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Kelvin ROCORE F Series, Инструкция по установке, эксплуатации и обслуживанию, Страница: 1 / 47

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F Style 

VB Style 

N Style 

H Style 

HB Style 

V Style 

To access digital copies of this 

manual, other manuals or  
additional information, scan the 
code on the left or visit 

www.rocore.com 

STANDARD RADIATOR 

IOM MANUAL 

 

 
 

 
 
 

 

 

 
 

 
 
 

 

 

 

INSTALLATION, 

OPERATION AND 

 

 

MAINTENANCE MANUAL 

FOR ALL STANDARD 

RADIATOR MODELS 

 

 

 
 

 
 
 
 

 
 
 

 
 

 
 
 

 

 

 

 
 

July 2019

Содержание ROCORE F Series

Страница 1: ...e To access digital copies of this manual other manuals or additional information scan the code on the left or visit www rocore com STANDARD RADIATOR IOM MANUAL INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR ALL STANDARD RADIATOR MODELS July 2019 ...

Страница 2: ...w The complete terms and conditions of the Limited Warranty accompany the product packaging and shipping material If you cannot find or misplace this limited warranty information please call 1 317 227 2929 for information and or replacement Outside of the U S call 001 317 227 2929 9845 South 57th Street Franklin WI 53132 Telephone 414 421 4666 Fax 414 421 0712 ...

Страница 3: ...g and Lifting 9 E Safety and Advisory Messages 11 III INSTALLATION A Placement and Mounting 12 B Mounting Surge Tanks on Remote Radiators 13 C Piping 16 D Electrical Wiring 26 E Coolant Level Switches 27 F Filling 27 G Coolants 28 H Fan Drive Components 32 I Fan Position 32 J Startup 32 K Cogen Combined Heat and Power CHP 35 Cold Weather Climate Applications ...

Страница 4: ...ENERAL MAINTENANCE A Lubrication 36 B Belt Tension 38 C Bolts and Torque Requirements 39 D Core Cleaning 40 E Fans 40 F Coolants 41 G Replacement Parts 42 H Miscellaneous Maintenance 43 V TROUBLESHOOTING 44 ...

Страница 5: ...roduct manufactured by it which has defects in material or workmanship provided a Customer notified Rocore in writing of any claim of defect in material or workmanship within sixty 60 days from the date of the failure of the cooling product b Customer has complied with the Repair and Replacement Procedure set forth in this warranty document and c the cooling product is found defective in materials...

Страница 6: ...ent freight collect on approval by Rocore and the following information with each returned unit a In Service date b Number of miles in service1 c Number of hours in service2 d Mode and details of failure e Name of Customer and OEM f Serial number of transmission or equipment3 g VIN Number of the vehicle4 h Transmission or equipment model5 i Rocore Identification tag must be legible and attached to...

Страница 7: ... arbitration before beginning formal proceedings for the judicial resolution of such dispute This Standard Limited Warranty and all matters relating thereto will be deemed to have been entered into in the State of Indiana and will be governed under the law of Indiana without regard to principles of conflict of laws Subject to the dispute resolution procedures contained herein the parties each here...

Страница 8: ...s been received Accessories and ship loose items may be banded to the skid or a separate skid s and should be included on the packing slip and bill of lading Check the radiator and or accessories for damage especially the radiator core area Any visible damage must be noted on the bill of lading prior to the trucker s departure Any visible or concealed damage should be immediately reported to the c...

Страница 9: ...the shafts several turns once per month to redistribute the grease in the bearings D MOVING AND LIFTING When the radiator is moved from the receiving area use the following recommended procedures It is recommended that the radiator remain on its skid and be moved with a forklift The small horizontal radiators may be shipped in the horizontal position but the larger horizontal radiators may be ship...

Страница 10: ...d rotating To rotate move in this direction while lifting Figure 1B Lifting horizontal radiators Figure 1A Rotate from vertical to horizontal NOTE Refer to the radiator assembly drawing for more exact lifting hole locations NOTE Refer to the radiator assembly drawing for more exact lifting hole locations ...

