XLP2 Evaporative Condenser
Contents
1. SEALER Figure 12 140 920 IOM NOV 09 XLP2 EVAPORATIVE CONDENSERS Page 8 OPERATION PE dr See Prick BY JOHNSON CONTROLS OPERATION Do not perform any service on or near AWARNING the fans motors drives or inside the unit without first ensuring that the fans and the pumps are disconnected and locked out NOTES 1 Recommended service intervals are for typical installa tions Different environmental conditions may dictate more frequent servicing 2 When operating in ambient temperatures below freezing the unit should be inspected more frequently Refer to Cold Weather Operation section for more details see Table of Contents 3 Tension on new belts must be readjusted after the first 24 hours of operation and quarterly thereafter INITIAL AND SEASONAL START UP General If the unit is mounted on vibration isolators or isolation rails refer to the vibration isolation manufacturer s guidelines before loading unloading weight from the unit Verify fan and spray pump motors are disconnected and locked out Conduct external inspection of the equipment Check for leaks corrosion and any structural damage Inspect piping and connections Cleaning Drain the cold water basin with the strainers in place Remove all dirt and debris from the fan guards Clean all mechanical components2. 9 140 920 IOM NOV 09 Clean the basin strainer and re install Lubricate the fan shaft bearings motor base and motor base adjusting screw Close the shutoff valve in the makeup water line supplied by others and drain all exposed makeup water piping Heat trace and insulate all exposed piping Inspect the protective finish on the unit Clean and refinish as required Refer to the CORROSION PROTECTION section for more details see Table of Contents Secure the fan motors starting device s in the OFF position to ensure personal safety in case of future inspection or service COLD WEATHER OPERATION Frick condensers can be operated at subfreezing ambient tem peratures provided proper operating methods are established and diligently followed Inspection and Maintenance Carry out the frequent visual inspections and routine maintenance services during operation in subfreezing weather Ensure all controls for capacity and freeze protection are set properly and functioning normally Prevent excessively high water levels and possible overflow of the cold water basin due to overpumping clogged strainers or makeup valve malfunction Resolve any icing condition that develops which may damage the unit or the supports or impair system performance Fan Section Icing Protection There are three basic operational methods which can be used to provide the system s required cooling Temperature Setting Fan Control an
3. Branches Drift Eliminators Casing XLP2 Evaporative Condenser Heat Transfer Coil Section e e XLP2 EVAPORATIVE CONDENSERS 140 920 IOM NOV 09 ee INSTALLATION OPERATION MAINTENANCE Page 3 Plenum Partition Two Stage Axial Flow Fan Fan Ball Bearing Access Door Fan Screen Water Bleedline Fan Drive FA De a Cal Motor Base ck Step Water Makeup Valve Assembly a e y Adjustment Strainer s Fan Shaft Spray Pump Adjustable Float XLP2 Side Discharge Evaporative Condenser Water Makeup Valve Assembly Adjustable Float Strainer Two Stage Axial Flow Fan Fan Ball Bearing Spray Pump Water Bleedline Access Door Z 4 Fan Shaft Fan Drive Motor Base Adjustment Fan Motor XLP2 End Discharge Evaporative Condenser 140 920 IOM NOV 09 Page 4 XLP2 EVAPORATIVE CONDENSERS INSTALLATION Frick BY JOHNSON CONTROLS INSTALLATION INTRODUCTION XLP2 units should be rigged and assembled as outlined in this bulletin These procedures should be thoroughly reviewed prior to the actual rigging operation to acquaint all personnel with procedures to be followed and to assure that all necessary equipment will be available at the jobsite Locate the unit nameplate on the connection end of the unit and record the unit serial number and model number for reference Have a copy of the unit certified drawing available for reference If you do not have a copy of thi
4. days a week O NET distributed architecture mean faster easier economical installations Q NET delivers increased operating efficiency and lowers energy costs Available on Frick screw compressors condensers evaporators AcuAir hygienic air handlers and refrigerant vessels Form 140 920 IOM 2009 11 JOHNSON CONTROLS Supersedes NOTHING y 100 CV Avenue P O Box 997 Subject to change without notice Johnson dy K Waynesboro PA 17268 0997 USA Published in USA GUI 1M Phone 717 762 2121 FAX 717 762 8624 2009 Johnson Controls Inc ALL RIGHTS RESERVED Control S www johnsoncontrols com
5. designed to support the weight of the entire assembled unit The proper rigging sequence is to lift the basin section into place apply sealer to the basin where the casing s will be located BEE dk Reeg Prick BY JOHNSON CONTROLS and then lift the casing s into place Lifting devices have been provided on all sections Spreader bars spanning the full width of the section must be used between the lifting cables to prevent damage to the section In the event of extended lifts or where AWWARNING hazards exist the lifting devices should be used in conjunction with safety slings placed under the unit Refer to Table 1 for the recommended minimum size of the spreader bar and the recommended vertical dimension H from the lifting device to the spreader bar 1 Rig the basin section The rigging hook must be placed above the section s center of gravity as detailed in Figures 1 and 2 Before proceeding bolt the basin section A CAUTION securely to the eer eg steel Units with multiple cold water basins may employ flume boxes to equalize the water level in the basin of each cell Follow the directions in the Flume Box Installa tion section see Table of Contents Figure 1 Table 1 No of Basin Model Number sections No of Casing Sections XLP2 EVAPORATIVE CONDENSERS INSTALLATION Page 5 140 920 IOM NOV 09 2 Wipe down the flanges with acetone to remove dirt or mois ture which may have accumu
6. from damage Solid bottom panels may be desirable or necessary for safety and other reasons depending on the location and conditions at the installation site PVC eliminators on this product are not AWARNING designed to support the weight of a person or to be used as a storage or work surface for any equipment or tools Use of these plas tic eliminators as walking working or storage surface may result in injury to personnel or damage to equipment If covering a unit which has PVC eliminators do not use a clear plastic tarpaulin For a discussion of Safety Precautions to be followed when operating or maintaining this equipment please refer to the Operation and Maintenance Sections of this manual WARRANTIES Please refer to the Limitation of Warranties applicable to and in effect at the time of the sale purchase of these products FREEZE PROTECTION These products must be protected by mechanical and operational methods against damage and or reduced effectiveness due to possible freeze up Please refer to the Operation and Maintenance sections of this Manual or contact the local Frick Representative for recommended protec tion alternatives Rigging To simplify rigging and installation most XLP2 Series Units are shipped in sections consisting of the basin and casing sections The basin and casing components must AWARNING be rigged separately Never assemble the unit before lifting as the lifting de vices provided are not
