed circuit system
glycol/water loss. All General AFC units have a 1/2 NPT drain valve connection and 1/2
vent connection installed. Drain and vent valves should be installed in these connections. The
General FPS pumping station has a 1/2 NPT drain valve. A fill valve assembly should be
installed at the high point of system for charging.
An emergency water supply line to the compressor or heat source components should be used
in case of fluid cooler downtime. Shut off/isolation valves should be located outside of closed
system loop. Do not open the emergency water supply during system operation, because
water could leak into the closed system supply and dilute the mixture or cause erratic pump
performance.
All General FPS pumping stations are completely plumbed to reduce installation costs of
system components. A closed expansion tank is provided utilizing a rubber diaphragm to
compensate for surges in the system. The diaphragm is actuated by air pressure
(approximately 12 PSI charged); a valve is located on the tank for changing the air charge.
An air purger and automatic air vent are included for removal of air bubbles, which are
induced in the system during filling. Additional air bubbles will continue to be purged and
vented as the system operates at higher temperatures. It is recommended that an additional
vent (unless the AFC cooler unit is at the highest point) be placed at the high point of piping
to assure release of air.
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General AFC accessories are optional and are to be piped as follows:


1.

TRIM COOLERS series piped if for single heat source or parallel piped if for multiple
heat sources. Pipe the closed-loop cooling system glycol/water solution through the
shell side (larger) connection, and trim water supply (city water, etc.) through the tube
side (smaller connection located on the end bonnet), connecting inlet closest to
glycol/water discharge thereby maximizing cooling effect. Always pipe trim coolers on
the discharge side of AFC cooler unit.
Note:
During cold weather months when the trim cooler is not in use, the tube side water
MUST be drained to prevent freeze up and damage to the trim cooler.

MODEL

TC1030
TC3060
TC60-120
TC120-240
2.

TRIM WATER MODULATING VALVES on trim water supply, with sensing bulb in
discharge side of trim cooler. Factory setting is approximately 103 degrees; every full
revolution of the set screw changes this setting by approximately 5 degrees. Valves
can be adjusted with a screwdriver by turning adjustment screws clockwise to decrease
opening temperature, and counter-clockwise to increase opening temperature. Valves
are not calibrated, so final desired temperature setting must be established
experimentally. Maximum trim water flow rates at 55 PSI are as follows:
MODEL
NUMBER
WV075
WV125
WV200

3.

TRIM COOLER SPECIFICATIONS


PRESSURE DROP AT
FLOW RATE (GPM)
MAXIMUM FLOW (PSI)
SHELL SIDE
TUBE SIDE
SHELL
TUBE SIDE
COOLANT
TRIM WATER
SIDE
TRIM
COOLANT
WATER
10-30
5-15
6
11
30-60
15-30
6
5
60-120
30-60
7
5
120-240
60-120
5
5

