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1. IN V SINGLE UNIT OOO DUAL UNITS AOOO END TO END Figure 17 ECOSS Induced Draft Condenser Configurations For Corresponding Air Inlet and Basin Heights See Table ECOSS CONFIGURATIONS AND AIR INLET amp BASIN HEIGHTS in Dual End to End Dual Side by Side QuadUnit 10 x 12 D E AZ 36 65 7355 78 5S f 78 ae 4 Inlet Louver Basin nlet Louver Basin Height Inlet Louver Basin Inlet Louver Basin Height L Height H Height L H Height L Height H Height L Height H N 36 8 36 8 88 88 NOTE Consult Factory for additional information For reference only use certified drawings for design purposes BY JOHNSON CONTROLS eeh y Prick BY JOHNSON CONTROLS System side safety requirements For safety information please refer to Appendix I 5 1 2 System side safety requirements Customer side safety precautions Danger of injur
2. ZZ 10 WIDE UNITS 18 LONG UNITS A 1 AW A 134 8 11 2 8 Af 8 12 LONG UNITS 12 WIDE UNITS Figure 13 Lower Section of the Unit Lifting Guidelines Erick ECOSS EVAPORATIVE CONDENSERS 140 010 IOM JUL 2014 or INSTALLATION Page 9 v Align the top section with the bottom section see Figure v Appropriately guiding the top section safely above the 14 section joint and free from pinch points see Figure 15 a 4 1 i 0 Figure 14 Aligning Top and Bottom Sections Figure 15 Positioning the Top Section of the Unit 10 WIDE UNITS 18 LONG UNITS 2 12 WIDE UNITS 12 LONG UNITS Figure 16 Upper Section of the Unit Lifting Guidelines 140 010 IOM JUL 2014 v Bolt the top section and the bottom section together from the inside v Close the gap between the lower and the upper riser pipe section with the pipe connector o Tip liquid soap will help slide the pipe connector over the PVC pipe v Clamp pipes together Ladder And Platform See specific c
3. 5 12 PUTTING THE UNIT INTO OPERATION AFTER A SHUTDOWN NOTICE The pressure test with recommissioning must only be carried out with appropriate media at appropriate test pressure by trained personnel 6 MAINTENANCE Danger of slipping and falling Only step onto the unit with firm tough and safe footwear and only when required If the units do not have any railings always only walk on them with a safety device that prevents falling 140 010 IOM JUL 2014 ECOSS EVAPORATIVE CONDENSERS as Page 30 APPENDIX er 6 1 BEFORE STARTING ALL MAINTENANCE drain the unit s heat exchanger clean and blow out the unit s heat exchanger 6 2 WITH ALL MAINTENANCE WORK Danger of injuries and damage to property with escaping refrigerant see Appendix I 2 7 Residual hazards with refrigerant Danger of injuries and damage to property with escaping refrigerant see Appendix I 2 7 Residual hazards with Only perform maintenance work especially welding work refrigerant on the leaking unit after completely removing the refrigerant from the leaking unit Escaping refrigerant with leaks can cause the following hazard Perform the following safety measures before beginning all situations and injuries maintenance work Warning against explosion risk and fire risk substances in the setup space Unintentionally carried in oil resi dues can ignite Ensure that there is no unintentionally carried in oil in the setup
4. Do not operate fans without guard grille Pinch trap point hazard With automatic fan start during mainte nance work there is a danger of pinching trapping for the hands and fingers Power off the unit before you begin maintenance work with which you must remove the guard grille Ensure that all electrical switchgear for the fans must be disconnected locked out and tagged out ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 21 140 010 IOM JUL 2014 2 5 ELECTRICAL RESIDUAL HAZARDS Warns against dangerous electrical voltage Direct and indirect contact with voltage carrying parts of motors and electrical lines can cause serious injuries or death Power off the unit before you begin maintenance work See the refrigeration system documentation for this Ensure all electrical switchgear have been discon nected locked out and tagged out Please note that the main cables may also be carrying voltage even if the unit is powered off Work on electrical equipment must only be performed by people that have the required expertise ex an electrician or an electro technically instructed person and who are authorized to do so by the facility operator 2 6 THERMAL RESIDUAL HAZARDS Danger of burns Warning against hot surfaces During operation the coil of the unit and heater elements option have temperatures of over 110 F Contact can cause burns With refrigerant temperatures of above 110 F th
5. Ammonia is a flammable explosive gas The fire and explosion hazard is low be cause of the high ignition temperature small ignition range low explosiveness potential and high affinity with air humid ity Leaks in the unit can cause the NH3 refrigerant to escape into the installed area Direct and indirect ignition sources can cause the NH3 refrigerant to burn and or explode Do not store potentially explosive and fire risk substances in the installed area Test for leaks of the unit regularly as specified in these operating instructions Provide firefighting equipment in sufficient numbers in the unit s installed area Ob serve the details for firefighting in the NH3 refrigerant safety data sheet Chemical burn hazard Leaks in the unit can cause the NH3 re frigerant to escape into the installed area NH3 refrigerant is corrosive in combina tion with moisture Contact with the skin mucous membranes and the eyes with the NH3 refrigerant causes chemical burns on the skin mucous membranes and the eyes If the NH3 refrigerant gets into the eyes the eyes can no longer be kept open because of the strong burning and thus orientation is lost Danger of poisoning Leaks in the unit can cause the NH3 re frigerant to escape into the installed area Ammonia is a toxic irritant gas Inhaled NH3 refrigerant causes agitation dizziness vomiting and cramps with heavy concen trations suffocation and life threatening pulm
6. Only remove the sealing caps on the distribution and header pipe immediately before installation NOTICE Danger of corrosion and dirt build up for units using ammonia as refrigerant ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 27 140 010 IOM JUL 2014 The refrigerant ammonia is highly hygroscopic i e it attracts humidity Humidity and dirt may not get into the unit s in terior If humidity or dirt gets into the unit s interior fittings and other components of the refrigeration installation can be damaged Protect the unit against dust contamination moisture and wetness damage and other harmful influences Harmful influences are for example Mechanical Damages caused by impacts objects falling on or against collisions with transport equipment etc Physical Damages caused by close by concentrated flam mable gases Chemical Damages caused by contaminated atmospheres salt acid chlorine sulfur containing or similar Thermal Damages caused by close by heat sources Start as soon as possible with installation The electrical installation must only be performed by electricians in compliance with relevant rules or ap plicable national and international regulations 5 1 2 System side safety requirements The unit is a component of an installation and can only be operated in conjunction with the installation All equipment required for operating the unit must be integrated into the switching and activ
7. 14 6 1 BEFORE STARTING ALL MAINTENANCE 30 AFTER ALL MAINTENANCE 14 6 2 WITH ALL MAINTENANCE 30 INSPECTION AND MAINTENANCE PLAN 14 6 3 AFTER ALL MAINTENANCE WORK sasseeseeeeeeeen 31 CLEAN 15 6 4 INSPECTION AND MAINTENANCE PLAN 31 General 0 Ee 15 6 5 MAINTENANCEWORkK rnanan 32 Cleaning Of Coil Casing And Basin tees 15 6 6 CLEAN 32 WATER TREATMENT sek NK NNN ERR ENKEN ERKENNEN ERR ENN 16 7 WATER TREATMENT ccecececcccececececcncecececcccecececes 32 WATER TREATMENT AND MINIMUM WATER QUALITY 71 WATER TREATMENT AND MINIMUM WATER REQUIREMENTS geg eege eege dee ER Ee 16 QUALITY REQUIREMENTS oniiir 32 Stelle rue alk C eege EE 16 8 TROUBLESHOOTING ee ce coccccoccccoccccaceccecececcececcecececcecece 32 Chemical treatment scsecsccsseeeceesersersensensenses 16 8 I SERVICE EnO 32 TROUBLESHOOTING kk NENNEN NN ENNEN NK ENNEN NK ENKEN 16 82 TROUBLESHOOTING cc cccccocccocccccccccccnccecs 32 0 16 refrigerant Se Ot RR ORE GE eeneg 32 140 010 IOM JUL 2014 ECOSS EVAPORATIVE CONDENSERS Page 4 INSTALLATION OPERATION MAINTENANCE Frick BY JOHNSON CONTROLS GENERAL INFORMATION This manual has been written for professionals in the re frigeration field Basic knowledge of handling evaporative condensers Is presupposed Always keep the operating instructions including Appendix Safety Installation Operation amp Maintenance in the uni
8. The mounting bolts are secured against loosening by means of an appropriate locking device The mounting bolts are not over tightened or stripped All mounting bolts are tightened equally to achieve a load distribution on the connections that is as balanced as possible All mounting points maintain the same spacing to the support structure permanently and under load so that no mechanical stress occurs in the unit structure The units are anchored in their position in order to prevent the equipment from moving The functional safety of the mounting bolts is tested as part of the maintenance periods The unit is fixed and set up so that it is not damaged by environment conditional hazard sources production transport and other processes at the setup point or its functioning is not disturbed by the interventions of un authorized persons The units are fixed and set up so that unobstructed air inlet outlet is constantly available without any air short circuiting The units are fixed so that they can be inspected checked and maintained from all sides at all times i e there must be unobstructed access to the refrigerant carrying and electrical components connections and lines the pipeline labeling must be identifiable and adequate space must be available for testing The refrigerant carrying lines are protected against me chanical damage On site connections when installing keep the unit free of load force must not be exerted on the di
9. This can cause damage and subsequent leaks Lift the unit carefully Avoid setting the unit down hard in particular 4 1 TRANSPORTATION NOTICE Read and observe all transport signs on the unit packaging Prolonged mechanical stresses caused by uneven road sur faces and potholes cause transportation damage Transporting the unit at the installation point Unloading the unit Transport and unload the packed unit with suitable trans port equipment ex crane at the setup point Do NOT use a fork lift ECOSS EVAPORATIVE CONDENSERS Page 26 APPENDIX Frick BY JOHNSON CONTROLS 4 2 STORAGE NOTICE Danger of corrosion and dirt build up see Appendix l 5 Connecting the unit 5 1 Safety instructions 5 1 1 Safety instructions for setup and start up Moisture and dirt must be prevented from entering the unit v Protect the unit against dust dirt moisture and wetness damage and other harmful effects v Harmful effects see Appendix 5 Connecting the unit 5 1 Safety instructions Safety instructions for setup and start up v Do not store the unit for longer than necessary Only store the units in their original packaging until installation v Store the unit at a protected place free of dust dirt and moisture and damage free until it is set up well ventilated halls or roofed storage site v Ifthe unit setup is delayed with regard to the planned in Stallation time protect the unit against weather a
10. Transportation Storage Unpacking amp Mounting TRANSPORTATION NOTICE Read and observe all transport signs on the units pack aging see Appendix l 4 1 Transportation STORAGE NOTICE Danger of corrosion and dirt build up see Appendix 4 2 Storage UNPACKING The two parts of the unit are packed and shipped separately on their own substructure See Figure 10 After removing both sections of the unit from the truck remove plastic wrapping loosen bolts connecting the unit to the substructure remove clamps etc remove any accessories shipped loose in the basin boxed ensure that delivery is complete and without damage In case of damage or missing parts contact the manufacturer Immediately re i Figure 10 Upper Section of Unit On Substructure MOUNTING Condensers will need to be structurally supported with two parallel beams traversing the entire length of the unit See Figure 11 I beams must be level to within 1 8 over a D span Shims cannot be used to level the unit as this will compromise the load bearing surface ECOSS EVAPORATIVE CONDENSERS INSTALLATION Page 7 140 010 IOM JUL 2014 Mounting holes 13 16 diameter are provided at the base of the basin section in the side panel flanges to enable secur ing each unit to the support structure utilizing 3 4 diameter bolts Refer to the Frick unit certified drawing for the bolt hole locations All su