7. lift indi viduals responsible for rigging Frick units must inspect the equipment before the lift to make certain that all water or other liquids have been drained from the unit and any debris removed During cold weather the pre lift procedure must include a check for and removal of accumulations of ice and snow which will not naturally drain from the equipment and would add substantially to the equipment s lifting weight Anchoring Unit must be properly anchored in place CAUTION before operation begins Seven eighths inch 7 8 diameter bolt holes are provided in the bottom flange of the basin section for bolting the unit to the support beams Refer to the suggested support details on the certified drawing for locations of the mounting holes Anchor bolts are supplied by others Leveling The support beams and unit must be level for proper operation Shims should not be used between the basin and support beams to level the unit Operation maintenance and repair of AWARNING this equipment should be undertaken only by personnel qualified to do so Proper care procedures and tools must be used in handling lifting installing operating maintaining and repairing this equipment to prevent personal injury and or property damage Adequate precautions appropriate for AWARNING the installation and location of these products should be taken to safeguard the public from possible injury and the equipment and the premises
8. recommended operating level XLP2 EVAPORATIVE CONDENSERS MAINTENANCE eS dr Gemeen Prick BY JOHNSON CONTROLS Closely monitor the water level in the cold water basin and adjust the level if necessary during the first 24 hours of operation Operating at the recommended water level will ensure that the unit basin contains sufficient water volume to prevent air entrainment in the circulating spray pump during system start up Optional Electric Water Level Control Package As an option an electric water level control package is avail able in lieu of the mechanical makeup assembly The package consists of a probe type liquid level control assembly and a slow closing solenoid valve Stainless steel electrodes factory set at predetermined lengths extend from an electrode holder into the cold water basin Inspection and Maintenance Clean the stainless steel electrodes periodically to prevent accumulations of scale corrosion sludge or biological growth which could interfere with the electrical circuit The water level is maintained at the recommended operating level regardless of the system thermal load Therefore it is not recommended that the operating level be adjusted During the start up of units equipped with the electric water level control package by pass the control unit in order to fill the unit to the overflow connection SYSTEM CLEANING Coil Cleaning Both the inside and outside of the heat exchange coil
9. the optional SmoothLink Piping Arrangement It is essential to drain water from the SmoothLink Piping Arrangement and internal piping whenever the potential for freezing temperatures exits Drain the water by using 1 2 NPT drain port located on the inboard side of the SmoothLink Piping Arrangement There are three recommended methods for draining the piping 1 Preferred Install a normally open 1 2 solenoid valve on the 1 2 drain connection of the SmoothLink Piping Arrangement Wire the valve in the pump circuit such that the valve closes when the pump is energized Select the solenoid valve to operate with a minimum pressure differential of O psi which is required to limit the static head imposed on the valve from the water column 2 Install a 1 2 manual valve on the 1 2 drain connection of the SmoothLink Piping Arrangement Open the valve during cold weather operation Keep the valve closed during warm weather to achieve full thermal performance 3 Remove the 1 2 plug from the 1 2 drain connection of SmoothLink Piping Arrangement during cold weather operation Reinstall the plug during warm weather to obtain full thermal performance PER d Eege Prick BY JOHNSON CONTROLS CORROSION PROTECTION Frick products are constructed of corrosion resistant materi als The fill if applicable is made of a polyvinyl chloride PVC which requires no protection against rot decay rust or biolo
10. the spray pattern in Figure 20 Figure 20 Nozzle Spray Pattern 4 Clean any nozzles which are clogged If necessary the nozzle and rubber grommet may be removed for cleaning If additional cleaning is necessary the branch may be removed for cleaning Tools are not required to remove eliminator support channel or branches 140 920 IOM NOV 09 Page 16 5 Inspect the coil surface Any corrosion damage or obstructions must be corrected Some units are provided with an extended surface finned coll During the winter season when the ambient temperature is well below design units can operate with the spray pump off The coil is designed for seasonal dry operation followed by seasonal wet operation and not for frequent cycling of the spray pump Frequent spray pump cycling may lead to exces sive scale buildup Don t use steam or high pressure water A CAUTION to clean PVC eliminators or materials other than steel WATER LEVEL CONTROL There are two types of water level controls used on XLP2 units Mechanical makeup valve assembly Optional electric water level control package The unit water makeup valve assembly is located within easy reach from the access door at the connection end of the unit Mechanical Makeup Valve Assembly A float operated mechanical water makeup assembly is furnished as standard equipment on the unit The standard makeup as sembly consists of a corrosion resistant makeup valve connected to a
11. 1139 1196 1281 No of Casing sections 1 and H 12 4 140 920 IOM NOV 09 Splice Sealer Tape Along Flanges With Bolt Holes Figure 3 6 Insert drift pins downward through the four corner screw holes in the casing Figure 5 Continue to lower the casing slowly maintaining alignment with the drift pins until it rests on the basin section Casing Section 1 Flat Sealer Tape Laid Over Punchline Wide Side Down Figure 4 7 Working from the corners towards the center install the 3 8 bolts using the drift pin to align the screw holes 8 Secure the hose connecting the sections of the pump dis charge pipe with the hose clamps provided 9 On units with more than one casing install the remaining casings using the same procedure as the first When installing two or more casings on the basin section sealer tape must be applied to both cross flanges Figure 3 10 On units operating with a remote sump tank install a bleed line with valve between the system circulating pump discharge riser and a convenient drain Locate the bleed line in a portion of the riser piping that drains when the pump is off Units that are furnished with a factory installed circulating pump include a bleed line with valve Bleed valves should remain open when A CAUTION the unit is in operation unless the bleed XLP2 EVAPORATIVE CONDENSERS Page 6 INSTALLATION PE dr See Prick BY JOHNSON CONTROLS rate is automatically contr
12. RER Ak Form 140 920 IOM NOV 2009 Prick INSTALLATION OPERATION MAINTENANCE File SERVICE MANUAL Section 140 Replaces NOTHING BY JOHNSON CONTROLS Dist 3 3a 3b 3c XLP2 Evaporative Condenser THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION OF THE UNIT Please check www johnsoncontrols com for the latest version of this publication 140 920 IOM NOV 09 XLP2 EVAPORATIVE CONDENSERS Frick Page 2 INSTALLATION OPERATION MAINTENANCE Y JONNSONCONTROLS Contents INSTALLATION Chemical Treatment Requirements seerne 11 RIGGING AND ASSEMBLY INSTRUCTIONS A Ber e SS Check Unit Before Rigging eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeens GC ee UNIT WEIGHT 4 MAINTENANCE ee Deeg j COLD WATER BASIN coccccccccccccccccececcececceeecceccsccce 13 ee ee E E 4 El EE 13 coos EE Table 3 Cold Water Basin Water E ce cc cu oe 13 ee ti d Maint B FLUME BOX INSTALLATION 6 1 e e POSITIVE CLOSURE PLATE ORTION een 7 inspection and Maintenance E sete gs Soe bot 13 Positive Closure Plate Installation Figures 11 and 12 7 FAN DRIVE SYSTEM 13 OPERATION Inspection and Maintenance 13 INITIAL AND SEASONAL START AUR nannnnnn 8 Fan Belt HE EE 14 EE 8 EE e CVG PINS otters EE 8 FAN MOTORS EE 14 Aspect NO ii sesso E 8 Inspection and Maintenance EE 14 EE e