CONNECTION
SIZE
NPT
1 NPT
2 FLANGED

MAXIMUM FLOW
THROUGH VALVE
40 GPM
75 GPM
150GPM

SYSTEM FLOW
RATE
1 TO 80 GPM
80 TO 150 GPM
150 TO 300

3-WAY THERMOSTATIC MIXING VALVES piped so as to maintain constant fluid


temperature to the heat source. This helps eliminate condensation; which results from
too cold a cooling supply. Connect the outlet from the heat source to the inlet of the
mixing valve; port A. Connect the mixing valve outlet, port C, to the inlet of the fluid
cooler. Connect the hot liquid bypass, port B, to the outlet of the fluid cooler.
Connect the outlet of the fluid cooler and bypass valve, port B, to the inlet of the
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pumping station. Refer to fluid cooler flow diagram for recommended accessory
piping. Also see unit drawing.
If a General Fluid Pumping Station pumping station is not supplied, the following practices
and parts are recommended. Pressure and temperature gauges should be field installed to
monitor the system. Locate the circulating pump in such a manner to create static head
pressure at the pump suction. If more than one pump is used, install check valves to prevent
back flow. An expansion tank on the suction line of pump and air purger/air vent installed on
discharge line of pump are recommended.
Once all piping and accessory installation has been completed, the system is ready to leak test.
Charge system with at least 50 - 70 PSIG of air (or water) and check around each connection
and joint with water/soap solution (or visual check). If no leaks are found, the system can be
charged with its required glycol/water solution.
RECOMMENDED PROPYLENE GLYCOL TO WATER RATIO
VOLUME PERCENT
VOLUME PERCENT
FREEZE
GLYCOL
WATER
PROTECTION
0
100
32oF
10
90
26oF
20
80
19oF
30
70
9oF
40
60
-7oF
45
55
-16oF
50
50
-28oF
Glycol will provide freeze protection, and act as a rust inhibitor; do not use excessive
amounts, as heat transfer efficiency will be reduced. Inhibited propylene glycol is the
preferred coolant because of environmental concerns, but your system may have been selected
and rated based on plain water or an ethylene glycol mixture Consult the sales quote for your
equipment to determine optimal coolant mixture.
Please review the discussion in Section D PIPING regarding material compatibility.
When charging the system, open all vents and valves (except drain valves) and fill pre-mixed
coolant mixture at high point fill valve, closing each vent or valve as it leaks liquid. When
system is full and prior to system startup, run pumps and allow air to purge from mixture.
Add coolant mixture as necessary. (This practice should be done several times until all air is
removed from system solution.)
E. Wiring
The electrical installation should be in accordance with the National Electrical Code and any
local codes and regulations. Fan motors have inherent thermal overload protection. Standard
units may be wired for either 208-230/3/60 or 460/3/60 power. Check nameplate voltage to
be sure it is in agreement with the power supplied. All fan motors come pre-wired to a
weatherproof junction box on the unit as standard. Special control panels are available to
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provide motor fusing and fan cycling control. The disconnect switch (fused or non-fused)
must be provided by others in the field. Refer to wiring diagram for units supplied.
General AFC units equipped with fan cycling controls are shipped factory set to maximize
system efficiency and reduce operating costs. The unique design allows all fans to cycle
around a single thermostat installed in the fluid cooler discharge header, sensing liquid
temperature. The thermostat sensing bulb is shipped loose and must be installed into the
tubing header.
The fan cycling set points are as follows:
CONTROL

SET POINT

FAN ON

FAN OFF

TC 1

70

ONE FAN UNIT


85

70

TC 1
TC 2

60
-

TWO FAN UNIT


70
85

60
75

TC 1
TC 2
TC 3

THREE FAN UNIT or 2 X 3 FANS


60
70
80
85

60
70
75

TC 1
TC 2
TC 3
TC 4

FOUR FAN UNIT or 2 X 4 FANS


60
70
75
80
85

60
65
70
75

TC 1
TC 2
TC 3
TC 4
TC 5

FIVE FAN UNIT or 2 X 5 FANS


60
65
70
75
80
85

60
65
70
75
80

TC 1
TC 2
TC 3
TC 4
TC 5
TC 6

SIX FAN UNIT or 2 X 6 FANS


55
60
65
70
75
80
85

55
60
65
70
75
80

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F. Start-up and Maintenance


Prior to start-up, each fan motor should be checked for freedom of movement and that
the fan blade is securely fastened to its fan motor shaft. On start-up, each fan should
be checked for proper rotation in accordance with the fan direction arrow decal
located on the fan opening. Also check pump(s) for proper wiring and rotation.
Fans and motors are direct connected. Motors are permanently lubricated for the life
of the motor. If a fan or motor needs replacing, it should be done through the fan
opening after removing the fan guard.
Each AFC unit comes equipped with access panels located on the side of the unit for
easy access to the fan motors and for cleaning of the coil surfaces.
When replacing fan motors, it is best to place a plywood panel below the fan motor to
protect the coil surface should the motor be dropped.
Use compressed air (low pressure) to clear dust and debris from the coil. Fin material
is sensitive; DO NOT WIRE BRUSH! Mild cleaning solution or low pressure steam
cleaning may be used to clean the unit.
All pumps have maintenance-free pump seals.
Job site environmental conditions should be reviewed periodically to assure coil and
component life expectancy.

