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IDSC / 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.johnsoncontrols.com/frick for the latest version of this publication.
Form 140.010-IOM (APR 2018)
INSTALLATION - OPERATION - MAINTENANCE
File:
SERVICE MANUAL - Section 140
Replaces:
140.010-IOM (OCT 2017)
Dist:
3, 3a, 3b, 3c
™
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Summary of Contents for Frick IDSC / ECOSS Series
- Page 1 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.johnsoncontrols.com/frick for the latest version of this publication.
- Page 2 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.
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Page 3: Table Of Contents
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ INSTALLATION - OPERATION - MAINTENANCE Page 3 Contents GENERAL INFORMATION APPENDIX I SAFETY ............... 4 1 GENERAL INFORMATION ..........18 INFORMATION ON COMPONENT PARTS ...... 4 1.1 RESPONSIBILITIES ..........18 CASING/COIL/BASIN/WATER SYSTEM ......4 1.2 LEGAL NOTES ............18 EC FANS WITH AXITOP .......... -
Page 4: General Information
CASING/COIL/BASIN/WATER SYSTEM All Frick IDSC/ECOSS evaporative cooling products are ™ fully constructed with 304/304L materials which are self- passivating. The ASME certified and constructed condenser coils are fabricated with ANSI rated materials. -
Page 5: Ec Fans With Axitop
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ INSTALLATION - OPERATION - MAINTENANCE Page 5 The inlet louvers are watertight, UV and corrosion resistant, All EC direct drive fan motors are wired (power and control) with a robust, aerodynamically optimized construction. They to a common junction box, eliminating associated field wir- have low pressure loss and zero line of sight to water in the ing and labor. -
Page 6: Pumps
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 6 INSTALLATION - OPERATION - MAINTENANCE PUMPS 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;... -
Page 7: Installation
¾” diameter TRANSPORTATION, STORAGE, bolts. Refer to the Frick unit certified drawing for the bolt UNPACKING AND MOUNTING hole locations. WARNING... - Page 8 140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 8 INSTALLATION WARNING Danger of injury and damages to the property! (see Appendix I, 4.4 Mounting) ü Lift bottom section of unit from the substructure to in- tended place of use. ü Secure bottom section of unit to the support structure with ¾”...
- Page 9 IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ INSTALLATION Page 9 ü Align the top section with the bottom section (see Figure ü Appropriately guiding the top section safely above the 14). section joint and free from pinch points (see Figure 15). Figure 14 - Aligning Top and Bottom Sections Figure 15 - Positioning the Top Section of the Unit 120.0...
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Page 10: Adjustment Of Mechanical Float Assembly
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 10 INSTALLATION ü Bolt the top section and the bottom section together from WARNING the inside. ü Close the gap between the lower and the upper riser pipe Danger of injuries and damage to property with escap- section with the pipe connector. -
Page 11: System-Side Safety Requirements
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ INSTALLATION Page 11 System-side safety requirements NOTICE For safety information, please refer to Appendix I, 5.1.2 System-side safety requirements. Lightning protection rods beside the unit are recom- mended. Customer-side safety precautions WARNING NOTES ON CONNECTING THE UNIT WARNING Danger of injuries and damage to property! (see Ap- pendix I, 5.1.3 Customer-side safety precautions) -
Page 12: Important Considerations Regarding Installation
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 12 INSTALLATION ü Fix the unit in its position and prevent the unit from shift- ü Check and retighten all threaded connections, especially ing. Tighten and secure the mounting bolts. on the fans. ü... -
Page 13: Operation
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ OPERATION Page 13 OPERATION PUTTING THE UNIT INTO OPERATION FOR THE NOTICE FIRST TIME With shutdown times of a month or longer put the fans WARNING into operation for approximately 2-4 hours a month to maintain their functionality. -
Page 14: Maintenance
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 14 MAINTENANCE MAINTENANCE NOTICE CAUTION 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 WARNING... -
Page 15: Clean Unit
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ MAINTENANCE Page 15 MAINTENANCE WORK ü Put a megohmmeter on the windings to check for insula- tion failure. Remove leaks: Elimination Of Water Drops WARNING Clean and remove debris from drift eliminators. Danger of injuries and damage to property with escap- Water Distribution System And Nozzles ing refrigerant (see Appendix I, 6.5 Maintenance work) Inspect and clean threaded nozzles if necessary. -
Page 16: Water Treatment
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 16 MAINTENANCE Water Treatment Guidelines: ü Heavier moisture or greasy dirt must be removed with a high-pressure water jet (max. 725 psi pressure), steam Water related problems that typically occur in an evaporative pressure jet (max. -
Page 17: Troubleshooting
SERVICE Evaporative units should be tested for Legionella within the Contact your nearest Frick Factor. water distribution system. This testing must be specific for Legionella. "Total bacteria" testing, promoted by some water TROUBLESHOOTING TABLE treatment companies is inadequate since there is no correla- tion between total bacteria and Legionella concentrations. -
Page 18: General Information
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 18 APPENDIX that prevent consequential damage for people and property APPENDIX I should faults occur. 1 GENERAL INFORMATION ü Install emergency STOP switches that can be actuated without danger. This equipment is relatively complicated and the installa- ü... -
Page 19: Operating Instructions
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 19 The operating instructions may not be reproduced electroni- Warns against fire-risk substances at cally or mechanically, circulated, changed, passed on to third setup point. parties, translated or otherwise used, in full or in part, without prior explicit written approval from Johnson Controls. -