11. With refrigeration system shutdown state under cooled liquid is only present in the lowest possible amount in system components minimized number of fluid sacks Frick BY JOHNSON CONTROLS 5 5 1 Important considerations regarding installation The unit must only be put into operation operated maintained and repaired by trained experienced and qualified personnel see Appendix l 2 2 1 Personnel care requirements Any work done to connect the unit to the system must be done carefully ex welding the connecting pieces Warranty for damages caused by careless handling is ex cluded 5 6 UNIT ELECTRICAL CONNECTION amp PROTECTION Danger of injuries and damage to property the fusing is too high there is the danger of injuries to people and damage to property Make sure that the supply lines are always fused in accor dance with the smallest wire cross section 5 7 PERFORM ACCEPTANCE TEST Danger of injuries and damage to property Escaping refrigerant can cause injuries or even death see Appendix 2 7 Residual hazards with refrigerant Perform the following acceptance test with an expert before starting up the unit after making important changes and after a unit swap out 5 8 TEST READINESS FOR OPERATION No specific dangers at this point 5 9 PUTTING THE UNIT INTO OPERATION FOR THE FIRST TIME Danger of injuries and damage to property with escap ing refrigerant Escaping re
12. practice etc or portion thereof which is essential to highlight 1 4 2 Warning signs and their meaning in these operating instructions Warns against hand injuries Hands or fingers can be crushed pulled in or otherwise injured with non com pliance Warns against hot surfaces The temperature is over 110 F protein clotting and can cause burns Warns against dangerous electrical voltage Danger of an electric shock if voltage carrying parts are touched ECOSS EVAPORATIVE CONDENSERS Page 18 APPENDIX Frick BY JOHNSON CONTROLS Warns against fire risk substances at setup point Use of ignition sources can cause fire at setup point Warns against harmful to health or ir ritant substances at setup point Contact with or inhaling harmful to heal or irritant substances can cause injuries or damage the health Warns against potentially explosive substances at setup point Use of ignition sources can cause explo sions at setup point 1 4 3 Prohibitory signs and their meaning in these operat ing instructions Fire open flame and smoking are prohibited Ignition sources must be kept away and ignition sources must not develop No smoking Smoking is prohibited 1 4 4 Mandatory signs and their meaning in these operat ing instructions Use eye protection Eye protection Use protective cover pro tective glasses or face protection Use hand protection Protective gloves m
13. refrigerants refrigerant oil heat exchangers fans must be disposed of properly as specified Used refrigerant that is not determined for reuse must be treated as waste and safely disposed of There must be no emissions into the environment The refrigerant must be filled into a special refrigerant container in compliance with the respective safety mea sures This special refrigerant container must be suitable for the refrigerant It must be easy to identify and labeled for the refrigerant A disposable single use container must not be used as refrigerant vapor residues in the container escape during disposal The refrigerant container must not be overfilled The maximum permissible pressure of the refrigerant con tainer must not be exceeded during the work process The refrigerant must not be filled in a liquid container that contains another or an unknown refrigerant This other or unknown refrigerant must not be released into the atmosphere but rather identified treated again or properly disposed of as specified An officially authorized facility can be used for destroying the refrigerant Used refrigerant oil that has been recovered from the unit and cannot be treated again must be kept in a separate suitable container treated as waste and safely disposed It must be ensured that all unit components containing refrigerants and refrigerant oil are disposed of properly as specified The unit consists predominantly of the bas
14. 14 motor 15 motor bearing life 5 mounting bolts 8 11 24 mounting holes 11 mounting points 11 15 24 N NH3 23 25 30 nozzles 15 O operating conditions 13 Operating Conditions 20 operating pressure 13 oscillations 12 owner 17 P personal protective equipment 21 phase failure protection 5 pipe connections 12 piping 12 Piping supports 12 power factor correction 5 power supply 27 pressure test 12 pressurized parts 24 protective clothing 18 27 pump 11 15 pump bearing 15 pump discharge 11 pump flanges 15 pump inlet 4 PVC riser pipe 26 140 010 IOM JUL 2014 Page 34 R recirculation 11 refrigerant 13 17 21 23 25 28 31 32 refrigerant circuit 27 Refrigerant leak 16 Refrigerants 20 refrigerant vapor 19 30 Remote Sump 6 repiratory protection 18 Residual hazards 25 respiratory protection 19 31 responsibilities 17 riser pipe 10 Rust 27 5 safety 4 Safety Instructions 10 safety precautions 13 safety signs 18 sanitizing 14 Shims 7 shutdown 13 29 soldering 22 spare parts 7 spray nozzle 5 stainless steel 25 Stainless Steel Coil 4 stainless steel strainer 5 Steel Support Dimensions 7 strainer 4 Strainer 15 32 sub cooled liquid 25 Sulfates 16 support structure 7 8 switch off device 27 system installer 17 T TEFC motor 6 terminal box 27 thermostat 6 threaded connections 12 U Unstable oils 27 V vapor
15. Ap pendix I 8 Troubleshooting SERVICE Contact your nearest Frick Factor TROUBLESHOOTING TABLE Possible cause s Fan motor not Power supply running interrupted Bearing noises Defective fan motor Excessive vibra Defective fan blades 000034 Loose fan fixture tion of the unit Refrigerant leak Unit refrigerant carrying compo nents leaking Restore power supply Enable fan to rotate freely Renew bearing or fan motor Change fan blades Tighten fixtures Switch off refrig erant feed and fans close leak Een peemmmeeeg Prick BY JOHNSON CONTROLS APPENDIX 1 GENERAL INFORMATION This equipment is relatively complicated and the installa tion operation maintenance and servicing should only be carried out by suitable individuals who are qualified to carry out these functions These individuals shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the function s v Always keep the operating instructions including Appendix Safety Related Information in the unit s immediate vicinity at all times v Ensure that the operating instructions including Appendix Safety Related Information are accessible to all people that have anything at all to do with the unit at all times v Ensure that the operating instructions including Appendix Safety Related Information are read and understood by all people t
16. Monitoring of the adjustment of circuit breakers according to the fan manufacturer s manual Maintenance and Cleaning Inspections gt gt O JO ct let O JO Ska J gt ct or DIO le Site Q let olS c o Slo Jec 7 DiD SCH D S a O u Ee DI ct 5 Jo 5 O ef Get gt Q O O 5 Le s 2 o Q D oa CG Les D my Le gt D 2 Le D 5 A D o 5 Q 3 O O Se oa may O oo ZA o D A O D 5 Q D Q eeh y Prick BY JOHNSON CONTROLS MAINTENANCE WORK Remove leaks Danger of injuries and damage to property with escap ing refrigerant see Appendix I 6 5 Maintenance work Strainer And Basin Clean per maintenance schedule Level Of Water v Fill level prior to energizing the recirculation water pump is 17 measured from the inside of the depressed area of the basin v The operating water level in the basin is 1414 measured from the inside of the depressed area of the basin Fans Maintenance Required every 6 months v Check the fans for dirt build up and clean as required v Check that fan drive runs smoothly o If vibrating remove imbalances Tighten and correct blade fixtures and blade settings where required v Check and replace fan bearing if running sound and smoothness changes v Check and replace fan m
17. With work involving fire or sparks ex grinding welding etc ensure suitable firefighting equipment is on site In particular be aware of the danger of ignition of residues or halocarbon refrigerant unintentionally carried in oil Ensure that firefighting equipment is provided in sufficient quantities that it functions properly and that the ex tinguishing agent does not react with the halocarbon refrigerant Smoking during work is prohibited Frostbite hazard Splashing halocarbon refrigerant under boiling retardation can cause frostbit on the eyes and skin When removing faults after halocarbon refrigerant spills you must be vigilant for remaining halocarbon refrigerant still under boiling retardation Danger of poisoning Halocarbon refrigerant contact with fire can form toxic combustion products Prevent halocarbon refrigerant contact with open fire Welding and soldering must therefore only take place after completely drain ing the relevant section of the system of the halocarbon refrigerant Ensure good ventilation With emergency work in high refrig erant concentrations in the room air wear a room air independent breathing apparatus Ammonia Danger of injuries and damage to property with Am monia as refrigerant Ammonia can cause the following hazard situations and injuries ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 23 Prick BY JOHNSON CONTROLS Explosion hazard Fire hazard
18. and physical effects from the inside on the materials surrounding them The unit must only be pressurized with a specified refrigerant Pressurizing the unit with another refrigerant results in material wall thickness tensile strength corrosive resis tance shaping process and testing are not suitable for the refrigerant used and do not withstand the possible pressures and stresses that might occur the unit not being resistant to the other refrigerant and the other refrigerant mixture the unit not remaining tight during operation and when shut down a possible sudden escaping of refrigerants could directly endanger people and or property and the environment The maximum permissible operating pressure specified on the name plate must not be exceeded If the operating pres sure is exceeded the structural and welding materials will not withstand the foreseeable mechanical thermal and chemical stresses and the pressure that can occur during operation and when shut down the unit will not remain tight during operation and when shut down there may be a possible sudden escaping of refrigerants after a break or leakage on refrigerant carrying compo nents which would result in the following dangers o Danger of escaping materials o Dangers caused by oxygen displacement Frick o Fire hazard caused by refrigerator oil parts o Frostbite hazard caused by liquid coolant squirting splashing o Suffocation hazard o Hazards caused
19. damage caused by environment conditional hazard sources production transport and other pro cesses at the setup point ECOSS EVAPORATIVE CONDENSERS Page 24 APPENDIX Bee dr See Frick BY JOHNSON CONTROLS unit functional faults caused by air inlet outlet obstructions obstruction of all side inspection checks and mainte nance i e no unobstructed accessibility to the refrig erant carrying and electrical components connections and cables no recognizable identifiers on the pipes and insufficient space for tests With ammonia units defective installation may also result in hazards caused by under cooled liquid in system sections If system sec tions are opened with repairs and the pressure is bal anced with the atmosphere there is a danger that liquid under cooled ammonia will still be in the opened area Ammonia has a very high evaporation heat so that the heat penetration in the pipes for example which are laid with a fluid sack is not sufficient to evaporate the liquid ammonia quickly especially if this is an insulated line Ensure that The units are to be installed on the mounting points corre sponding with their weights and tightened with mounting bolts The operator or installer is responsible for ensuring that the bolted connections are of adequate strength The diameters of the mounting holes have been statically determined by the manufacturer and the mounting bolts are adapted accordingly
20. safety reguiremente 1 4 TRANSPORTATION STORAGE Customer side safety Drecautons 11 UNPACKING amp MOUNTING 6 LOCATION REQUIREMENTS emmmer 11 4 1 TRANSPORTATION c sscssesseessesseessecsscssecseesseceseeees 26 NOTES ON CONNECTING THE settee 11 A ai 26 CONNECTING THE WATER PIPES neen 11 26 RECIRCULATED WATER SYSTEM en 11 AA E 26 CONNECTING THE UNIT TO THE SYSTEM 11 5 CONNECTING THE UNIT 0 26 Important considerations regarding installation 12 5 1 SAFETY 5 26 UNIT ELECTRICAL CONNECTION amp PROTECTION 12 5 2 LOCATION BEOUIREMENTS 28 PERFORM ACCEPTANCE 12 5 3 NOTES ON CONNECTING THE 28 Acceptance 0 12 5 4 CONNECTING THE WATER PIPES 28 TEST READINESS FOR OPERATION 12 5 E CONNECTING THE UNIT TO THE 28 5 6 UNIT ELECTRICAL CONNECTION 8 PROTECTION 29 PUTTING THE UNIT INTO OPERATION FOR THE FIRST 5 7 PERFORM ACCEPTANCE a 29 oaeen a E A 13 5 8 TEST READINESS FOR 0 29 TAKING A UNIT OUT OF OPERATION 13 5 9 PUTTING THE UNIT INTO OPERATION FOR THE SHUTTING THE UNIT lt annann 13 FIRST Hl LEE 29 PUTTING THE UNIT INTO OPERATION AFTER 5 10 TAKING THE UNIT OUT OF OPERATION 29 A SHUTDOWN cairia aa 13 5 11 SHUTTING THE UNIT DON 29 5 12 PUTTING THE UNIT INTO OPERATION AFTER A SHUTDOMWN 29 BEFORE STARTING ANY MAINTENANCE nannnnnennennn 14 6 29 WITH ALL MAINTENANCE WORK