13. Tip Clearance Check the clearance between the tip of the blade and the fan cowl The clearance should be within 3 16 and 3 4 Blade Pitch Check to ensure that the blades are all at the same pitch If uncertain measure the pitch with an inclinometer All blades should be within 1 2 to O Rotation Turn the fan shaft by hand to ensure that the shaft moves freely with no rough spots binding or other malfunctions that could cause vibration or fan motor overload Direction of Rotation On initial start up or if the fan motor has been rewired bump the fan motor and note the direction of rotation While rotating the fan check the blade tracking All blades should track within a 3 4 band at any single point around the cowl Operation On initial start up run the fan in the manual position for several minutes and check for any unusual noises or vibration FAN DRIVE SYSTEM Inspection and Maintenance These drives require a periodic check of the belt condition and when necessary tension adjustment The recommended service intervals are as follows 1 Initial Start up Servicing is not required prior to initial unit start up The drive has been tensioned and aligned at the factory Seasonal Start up Readjust the belt tension 3 Operation After the first 24 hours of operation readjust the belt tension on a new unit start up or installation 140 920 IOM NOV 09 Page 14 of a new belt Thereafter check the belt con
14. and can be ordered from Frick In most cases they can ship overnight In addition most Frick Representatives maintain a local inventory of commonly used parts Even with this fast delivery capability it is still recommended that certain essential emergency repair parts be maintained in your local inventory to minimize any potential downtime Basic Recommended Spare Parts Bearing set Float valve or repair kit Float ball Solenoid valve if unit is equipped with electric water level control Powerband or set of belts Spray nozzle kit with grommets Basin heater and low water cut out Door gasket Strainer inlet and suction Fan and sheave bushings Pump seal and gasket kit for coil products Automatic bearing greaser refill kit Parts to Consider if Extended Downtime is a Concern Spray pump for coil products Fan or fan wheel Fan shaft Sheave set Fan motor O NET network technology Di Vessels Connect Your PC Q Ne t with QUANTUM LX Controls Take full advantage of Q NET technology with all Frick products System integration is what we do O NET Ve Supports open protocols for SCADA systems i e Allen Bradley DEI Modbus RTU Modbus ASCII and Industrial Ethernet Protocols e O NET _ connects instantly for local or remote access no software required ge O NET can be applied to both new and existing systems O NET means precise control 24 hours a day seven
15. asin passes through the suction strainer and is pumped back to the distribution system The cold water basin is constructed from one of the following materials Galvanized steel TripleGuard Corrosion Protection System Welded Type 304 stainless steel Water Levels Table 3 Cold Water Basin Water Levels Operating Nominal Water Box Level Size Below Top Model Number ft x ft of Basin XLP2 1236 989 thru 1236 2148 12 x 36 XLP2 512 130 thru 512 203 XLP2 1224 644 thru 1224 XLP2 712 164 thru 712 27 End S 634 XLP2 812 235 thru 812 34 Discharge XLP2 818 320 thru 818 474 The makeup valve controls the operating level which is maintained at the levels shown in Table 3 9 5 1405 12 x 24 8 6 3 The operating water level in the cold water basin will vary with system thermal load evaporation rate the bleed rate employed and the makeup water supply pressure Check the operating water level monthly and readjust the float when necessary to maintain the recommended operating level Inspection and Maintenance Openings and or submerged obstruc AWARNING tions may exist in the bottom of the cold water basin Use caution when walking inside this equipment Inspect the cold water basin regularly Remove trash or debris accumulated in the basin or on the strainer Quarterly or more often if necessary drain clean and flush the entire cold water basin with fresh water This will remove the silt and sediment which
16. d Dry Operation The method of controls employed on a given application depends upon the climatic extremes which are expected the variations in heat load that will be encountered and the compatibility of the control system with other portions of the installation Effective icing control in subfreezing ambient conditions will require a combination of these three methods Temperature Setting Low leaving fluid temperature promotes ice formation During operation in subfreezing ambient temperatures maintain the leaving fluid temperature as high as possible Ensure the unit operates with the maximum possible heat load The recom mended minimum fluid temperature is 45 F Fan Control Reduce the unit capacity by cycling fans thus modulating the airflow through the unit Rapid on off cycles can cause the fan motor to overheat Set the controls to allow a maximum of 6 on off cycles per hour Periodically cycle the fans off to prevent ice formation and or to melt ice that accumulates on the intake louvers or combined inlet shields and face of the fill Fan Cycling Operate each unit with the highest thermal load it can handle rather than evenly dividing the total heat load across all cells During prolong periods bypass the idle units and drain the basins 140 920 IOM NOV 09 Page 10 Multi Speed Motors If the unit is equipped with 2 speed mo tors or Sentinel Sentinel PLUS Fan System operation at a lower speed may be sufficient t
17. dition monthly and adjust tension as necessary Readjust tension at least once every 3 months Fan Belt Adjustment To properly adjust the belt tension position the fan motor so that moderate pressure on the belt midway between the sheaves will produce the deflection shown in Figures 15a and 15b Side draft motor base and idler adjustment 1 Loosen four motor base locknuts 2 Rotate adjusting nut counterclockwise to tighten belt clockwise to loosen belt 3 Check belt tension 4 Tighten four motor base locknuts End draft motor base adjustment 1 Loosen two motor base locknuts on top side of J Bolts 2 Adjust motor base on J Bolts by turning motor base nuts on bottom side of J Bolts 3 Check belt tension 4 Tighten two motor base locknuts on top side of J Bolts Belt tension check 1 Place a straight edge along the belt from sheave to sheave as shown in Figure 15a or use a tape measure as shown in Figure 15b to measure belt deflection 2 Apply a moderate force by hand approximately 40 lb 18 1 kg evenly across the width of the belt in the center of the span between the sheaves 3 There is adequate belt tension if the belt deflects between 1 4 and 3 8 as shown in Figures 15a and 15b Belt tension adjustment if required 1 Loosen the locknut on the motor base adjusting screw 2 Turn the motor base adjusting screw clockwise to tension the belt or counterclockwise to relieve belt tension During adjust