Page 20: Safety
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 20 APPENDIX o Sudden large release (release and evaporation of the Deactivate before work! greater part of the entire refrigerant filling in a short Deactivate the electrical system and ensure time, e.g. in less than 5 minutes). all electrical switchgear for the fans are o Activation of the refrigerant detector: disconnected, locked out and tagged out... -
Page 21: Proper Intended Use
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 21 o Call an emergency doctor immediately! Operating Conditions: o Liquid ammonia can cause frostbite or corrosive inju- The unit is a component of a cooling system including its ries to the skin or eyes. The injured person must keep refrigerant circuit. -
Page 22: Mechanical Residual Hazards
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 22 APPENDIX o Fire hazard (caused by refrigerator oil parts) 2.5 ELECTRICAL RESIDUAL HAZARDS o Frostbite hazard (caused by liquid coolant squirting/ WARNING splashing) o Suffocation hazard Warns against dangerous electrical o Hazards caused by panic reactions, voltage! o Environmental pollution Direct and indirect contact with voltage-... -
Page 23: Residual Hazards With Refrigerant
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 23 When not in operation the water in the basin may freeze Ignition and fire hazard! in the event of very low temperatures. Make sure the basin • With work involving fire or sparks, ex. is drained whenever the unit is not in operation or use the grinding, welding, etc. -
Page 24: Residual Hazards Caused By Vibrations
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 24 APPENDIX Explosion hazard! Fire hazard! Frostbite hazard! Ammonia is a flammable, explosive gas. Leaks in the unit can cause the NH The fire and explosion hazard is low be- frigerant to escape into the setup area. cause of the high ignition temperature, Liquid NH refrigerant has a temperature... -
Page 25: Combined Residual Hazards
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 25 2.9 COMBINED RESIDUAL HAZARDS • unit functional faults caused by air inlet/outlet obstructions • obstruction of all-side inspection, checks and mainte- Residual hazards caused by pressurized parts: nance, i.e. no unobstructed accessibility to the refrig- WARNING erant-carrying and electrical components, connections and cables, no recognizable identifiers on the pipes and... - Page 26 140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 26 APPENDIX could be endangered by an explosion or the toxic ef- The following notes are recommendations for the proper fect of NH professional disposal of the unit. Applicable waste disposal o Provision of measures to safeguard protective objects laws are binding for the country of operation: from an NH concentration of more than 200 ppm.
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Page 27: Information On Component Parts
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 27 • Operate the facility for recovering or disposing of refriger- The unit is intended for outdoor use only. To protect the ants so that the danger of a refrigerant or refrigerant oil unit from damage due to the elements, the unit should be emission into the environment is kept as low as possible. - Page 28 140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 28 APPENDIX Follow the setup instructions in this chapter precisely and The refrigerant ammonia is highly hygroscopic, i.e. it attracts exercise extreme caution! humidity. Humidity and dirt may not get into the unit's in- terior.
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Page 29: Location Requirements
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 29 • Ensure that no refrigerant enters water systems or sew- Ensure that: age. • Release devices to prevent liquid escapes are provided • Operate the facility for recovering or disposing of refriger- and available. -
Page 30: Unit Electrical Connection & Protection
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 30 APPENDIX 5.5.1 Important considerations regarding installation NOTICE CAUTION With shutdown times of a month or longer energize the fans for approximately 2-4 hours a month to maintain The unit must only be put into operation, operated, their functionality. -
Page 31: Before Starting All Maintenance
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 31 6.1 BEFORE STARTING ALL MAINTENANCE • drain the unit's heat exchanger • clean and blow out the unit's heat exchanger WARNING 6.2 WITH ALL MAINTENANCE WORK Danger of injuries and damage to property with escaping WARNING refrigerant (see Appendix I, 2.7 Residual hazards with refrigerant). - Page 32 140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 32 APPENDIX 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.
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Page 33: After All Maintenance Work
IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ APPENDIX Page 33 6.3 AFTER ALL MAINTENANCE WORK 6.6 CLEAN UNIT 6.6.1 General WARNING NOTICE Danger of injuries and damage to property with escaping refrigerant (see Appendix I, 2.7 Residual hazards with If during maintenance or cleaning any corrosion is be- refrigerant). -
Page 34: Troubleshooting
140.010-IOM (APR 2018) IDSC/ECOSS EVAPORATIVE CONDENSERS ™ Page 34 APPENDIX This cycles of concentration equation reflects the degree to 2. Controlled Blow Down - dependent on an automated which the dissolved solids in the makeup water are allowed monitoring of the dissolved solids (water hardness) as to concentrate in the recirculating water system. - Page 35 IDSC/ECOSS EVAPORATIVE CONDENSERS 140.010-IOM (APR 2018) ™ INDEX Page 35 Index acceptance test, 13 ebm-papst fans, 5 leaks, 15,32 Acidification, 27 electrical connections, 11 Leaks, 12 airborne particulate, 5 electrical installation, 10 Legionella, 28 air flow, 12 electrical lines, 12 Lightning protection rods, 11 airflow, 11 Electric Basin Heaters, 6...
- Page 36 JOHNSON CONTROLS Supersedes: 140.010-IOM (2017-10) 100 Cumberland Valley Avenue Subject to change without notice Waynesboro, PA 17268-1206 USA Published in USA • 04/18 • PDF Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/frick © 2018 Johnson Controls Int'l PLC - ALL RIGHTS RESERVED...
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