21. space Keep the risk area free of direct and indirect ignition sources Before releasing for maintenance obtain the required approvals for work for the unit that can involve ignition sources ex grinding welding soldering etc With all work involving ignition sources ex grinding welding soldering etc in the work area keep suitable fire extinguishing equipment at hand Do NOT bring any open flames or hot gases ex candles matches welding beads sparks glowing cinders or tobacco into the setup space Ensure that there are no warmed up or hot surfaces ex heaters hotplates bulbs motor housings in the setup space Warns against corrosive substances in the setup space NH3 refrigerant still present is corrosive Contact with the skin mucous membranes and the eyes with NH3 refrigerant under effervescence causes chemical burns on the skin mucous membranes and the eyes Use eye protection Use hand protection Warns against toxic and health endangering irritants in the setup space Still present NH3 refrigerant under retardation of boiling can evaporate Inhalation of refrigerant vapor Is poi SONOUS Escaping refrigerant vapor and escaping refrigerant liquid must not reach adjacent rooms staircases yards passages or drainage systems Use respiratory protection Use a room air independent breathing apparatus with maintenance work in high ammonia concentrations in the room air Ensure the setup space is
22. temperature 13 condenser coils 4 Conductivity 16 connection seals 12 contamination 27 28 control setpoint 5 corrosion 10 15 27 Corrosion 27 corrosive solution 11 D diagnostics 5 diffuser 5 dirt build up 10 discharge air 11 dissolved solids 11 drift eliminators 15 ECOSS EVAPORATIVE CONDENSERS INDEX Index E ebm papst fans 5 electrical connections 11 electrical installation 10 electrical lines 12 Electric Basin Heaters 6 emergency 17 emissions 25 environment 23 Evacuate 13 Explosion hazard 24 eye protection 30 F fan blades 12 15 21 fan capacity 21 fan motor bearing 15 fan motor drives 13 fan motors 5 fans 25 Fans 27 fire extinguishing equipment 30 fittings 12 flammable 25 float 12 flow regulating valve 11 fluid sacks 25 fluid traps 25 freeze 22 frostbite 31 Frostbite 21 22 G grease 15 H hand protection 30 Hardness 16 harmonics filters 5 header inlets 21 header pipes 24 heater elements 21 heat exchanger 12 19 30 Hinged fan panels 4 IIAR 17 IIAR standards 17 immersion heater 6 impeller 5 inlet louvers 5 Inspection 14 intake air 11 inverter duty motors 5 140 010 IOM JUL 2014 Page 33 L leaks 15 32 Leaks 12 Legionella 28 Lightning protection rods 11 Liquid ammonia 20 Lubricate 15 M maintenance 11 30 Mechanical Float Assembly 10 megohmmeter 15 Moisture 27 monitoring
23. with appropriate media and at the appropri ate test pressure v Put the unit into operation see section 5 9 Putting the unit into operation for the first time 140 010 IOM JUL 2014 ECOSS EVAPORATIVE CONDENSERS Frick Page 14 MAINTENANCE BY JOHNSON CONTROLS NOTICE Danger of slipping and falling see Appendix I 6 Main Danger of damage to property see Appendix I 6 2 With tenance all maintenance work Danger of damage to property BEFORE STARTING ANY MAINTENANCE AFTER ALL MAINTENANCE WORK Danger of injuries and damage to property with escap ing refrigerant see Appendix I 6 1 Before starting all maintenance Danger of injuries and damage to property with escaping refrigerant see Appendix I 6 3 After all maintenance work WITH ALL MAINTENANCE WORK INSPECTION AND MAINTENANCE PLAN See Table Danger of injuries and damage to property with escaping refrigerant see Appendix I 6 2 With all maintenance work Maintenance Plan for Evaporative Condenser ECOSS Start Action to be taken after each Type of action Action step ii period of days P f 1 J 15 30 90 180 ead the ECOSS IOM amp Appendix I Safety IOM heck the water distribution in the upper module heck the rotation direction of the water pump Checks and heck the basin water level adjustments Adjusting water displacer heck the direction of axial fans heck installation of additional accessories djustment of the operating
24. Form 140 010 IOM JUL 2014 9 INSTALLATION OPERATION MAINTENANCE 1 iC File SERVICE MANUAL Section 200 Replaces NOTHING 3 3a 3b 3c BY JOHNSON CONTROLS Dist ECOSS Stainless Steel Evaporative Condenser THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH DAMAGE TO THE UNIT OR IMPROPER OPERATION Please check www jci com frick for the latest version of this publication 140 010 IOM JUL 2014 ECOSS EVAPORATIVE CONDENSERS Frick Page 2 INSTALLATION OPERATION MAINTENANCE BY JOHNSON CONTROLS IMPORTANT READ BEFORE PROCEEDING This manual provides the information needed for safe installation operation and maintenance for ECOSS Evaporative Con densers Close attention to the instructions provided in this manual will ensure proper installation and operation and a long satisfactory unit life It is strongly recommended that one becomes fully familiar with this manual prior to operating or working on an ECOSS Evapo rative Condenser After installation the unit must be properly connected to an appropriately designed and installed refrigeration system The engi neering plans piping layouts etc must be detailed in accordance with local codes and applicable industry standards and practices Units should be rigged and installed as outlined in
25. R standards Component supplier system installer interfaces Inform Johnson Controls immediately if faults occur during the setup installation start up and operation The responsibilities of the system installer in particular include Planning and preparing emergency measures To avoid consequential damage caused by operational disrup tions a warning system which immediately signals all faults must be provided on site Prepare emergency measures ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 17 140 010 IOM JUL 2014 that prevent consequential damage for people and property should faults occur v Install emergency STOP switches that can be actuated without danger Vv Specify checking and maintenance intervals The complete system must be configured and equipped with all required equipment for maintenance and sufficient servic ing and testing accordance with IIAR standards With the integration of the unit into the refrigeration sys tem the refrigerant and unit model must not deviate from the order related information specified in the order related documents The installer of the system must refer to the requirement for sufficient instruction of the operating and supervision staff when operating and maintaining the equipment It is recommended that the future customer staff be present during setup and installation tightness test and cleaning filling with refrigerant and setting of the equipment 1 1 3 Owner
26. THE UNIT DOWN Danger of injuries and damage to property see Ap pendix I 5 11 Shutting the unit down NOTICE Danger of dirt build up see Appendix I 5 11 Shutting the unit down Danger of injuries and damage to property with escaping refrigerant see Appendix l 2 7 Residual hazards with refrigerant v Take the unit out of operation see Appendix I 5 10 Taking the unit out of operation v Secure the unit o Secure the fan motor drives and ensure that they are disconnected locked out and tagged out o Secure refrigerant carrying lines by pressurizing with refrigerant o Secure the unit at the installation or storage location to protect from external sources damaging the unit see Appendix l 5 Connecting the unit 5 1 Safety instructions 5 1 1 Safety instructions for setup and start up o Evacuate the unit Completely capture all of the re frigerant must not release any refrigerant into the atmosphere and if applicable the refrigerant oil see Appendix 2 9 Combined Residual hazards Residual hazards with disposal PUTTING THE UNIT INTO OPERATION AFTER A SHUTDOWN The unit must be put back into operation after a shutdown in accordance with the operating instructions manual as follows v Test the unit s readiness for operation see 5 8 Test readi ness for operation v Perform pressure test and visual inspection for corrosion NOTICE The pressure test with recommissioning must only be carried out
27. ation equipment o Electrics Fans o Working fluids valves and fittings An emergency STOP switch that can be actuated without danger must be installed The refrigerant side and electrical connections must be available on the system The connections must be speci fied in the order related documents The power supply of the fans must be provided in ac cordance with the specifications on the name plate on the fan motors A switch off device for preventing unexpected start up repairs switch which separates all active conductors from the power supply all pole switch off must be provided for the fans The fans switch on off device must be secured ex with a padlock to prevent uncontrolled fan start up The electrical motor repairs switch terminal box and switching cabinet connections must be provided in ac cordance with the respective connection diagrams It must be possible to shut off the unit if a leak occurs People wearing ambient air independent breathing ap paratus in full protective clothing must also be able to activate all safety relevant shutoff fittings It must be possible to activate all devices meant for di verting escaping working fluids from a safe location 5 1 3 Customer side safety precautions Halocarbons Danger of environmental pollution 140 010 IOM JUL 2014 Ensure that no refrigerant enters water systems or sew age Operate the facility for recovering or disposing of refriger ant so t
28. by panic reactions o Environmental pollution Danger of injuries and damage to property ECOSS Evaporative condensers may not be used where it is possible that short or prolonged effect caused by contact inhalation or ingestion of the refrigerant might result in harmful hazards where the possibility exists of a sudden large release release and evaporation of the greater part of the entire refrigerant filling in a short time ex in less than 5 minutes The unit must not be changed without prior written consent by Johnson Controls Changes to the unit are changing the operating point see chapter Unit changing the fan capacity air volume changing the refrigerant flow through volume changing over to another refrigerant The unit must not be operated if safety devices recommended by the manufacturer are not available not properly installed or not fully functional The unit must not be operated it is damaged or demon strates faults All damages and faults must be reported to Johnson Controls immediately and must be removed im mediately Work on the unit must not be performed without the per sonal protective equipment specified in these operating instructions 2 4 MECHANICAL RESIDUAL HAZARDS Danger of cutting off pulling in There is a danger of cutting off fingers on the rotating fan blades injury hazard for the hands and pulling in danger for lose elements such as hair necklaces or clothing parts
29. d maintained and repaired by trained experienced and qualified personnel see Appendix 5 5 1 Important considerations regarding installation UNIT ELECTRICAL CONNECTION amp PROTECTION v Seal all electrical lines to the connection boxes in accor dance with their protection class The connection class is specified in the order related documents Danger of injuries and damage to property see Appendix I 5 6 Unit Electrical connection amp protection PERFORM ACCEPTANCE TEST Danger of injuries and damage to property see Ap pendix I 5 7 Perform acceptance test Acceptance Test v Ensure sufficient air flow v Ensure that the electrical supply feed is sufficient for the required energy Compare the unit inside of the system with the plans of the system and the electrical wiring diagrams v Test the unit for excessive vibrations and movements that can be caused by the fans and operation of the system Remove oscillations vibrations and movements following consultation with the manufacturer or independently v Perform visual inspection of the structural design the brackets and fixtures materials sequence and connec tions the arrangement of the fittings and the ability to operate ECOSS EVAPORATIVE CONDENSERS Page 12 INSTALLATION Bee dr See Frick BY JOHNSON CONTROLS v Check and retighten all threaded connections especially on the fans Check installation of pipe connections Ch
30. d within the casing to prevent breakage and a stainless steel strainer da Figure 5 Water Spray Nozzle EC FANS WITH AXITOP ECOSS EVAPORATIVE CONDENSERS INSTALLATION OPERATION MAINTENANCE Page 5 Figure 6 Direct Drive Fan Motor 140 010 IOM JUL 2014 All EC direct drive fan motors are wired power and control to a common junction box eliminating associated field wir ing and labor They allow for variable motor speed with no efficiency losses and additional equipment requirements VFD s filters or inverter duty motors Motor speed control is achieved without efficiency penalty Soft start keeps the start up current below FLA reducing the load on power supply components Integrated phase failure protection power factor correction harmonics filters locked rotor and over temperature protection real time diagnostics measured process value motor speed operating hours power consumption and motor temperatures lower EC motor temperature rise at reduced speed resulting in longer motor bearing life no resonant frequency harmonics or vi bration to encounter no location or lead length constraints and no shielded cables The mounting arms are bolted to the flange on the fan orifice and allow for a quick and simple removal if required The motors can be lifted and removed by one person NO motor davits required MMC Motor Management Controller factory wired to all dir