Страница 11: ... procedures 7 DANGER High voltage and rotating parts may cause serious or fatal injury 8 WARNING Over tensioning belts shortens belt and bearing life See Section IV B for correct belt tensioning 9 WARNING Under tensioning belts can cause the following See Section IV B for correct belt tensioning Premature belt wear Reduced radiator cooling performance as a result of slower fan speed Fan failure So...

Страница 12: ...ors usually are not sized to accommodate engine room or any other air rise or external static restrictions to airflow unless specified in the application design data Standard remote radiators should be bolted to a level solid foundation or structure Spring type isolators are not recommended for applications that require vibration isolation between the radiator and the foundation or structure Sprin...

Страница 13: ...ped loose and must be installed by the customer See the radiator assembly drawing for the proper location and orientation of the surge tank on the radiator See Figure 3 for additional details on connecting the surge tank to a horizontal remote radiator To help prevent pump cavitation on horizontal radiators it is recommended that the surge tank be mounted on the radiator water outlet end pump suct...

Страница 14: ...14 CUSTOMER SUPPLIED BRACES 2 Figure 2A Model N engine mounted radiator installation CUSTOMER SUPPLIED BRACES 2 Figure 2B Model F engine mounted radiator installation ...

Страница 15: ...15 Outlet Figure 3 Mounting surge tanks on horizontal radiators ...

Страница 16: ...iator top tank is recommended A fast fill port may be provided on radiators with a deaeration baffle This port is used to initially fill the radiator If a fast fill port is not available fill through the radiator inlet s After initial run up recheck the system to be sure it is filled Connection of the deaeration system should be in accordance with the engine manufacturer s recommendations 2 VERTIC...

Страница 17: ...ator Engine Pump Flexible Connections Typical Drain Outlet Inlet Cap Keep Top Tank 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator top tank ...

Страница 18: ...o Engine Pump Suction Engine Pump Flexible Connections Typical Drain Outlet Inlet Cap Keep Top Tank 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line from Thermostat Housing Fast Fill Port If Included NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator top tank ...

Страница 19: ...er Optional Drain Engine Pump Flexible Connections Typical Drain Outlet Inlet Cap Keep Top Tank 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator top tank ...

Страница 20: ... Pump Strainer Optional Drain Drain Outlet Inlet 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It 1 4 to 1 2 Vent Line 3 4 to 1 Fill Line to Engine Pump Suction Keep Surge Tank 1 4 to 1 3 Full when Cold Cap NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator surge tank ...

Страница 21: ...ed as a two circuit radiator it should be piped as shown in Figure 10 When low flow in the aftercooler circuit requires a two pass arrangement both the inlet and outlet will be in the bottom tank The radiator top tank must be the highest point in the system A 1 4 inch to 1 2 inch vent line may be required from the engine thermostat housing to the jacket water side of the top tank An aftercooler ci...

Страница 22: ... Strainer Optional Drain Outlet Inlet 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It 1 4 to 1 2 Vent Line 3 4 to 1 Fill Line to Radiator Outlet Tank Keep Surge Tank 1 4 to 1 3 Full when Cold Cap NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator surge tank ...

Страница 23: ...4 to 1 Fill Line to Engine Pump Suction Cap 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It Flexible Connections Typical Auxiliary Pump Strainer Optional 3 4 to 1 Fill Line to Radiator Outlet Tank Outlet Inlet Cap Keep Surge Tanks 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line NOTE All lines are shown schematically and all respective circuit piping should be lower than the respe...

Страница 24: ...rain JW Outlet JW Inlet JW Cap Engine AC Pump Strainer Optional Drain AC Outlet AC Inlet AC Cap Drain 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It Keep Both Circuits of Top Tank 1 4 to 1 3 Full when Cold NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator top tank ...