18. e and other micro organisms Uncontrolled this can reduce heat transfer promote corrosion and promote the growth of potentially harmful organisms such as Legionella To avoid biological contamination and minimize the risk of Legionella initiate the biocide treatment program at start up and continue on a regular basis thereafter in accordance with the treatment supplier s instructions Bleed blowdown or chemical treatment used for corrosion and scale control alone is not adequate for control of biological contamination Introduce solid or granular biocides through a chemical pot feeder installed in parallel with the system circulating pump Diluted liquid biocides may be added directly to the cold water basin If ozone water treatment is used at no point should concentrations exceed 0 5 ppm Initial Start up and Start up Following a Shutdown Period 1 To minimize the risk of biological contamination during a shutdown period of three days or more it Is recommended that the entire system evaporative cooling equipment system piping heat exchangers etc be drained 2 To resume operation of a drained system and at initial start up clean all debris from the cold water basin and fill the system with fresh water Then execute one of the following biocide treatment programs while operating the circulating pump and prior to operating the unit fans a Resume treatment with the biocide that was used prior to shutdown Then
19. e 8 Adjustable Motor Base EEN 14 EXTENDED SHUTDOWN 9 FAN SHAFT SUPPORTEREN 15 COLD WEATHER OPERATION eee eee 9 pees ENEE DEE EE 15 Inspection and Maintenance ccccccscccssecsssesssesssessssecssecsseeee 9 Locking EE 15 Fan Section Icing Protection seessssessseereeerrererrrrerrrrerrre 9 SPRAY NOZZLES AND HEAT TRANSFER ssssennnnn 15 Temperature Setting sai eebe leaned des 9 WATER LEVEL CONTROL ccssceteeseeeseseeeeeneenes 16 Fan eu ee EE 9 Mechanical Makeup Valve Assemblv 16 Dry Ope ra tio Ns cerisier e 10 Inspection and Maintenance cccscccseeeeeeeeaeeeseeeeeeeeaes 16 Coil Freeze Protection ssssessssersserrrrerrrrsrrrrsrrrrerrererrren 10 Optional Electric Water Level Control backage 16 Minimum Operati DEE 10 Inspection and Maintenance cccceecceecceeeeeeeeeeeeeeeeees 16 Positive Closure Damper Hoog ana Eege 10 SYSTEM CLEANING eege 16 Emergency Coil Dram 10 Coil Cleaning 16 Baan Water sad inferaal Piping reee PIEN oa TO ares SE tert yproduct Cleah g Sparelag E 16 Cold Water Basin Protection c cccccsseeeeeeeeeeeeeeseeeees 10 Piping Freeze brotechon 10 A T N CHEN z CORROSION PROTECTION SE 11 eee ee eee eee eee ee Corrosion and Treatments essssesneeserereerrrerrrrerrrrernene 11 RECOMMENDED MAINTENANCE SERVICES Corrosion and Scale Control 11 RECOMMENDED SPARE PARTS enn 19 Table 2 Quality Guidelines for Chemically Treated Circulating Water 11 Spray
20. e the evaporative condenser is operating check the current and voltage of all three phases legs of the fan motors with a heat load on the unit under warm ambient conditions The current must not exceed the nameplate ratings Check the operation of the optional vibration cutout switch After 24 hours of operation under thermal load perform the following services Check the unit for any unusual noise or vibrations Check the operating water level in the cold water basin Adjust makeup valve if necessary Check the belt tension and readjust if necessary EXTENDED SHUTDOWN Do not perform any service on or near AWARNING the fans motors and drives or inside the unit without first ensuring that the fans and the pumps are disconnected and locked out Perform the following services whenever the evaporative con denser is shut down in excess of 3 days If the unit is mounted on vibration isolators or isolation rails refer to the manufacturer s guidelines before loading unloading weight from the unit Drain the cold water basin and all the piping that will be exposed to freezing temperatures Heat trace and insulate all exposed piping Clean all debris such as leaves and dirt from the interior and exterior of the unit Clean and flush the cold water basin with the basin strainers in place Leave the cold water basin drain open so rain and melting snow will drain from the unit XLP2 EVAPORATIVE CONDENSERS OPERATION Page
21. ed by a competent water treatment expert NOTE The solenoid valve and conductivity meter must be supplied by others 2 Alternatively use a bleed line with a valve to continuously bleed from the system In this arrangement adjust the rate of bleed using the valve in the bleed line Measure the rate of bleed by filling a container of known volume while noting the duration Check the bleed rate and water quality periodically to ensure that adequate control of the water quality is being maintained Bleed Line Calculations Bleed rate is determined by the fol lowing formula E Bleed Rate B n 1 Where B Bleed Rate GPM E Evaporation Rate GPM Q Process Fluid Flow Rate G R Range n Number of Cycles of Concentration CR CM CR Concentration in Recirculating Water CM Concentration in Makeup Water O GPM x R F x 001 PM The evaporation rate EI can be determined by any one of the following methods 1 The evaporation rate is approximately 2 GPM per 1 million BTUH of heat rejection 2 The evaporation rate is approximately 3 GPM per 100 tons of refrigeration XLP2 EVAPORATIVE CONDENSERS MAINTENANCE 140 920 IOM NOV 09 Page 17 3 Evaporation Rate Q GPM x R x 001 as shown in the example The following example illustrates a bleed rate calculation Given Condenser Process Fluid Flow Rate 800 GPM Maximum Allowable Chloride Concentration 250 ppm Concentration of Ch
22. en in Table 2 In cases where bleed blowdown alone is being employed for corrosion and scale control without chemical treatment your water treatment specialist may recommend more conservative limits than those shown in Table 2 Table 2 Quality Guidelines for Chemically Treated Circulating Water Property of Water Recommended Level Conductivity 2400 micromhos 250 ppm maximum Cl 410 ppm maximum as NaCl Silica NOTES 1 Galvanized steel units require passivation in order to prevent white rust refer to passivation below 2 Hardness and alkalinity limits may be exceeded under certain circumstances Consult your water treatment specialist for recommendations 3 The conversion factor used to determine conductivity is 0 625 TDS 0 625 x Conductivity Chemical Treatment Requirements Chemical treatment programs must meet the following require ments The chemicals must be compatible with the unit materials of construction as well as other materials used in the system pipe heat exchanger etc Chemical scale and corrosion inhibitors particularly acid if used should be introduced into the circulating water through automatic feeders This should be done at a point in the system where total mixing and dilution occur before reaching the evaporative cooling equipment The preferred injection point for chemical scale and corrosion inhibitors is on the discharge side of the system circulating pump s These che