31. damage to property with escap ing refrigerant see Appendix l 2 7 Residual hazards with refrigerant In case of improper installation leak of refrigerant can occur during operation of the installation this can lead to injuries or damage to property Prevent refrigerant from escaping from the unit into the environment Secure all refrigerant carrying lines against mechanical damage In areas that are used for internal traffic only lay the pipelines to and from the unit with connections and fit tings that cannot be removed Ensure that the on site connections do not exercise any forces upon the distribution and header points This can cause leaks on the refrigerant connection points of the unit and on connection points of the on site pipe laying ECOSS EVAPORATIVE CONDENSERS Page 28 APPENDIX Bee dr See Frick BY JOHNSON CONTROLS Ensure that Release devices to prevent liquid escapes are provided and available With refrigeration system shutdown state under cooled liquid is only present in the lowest possible amount in system components minimized number of fluid sacks 5 4 CONNECTING THE WATER PIPES Recirculated water system Danger of injury due to biological contamination see Appendix I 5 4 Connecting the water pipes Biological contamination of the water must be regularly monitored and treated accordingly when detected Untreated this biological contamination can lead to sludge slime co
32. dual hazards caused by vibration see Appendix 2 8 Residual hazards caused by vibrations This results in dangers caused by leaking materials see Appendix I 2 9 Combined Residual hazards Residual hazards caused by pressurized parts released refrigerant see Appendix 2 7 Residual hazards with refrigerant halocarbons and Ammonia Ensure that The installation is fault free The maximum permissible operating pressure is always adhered to Pressurized line sections are depressurized before all maintenance and repair work Vibrations from the refrigeration system vibrations caused by the complete system s compressors compo nents and lines and from the fans imbalances caused by frosting icing or dirt build up or damages are reduced with all available means and brought down to an absolute minimum Release devices to prevent liquid escapes are provided and available Under cooled liquid is only present in the lowest possible amount in system sections in shutdown state minimized number of fluid sacks Residual hazards with disposal Danger of injuries and damage to property caused by refrigerant ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 25 140 010 IOM JUL 2014 The following notes are recommendations for the proper professional disposal of the unit Applicable waste disposal laws are binding for the country of operation Disposal must only be carried out by experts All unit components ex
33. e danger of a refrigerant or refrigerant oil emission into the environment is kept as low as possible 3 INFORMATION ON COMPONENT PARTS No specific dangers at this point in service life 4 TRANSPORTATION STORAGE UNPACKING amp MOUNTING Crushing danger with falling down The unit can slip and fall off the means of transport causing serious injuries or death Heavy impacts or vibrations can damage the unit Observe the instructions on the transport labels on the packed units Ensure that the assigned staff is trained for proper unloading Use a transporting device appropriate for the unit s weight 1 5 x the weight of the unit You will find the weight of the packed unit in the order related documents Ensure that nobody is under the unit or near the loaded area during the transport Observe even distribution of unit weight for transport Ob serve the instructions on the transport labels on the packed units see Appendix 2 1 2 Other signs and notes on the unit No specific dangers at this point in service life Secure the unit against slipping and mechanical damage When lifting by crane The hooks and lifting gear of the load lifting equipment must be only attached at the points speci fied by the manufacturer Ensure that the unit enclosure is not crushed by slings Use auxiliary lifting equipment where required Do not use connection pieces and header pipes as hooking points for lifting pulling fixing or mounting
34. eck support of refrigerant carrying connection pipes Ensure that the unit is protected against mechanical dam age v Ensure that the unit is protected against inadmissible heating up and cooling down v Check the fan blades protection v Ensure that the unit control is readily accessible o Is the unit placed so that it can be monitored and controlled from all sides at all times o ls there sufficient space for maintenance o Are all refrigerant carrying components connections and lines and all electrical connections and lines easy to access o Are the pipes easy to identify v Check heat exchanger surfaces for dirt and clean where necessary see section CLEAN UNIT v Ensure that the water level does not exceed the fill level of 17 prior to energizing the recirculation water pump measured from the inside of the depressed area of the basin v Ensure that the circular float for basin water level adjust ment is set so that water level does not exceed 1414 inches when in operation measured from the inside of the depressed area of the basin v Perform function tests on the fans rotation direction power consumption etc v Check electrical connections of the fan motors for dam age v Check the quality of the soldering connections the elec trical connections and the fixture connections v Perform pressure test with test gas and with a test pres sure of 1 1 times the permissible operating pressure check the connec
35. ect drive EC motors for controlling fan speed and control setpoint During longer storage or downtime periods the fans must be operated for 2 to 4 hours each month NOTICE In the case of fans with protection type IP55 or higher any sealed condensate drain holes must be opened at least every six months NOTICE The fan motors use a separate electronic power circuit that is controlled via Motor Management Control MMC The motors can be powered at three phase 3 380 480 V AC 50 60 Hz voltages Please refer to the wiring diagrams or motor terminal box information for the elec trical connection The AxiTop diffuser is designed to recover wasted energy by purposely and efficiently decelerating the flow and reducing swirl boosting the pressure rise of the impeller Aerodynamic efficiency is increased and acoustic noise is reduced AxiTop is currently available for ebm papst axial fan sizes 800 mm and 910 mm There are no moving parts and it can be retrofitted with ease onto existing systems that already use ebm papst fans allowing for space 140 010 IOM JUL 2014 PUMPS A O P lt lt Figure 7 Water Pump The water pump is a close coupled centrifugal unit with ductile iron housing closed impeller mechanical seal TEFC motor vertical alignment reduces installation footprint bleed line from riser pipe supplied complete with regulating valve lower recirculating flow rate re
36. ed by escaping materials fans are damaged during fan operation flying parts of the fan blades can injure people or cause damage to property close to the fan Fans components and cables in the system must be de signed constructed and integrated so that dangers caused by vibrations are reduced to an absolute minimum NOTICE Damage to property caused by vibrations Vibrations that are increased by imbalances due to dirt or fan blade damage can cause further damage to the unit the unit mounting or refrigeration system components con nected to the unit Check the fan blades and guard grille regularly for dirt and ensure that the fans operate smoothly see Appendix I 6 5 3 Fans and pumps 140 010 IOM JUL 2014 2 9 COMBINED RESIDUAL HAZARDS Residual hazards caused by pressurized parts Injury and damage to property caused by pressurized parts that contain CFC HFC or ammonia refrigerant Breaks in pressurized pipes or pressurized components of the unit can cause injuries or damage to property caused by leaking materials A sudden large release of the refrigerant with its hazardous properties after a break or leak on pressur ized components of the unit can cause the following hazards Halocarbons Ammonia Oxygen displacement Flammability Flammability caused by l refrigerant oil present Explosion hazard Frostbite caused by liquid Frostbite caused by liquid refrigerant squirting refri
37. ere is haz ard of burns on pipe components and header inlets Use appropriate hand protection Danger of frostbite Warning against cold When doing maintenance work consider that residual refrig erant still under defervescence has a temperature of 32 F Contact with refrigerant under defervescence caused by spraying causes frostbite Use appropriate eye protection Use appropriate hand protection Danger of damage to the property in the event of the unit freezing 140 010 IOM JUL 2014 When not in operation the water in the basin may freeze in the event of very low temperatures Make sure the basin is drained whenever the unit is not in operation or use the heating elements to ensure the water in the basin does not freeze Warranty is void in case of non compliance with these instructions 2 7 RESIDUAL HAZARDS WITH REFRIGERANT Danger of injuries Halocarbons The halocarbon refrigerants that are used R134a R404A R407C R507 are Group L1 A1 refrigerants in compliance with classification according to flammability L and toxicity A Refrigerants that when gaseous are non flammable ir relevant of their concentration in air Refrigerants with a time weighted averaged concentra tion that have no adverse effects on the majority of staff that are exposed every day during a normal 8 hour working day and a 40 hour working week to this concentration which is greater than or equal to 400 ml
38. frigerant can cause injuries or even death see Appendix 2 7 Residual hazards with refrigerant 5 10 TAKING THE UNIT OUT OF OPERATION NOTICE For unit shutdown consider the maximum operating pressure If necessary take precautions so that it cannot be exceeded ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 29 140 010 IOM JUL 2014 NOTICE With shutdown times of a month or longer energize the fans for approximately 2 4 hours a month to maintain their functionality 5 11 SHUTTING THE UNIT DOWN Danger of injuries and damage to property with escap ing refrigerant Escaping refrigerant can cause injuries see Appendix 2 7 Residual hazards with refrigerant and Appendix 2 9 Combined Residual hazards Residual hazards caused by pressurized parts Ensure that the maximum operating pressure is not exceeded after shutdown NOTICE Danger of dirt build up Moisture and dirt must be prevented from entering the condensing coll Protect the unit against dust dirt moisture wet conditions damaging and other detrimental influences see Appendix 5 Connecting the unit 5 1 Safety instructions 5 1 1 Safety instructions for setup and start up With shutdown times of a month or longer energize the fans for approximately 2 4 hours a month to maintain their functionality Danger of injuries and damage to property with escaping refrigerant see Appendix I 2 7 Residual hazards with refrigerant
39. gerant squirting splashing splashing Panic Panic Environmental pollution Environmental pollution Po Chemical burns v Ensure that the unit in question is pressure free before maintenance work begins or remove the refrigerant from the unit in question Only perform maintenance work especially soldering work on the unit in question after completely removing the refrigerant from the unit Residual hazards caused by defective installation Injuries and damage to property caused by defective installation Defective installation results in hazards caused by break or leak on refrigerant carrying unit components and pipes absence of release devices to prevent liquid escape Liquid that can heat up during a refrigeration system shutdown state and cause pipes or connection flanges to break when it expands must not be locked in uneven load distribution on the fixtures with the danger of stresses within the unit or unit displacement breaks or leaks on refrigerant carrying components of the unit and pipes danger of breaking off insufficient securing of refrigerant carrying lines against mechanical damage On site connections loaded installa tion effect of forces on the distribution and header pipes with the danger of breaks or leaks on refrigerant carrying components of the unit and pipes danger of breaking off break off and fall danger of the unit with hazard of escap ing refrigerant and exposed electrical cables danger of
40. h a time weighted averaged concentra tion that have no adverse effects on the majority of staff who are exposed every day during a normal 8 hour work ing day and a 40 hour working week to this concentration which is greater than or equal to 400 ml m ppm V V There is no imminent danger for the staff However refriger ants of the Group L1 A1 are generally heavier than air and may flow off to rooms on a lower level In still air there may be an increase of the ground level concentration With high concentrations there is a danger of suffering from disordered cardiac rhythm and suffocation due to a reduced oxygen concentration especially at ground level Unauthorized people must not have access to the unit Please ensure that the halocarbon refrigerant leaking from the unit cannot penetrate the interior of the building or put people at risk in any other way Safety measures and procedure With unexpected serious refrigerant escapes leave the setup space immediately and activate the emergency STOP switch set up in a safe place e g with o Visibly leaking refrigerant liquid or vapor from the heat exchanger or pipe components ECOSS EVAPORATIVE CONDENSERS APPENDIX Page 19 140 010 IOM JUL 2014 o Sudden large release release and evaporation of the greater part of the entire refrigerant filling in a short time e g in less than 5 minutes o Activation of the refrigerant detector Have experienced trained personne