Страница 25: ...rainer Optional Drain Drain Strainer Optional Engine AC Pump Engine JW Pump JW Inlet AC Outlet Flexible Connections Typical JW Outlet AC Inlet 3 4 to 1 Fill Lines 1 4 to 1 2 Vent Lines AC Circuit 1 4 to 1 2 Vent Lines JW Circuit Caps NOTE All lines are shown schematically and all respective circuit piping should be lower than the radiator surge tank ...

Страница 26: ...t be changed allow the motor to stop completely disconnect power lockout tagout and then interchange any two leads of a 3 phase motor 3 Dual voltage and single voltage motors can be connected for the desired voltage by following the connection diagram shown on the motor nameplate or inside the motor conduit box Motors must be wired for across the line unless using a Wye Delta starter then wire for...

Страница 27: ...is shown in Figure 12 The top connection of the switch is piped to the lowest acceptable coolant level port in the top tank The lower connection is piped to a drain port in the radiator bottom tank The lower connection should not be close to the radiator outlet If you are using a horizontal radiator or a vertical radiator with a surge tank the level gauge is installed on the surge tank as shown in...

Страница 28: ...ne The datasheet which accompanies your radiator will show the type and concentration of coolant antifreeze that the radiator is designed to operate with Rocore and engine manufacturers strongly recommend a minimum of 30 70 antifreeze water mix and very strongly recommend 50 50 antifreeze water mix and recommend pre mixed coolants that ensure use of good quality water Check your engine manual as s...

Страница 29: ...n distilled or deionized water is not available use the following guidelines Never use salt water Never use softened water Select the best quality fresh water available Test the water to determine water quality See below Never use water alone as a coolant Coolant additives are required because water is corrosive at normal system operating temperatures However adding coolant additives to poor quali...

Страница 30: ...UTION Most Rocore radiators are made of steel copper brass and solder materials Some radiators may include aluminum materials If you have an aluminum radiator special attention must be made in selecting a coolant that is compatible for use with the aluminum materials See the engine manufacturer s manual for more information on recommended coolants coolant additives and maintenance ...

Страница 31: ...s below the centerline location of the level switch Level Switch Figure 13 Surge tank coolant level switch installation Radiator In this case the level switch will indicate a low coolant level when the coolant level falls below Port A Level Switch Port A Figure 12 Radiator coolant level switch installation ...

Страница 32: ...ne mounted radiators that use the engine mounted fan for cooling the fan must be correctly positioned in the radiator s fan shroud opening to obtain optimum fan performance The projected blade width needs to be 1 3 for blower fan applications or 2 3 for sucker fan applications into the fan shroud opening See Fig 15 J STARTUP If the radiator has been in storage idle for an extended period of time o...

Страница 33: ...33 Belts Level OR Straight Edge Engine Crank Sheave Idler Sheave Belts Fan Sheave Figure 14 Sheave alignment ...

Страница 34: ... Fan Shroud Radiator Sucker Fan Application Airflow Fan Shroud Radiator Blower Fan Application Projected Fan Width 2 3 of Projected Fan Width Projected Fan Width 1 3 of Projected Fan Width Figure 15 Fan position ...

Страница 35: ... hot coolant The solder joint construction used to bond the radiator s core tubes to the radiator s headers will eventually fail from stresses created by the thermal expansion and contraction of the surrounding materials A proven method to avoid the above thermal shocking problem is to constantly circulate some hot coolant through the radiator during any time that the system is in operation This c...

Страница 36: ...mended that the housing be filled until a bead of grease starts to come out around the seals Do not use excessive pressure as this can damage the bearing seals Do not mix grease types Grease compatibility is critical Re lubricate with grease that is compatible with grease supplied from the factory For Single pillow block spherical bearing units such as QM Timken Blue Brute Model QMPL Browning Mode...

