Fernstrum GRIDCOOLER Installation And Maintenance Manual Download Page 3

Page: 3 / 24

Installation and Maintenance Manual form 185

Page 1

1.0

PLANNING & LOCATION

1.1

Determining Proper Location -

Typical 2

1.2

Determining Proper Location –
Displacement Vessels

1.3

Determining Proper Location –

Planing Vessels

1.4

Improper (Not Recommended)

Locations 3

1.5

Mounting Considerations - Typical

1.6

Mounting Considerations -
Displacement Vessels

1.7

Mounting Considerations -

Planing Vessels

1.8

Bonding or Isolation

2.0

INSTALLATION

2.1

Making Holes

2.2

Fitting Up

2.3

Copper-Nickel Installation

2.4

Aluminum Installations

2.5 Plumbing

2.6

Filling & Testing

3.0

SPECIAL INSTALLATIONS

3.1

Cofferdam Installation

with Compression Sealing Kit

3.2

Z Option™ Installations

3.3

L Option™ Support Plate Installation 10

3.4

Mounting Copper-Nickel Coolers

on an Aluminum Hull

4.0

FORMING THE GRIDCOOLER®

KEEL COOLER

5.0

PERFORMANCE ISSUES

6.0

MAINTENANCE

7.0 REPAIR

8.0

STRAY-CURRENT CORROSION

9.0

REPLACEMENT PARTS

10.0

LIMITED WARRANTY

11.0

RECOMMENDATION FORM

Contents

Summary of Contents for GRIDCOOLER

Page 1: ...GRIDCOOLER KEEL COOLER Installation and Maintenance Manual Form 185 R W Fernstrum Company ...

Page 2: ......

Page 3: ...ding or Isolation 4 2 0 INSTALLATION 5 2 1 Making Holes 5 2 2 Fitting Up 5 2 3 Copper Nickel Installation 5 2 4 Aluminum Installations 6 2 5 Plumbing 6 2 6 Filling Testing 7 3 0 SPECIAL INSTALLATIONS 8 3 1 Cofferdam Installation with Compression Sealing Kit 8 3 2 Z Option Installations 9 3 3 L Option Support Plate Installation 10 3 4 Mounting Copper Nickel Coolers on an Aluminum Hull 11 4 0 FORMIN...

Page 4: ...cooler circuit lower on the hull i e closer to the skeg or keel and a divider plate between the high and low temperature units 1 1 4 When the GRIDCOOLER unit is used on a generator set or if your application requires sizing for a hull speed of 0 knots make sure that sea water can freely circulate past the cooler tubes Do not recess a generator set unit on the bottom of a flat bottom boat unless th...

Page 5: ...AL 1 5 1 Some classed vessels ABS or Coast Guard for example may require cofferdams check with your local officials for more information For this type of installation see Cofferdam Installation in Section 3 1 1 5 2 The GRIDCOOLER unit can be canted from the hull sideways to vertically align the nozzles This can reduce interference problems with stringers on cofferdam installations See Figure 4 ref...

Page 6: ...ordered with additional vents in the stud end of the cooler FIG 8 U Flow unit with E1 OPTION end mounted anodes mounted on rake of vessel with nozzles positioned to avoid air entrapment 1 6 5 If side plates and fairing blocks are used make sure that the side plates are scalloped notched out so they will not entrap water Fairing blocks are most effective when installed with a 4 to 1 slope See Figur...

Page 7: ...bolt nuts when applicable to prevent them from working loose To seal out water apply a bead of sealant to the exterior of the gaskets and around the points where the nozzles and support bolts penetrate the hull before assembly 2 2 2 Remember to tighten the nuts again after the caulking has set 2 3 COPPER NICKEL INSTALLATION 2 3 1 Mounting gaskets supplied with the GRIDCOOLER Keel Cooler must be us...

Page 8: ... torques for all normal installations 2 4 4 Most aluminum units have tapered threads on the nipples and no hose connectors see installation drawing These units can be piped directly to the engine provided flexible couplings are used to remove engine vibration between the engine and the cooler 2 4 5 If a wire reinforced rubber hose is used to connect the unit to the engine put a screw on coupling o...

Page 9: ...pending on installation special air bleeding vents are available as an option 2 5 8 For piping diagrams for multiple cooler installations see Figures 11 through 14 FIG 11 Coolers connected in parallel FIG 12 Multiple pass coolers connected in parallel FIG 13 Coolers connected in series FIG 14 Coolers connected in series parallel 2 6 FILLING TESTING NOTE Do not exceed 35 PSI 2 41 Bar when pressure ...

Page 10: ...tion The exterior header gasket must be in full contact with the hull 3 1 4 Place the nipple gasket harder of the two interior gaskets down over the nozzle as far as possible 3 1 5 Place the unfinished cast washer down over the nipple as far as possible The side of the washer marked up must face away from the hull 3 1 6 Place the compression gasket softer of the two interior gaskets down over the ...