41. h the Frick ECOSS electrical panel All wiring must be in accordance with Johnson Controls Frick pub lished specifications and must be performed ONLY by qualified Johnson Controls Frick personnel Johnson Controls Frick will not be responsible for damages problems resulting from improper connections to the controls or application of improper control signals Failure to follow this will void the manufacturer s warranty and may cause serious dam age to property or injury to persons NOTICE This manual in combination with the applicable cooling coil data unit G amp A drawing unit electrical drawing and structural support drawing provides the information necessary to safely install and start up a Frick ECOSS unit Due to the possibility of customization associated with the ECOSS product line there may be areas beyond the scope of this manual If there are any questions about a special application lacking the required information please contact the installing contractor or your local Frick Sales Office SAFETY PRECAUTION DEFINITIONS Indicates an imminently hazardous situation which if not avoided will result in death or serious A DANGER Injury i Indicates a potentially hazardous situation or practice which if not avoided will result in death or serious injury Indicates a potentially hazardous situation or practice which if not avoided will result in damage to equipment and or minor injury NOTICE Indicates an operating
42. hat have anything at all to do with the unit 1 1 RESPONSIBILITIES 1 1 1 Manufacturer s responsibilities The notes provided in these operating instructions on maintaining the unit s functional safety preventing possible hazards when transporting setting up and installing start up and operation and with maintenance activities cleaning servicing and repairing refer exclusively to the unit The construction soldering and welding materials are con figured so that they withstand the foreseeable mechanical thermal and chemical stresses and are resistant to the refrigerant and the refrigerant refrigerator oil mixture used The refrigerant carrying parts of the unit coil and header outlet are configured so that they remain tight with the foreseeable mechanical thermal and chemical stresses and withstand the maximum operating pressure Material wall thickness tensile strength corrosive re sistance shaping process and testing are suitable for the refrigerant used and withstand the possible pressures and stresses that might occur All responsibilities regarding the equipment into which the unit is integrated are the exclusive responsibility of the people involved in the individual workflows 1 1 2 Responsibilities of the system s installer The responsibilities of the system installer are documented in the system s version design manufacture and testing cooling equipment and refrigeration system in accordance with IIA
43. hat the danger of a refrigerant or refrigerant oil emission into the environment is kept as low as possible Ammonia Danger of environmental pollution The ammonia NH3 refrigerant is classified in accordance with the Catalogue of Substances Hazardous to Waters as water hazard class 2 Refrigerant must never enter water systems or sewage Escaping ammonia can enter the environment wind born Ammonia is lighter than air and rises quickly It is diluted with the air to harmless concentrations But even if the concentration is harmless the ammonia smell is still irritat ing Ammonia s classification as toxic means that people in the area will be concerned Set up the unit so that liquid ammonia which can escape from the unit in the event of a fault cannot enter water systems or sewage With serious ammonia escapes into the waste water sys tem for example when ammonia vapor is broken down by water immediately report the incident to the responsible office for the local waste water system an ammonia puddle has formed on the floor under the unit covering with a film PE for example or synthetic medium expansion foam fire department can cut off almost all the heat dissipation to this liquid and therefore the vapor formation so that there is enough time for disposal measures 5 2 LOCATION REQUIREMENTS No specific dangers at this point 5 3 NOTES ON CONNECTING THE UNIT Danger of injuries and
44. ic materi als stainless steel polyamide motors and water spray nozzles These materials can be handled by the waste industry including in paint treated state to recycling via mechanical and thermal separation Before scrapping the refrigerant carrying unit compo nents they must be drained whereby the pressure must be reduced to at least 8 7 psia for a unit pipe volume up to and including 200 and to 4 3 psia for a unit pipe vol ume over 200 The pressure reduction process is then ended when the pressure no longer increases and remains constant and the unit is at ambient temperature Danger of environmental pollution The facility for recovering or disposing of the refrigerant must be operated so that the danger of a refrigerant or refrigerant oil emission into the environment is kept as low as possible The ammonia NH3 refrigerant is classified in accordance with the Catalogue of Substances Hazardous to Waters as water hazard class 2 Escaping ammonia can enter the environment wind born Ammonia is lighter than air and rises quickly It is diluted with the air to harmless concentrations But even if the concentration is harmless the ammonia smell is still irritat ing Ammonia s classification as toxic means that people in the area will be concerned 140 010 IOM JUL 2014 Ensure that no refrigerant enters water systems or sew age Operate the facility for recovering or disposing of refriger ants so that th
45. ies and damage to property see Ap pendix I 5 1 3 Customer side safety precautions Ammonia Danger of environmental pollution see Ap pendix I 5 1 3 Customer side safety precautions LOCATION REQUIREMENTS You will find the dimensions and weights in the order related documents In order to not compromise the performance of the evapo rative condenser s it is imperative that the location allows for unrestricted airflow into each condenser and that there is no recirculation of the saturated discharge air Locations on open rooftops or at ground level with no obstructions such as walls or adjacent buildings are preferred However in many instances this is not possible Positioning in wells next to high walls adjacent buildings occupied areas or spe cific enclosures all pose a risk of recirculating the saturated discharge air This will increase the wet bulb temperature of the intake air and compromise the performance of the condenser which typically results in higher condensing temperatures Units that are located in a well an enclosure or close to adjacent walls or buildings must be positioned such that the discharge of the condenser at the top is either level or higher than these adjacent obstacles If the unit s is are to be located in occupied areas or close to adjacent buildings it is advisable that the discharge air 5 not in the direction of or in close proximity to any air intake location for the building s vent
46. ilation system the units are intended to be put into a dual or quad position the height of the louver section in the lower box sections is Increased to almost the double that of the original model type in order to ensure sufficient air intake See Figure 15 v Ensure that the unit is set up so that it is not damaged by environment conditional hazards production transpor tion and other sources at the installation site and that its functioning is not disturbed by the interventions of unauthorized persons v Enable optimal unit control and accessibility o Place the unit so that it can be monitored and controlled from all sides at all times o Ensure that sufficient space is provided for mainte nance o Ensure that all liquid carrying components connection lines and all electrical connections and lines are easy to access o Ensure that the pipe connection points are visible ECOSS EVAPORATIVE CONDENSERS INSTALLATION Page 11 140 010 IOM JUL 2014 NOTICE Lightning protection rods beside the unit are recom mended NOTES ON CONNECTING THE UNIT Danger of injuries and damage to property with escaping refrigerant see Appendix l 5 3 Notes on connecting the unit CONNECTING THE WATER PIPES RECIRCULATED WATER SYSTEM Depending on the location impurities within the air chemi cals in an industrial environment or salt laden air when close to the ocean are also absorbed by the water and can
47. itating immediate irrita tion of the eyes nose and air passages o Activate NH3 alarm device NH3 concentration gt 200 ppm Have experienced trained personnel with prescribed protective clothing perform all necessary protective and other measures o Use respiratory protection o Use a room air independent breathing apparatus with maintenance work in high ammonia concentrations in the room air o Ensure the setup space is well ventilated o Divert escaped refrigerant vapor and escaped refriger ant liquid safely Instructions for dealing with injuries 140 010 IOM JUL 2014 o Call an emergency doctor immediately o Liquid ammonia can cause frostbite or corrosive inju ries to the skin or eyes The injured person must keep breathing apparatus on until further notice to prevent inhalation of vapors from ammonia contaminated clothing o Shower the injured person for five to fifteen minutes with water Be careful when removing the clothing during the shower If ammonia contaminated clothing is removed without wetting with water first the injury can worsen as firmly frozen skin may be torn away Showering should be with warm water as much as possible to prevent a temperature shock If available use an emergency shower otherwise use a water hose 2 2 3 Personnel care requirements The unit must only be put into operation operated maintained and repaired by trained experienced and qualified personnel People that are
48. l with prescribed protective clothing perform all necessary protective and other measures o Use respiratory protection o Use a room air independent breathing apparatus with maintenance work in high refrigerant concentrations in the room air o Ensure the setup space is well ventilated o Divert leaking refrigerant vapor and leaking refrigerant liquid safely o Ensure that no refrigerant enters water systems or sewage 2 2 2 How to act in an emergency with Ammonia Danger of injuries and damage to property If the unit contains ammonia as a refrig erant NH3 Ammonia is a potentially explosive and fire risk substance Un intentionally carried in oil residues and unintentionally carried in refrigerant can ignite An explosion can cause the most serious injuries and loss of limb Ammonia Is a corrosive toxic irritant gas From ammonia concentration of 0 2 vol in the ambient air or with a long stay in the ammonia containing ambient air ammonia can be life threatening or fatal Safety measures and procedure With unexpected serious refrigerant leaks leave the setup Space immediately and activate the emergency STOP switch set up in a safe place e g with o Visibly leaking ammonia liquid or vapor from the heat exchanger or pipe components o Sudden large release release and evaporation of the greater part of the entire refrigerant filling in a short time e g in less than 5 minutes o Sudden strong smell very irr
49. ls Dust and dirt of all kinds Moisture in the refrigerant carrying components of the unit can have the following consequences Water separation and ice formation cause faults in the switching and control fittings of the refrigeration system Acidification Aging and refrigerant oil decay Corrosion Atmospheric air and other non condensable gases can have the following consequences Refrigerant oil oxidation Chemical reactions between refrigerant and refrigerant oil Increased condensing pressure in the system Chemical reactions between refrigerant and refrigerant oil with the absence of moisture or atmospheric air with aging and refrigerant and refrigerant oil decay can have the fol lowing consequences Formation of organic and inorganic acids Increased compressed gas temperature in the system Corrosion Bad lubrication increased wear and tear through to sys tem or failure Other contaminants can cause Accelerated chemical processes decomposition Mechanical and electrical faults in the refrigeration system Ensure with installation connecting the refrigerant carrying components of the unit to the refrigerant carrying system of the installation that internal contamination is strictly avoided Perform the installation with extreme cleanliness Finish all on site pipe installation work before releasing the transport pressure Only release the transport pressure on the Schrader valve immediately before installation