23. f the following conditions Maintain the minimum recommended flow through the coll at all the times per the job specifications Maintain a minimum heat load on the circulating fluid so that the temperature of the fluid leaving the coil will not fall below 50 F 10 C To maintain the leaving fluid temperature at 50 F 10 C when the process load Is extremely light or shut off apply an auxiliary heat load to the circulating fluid Positive Closure Damper Hood and Insulation The amount of auxiliary heat required can be substantially re duced by the use of a positive closure damper hood and insula tion The heat loss data can be found in publication 140 920 SED Emergency Coil Drain Do not drain the coil as a normal method of freeze protection Frequent draining promotes corrosion inside the coil tube However draining is acceptable as an emergency method of freeze protection if the coil is not protected by a glycol solu tion If the coil is not protected an automatic drain valve and vacuum breaker are recommended to drain the coil if flow stops or fluid temperature drops below 50 F 10 C when the ambient temperature is below freezing Contact your local Frick Representative for guidelines on the installation of an emergency coil drain system XLP2 EVAPORATIVE CONDENSERS OPERATION eS dr Gemeen Prick BY JOHNSON CONTROLS Further protection against coil freeze up is possible with the installation of an alarm to aler
24. float arm assembly actuated by a polystyrene filled plastic float The float is mounted on an all thread rod held in place by wing nuts The cold water basin operating water level can be adjusted by repositioning the float and all thread rod using the wing nuts provided NOTE If the unit has been ordered with the optional electric water level control package or is intended for remote sump application a mechanical water makeup valve will not be provided Inspection and Maintenance Inspect the makeup valve assembly monthly and adjust if necessary Inspect the valve annually for leakage Replace the valve seat if necessary Maintain the makeup water supply pressure between 15 psig and 50 psig for proper operation A surge protector provided by others is recommended for pressures over 50 psig Set the initial basin water level by adjusting the wing nuts so that the makeup valve is completely closed when the water level in the cold water basin is at the overflow connection With the design thermal load and the average water pressure 15 to 50 psig at the valve the above setting will produce operating water levels as stated in Table 3 in the Water Level section see Table of Contents If the thermal load is less than the design load at the time of unit start up the procedure may produce operating levels greater than those shown in Table 3 If operating levels are higher than specified readjust the float in order to attain the
25. gi cal attack Other materials listed below are used in the equipment con struction Galvanized Steel Components Inspect the galvanized steel components for blemishes or corrosion Wire brush and recoat the affected areas with a cold galvanizing compound such as zinc rich compound ZRC Thermosetting Hybrid Polymer Components Galvanized steel components protected with the Thermosetting Hybrid Polymer may develop scratches scrapes or blemishes Touch up these with a repair kit In the unlikely event that the damage is more extensive than simple scratches or minor blemishes contact your local Frick Representative Stainless Steel Components Inspect stainless steel components for signs of blemishes or corrosion Clean with stainless steel wool as necessary If more extensive corrosion is prevalent contact your local Frick Representative TripleGuard Corrosion Protection System Inspect compo nents protected with the TripleGuard Corrosion Protection System for signs deep scratches or blemishes especially in areas with field penetrations Touch these up with either rub berized polyurethane caulking such as Vulkem or a repair kit Corrosion and Treatments Corrosion Red rust on steel components and white rust on galvanized surfaces will affect the longevity of the unit Scale Formation Scale not only reduces heat transfer and system efficiency but also may lead to under deposit corrosion Biological Fou
26. gure 7 6 Position Cell 2 on the unit supports exactly 1 between basins Figure 7 Wipe down the mating surface by the flume opening to remove any dirt or moisture 7 Using drift pins to ensure alignment draw Cell 2 tight against the flume box Figure 8 Figure 9 XLP2 EVAPORATIVE CONDENSERS INSTALLATION Page 7 SEALER TAPE Figure 11 mrt t J LD 140 920 IOM NOV 09 NOTE Units equipped with the positive closure plate option skip step 8 and go to the positive closure plate section of this document 8 As illustrated in Figures 9 and 10 insert 3 8 self tapping screws in each hole from the flume box into the basin wall and tighten POSITIVE CLOSURE PLATE OPTION The optional Positive Closure Plate and gasket are furnished on multicell units to allow individual cells to be isolated for cleaning and maintenance The plate ships loose inside the basin To install the Positive Closure Plate and gasket follow the steps from the Flume Box Installation section then complete the installation using the instructions listed Positive Closure Plate Installation Figures 11 and 12 1 Thread 3 8 self tapping screws from the flume box into the basin wall with the positive closure plate as shown 2 Position gasket and positive closure plate over the bolts and fasten in place with 3 8 wing nut and flat washers
27. lated during shipment and storage 3 Install sealer tape on the mating flange of the basin section to ensure an airtight seal between the casing and basin sec tion Apply a layer of 1 4 x 1 sealer tape around the face of the flange over the centerline of the holes Do not overlap or stretch too thinly at the corners When it is necessary to splice the sealer press the two ends together to form a smooth con tinuous strip The sealer is to be spliced only along the flanges with holes Figure 3 NOTE The sealer tape is trapezoidal in shape and must be installed with the wide side down see Figure 4 Gravity Figure 2 4 Lower the flexible connection on the pump discharge piping below the elevation of the basin section top section before rig ging the casing section 5 After applying sealer tape to the basin flanges remove the casing skid Lift the casing see Figure 6 and position it so that the casing flanges are about 2 above the basin section Do not permit the casing to damage the sealer Casing Section Spreader Bar ZE aks Minimum Height H Minimum Spreader Bar Height H SE Length L 205 LZ LB wos w J e f sw ws f w fo e f sr w J s f w e a a er e e j ew os w e ow sr w e ew For Models 1024 660 668 706 745 T 799 822 833 879 881 892 940 em of Casing sections 1 and H 12 4 For Models 1224 743 775 812 876 917 965 992 1012 1034 1064 1084 1090
28. ling Slime and algae formations may reduce heat transfer promote corrosion and harbor pathogens such as Legionella Since the quality of the ambient air and makeup water varies significantly from job site to job site Frick strongly recom mends obtaining the services of a competent water treatment specialist prior to the initial start up of the evaporative cooling equipment Additionally to protect against the risk of Legionella contamination never operate the cooling equipment without adequate biological control Corrosion and Scale Control To control corrosion and scale maintain the water chemistry of the recirculating water within certain parameters The specific measures required vary from system to system and are dependent on the chemistry of the makeup water the metallurgy of the piping and heat transfer devices exposed to the recirculating water and the temperatures at which the system will be operating Bleed blowdown the continuous flow of a small portion of the recirculating water to a drain is used to control the concentration of dissolved solids On rare occasions this may be adequate to control scale and corrosion More often however chemical scale and corrosion inhibitors XLP2 EVAPORATIVE CONDENSERS OPERATION 140 920 IOM NOV 09 Page 11 are necessary which raise the allowable level of dissolved solids without the risk of scale and corrosion Keep the chemically treated water within the guidelines giv