Page 11: ...ull Special extra heavy lock nuts and washers are provided for a secure installation 3 2 3 Flange mounting hardware can be found in a cardboard box inside the unit shipping box 3 2 4 The mating steel flange is welded to a pipe stub extending from the hull of the vessel This pipe stub must be long enough to allow access to the flange lock nuts for tightening Alignment of the flanges on the hull is ...

Page 12: ... a securing means The customer can then install the appropriate fasteners for the support plates Figures 18 and 19 show examples of this style of mounting The combination of the neoprene gasket and the nylon shoulder washer provide isolation of the cooler from the hull NOTE Do not cut off the center stud on your GRIDCOOLER Keel Cooler The center stud is there to provide necessary support for your ...

Page 13: ...wing technique has been used on hundreds of boats 3 4 2 Sandblast the area of the hull where the unit will be installed 3 4 3 Coat the sandblasted area with a two part fiberglass epoxy resin 3 4 4 Spray the resin on in four separate coats Do not use any matting Spray each coat just heavy enough so that it does not start to run off 3 4 5 After spraying on the fourth coat and while the resin is stil...

Page 14: ... measuring instrument along with a template of the hull profile can be used to measure your progress See Figures 20 and 21 TWISTING A GRIDCOOLER KEEL COOLER To produce a twist first fabricate a hook onto the end of a short length of pipe using barstock Hook this bar across the header as close to the nipple or stud as possible The cooler may be secured in a press or placed on sawhorses with a perso...

Page 15: ...reduce the heat transfer rate of the unit The standard recommendation is to not coat the keel cooler WATER AERATION Could the water around the cooler be aerated in any way Aeration will reduce the heat transfer rate of the keel cooler MOORED AT DOCK Is the engine temperature rising while the vessel is moored in dock If the unit is installed near the propeller engage the propeller to circulate wate...

Page 16: ...ld be used For suction blast do not exceed 90 psi 6 21 bar For pressure pot blasting do not exceed 35 psi 2 41 bar NOTE Never sandblast an ALUMINUM GRIDCOOLER unit PAINTING Coolers do not require painting Doing so will decrease the unit s efficiency ANODES Anodes are standard equipment with most copper nickel units They minimize the effects of galvanic corrosion and should be replaced when deterio...

Page 17: ...r nickel or monel 67 wire may be used TEMPORARY REPAIR For temporary repairs liberally apply an epoxy compound Before applying the epoxy compound clean the surface of the GRIDCOOLER unit and relieve any internal pressure For major repairs not covered by our Limited Warranty contact us Give us a complete description of the damage and we will tell you if and how your unit can be repaired TUBE COUPLI...

Page 18: ...ble stray current corrosion For guidance on proper welding equipment connections for waterborne vessels we suggest consulting either NAVSEA S9086 CH STM 010 CH 074R4 Welding and Allied Processes Naval Ships Technical Manual Chapter 74 Volume 1 or ANSI AWS D3 5 1993 R2000 Guide for Steel Hull Welding Section 6 Stray Current Protection Note that the Section 6 of the ANSI AWS D3 5 1993 standard comes...

Page 19: ...Installation and Maintenance Manual form 185 Page 17 9 0 REPLACEMENT PARTS FIG 28 Single Pass Gridcooler Keel Cooler FIG 29 Multi Pass Gridcooler Keel Cooler ...

Page 20: ...te sets Gasket sets include all internal gaskets exterior gaskets and isolators NOTE Anodes are sold in kits consisting of anodes and mounting hardware Most Keel Coolers require one 1 anode kit Larger Keel Coolers may require two 2 anode kits Keel Cooler model number is needed to identify correct kit Anodes are standardly sold in zinc but can be aluminum upon request 9 0 REPLACEMENT PARTS ...

Page 21: ...s or events beyond our reasonable control 10 4 WHAT IS THE PERIOD OF COVERAGE This limited warranty starts on the date of delivery and lasts for 90 days for the aluminum GRIDCOOLER Keel Cooler and lasts for 2 years for the copper nickel GRIDCOOLER Keel Cooler the Warranty Period The Warranty Period is not extended if we repair or replace the product We may change the availability of this limited w...

Page 22: ...el Cooler to which repairs or alterations have been made unless authorized or performed by the manufacturer nor to defects arising because of improper installation misuse accident or other causes beyond the control of the manufacturer Should any disputes arise with regard to their respective rights duties and responsibilities under the Limited Warranty all such disputes shall be governed by the la...

Page 23: ... Power under full load _________________________________________ Maximum Sea Water Temp _________________ Engine Age_________ Antifreeze Used ___________ Make Model of Gear_______________________________________________________________________ Type of Boat ferry trawler pleasure boat etc __________________________________________________ Hull Construction Steel Fiberglass Wood Aluminum Painted Cof...

Page 24: ... 5553 Fax 906 863 5203 Email sales fernstrum com P O Box 97 1716 11th Avenue Menominee Michigan 49858 USA 2022 R W Fernstrum Company All Rights Reserved FERNSTRUM and GRIDCOOLER are registered trademarks of R W Fernstrum Company ...

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