50. m3 400 ppm V V There is no imminent danger for the staff With good air ventilation and removal by suction will fall easily and clearly below the allowed limit values Danger of harm to health and environmental damage Refrigerants of the Group L1 A1 are generally heavier than air and may flow off to rooms on a lower level In still air there may be an increase of the ground level concentration With high concentrations there is a danger of suffering from disordered cardiac rhythm and suffocation due to a reduced oxygen concentration especially at ground level Unauthorized people must not have access to the unit Ensure working rooms are well ventilated in order to prevent inhalation of high vapor concentrations Please ensure that the halocarbon refrigerant leaking from the unit cannot penetrate the interior of the building or put people at risk in any other way Halocarbon refrigerant vapor or gas must be kept from penetrating neighboring rooms staircases yards passages or drainage systems and must be discharged without risk Monitor the halocarbon refrigerant concentration in the ambient air to ensure constant compliance with limit values Test the tightness of the unit regularly as specified in these Operating instructions see Appendix 6 4 Inspection and maintenance plan ECOSS EVAPORATIVE CONDENSERS Page 22 APPENDIX Bee dr See Frack BY JOHNSON CONTROLS Ignition and fire hazard
51. nd damage to property with escaping refrigerant see Appendix I 2 7 Residual hazards with refrigerant Have leaks repaired as quickly as possible by an expert Do not fill with a refrigerant other than that specified in accordance with the order related documents Only put the unit back into operation when all leaks have been repaired v Perform all required work including pressure acceptance and functional test 6 5 1 Strainer and basin No specific dangers at this point in service life 6 5 2 Water level No specific dangers at this point in service life 6 5 3 Fans and pumps No specific dangers at this point in service life 6 5 4 Elimination of water drops water carry over No specific dangers at this point in service life 6 5 5 Water distribution system and nozzles No specific dangers at this point in service life 6 6 CLEAN UNIT 6 6 1 General NOTICE If during maintenance or cleaning any corrosion is be ing detected please contact the manufacturer directly 6 6 2 Cleaning coil casing and basin No specific dangers at this point in service life 6 6 3 Cleaning fans and water pump s No specific dangers at this point in service life ECOSS EVAPORATIVE CONDENSERS Page 32 APPENDIX Frick BY JOHNSON CONTROLS 7 WATER TREATMENT 7 1 WATER TREATMENT AND MINIMUM WATER QUALITY REQUIREMENTS No specific dangers at this point in service life 7 1 1 Biological control No specific dangers at this p
52. nd other harmful effects and dirt and other contaminants with an appropriate cover The unit must also be well ventilated 4 3 UNPACKING No specific dangers at this point in service life 4 4 MOUNTING Danger of injury and damages to the property There is already a gap designed between the PVC riser pipe in the basin and casing sections Care should be taken when lifting the casing section such that it is lifted level with little or no tilt to ensure the PVC riser pipe does not come In contact with the ground any objects or the basin section to prevent damage instructions are not followed warranty will be void CONNECTING THE UNIT 5 5 1 SAFETY INSTRUCTIONS 5 1 1 Safety instructions for setup and start up Danger of injuries and damage to property with escap ing refrigerant Incorrect installation causes the danger of refrigerant escap ing when the unit is operated and injuries or damage to prop erty see Appendix I 2 7 Residual hazards with refrigerant Follow the setup instructions in this chapter precisely and exercise extreme caution zy y N Frick BY JOHNSON CONTROLS NOTICE Damage to the system s cooling equipment Foreign materials and contaminants in the refrigerant circuit can impair the effectiveness or damage components Par ticularly harmful contaminants are Moisture Atmospheric air Soldering welding residues Rust Soot ash cinders Metal cuttings Unstable oi
53. nlet and outlet feeds of the fans and heat exchanger objects can get into the fans and therefore cause faults and damage to the components Power off the fans before beginning maintenance work ensure all are disconnected locked out and tagged out After the work has finished do not allow any objects to get back into the inlet and outlet feeds of the fans or the installed space 6 3 AFTER ALL MAINTENANCE WORK v Ensure that the hinged fan panels and the side covers are fixed in their original position and secured against unintentional or unauthorized opening v Check the identification of the pipelines and ensure labels are visible and legible Danger of injuries and damage to property with escaping refrigerant see Appendix I 2 7 Residual hazards with V Check the mounting of the components in question refrigerant v Ensure the electrical connections fans are functioning SC properly Perform the following safety measures after finishing all V Perform a pressure test and a leak check maintenance work v Perform an acceptance test See INSTALLATION section v Ensure the switching and activation devices the measur PERFORM ACCEPTANCE TEST ing and display devices and the safety devices function 6 4 INSPECTION AND MAINTENANCE PLAN properly D v Ensure the refrigerant fittings are functioning properly No specific dangers at this point in service life 140 010 IOM JUL 2014 6 5 MAINTENANCE WORK Danger of injuries a
54. ntinuous algae growth and other possible harmful micro organisms such as Legionella As such all internal surfaces inlet louvers and drift eliminators must be kept clean at all times It is therefore essential that there is an ongoing water treatment program in place to monitor analyze and main tain the water quality being recirculated through the unit This should only be carried out by a suitably qualified water treatment company who can devise a program specific to the location quality water source could be multiple and the construction materials of the unit 5 5 CONNECTING THE UNIT TO THE SYSTEM In case of improper installation leakage of refrigerant can occur during installation This can lead to injuries or damage to property see Appendix I 2 7 Residual hazards with refrigerant Only mount the unit to the mounting points intended Prevent refrigerant from escaping from the unit into the environment Secure all refrigerant carrying lines against mechanical damage In areas that are used for internal traffic only lay the pipelines to and from the unit with connections and fit tings that cannot be removed v Ensure that the on site connections do not apply any forces on the distribution and header points This can cause leaks on the refrigerant connection points of the unit and on connection points of the on site pipe laying Ensure that Release devices to prevent liquid escapes are provided and available
55. oint in service life 7 1 2 Chemical treatment No specific dangers at this point in service life 8 TROUBLESHOOTING Danger of injuries and damage to property Faults that are not described in these operating instructions must only be removed by Johnson Controls Faults that are described in these operating instructions must only be removed by appropriately trained personnel see 2 2 1 Personnel care requirements With faults that occur during the operation monitoring and maintenance of the complete system inform Johnson Controls immediately 8 1 SERVICE No specific dangers at this point in service life 8 2 TROUBLESHOOTING TABLE No specific dangers at this point in service life Een peemmmeeeg Prick BY JOHNSON CONTROLS A acceptance test 13 Acidification 27 airborne particulate 5 air flow 12 airflow 11 Airflow 11 air inlet outlet 24 Air inlet temperature 13 algae growth 28 Alkalinity 16 ammonia 10 20 28 Ammonia 19 23 25 anchoring bolts 7 ASME certified 4 Atmospheric air 27 axial fan 5 basin 4 6 22 32 Basin 15 basin section 7 basin water level 10 Bearing 16 bearing damage 15 biological contamination 11 Biological Control 16 breathing apparatus 30 burns 21 C catwalk 6 CFC HFC 25 CFC HFC refrigerants 22 Chemical treatment 16 Chlorides 16 chlorine 27 Cleaning 14 cleaning agent 15 coil surface 5 compensators 12 Condensation
56. onary edema Panic sets in From an ammonia concentration of 0 2 vol in the ambient air or with a long stay in the ammonia containing ambient air ammonia can be life threatening or fatal Ensure that the maximum permissible limit values in the setup room are not exceeded Monitor the ammonia concentration in the ambient air with detectors and alarm devices 140 010 IOM JUL 2014 Frostbite hazard Leaks in the unit can cause the NH3 re frigerant to escape into the setup area Liquid NH3 refrigerant has a temperature of 28 F Contact with the skin and eyes will cause frostbite Test the tightness of the unit regularly as specified in these operating instruc tions Ammonia is considered toxic at low concentration levels of 35 50 ppm Large quantities of ammonia should not be vented to enclosed areas near open flames or heavy sparks Ammonia 8 16 25 by volume burns and can explode in air in the presence of an open flame Danger of injury damage to property or the environment with ammonia water combinations If water gets in contact with hydrous ammonia this can result in strong gas development and liquid ammonia splashing Never sprinkle water on liquid ammonia Do not use water in the machine room to bind vaporous ammonia Ensure that ammonia water ammonia solution never enters water systems or sewage 2 8 RESIDUAL HAZARDS CAUSED BY VIBRATIONS Danger of injuries and damage to property caus
57. onfiguration installation instructions for the posts railing ladders cages and gates included in the packaged materials Walkway toe boards and post bases are pre assembled Adjustment Of Mechanical Float Assembly The brass makeup water valve with armature and circular float for basin water level adjustment is delivered pre assembled Set circular float height to a maximum water level of 14 inches CONNECTING THE UNIT SAFETY INSTRUCTIONS Safety Instructions For Setup And Start Up YOO Ae E DUAL UNITS ae SIDE TO SIDE ECOSS EVAPORATIVE CONDENSERS Page 10 INSTALLATION Frick Danger of injuries and damage to property with escap ing refrigerant see Appendix I 5 1 Safety instructions Danger of injuries and damage to property with escap ing refrigerant NOTICE Danger of damage to the system s cooling equipment see Appendix I 5 1 Safety instructions Damage to the system s cooling equipment NOTICE Danger of corrosion and dirt build up for units using ammonia as refrigerant see Appendix I 5 1 Safety instructions Danger of corrosion and dirt build up for units using ammonia as refrigerant The electrical installation must only be performed by electricians in compliance with relevant rules or ap plicable national and international regulations ana AMX a 5 1 eg JOO QUAD UNITS
58. or operator responsibilities The owner or operator responsibilities are documented in accordance with IIAR standards The owner or operator must ensure that the proper people have sufficient knowledge and experience and are sufficiently trained and qualified for operating monitoring and servic ing the system Before the system start up the owner or operator must en sure that the operating personnel are sufficiently instructed with the system s documentation on the setup monitoring mode of operation and servicing of the system and the safety measures to be observed and with regard to the properties and handling of the refrigerant to be used The owner or operator must ensure that when operating monitoring and maintaining the system the refrigerant and unit model must not deviate from the details specified in the order related documents Planning and preparing emergency measures To avoid consequential damage caused by operational disruptions a warning system must be installed on the customer s premis es Prepare emergency measures that prevent consequential damage for people and property should faults occur Responsibility remains with the owner or operator of the system the system is used by somebody else unless there is an agreement on sharing responsibility 1 2 LEGAL NOTES Warranty claim expires as follows With faults and damages that can be attributed to non compliance with the specifications of these opera
59. otor bearing if required clean and repair motor v Check bolts on fan wheels with threaded blades corrosion present replace bolts v Check fan blades for corrosion and replace if necessary Pumps v Check for leaks while the pump is running v Listen for unusual sounds or vibrations v Note any strange odors v Perform lockout tagout NOTICE Proper isolation is not just the electrical but hydraulic energy valves as well Mechanical Inspection v Check that mounting points are secure v Inspect the mechanical seal and packing v Inspect the pump flanges for leaks v Inspect coupling Lubrication v Lubricate the motor and pump bearing per manufacturer s guidelines Do not over lubricate More bearing damage occurs as a result of over greasing than under greasing the bearing has a vent cap remove the cap and run pump for 30 minutes before reinstalling cap This allows excess grease to work its way out of the bearing Electrical motor v Check that all terminations are tight v Inspect motor vents and windings for dust dirt build up Clean as necessary v Inspect starter contactor for arcing overheating etc ECOSS EVAPORATIVE CONDENSERS MAINTENANCE Page 15 140 010 IOM JUL 2014 v Put amegohmmeter on the windings to check for insula tion failure Elimination Of Water Drops Clean and remove debris from drift eliminators Water Distribution System And Nozzles Inspect and clean th