29. lorides in Makeup Water 45 ppm Range 10 F Find Bleed Rate Solution So in this case E x R x 0 001 800 x 10 x 0 001 8 GPM CR 250 ppm 5 55 CM 45 ppm Therefore in this case we must bleed approximately 1 75 GPM to limit the concentration of impurities NOTE This example focuses on a single parameter chloride concentration of water only The bleed rate required for a system when evaluating more than one parameter is the highest bleed rate required to keep all parameters within recommended limits 140 920 IOM NOV 09 XLP2 EVAPORATIVE CONDENSERS ay a Page 18 MAINTENANCE Prick RECOMMENDED MAINTENANCE SERVICES Type Service Start Up Monthly Quarterly Annually Shutdown Inspect and clean as necessary Inspect general condition of the unit and check unit for unusual noise or vibration Clean and flush basin Inspect spray nozzles Clean basin strainer Drain basin and piping Check and adjust water level in basin Check operation of makeup valve Check and adjust bleed rate Inspect heat transfer section Inspect protective Finish Mechanical equipment system Check belt condition Adjust belt tension Lubricate fan shaft bearings Lubricate motor base adjusting nut Check drive alignment Check motor voltage and current Check fan bearing locking collars Check fan motors for proper rotation Clean and flush en Inspect spray nozzles XX Clean basin strainer
30. may require occasional cleaning The chemicals used must be compatible with the materials being treated For example the standard coil outside Is galvanized steel The inside of the coil is black carbon steel For finned coils the coil cleaning must be careful not to damage the fins outside of the coils and the coils themselves For specific recommendations on coil cleaning contact a quali fied consultant Weld Byproduct Cleaning The installation and manufacturing processes commonly used for field assembly of steel piped systems may leave weld byproducts inside coils and connecting piping especially in refrigeration systems It is common practice to install filters and or strain ers that remove contaminants during initial system operation Shortly after system start up the filters and or strainers should be cleaned or replaced WATER TREATMENT A proper water treatment program administered under the supervision of a competent water treatment specialist is an essential part of routine maintenance to ensure the safe opera tion and longevity of evaporative cooling equipment as well as other system components Bleed Rate In evaporative cooling evaporation of a small portion of the recirculating spray water as it flows through the equipment causes the cooling effect As this water evaporates the impurities originally present remain in the recirculating Frick BY JOHNSON CONTROLS water The concentration of the dissolved
31. ment of belt tension rotate the drives several times by hand to evenly distribute the tension throughout the belt When the belt is properly tensioned retighten the locknut on the motor base adjusting screw NOTE There should be no chirp or squeal when the fan motor is started DRIVEN SHEAVE DRIVER SHEAVE 1 4 TO 3 8 DEFLECTION PROPER BELT TENSION Figure 15a Checking Belt Tension XLP2 EVAPORATIVE CONDENSERS MAINTENANCE PE dr Geen Prick BY JOHNSON CONTROLS DRIVEN SHEAVE TAPE MEASURE 1 4 TO 3 8 DEFLECTION PROPER BELT TENSION Figure 15b Checking Belt Tension Alignment Check the drive alignment annually to ensure maximum belt life Drive alignment check and adjustment 1 Place a straight edge across the driver and the driven sheaves as shown in Figure 16 2 The straight edge should contact all four points as shown in Figure 16 indicating proper drive alignment 3 There should be no more than 1 16 deviation from four points of contact 4 In case of realignment loosen the motor sheave and align it with the fan sheave Allow 1 4 for draw up as the bushing screw is retightened STANDARD DRIVER SHEAVE POINTS OF CONTACT Figure 16 Standard Drive Alignment FAN MOTORS XLP2 Evaporative Condensers use inverter duty premium efficient totally enclosed single speed single winding reversible ball bearing type motor s Inspection and Maintenance Clea
32. micals should not be batch fed directly into the unit s cold water basin or water distribution system as this can severely damage areas directly contacted When chlorine is added to the system free residual chlorine should not exceed 1 ppm except as noted in start up and shutdown section Exceeding this limit may accelerate corrosion Passivation Passivation is the formation of a protective passive carbonate layer on galvanized steel surfaces On the newly installed units to provide maximum protection from corrosion take special measures to passivate galvanized steel surfaces 140 920 IOM NOV 09 XLP2 EVAPORATIVE CONDENSERS Frick Page 12 OPERATION To ensure proper passivation of the galvanized steel keep the pH of the circulating water between 7 0 to 8 2 for four to eight weeks after start up or until new zinc surfaces turn dull gray in color If white deposits form on galvanized steel surfaces after the pH is returned to normal service levels it may be necessary to repeat the passivation process NOTE Stainless steel cold water basins and basins pro tected by the TripleGuard Corrosion Protection System or Thermosetting Hybrid Polymer do not require passivation However if the upper structure is galvanized steel passiv ation is required BIOLOGICAL CONTROL The warm oxygen and nutrient rich environment inside evaporative cooling equipment provides an ideal environment conducive to the growth of algae slim
33. n the outside of the motor at least quarterly to ensure proper motor cooling After prolonged shutdowns check the motor insulation with an insulation tester prior to restarting the motor Adjustable Motor Base Coat the motor base slides and adjusting screws see Figure 14 in the Operation section every 3 months using good qual ity corrosion inhibiting grease such as one recommended for lubricating the fan shaft bearings Frick BY JOHNSON CONTROLS FAN SHAFT SUPPORTS The fan shafts are supported by ball bearings see Figure 17 in the middle of the shaft with fans at each end Each bearing is equipped with a lubrication fitting and locking collar Lubrica tion lines are extended to the outside of the unit as standard see Figure 18 Ball Bearings Figure 17 Ball Bearing Under normal operating conditions the bearings should be greased every 2 000 operating hours or at least quarterly The bearings should also be greased at seasonal start up and shut down Only lubricate the bearings with one of the following water resistant inhibited greases which are good for ambient temperatures ranging from 65 F 53 9 C to 250 F 121 1 C MobilGrease AW2 Shell Alvania RL3 Shell Alvania 3 Shell Dolium R SKF LGHP2 Unocal76 Unilife Grease Amoco Rycon Premium 3 Chevron SRI Citgo Polyurea MP2 Conoco Polyurea 2 Exxon Polyrex EM Exxon Unirex N Only lubricate the bearings with a hand grease g
