ClimaCool UGW Manual - Manual (Page 5)

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Unit Installation
Unit Placement
ClimaCool modular chillers must be installed in a conditioned
and dehumidified space. The minimum foundation
requirement for the chiller is a level surface capable of
bearing the combined operating weight of the modules
(See Physical Data on page 5).
Service Access
The recommended service clearances for modules with
standard brazed plate heat exchangers are 36” for front
service access, 36” height clearance for service and 30”
for rear service access as identified in the Recommended
Service Clearances on page 9 . For the optional shell and
tube condenser design, allow 60” for front clearance . Local
building or electrical codes may require additional clearance –
please consult applicable codes .
Draining
When performing standard maintenance procedures such
as flushing a heat exchanger, it will be necessary to isolate
either heat exchanger. ClimaCool modular chillers offer
optional water isolation valves for this purpose . Access
to a floor drain is helpful when performing standard
maintenance procedures . Warning: Water valves must be
reopened after flushing is complete.
Assembling Modules
ClimaCool recommends locking down the chiller to a
concrete base or to three (3) 4” base mounting rails using
the six (6) bolt holes provided in each base pan. Although
the compressors are installed on anti-vibration mountings,
further isolation of the chiller from the structure is
recommended by installing vibration-eliminating springs
or pads under the base rails on which the chiller will rest
(See page 8 – Mounting Rail and Vibration Isolation). One
module should be chosen as the reference module and
carefully located .
Field installed mounting accessories are provided for
adjoining each module .
• Header grooved coupling kits containing four (4)
grooved couplings with gaskets
• Mounting hardware kit containing necessary bolts,
spacers, nuts and washers
• Header bank end cap kit containing four (4) grooved
couplings with gaskets and four (4) end caps
Field installing the mounting hardware kit will assist with
alignment of the modules in a bank and eliminate offset
inconsistencies . The 1/2” mounting holes are provided on
sides of the unit base pan . First module should be set, set
adjacent unit on mounting surface roughly aligned
1 ½” away from the first unit. While holding spacer
in place, work through the first modules front base
cutout to place a washer and insert bolt through the front
mounting hole and spacer . Repeat the process for the rear
mounting hole . Line up mounting hole of adjacent module
with bolt from previous module and working through
adjacent modules front base cutout, place a washer, split
lock washer and nut . Using the appropriate tools tighten
hardware assembly until seated .
Inspect the pipe ends to ensure they are free from any
indentations, projections, roll marks or other harmful
surface defects such as loose paint, scale, dirt, chips,
grease and rust . Inspect the grooved coupling gasket for
any defects . Apply a thin layer of silicone or other
non-petroleum lubricant to the sealing lips of the gasket
as well as to the exterior of the gasket . Install gaskets on
the pipe ends of one of the two modules to be mated .
Be sure the gasket is completely on the pipe to avoid
damage in the next step. Move the second module into
position and line up the piping . Ensure you are maintaining
alignment for any additional modules to be added . When
pipe ends are aligned, slide the gasket over the ends and
center it between the grooves . No part of the gasket
should protrude into the groove of either pipe end . Place
the coupling halves over the gasket and make sure that
the coupling keys (the part that goes into the groove) are
engaged into the grooves . Insert the bolts and install nuts
to hand tight . Ensure the oval neck of the bolt engages into
the bolt hole of the housing . Tighten nuts alternately and
equally until the bolt pads meet and make metal to metal
contact. Tighten nuts by another ¼ to ½ turn to make sure
the nuts and bolts are snug and secure . The use of a torque
wrench is usually not required . Uneven tightening of bolts
may cause the gasket to be pinched resulting in immediate
or delayed leaks.
Header Insulation
Chilled water piping is pre-insulated on each module at
the factory with ¾” closed cell insulation . After bolting
all modules together and leak testing, the entire coupling
connection will need to be insulated by the installing
contractor .
Sound Attenuation Panels and Gasket
Attenuation panels are enclosures made of 18 gauge
galvanized steel with powder coat paint finish and fiberglass
insulation. Panel package includes one (1) upper panel and
one (1) lower panel for each side of bank (field installed),
four (4) panels for each module in the bank (factory
installed) and gasket sealant tape for installation between
modules . Install panels by setting in place and locking down
with the half turn latches or self tapping screws . Note: Panel
package includes a compressed 1” x 1” gasket sealant tape
for installation between modules . Install the tape on the
outer frame on the side of one module prior to installing
the adjacent modules.