60. ous ammonia 23 variable motor speed 5 vent cap 15 ventilation system 11 vibration 16 vibration rails 12 vibrations 12 15 Vibrations 25 ECOSS EVAPORATIVE CONDENSERS INDEX W Walkway 10 warning system 17 Warranty 29 waste disposal 25 water level 12 Water level 32 water level controller 6 water spray 5 water systems 28 weight 11 Welding 22 welding residues 27 wet bulb temperature 11 windings 15 wiring diagrams 12 BE dr EN Frick BY JOHNSON CONTROLS lt ECOSS EVAPORATIVE CONDENSERS 140 010 IOM JUL 2014 Frick NOTES Page 35 BY JOHNSON CONTROLS 140 010 IOM JUL 2014 ECOSS EVAPORATIVE CONDENSERS Page 36 INSTALLATION OPERATION MAINTENANCE Frick Form 140 010 IOM 2014 07 JOHNSON CONTROLS Supersedes NOTHING dy 100 CV Avenue Subject to change without notice Waynesboro PA 17268 1206 USA Published in USA PDF Johnson Phone 717 762 2121 FAX 717 762 8624 2014 Johnson Controls Inc ALL RIGHTS RESERVED Control 5 www jci com frick
61. parameters of the GMM when applicable ing itizing ater distribution s asin cleaning and sanitizing AlSlalalElajalalz D DI Q N DI N eg D 5 oO WN ct CH 3 Li 2 CH SE Q D 00 oi Q N N 00 ct gt D 2 D aot O ou Q o 5 ct O 3 D GC D 5 O O N A D N fairings leaning and sanitizing drift eliminators leaning and sanitizing the closed loop water system Lubrication of water pumps motors according to the water pump manufacturer s manual ans maintenance according to the fan manufacturer s manual Inspection of safety recommendations of motorized fans according to the fan manufacturer s manual nspection of the level of founding from the water basin nspection of water infiltration into the switchboard and fans heck tightness of electrical box fan and bolts in general ontrol the water level of the reservoir water loop when applicable Monitoring by MMC when applicable Chemical treatment control in accordance with the water quality minimum analytical parameters required ontrol the water purge ontrol the level of fouling from the coils ontrol of the electric motor amperage of the pump water recirculation Control and ontrol of motorized fans amperage Monitoring Monitoring the links of thermal relays according to the fan manufacturer s manual
62. perating point Condensation temperature Fan kW Air inlet bulb temperature The specified operating point is provided in the order related documents ECOSS EVAPORATIVE CONDENSERS Page 20 APPENDIX Bee dr See Frick BY JOHNSON CONTROLS Operating Conditions The unit is a component of a cooling system including its refrigerant circuit The purpose of these operating instruc tions is to restrict the dangers to people and property and the environment from the unit and the refrigerant used in it to a minimum These dangers are essentially connected with the physical and chemical properties of the refrigerant and with the pressures and temperatures that occur in the refrigerant carrying components of the unit see Appendix 2 7 Residual hazards with refrigerant halocarbons and Am monia Danger of injuries and damage to property The unit must only be used in accordance with the proper intended use The operator must ensure that when operat ing monitoring and maintaining the unit the refrigerant and model type do not deviate from the order related information specified in the order specific documents The operator must ensure that maintenance measures are performed in compliance with the system s operating in structions manual Improper use Danger of injuries and damage to property Refrigerants and their combinations with water or other substances in the refrigerant carrying components have chemical
63. pport beams and anchoring bolts will be provided by others and must be selected in accordance with sound structural engineering standards When selecting the sup port beams each beam should be calculated with a uniform load equivalent to 2 3 66 of the unit s operating weight B1 B3 1 eS Figure 11 ECOSS Steel Support Dimensions See Table for Dimensions 1 ECOSS Steel Support Dimensions 10 Wide Models IDSC 1012 06 10 to 12 30 11 113 IDSC 1018 06 15 to 12 30 00 42 82 AL BE 24 Wide Models A3 B3 AL 140 010 IOM JUL 2014 ECOSS EVAPORATIVE CONDENSERS Frick Page 8 INSTALLATION BY JOHNSON CONTROLS Danger of injury and damages to the property see Appendix I 4 4 Mounting v Lift bottom section of unit from the substructure to in tended place of use v Secure bottom section of unit to the support structure with 34 diameter bolts not provided o Use all of the bolt holes to fix the unit to the support structure for bolt hole locations see unit certified drawing o Make sure that all mounting bolts are tightened equally to achieve a load distribution on the connections that is 85 balanced as possible v Lift top section of unit from the substructure and position on top of the bottom structure see Figure 12
64. procedure practice etc or portion thereof which is essential to highlight Erick ECOSS EVAPORATIVE CONDENSERS 140 010 IOM JUL 2014 E INSTALLATION OPERATION MAINTENANCE Page 3 Contents 0 4 1 GENERAL N NENNEN INFORMATION COMPONENT PARTS ke K NK KN ENN 4 1 1 5 CASING COIL BASIN WATER 57 4 fe af Ger NOTES EE EE 17 EC FANS WITH 0 00 5 1 3 OPERATING INSTRUCTIONS a 18 aenn 6 UE ee EE 18 OPTIONS AND 6655508 6 1 4 CONVENTIONS FOR SAFETY SIGNS AND NOTICES 18 Electric Basin 68 6 8 6 2 A E EE 19 2 1 LABELING ON THE 19 BASIC SAFETY NOTICES 19 TRANSPORTATION STORAGE 2 3 PROPER INTENDED USE 20 UNPACKING AND 6 8 7 2 4 MECHANICAL RESIDUAL HAZARDS 21 TRANSPORTATION eege ee eege dE AE 7 2 5 ELECTRICAL RESIDUAL HAZARDS 21 STORAGE EEN 7 26 THERMAL RESIDUAL HAZARDS 21 CIN PA GRIN Ve 7 27 RESIDUAL HAZARDS WITH REFRIGERANT 22 MOUNTING NEE EE 7 22 Adjustment Of Mechanical Float Assembly 10 22 CONNECTING THE UNIT aen eKa KK NN KKK KEN ENKE KEN ENK 10 2 8 RESIDUAL HAZARDS CAUSED BY VIBRATIONS 23 SAFETY INSTRUCTIONS EEN 10 29 COMBINED RESIDUAL HAZARDS 24 Safety Instructions For Setup And Start Up 10 3 INFORMATION ON COMPONENT PARTG 26 System side
65. r precision alignment during assembly The frame profile and panels fit tightly together with a structural interlocking design to ensure the correct alignment to prevent any water leakage at the seams Hinged fan panels open up to a service walkway located within the fan deck compartment giving open access to drift elimina tors and spray nozzles Figure 2 Hinged Fan Panels and Interior Walkway The fully welded leak free basin affords generous access to the strainer and pump inlet The fully welded step funnel design coupled with sloped panels in the basin minimizes sediment accumulation and standing water Figure 3 Stainless Steel Basin Figure 4 Inlet Air Louvers eeh y Prick BY JOHNSON CONTROLS The inlet louvers are watertight UV and corrosion resistant with a robust aerodynamically optimized construction They have low pressure loss and zero line of sight to water in the basin preventing any sunlight from entering the basin This retards biological growth and contributes to maintenance free operation The water spray distribution system consists of a stainless steel water distribution box a low pressure clog resistant Spray nozzle design with an increased nozzle diameter to prevent orifice blockage and to maintain continuous uniform flow despite debris from airborne particulate optimized water distribution over the entire coil surface area a riser pipe from the pump positione
66. readed nozzles if necessary CLEAN UNIT General For easy cleaning it is possible to open the fan panels at the top of the unit see Figure 18 i G Figure 18 Open Fan Panels on Top of the Unit If cleaning agents are used they must be compatible with 304 304L and must be environmentally friendly Any sub stances which are harmful to the environment are prohibited When cleaning agents are used the corrosion resistance of the unit s materials to the applied cleaning agent has to be observed and properly evaluated Warranty Is null and void in case of non compliance NOTICE If during maintenance or cleaning any corrosion is de tected please contact the manufacturer directly see Appendix 1 6 6 1 General Cleaning Of Coil Casing And Basin v Clean coil casing and basin by rinsing with warm wa ter approximately 80 F and or with environmentally friendly cleaning agents v If cleaning agents are used rinse thoroughly with water NOTICE Danger of damage to property Water or steam jets can damage fans electrical lines or other components v Ensure that electrical connections and motors as well as components and stored goods at the setup point are not touched by water or steam jets Cover these if required v Heavier moisture or greasy dirt must be removed with a high pressure water jet max 725 psi pressure steam 140 010 IOM JUL 2014 Page 16 pressure jet max 725 psig press
67. responsible for the operation maintenance repair and evaluation of systems and their components must have the required training and specialist knowledge Qualified or expert means the ability to satisfactorily perform the activities required for the operation maintenance repair and evaluation of refrigeration systems and their components The unit may be operated by personnel that have no specific knowledge of refrigeration engineering but have sufficient knowledge and experience with regard to the mode of operation operation and daily monitoring of this system These operating personnel may not make any interventions or settings on the system Changes to the unit which the manufacturer has first to agree to in writing may only be made by instructed and qualified personnel Electrical installation Work on the electrical equipment may only be performed by personnel that have the required expertise ex an electrician or an electro technically instructed person and who are authorized by the operator in compliance with the respective regulations and the TCCs of the EPCs 2 3 PROPER INTENDED USE Proper intended use ECOSS evaporative condensers are intended for installa tion in a refrigeration system and for outdoor installations The condensers condense the refrigerant by rejecting heat to the ambient air that is moved by fans over the wet heat exchanger surface The unit is delivered for operation with a specific o
68. result in a corrosive solution Therefore it is critical to the longevity of the condenser that these impurities are bled from the unit at a rate which is at least equal to that which is absorbed This continual bleed and replacement with fresh source water will determine the concentration of dissolved solids within the system and must be maintained at an acceptable level All evaporative condensers supplied with a factory fitted pump are furnished with a clear water bleed line with flow regulating valve Units supplied for remote sump applications must have a bleed line with flow regulating valve installed at the pump discharge Danger of injury due to biological contamination see Appendix I 5 4 Connecting the water pipes CONNECTING THE UNIT TO THE SYSTEM Prevent stresses on the unit v Ensure that all mounting points have the same spacing to the fixing level v Ensure that all mounting points maintain the same spacing to the support structure under load and permanently Set up units as follows Airflow must not be impaired by obstructions v The units must be installed on mounting points that are appropriate for the unit s weight and then bolted with mounting bolts The operator or installer of the equipment is responsible for ensuring that the bolted connections are of adequate strength The following instructions must be observed when mounting the units o The diameter of the mounting holes has been deter mined by the man
69. stribution and header pipes The following must be observed without fail when install ing the unit o Imperative adherence to spacing from objects that could be endangered by an effect of the halocarbon refrigerant o Imperative adherence to spacing from objects that eeh y Prick BY JOHNSON CONTROLS could be endangered by an explosion or the toxic ef fect of NH3 o Provision of measures to safeguard protective objects from an NH3 concentration of more than 200 ppm o Easily flammable materials must not be placed below the unit o Release devices to prevent liquid escapes must be provided and available o In units using ammonia as the refrigerant the sub cooled liquid must only be present in the lowest pos sible amount in system sections in shutdown state minimized number of fluid traps Residual hazards with break during operation Injuries and damage to property caused by break dur ing Operation The following may result in ruptures during operation and maintenance Residual hazards with break during operation see Ap pendix 2 9 Combined Residual hazards Residual hazards caused by defective installation Non compliance with maximum permissible operating pressure see Appendix l 2 3 Proper intended use Op erating Conditions Disregarding pressurized line sections with maintenance see Appendix 2 9 Combined Residual hazards Residual hazards caused by pressurized parts Disregarding resi