34. normally collects in the basin during operation If not removed sediment can become corrosive and cause deterioration of the protective finish of metallic basins When flushing the basin leave the strainers in place to prevent the sediment from re entering the system Remove the strainers after the basin has been flushed Clean and replace the strainers before refilling the basin with fresh water Adjust the float to maintain the design operating level See Table 3 Cold Water Basin Water Levels FAN The XLP2 Evaporative Condenser uses axial fans Thoroughly Inspect the fans for damaged or deteriorated fan blades and replace the fan as required Inspection and Maintenance If the unit is already in operation while the fans are still running check for any unusual noise or vibration With the fans off and the motor locked out and tagged check the general condition of the fans 1 Inspect for any loose or missing bolts in the fan shaft bushing fan hub and fan shaft bearing s 2 Check if the fan blades are loose first by twisting the blade by hand and then by moving the blade tip up and down There should be no play or slippage 3 Inspect each blade for excessive scale buildup that could cause vibration 4 Check each blade in the area of the shank for any signs of cracking If cracking is found the fan motor should be locked out immediately Contact your local Frick Representative for assistance
35. o X o o a Check and adjust water level in basin f O x Jo X Check operation of makeup valve x fJ x Check and adjust bleed rate Jo x oOo X Inspect heat transfer section OoOo x So x Check belt condition oo x o o x Adjustbelttension 0X lubricate fan shaftbearings XT Lubricate motor base adjusting nut fO O x Jooo Check motor voltage and current fO O x o Check fan bearing locking collars Jo x Jooo Check fan motors for proper rotation f O x Jooo Check fans for rotation without obstruction x Check fans for rotation without obstruction 1 Recommended service intervals are for typical installations Different environmental conditions may dictate more frequent servicing 2 When operating in ambient temperatures below freezing the evaporative condenser should be inspected more frequently Refer to Cold Weather Operation on Page N102 for more details 3 Tension on new belts must be readjusted after the first 24 hours of operation and quarterly thereafter Frick XLP2 EVAPORATIVE CONDENSERS 140 920 IOM NOV 09 BY JOHNSON CONTROLS INSTALLATION OPERATION MAINTENANCE Page 19 RECOMMENDED SPARE PARTS Frick parts are the Perfect Fit for your condenser These parts are specifically designed engineered and manufactured to work in a condenser environment They are the right parts at competitive pricing levels and Frick offers the best deliveries in the industry The most common repair and retrofit parts are in stock
36. o prevent icing When 2 speed motors are used the motor starter should include a minimum 15 second time delay when switching from high to low speed Variable Frequency Drives VFDs offer the most precise method of capacity control by modulating fan motor speed When us ing VFDs avoid operating at or near critical speeds Units with VFDs require inverter duty motors which are included as standard In subfreezing ambient temperatures cycle the fan off for 5 minutes every 15 to 20 minutes for each cell If ice continues to build on the louvers decrease the on time Observe inlet louvers every 4 to 8 hours NOTE Modulating the water flow rate to the unit is NOT a recommended method of controlling cooling capacity Dry Operation One method of protecting fans from icing is dry operation Dry operation of the evaporative condenser protects fans from ice formation due to mist and splash from the cold water basin Coil Freeze Protection Use an industrial grade inhibited glycol solution for protection against coil freeze up When the use of glycol is not practical the system must be designed to meet both minimum flow and minimum temperature requirements Recommended solutions are an industrial grade inhibited ethylene glycol or propylene glycol solution Coil volume for condenser models using liquid cooling circuits is job specific Minimum Operation When a glycol solution is not utilized operate the system to meet both o
37. olled by a water treatment system See Bleed Rate section under Water Treatment at the end of the MAINTENANCE section Figure 5 Figure 6 FLUME BOX INSTALLATION Required for Models XLP2 1024 xxxx 1224 xxxx 1036 xxxx and 1236 xxxx 1 Position Cell 1 on the unit support and bolt in place 2 Wipe down the mating surface by the flume opening to remove any dirt or moisture that may have accumulated during shipment 3 Wipe down the flanges on both ends of the flume box On one end apply a layer of 1 8 x 1 butyl sealer tape around the face of the flange over the centerline of the holes Do not overlap or stretch too thinly at the corners When it is necessary to splice the sealer be sure to press the two ends together to form a smooth continuous strip Apply a second layer of sealer tape over the first layer following the same procedure Refer to Figure 8 4 Using drift pins to align the bolt holes place the flume box over the opening in the basin of Cell 1 and fasten into place Insert the 3 8 self tapping screws or bolts from the flume box into the basin wall as illustrated in Figure 9 NOTE Flume boxes furnished with units constructed with stainless steel basins are assembled with stainless steel bolts washers and nuts in lieu of self tapping screws Frick BY JOHNSON CONTROLS 5 Apply sealer to the other end of the flume box as described in Step 3 Critical Hold 1 CELL SPACING DETAIL Fi
38. ricating Motor Base Adjusting Screws Prior to seasonal start up lubricate the motor base adjusting screws and the fan shaft bearings Then coat the motor base slides and adjusting screws every 3 months using good quality corrosion inhibiting grease such as one recommended for lubricating the fan shaft bearings see Figure 14 At initial start up no bearing lubrication is Frick BY JOHNSON CONTROLS required since the bearings are factory lubricated prior to shipment Fill the cold water basin with fresh water to the overflow level via the makeup valve 1 Water treatment for new installations Initiate the biocide water treatment program at this time Refer to BIOLOGICAL CONTROL section for more details see Table of Contents 2 Water treatment for seasonal start up or after a shutdown period in excess of 3 days Resume the biocide treatment program and administer a shock treatment of appropriate biocides prior to operating the fans This will eliminate accumulated biological contaminants Refer to the BIOLOGICAL CONTROL section for more details see Table of Contents Set the makeup valve to shut off below the top of the basin at the operating water levels stated in Table 3 in the COLD WATER BASIN section under MAINTENANCE Start the spray pump See SPRAY NOZZLES AND HEAT TRANSFER section under MAINTENANCE for more details Open the valve in the unit bleed line and adjust the bleed by closing or opening the valve Onc
39. run the pump only while maintaining the maximum recommended biocide residual for a sufficient duration residual and time will vary with the biocide as recommended by the BY JOHNSON CONTROLS water treatment supplier Start the fan only after this treatment period is completed Check the pH of the circulating water and if necessary adjust it to 7 0 7 6 pH Then running the pump only treat the system with sodium hypochlorite to maintain a level of 4 to 5 mg l ppm free chlorine as Cl2 over a 6 hour period Test kits for measuring the free residual of chlorine are commercially available Start the fan only after this treatment period is completed When it is not practical to drain the system during shutdown periods install a bypass line with shutoff valves to permit the recirculating water to circulate throughout the system including the unit basin while bypassing the fill section of the evaporative cooling equipment fans should remain off Treat the system as per one of the above described methods prior to restarting the unit PER d Eege Prick BY JOHNSON CONTROLS XLP2 EVAPORATIVE CONDENSERS MAINTENANCE 140 920 IOM NOV 09 Page 13 MAINTENANCE COLD WATER BASIN The refrigerant to be condensed Is circulated inside the tubes of the unit s heat exchanger Heat flows from the refrigerant through the coil to the spray water outside which Is cascading over the tubes The spray water collects in the cold water b