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GENERAL AIR PRODUCTS


START UP CHECK LIST FOR FLUID COOLER AND PUMPING STATIONS

1.

Check that all motors are securely fastened.

2.

Check that all fan blades are securely fastened to motor shaft.

3.

Is thermostatic mixing valve correctly piped?

4.

Is temperature bulb installed in bulb well on cooler?

5.

Has correct Glycol/water mixture been installed?

6.

Are all valves except drain valves open?

7.

Do units have the correct voltage connected?

8.

Is pump station interlock circuit wired to cooler run circuit?

9.

Are all fuses installed?

10.

Check all motors for proper rotation direction.

11.

After starting, temperature gauge should stabilize at that temperature which


approximates system design (typically 90-95 Deg F).

12.

System pressure should be in the 43 to 80 PSIG range.

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SIMPLEX PUMPING STATION OPERATING INSTRUCTIONS

1.

Operation is controlled by one selector switch, SS-1 in the control unit. SS-1 must be in
the ON position to run the pumping station. The jumper between 1& 3 on the terminal
block in the control unit may be removed and replaced with a set of normally open run
contacts. When the circuit is closed by SS-1, the local Green POWER pilot light will
light.

2.

When selector switch SS-1 is turned to the ON position, the pump will start and the
local Green PUMP pilot light PL-2 will light.

3.

Flow switch, FS-1, monitors that the fluid in the closed loop is flowing. If flow stops,
timer TD-1 will begin timing and after timing out, light local Red ALARM light PL-3
and sound local H-1 alarm horn. In addition, motor starter MS-1 and PUMP pilot
lights PL-2 will de-energize. The timer is factory set to 10 seconds.

4.

The alarm is silenced by depressing RESET push button PB-1, which will energize and
latch alarm relay CR-1.

5.

There is an interlock contact on the motor starter that can be wired to the fluid cooler (or
chiller) to energize the fan control circuit (or chiller) when the pumps are operating and
which will turn off the fans (or chiller) when the pumping station is turned off.

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DUPLEX PUMPING STATION OPERATING INSTRUCTIONS

1.

Operation is controlled by two selector switches, SS-1 in the main control unit and
SS-1R in the remote control panel, if supplied. Both must be in the ON position to run
the pumping station. When the remote control panel is not used jumper 1 & 1A on TB-2
in the main control unit. Note - the panel is shipped with these jumpers installed. When
the circuit is closed, then local Green POWER pilot light PL-1 and remote Green
POWER pilot light PL-1R (if used) will be lit.

2.

The Alternating Relay (ALT) should be set to ALTERNATE position to equalize run
time on pumps. When the station is turned on, one of the two pumps will start and the
matching local Green PUMP 1 or PUMP 2 pilot light PL-2 or PL-3 and remote
Green PL-R or PL-3R will be lit.

3.

Flow switch, FS-1 monitors that the fluid in the closed loop is flowing. If flow stops,
timer TD-1 will begin timing and after timing out, light local Red ALARM light PL-4
and PL-4R remote Red ALARM light and sound local H-1 and remote H-1R alarms.
This timer has 15 adjustable time ranges from .15 seconds to 100 hours. The factory
setting is 10 seconds and should not be changed.

4.

If timer TD-1 times for 10 seconds, its contacts change state. TD1 normally closed
contacts open, causing the alternator (ALT) contacts to switch position. This switches
the active pump. When flow resumes the flow switch opens and TD-1 is reset.

5.

The alarms may be silenced by depressing either local RESET push button PB-1, or
remote PB-1R, which breaks the seal up circuit of TD-1.

6.

There is an interlock contact on each motor starter, wired in parallel, that should be wired
to the fluid cooler to energize the fan control circuit when either one of the pumps is
operating and which will turn off the fans when the pumping station is turned off.

7.

Whenever the pumping station is de-energized, either by no flow or normal turn off with
either selector switch SS-1 or SS-1R, the transfer relay TR-1 contacts change state and
the opposite pump will start when the station is restarted. This will equalize the wear on
the two pumps and should double the expected time between pump or motor failures.

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IMPORTANT: Set switch as shown to share run time between pumps.