70. sults in less energy consump tion Two types of pumps are available 5 HP and 7 5 HP OPTIONS AND ACCESSORIES Electric Basin Heaters For low temperature climates immersion heater packages are provided factory fitted to maintain the water tem perature in the basin at 40 F The design temperature of 40 F has been determined with the fans being off and options are available for ambient temperatures of 20 F Factory installed electrical contactors and wiring are also an available option Additional available options include electri cal immersion heater s furnished with built in thermostat thermostat low water protection probe and controller and electronic water level heater control device Remote Sump an oversized 12 nominal flange mount con nection and includes the necessary gaskets and hardware to connect to the basin 12 flange not included ECOSS EVAPORATIVE CONDENSERS Page 6 INSTALLATION OPERATION MAINTENANCE Bee dr See Frick BY JOHNSON CONTROLS Ladder and Platform for easy access to the catwalk See Figure 8 Figure 8 Ladder and Platform Electronic water level controller includes alarm float switches indicating if water level is too low or too high see Figure 9 Figure 9 Electronic Water Level Controller Frick BY JOHNSON CONTROLS INSTALLATION TRANSPORTATION STORAGE UNPACKING AND MOUNTING Crushing danger with falling down see Appendix 4
71. t v You have performed a test for ensuring the system s readiness for operation see section Test Readiness For Operation v All safety precautions see Appendix 5 Connecting the unit have been taken v Contact the manufacturer immediately if you want to operate the unit under different operating conditions from those defined in the order related documents Putting the unit into operation v Switch on the system including the electrical system v Activate the unit o Open the valves on the inlet and outlet side of the system o Energize fans v Wait until the operating point is reached After the oper ating point is reached the unit is ready to operate see system Parameters for setting the operating setpoint see order related documents The operating point is defined by Condensation temperature Operating fan kW Air inlet temperature Ensure that the operating setpoint is secure from unauthor ized access TAKING A UNIT OUT OF OPERATION A unit taken out of operation by switching off the refrigerat ing system in accordance with the refrigerating system s IOM v Switch fans off v Switch electrical system off v Close refrigerant carrying lines NOTICE For unit shutdown take precautions so that the maxi mum operating pressure is not exceeded With shutdown times of a month or longer put the fans into operation for approximately 2 4 hours a month to maintain their functionality SHUTTING
72. t s immediate vicinity at all times Ensure that the operating instructions including Appendix I Safety Installation Operation amp Maintenance are accessible to all people that have anything at all to do with the unit at all times Ensure that the operating instructions including Appendix I Safety Installation Operation amp Maintenance are read and understood by all people that have anything at all to do with the unit SAFETY For safety information please refer to Appendix l 2 Safety INFORMATION ON COMPONENT PARTS For safety information see Appendix 3 Information on component parts CASING COIL BASIN WATER SYSTEM All Frick ECOSS evaporative cooling products are fully con structed with 304 304L materials which are self passivating The ASME certified and constructed condenser coils are fabricated with ANSI rated materials All coils are supplied standard as ASME U Stamp Compliant When ASME is re quired only the U stamp tag needs to be applied All coils are CRN certified and possess a less than 1 tube diameter leading to a reduced refrigerant charge The coils have an extended operating pressure range maximum operating pressure is 380 psig They are generously pitched to ensure complete drainage of the condensed refrigerant Figure 1 Stainless Steel Coil There is NO bowing of the tubes which often creates liquid traps in the coil that leads to incomplete drainage The 2 box sections allow fo
73. this manual These procedures should be reviewed in detail prior to the actual rigging operation to acquaint all personnel with the procedures to be followed If any questions or comments arise regarding this manual we encourage you to call your sales representative CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement the information contained in this document is subject to change without notice While Johnson Controls Frick makes no commitment to update or provide current information automatically to the manual owner that information if applicable can be obtained by contacting the nearest Frick Factor or the nearest Frick Sales office It is the responsibility of operating service personnel to verify the applicability of these documents to the equipment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equipment they should verify with the owner whether the equipment has been modified and if current literature is available External wiring is NOT to be connected inside an ECOSS factory mounted electrical panel unless specifically indicat ed as required field wiring on the JCI Frick electrical drawings provided Devices such as relays switches transduc ers and controls may NOT be installed inside the Frick ECOSS electrical panel NO external wiring is allowed to be run throug
74. ting instructions With complications that can be attributed to the use of Spare parts other than the original spare parts specified in the order related documents With changes to the unit refrigerant unit model function Operating parameters deviating from the order related information specified in the order related documents without the manufacturer s prior consent 140 010 IOM JUL 2014 The operating instructions may not be reproduced electroni cally or mechanically circulated changed passed on to third parties translated or otherwise used in full or in part without prior explicit written approval from Johnson Controls 1 3 OPERATING INSTRUCTIONS 1 3 1 Scope These operating instructions apply for all ECOSS evapora tive condensers NOTICE You will find the precise type of your unit in the attached order related documents 1 4 CONVENTIONS FOR SAFETY SIGNS AND NOTICES 1 4 1 General safety signs and their meaning in these operating instructions A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation or practice which if not avoided will result in death or serious injury Indicates a potentially hazardous situation or practice which if not avoided will result in damage to equip ment and or minor injury NOTICE Refers you to possible damage to property or indicates an operating procedure
75. tion seals and look for leaks e g with foaming agent or similar v Perform test run and check for o Smooth fan operation bearing noises contact noises imbalances etc o Fan power consumption o Leaks v Report all defects to the manufacturer immediately and request instructions on how to proceed v Check the unit and the unit s interaction with the system again after 48 hours of operation especially the connec tions and the fans Document the test results TEST READINESS FOR OPERATION v Ensure that all electrical protective measures are ready to function v Ensure that all refrigerant carrying connections are se curely in place v Ensure that all electrical connections fans are effected securely v Ensure that all threaded connections on the fans the unit mounting bolts and all other threaded connections are firmly tightened SAS Frick BY JOHNSON CONTROLS ECOSS EVAPORATIVE CONDENSERS OPERATION Page 13 140 010 IOM JUL 2014 NOTICE PUTTING THE UNIT INTO OPERATION FOR THE FIRST TIME Danger of injuries and damage to property with escaping refrigerant see Appendix 5 9 Putting the unit into operation for the first time Only put the unit into operation when v The unit has been properly mounted and connected see sections TRANSPORTATION STORAGE UNPACKING AND MOUNTING and CONNECTING THE UNIT v You have performed a complete acceptance test see section Perform Acceptance Tes
76. ufacturer the mounting bolts must be adapted accordingly When calculating the transferring bearing strength it is imperative to take into account the total weight of the unit structural weight all contents o The mounting bolts must be secured against loosening with an appropriate locking device o The mounting bolts must not be overtightened or stripped o All mounting bolts must be tightened equally 140 010 IOM JUL 2014 v Fix the unit in its position and prevent the unit from shift ing Tighten and secure the mounting bolts Only secure the unit at the intended mounting points Danger of injuries and damage to property with escap ing refrigerant see Appendix I 5 5 Connecting the unit to the system Important considerations regarding installation Condenser piping should be designed and installed in accor dance with generally accepted condenser piping engineering practice as detailed in ANSI IIAR 2 Piping Handbook All field piping which is external to the ECOSS evapora tive condenser must be supported and anchored separately External loads must not be placed on the condenser connec tions Piping supports must not be anchored to any part of the panels or frame of the evaporative condenser When condensers are installed on vibration rails or springs the field piping must incorporate compensators to prevent vibration transmission to the external piping The unit must only be put into operation operate
77. ure minimum 8 inches away with a flat jet nozzle or using a neutral cleaning agent where applicable NOTE o With oily and greasy dirt it helps to add a cleaning agent to the water o Cleaning should be done from inside to the outside always opposing the dirt onset and from top to bot tom o Continue cleaning until all dirt has been removed WATER TREATMENT WATER TREATMENT AND MINIMUM WATER QUALITY REQUIREMENTS Biological Control With the inlet louvers structure of the side coverings which effectively shut out the sunlight and the double inclination of the basin for complete drainage it is ensured that there will be minimal biological growth in the basin Chemical treatment For necessary measures to maintain the prescribed limit val ues see Table Guidelines for Water Quality please contact your local water treatment specialist Limit values for recirculated water Water quality levels for recirculated water Guidelines for Water Quality Recommended Value 6 5 8 5 gt 200 ppm maximum CI Chlorides as Cl lt 250 ppm maximum as NaCl Sulfates as S042 lt 300 ppm maximum lt 150 ppm lt 375 ppm Hardness as 3 Alkalinity as CaCO3 100 500 ppm as 68603 lt 1500 ppm lt 10 pom 2400 micromhos otal Dissolved Solids ppm Total Suspended Solids ECOSS EVAPORATIVE CONDENSERS MAINTENANCE Frick BY JOHNSON CONTROLS TROUBLESHOOTING Danger of injuries and damage to property see
78. ust protect against mechanical and chemical dangers Use repiratory protection Breathing apparatus must be suitable for the working fluid used Breathing apparatus must consist of at least two independent breathing devices self contained breath ing apparatus Use protective clothing Personal protective clothing must be suit able for the working fluid used and for low temperatures and must have good heat insulation properties eeh y Prick BY JOHNSON CONTROLS Deactivate before work Deactivate the electrical system and ensure all electrical switchgear for the fans are disconnected locked out and tagged out before starting installation maintenance and repair work 2 SAFETY 2 1 LABELING ON THE UNIT 2 1 1 Safety signs on the unit A DANGER Direct and indirect contact with voltage carrying parts of motors and electrical lines can cause serious injuries or death Disconnect 30 AMP switch before doing any main tenance Ensure all electrical switchgear have been disconnected locked out and tagged out 2 2 BASIC SAFETY NOTICES 2 2 1 How to act in an emergency with halocarbons Danger of injuries The halocarbon refrigerants that are used R134a R404A R407C R507 are Group L1 A1 refrigerants in compliance with classification according to flammability L and toxicity A Refrigerants that when gaseous are nonflammable ir relevant of their concentration in air Refrigerants wit
79. well ventilated Divert escaped refrigerant vapor and escaped refrigerant liquid safely lt ECOSS EVAPORATIVE CONDENSERS 140 010 IOM JUL 2014 Frick APPENDIX Page 31 BY JOHNSON CONTROLS Warns against health endangering irritants in the setup space Residual refrigerant still under effervescence can evaporate Inhalation of refrigerant vapor causes harmful to health irritations and lack of oxygen Escaping refrigerant vapor and escaping refrigerant liquid must not reach adjacent rooms staircases yards passages or drainage systems Use respiratory protection Use a room air independent breathing apparatus with maintenance work in high halocarbon refrigerant con centrations in the room air Ensure the setup space Is well ventilated Divert escaped refrigerant vapor and escaped refrigerant liquid safely Warns against cold Residual refrigerant still under effervescence has a temperature of 28 F Contact with refrigerant under effervescence caused by spraying causes frostbite Use eye protection Use hand protection Ensure that the unit in question is pressure free before maintenance work begins or the refrigerant is bled from the unit in question Power off the electrical system and ensure that all electrical switchgear are disconnected locked out and tagged out Separate the unit to be managed from the refrigeration system and secure it NOTICE Danger of damage to property With work in the i

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