Страница 37: ...perate at speeds greater than 1800 RPM should be lubricated on a more frequent maintenance schedule depending on duty cycle Do not mix grease types Table 3 Bearing type descriptions and maintenance SERVICE SYMBOL TYPE OF SERVICE SUGGESTED MOTOR RE GREASING INTERVALS A Infrequent operation or light duty in clean atmosphere 3 4 months B 8 16 hrs day in clean relatively dry atmosphere 4 5 days C 12 2...

Страница 38: ...8 16 0 12 7 15 5 18 9 23 4 13 7 17 1 22 1 25 5 The deflection force in the above table should be measured at the midpoint of the belt span distance between two sheave centerlines with a belt tension checker For more detailed instructions follow the belt tension checker s instructions New drives should be tensioned close to the maximum recommended deflection force Check the tension frequently durin...

Страница 39: ...essure The gaskets may swell enough to stop the leaking If not the bolts will need to be re torqued Remove the fan or core guards and re torque bolts in the area of the leak All header bolts should also be re torqued at this time The torque for these bolts should be 13 to 15 ft lbs Replace guards CAUTION Do not over torque Over torqueing may damage the gasket 2 STANDARD HARD JOINT TORQUE REQUIREME...

Страница 40: ...ged by high pressure close to the core E FANS For all fans clean any accumulated scale or foreign matter from the fan assembly when you perform the regular maintenance Also for all fans check the fan for any cracks dents or corrosion Plate hub fans manufactured by AirFlo Cooling Technologies formerly Chittom with model numbers starting with 7E 12F 18T 24T or P fan model numbers are shown on the ra...

Страница 41: ... 1 Level 2 2 Conventional Heavy Duty Coolant Antifreeze Every 250 hours or 6 months Yearly 3 Extended Life Coolant Optional 3 Yearly 3 1 A Level 1 test includes Glycol concentration for freeze and boil protection Ability to protect from erosion and corrosion pH Conductivity Visual analysis Odor analysis The results are reported and appropriate recommendations are made 2 A Level 2 test includes All...

Страница 42: ...or 6 years 1 Use the interval that occurs first 2 These intervals are only achievable with annual Level 2 coolant sampling and analysis See subsection G Coolants under section III Installation for more information on coolants G REPLACEMENT PARTS If it becomes necessary to replace any parts please record all the radiator nameplate information such as part no serial no and mfg date See the image bel...

Страница 43: ... all times Regularly inspect the radiator hoses and piping for leaks Regularly inspect for excessive vibration or noise Regularly inspect for loose or missing fasteners especially on or near moving parts Regularly inspect fans and guards for signs of fatigue cracks and loose or missing fasteners ...

Страница 44: ...ts Replace gaskets Defective radiator cap Replace cap Air in system settles out after initial filling running Add additional coolant Over pressurization of the radiator Repair or replace damaged components Coolant overflowing Overheating See section on overheating Surge tank or top tank initially overfilled Drain some coolant to proper cold fill level Surge tank or top tank not adequate size for t...

Страница 45: ... winds Relocate radiator Loose belts Correct belt tension Low coolant flow Check for pump cavitation Piping restrictions Check for correct venting makeup piping Vent all high points in the piping Low coolant level Refill to proper level Outside of radiator dirty or plugged Clean radiator Bent or loose radiator fins Straighten fins Coolant thermostat or temperature switch malfunction Repair or repl...

Страница 46: ...or incorrect wiring Wrong voltage applied to motor Check available operating voltage vs motor nameplate Operated by VFD Adjust VFD settings and or add noise filter and or proper wire type Operated by VFD at too much speed turndown ratio Reduce speed turndown Fan noise Fan hitting fan guard or fan openings Adjust fan position Radiator noise Loose or missing fasteners Tighten loose fasteners and rep...

Страница 47: ...missing or broken fasteners Mounted on spring isolators If vibration isolation is required use rubber pad type Vibration induced from engine or other equipment Use flex connectors between radiator piping engine or other equipment components Fan balance or tracking Check fan balance and tracking Loose or missing fan mounting fasteners Tighten and or replace missing or broken fasteners Loose belts C...

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