40. s drawing contact your local Representative RIGGING AND ASSEMBLY INSTRUCTIONS Check Unit Before Rigging When the unit is delivered to the jobsite check it thoroughly to ensure all required items have been received and are free of any shipping damage before signing the bill of lading The following parts should be inspected _ Interior Exterior Surfaces _ Eliminators Float Valve Assembly _ Strainer s _ Water Distribution System _ Miscellaneous Items L Sheaves and Belts _ Bearings _ Bearing Supports _ Fan Motor s _ Fan s and Fan Shaft s _ Coils If required for field assembly the following parts will be pack aged and usually placed inside the basin fan section Sealer Self Tapping Screws and Accessory Items A checklist inside the envelope attached to the side of the unit marked Contractor s Installation Instructions indicates what miscellaneous parts were included with the shipment and where they were packed Be sure to remove all accessory items from the basin before the unit is assembled UNIT WEIGHTS Before rigging any XLP2 Product the weight of each section should be verified from the unit certified drawing Some ac cessories add aditional weight as shown on the respective accessory drawings These weights are approximate only and AWARNING should be A by weighing before lifting when available hoisting capacity provides little margin for safety In preparing for a
41. solids increases over time and can reach unacceptable levels In addition airborne impurities are often introduced into the recirculating water If these impurities and contaminants are not effectively controlled they can cause scaling corrosion and sludge accumulations that reduce heat transfer efficiency and increase system operating costs potentially shortening the useful life of the equipment The degree to which dissolved solids and other impurities build up in the recirculating water may be defined as the cycles of concentration Specifically cycles of concentration is the ratio of the concentration of dissolved solids for example chlorides sulfates etc in the recirculating water to the concentration of the same material in the makeup water In order to optimize heat transfer efficiency and maximize equipment life bleed or blowdown a small amount of recirculating water from the system This controls the cycles of concentration to maintain the quality of the recirculating water within the guidelines given in Table 3 under Corrosion and Scale Control in the OPERATION section Replenish the bleed water with fresh makeup water thereby limiting the buildup of impurities Bleed Blowdown 1 Accomplish the bleed automatically through a solenoid valve controlled by a conductivity meter The conductivity meter setpoint is the water conductivity at the desired cycles of concentration and should be determin
42. such as the fans and motors Flush the cold water basin interior to remove any accumulated dirt and debris Remove clean and replace the strainers Inspection Do not perform any service on or near AWARNING the fans motors drives or inside the unit without first ensuring that the fans and the pumps are disconnected and locked out Thoroughly inspect the fan s for any mechanical or physical damage At seasonal start up or after prolonged shutdown check the motor insulation with an insulation tester prior to the motor start up Prior to the seasonal start up check and adjust the belt tension At the initial start up the belt tension may not require adjustment as the drive will be properly tensioned at the factory prior to shipment Start the fan motors and check for proper fan rotation Run the fans in manual mode for several minutes to check for any unusual noise or vibrations Check that the float operated makeup valve is operating freely Check to ensure the controls for the fan AWARNING motors are set to allow a maximum of 6 on off cycles per hour TOP OF COLD WATER le BASIN a Figure 13 Water Makeup Valve Assembly Start up Do not perform any service on or near AWARNING the fans motors and drives or inside the unit without first ensuring that the fans and the pumps are disconnected and locked out Locking Nuts Typical of Both Sides Adjusting Screw Figure 14 Lub
43. t personnel when the temperature of the fluid leaving the coil falls below 50 F 10 C For evaporative cooling applications only the glycol solution will maintain the leaving fluid temperature as low as 45 F 7 2 C Contact your local Frick Representative for necessary precautions Basin Water and Internal Piping Freeze Protection Cold Water Basin Protection The basin water could freeze when the unit is shut down and exposed to subfreezing ambient temperatures Indoor Sump The ideal method of protection is a remote sump located in a heated indoor area When the circulating pump stops the water in the connecting piping will drain by gravity to this indoor sump Basin Heaters On applications without a remote sump provide heat to the cold water basin Electrical immersion heaters steam coils or hot water coils can provide the required function Contact your local Frick Representative for details Electric Water Level Control An electric water level control will maintain the proper water level regardless of the thermal load or variations in makeup water supply pressure The two position slow closing solenoid valve provided in the Frick electric water level control package also minimizes valve freezing problems Heat Tracing Heat trace and insulate all exposed water piping including pump piping below the overflow level and makeup water lines with electrical heater tape Piping Freeze Protection Eliminate all water in
44. un Do not use high pressure grease guns since they may rupture the bearing seals When lubricating purge the old grease from the bearing by gradually adding grease until a bead of new grease appears at the seal Figure 18 Extended Lubrication Lines XLP2 EVAPORATIVE CONDENSERS MAINTENANCE 140 920 IOM NOV 09 Page 15 Locking Collars Each eccentric locking collar should be checked quarterly to ensure that the inner bearing race is secured to the fan shaft The locking collar can be set using the following procedure see Figure 19 Loosen the set screw Using a drift pin or center punch tap the collar in the hole provided tangentially in the direction of rotation while holding the shaft Retighten the set screw Direction of Rotation Figure 19 Locking Collar Assembly SPRAY NOZZLES AND HEAT TRANSFER The water is distributed through a corrosion resistant polyvinyl chloride PVC spray distribution system The drift eliminators are also made of PVC which requires no protection against rot decay rust or biological attack The spray nozzles and heat transfer section should be in spected and cleaned each month Inspect as follows 1 Shut off the fan lock out and tag out the fan motor but leave the system pump running 2 Remove the drift eliminators to allow a clear view of the spray distribution system and nozzle patterns 3 Check to see if the nozzles are all spraying consistently and producing
Download Pdf Manuals
Related Search