Pump A will run until power is cycled using on/off switch or flow switch is open
for at least 10 seconds. Then pump B will run until power is cycled or flow
switch is opened for At least 10 seconds.

Set to ALTERNATE position as shown.

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General Air Products Warranty Policy


GENERAL PROVISIONS & LIMITATIONS
General Air Products, Inc. (the Company) warrants to each
original purchaser (Purchaser) of its new products from the
Company or its Authorized Distributor that such products are,
at the time of delivery to the Purchaser, made with good
materials and workmanship. No warranty is made with respect
to:
1.

2.

3.

4.
5.

Any product, which has been repaired or altered in


such a way, in the Companies judgment, as to affect
the product adversely.
Any product, which has, in the Companies judgment
been subjected to negligence, accident, improper
storage, improper installation or application.
Any product, which has not been operated or
maintained in accordance with the recommendations
of the Company.
Components or accessories manufactured, warranted
and serviced by others.
Any reconditioned or prior owned product.

Claims for items described in 4. above should be submitted


directly to the manufacturer.
WARRANTY PERIOD
The Companys obligation under this Warranty is limited to
repair or, at its option, replacing during normal business hours
at the designated facility of the Company, any part that in its
judgment proved not to be as warranted within the applicable
Warranty Period as follows.

DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS
EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE COMPANY
MAKES NO OTHER WARRANTIES, EXPRESSED OR IMPLIED OR
STATUORY, INCLUDING ANY IMPLIED WARRANTY OR
MERCHANTABILITY.
THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE
SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE TO THE
PURCHASER AND IN NO CASE SHALL THE COMPANY BE
SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES. UNDER
NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR
SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER
CAUSED.

No statement, representation, agreement, or understanding,


oral or written, made by any agent, distributor, representative
or employee of the Company which is not contained in this
Warranty will be binding upon the company unless made in
writing and executed by an officer of the Company.
This warranty shall not be effective as to any claim which is
not presented within 30 days after the date upon which the
product is claimed not to have been as warranted. Any action
for breach of this warranty must be commenced within one
year after the date upon which the cause of action occurred.
Any adjustment made pursuant to this warranty shall not be
construed as an admission by the Company that any product
was not as warranted.

COMPONENTS
All non-consumable components are warranted for 12 months
from the date of purchase. Consumables are not covered
under warranty. The unit must have been installed by either a
factory authorized distributor or agent in accordance with the
factory recommendations taking into account all other local
site conditions not originally noted to the factory. The unit must
be operated and maintained in accordance with the Factory
recommendations and original design conditions. Failure to
provide such proof of the above may void warranty.

PROMPT DISPOSITION
The Company will make a good faith effort for prompt
correction or other adjustment with respect to any product,
which proves to be defective within the warranty period. Before
returning any product, write or call the distributor, agent or
authorized company from which the product was purchased,
describing defect and giving date and number of original
invoice, a well as proof of Factory supplied consumables and
proof of scheduled maintenance. Title and risk of loss pass to
buyer upon delivery to the common carrier.

LABOR TRANSPORTATION & INSPECTION


The Company will repair or replace any product or part thereof
which in the Companies judgment is proved to be not as
warranted. Labor costs are not covered under warranty.

PRODUCT SUITABILITY
Many States, Localities and Countries have codes and
regulations governing sales, construction, installation, and/or
use of products for certain purposes, which may vary from
those in neighboring areas. While General Air Products, Inc.
attempts to assure that its products comply with such codes, it
cannot guarantee compliance, and cannot be responsible for
how the product is installed or used? Before purchase and use
of a product, please review the product application, and
national and local codes and regulations, and be sure that the
product, installation, and use will comply with them.

All costs of transportation of product, labor or parts claimed


not to be as warranted and, of repaired or replaced parts to or
from factory shall be borne by purchaser. The Company may
require the return of any part claimed not to be as warranted to
one of its facilities as designated by the Company,
transportation prepaid by Purchaser, to establish a claim under
this warranty.
Replacement parts provided under the terms of the warranty
are warranted for the remainder of the Warranty Period of the

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