Frick XLP3 Installation Operation & Maintenance Download Page 19

140.925-IOM (APR 2019) 

Page 19

XLP3 EVAPORATIVE CONDENSERS

OPERATION

• 

Electric Water Level Control:

 An electric water level 

control will maintain the proper water level regardless of 
the thermal load or variations in make-up water supply 
pressure. The two-position, slow closing solenoid valve 
provided with the Frick electric water level control package 
also minimizes valve freezing problems (see page 28).

• 

Heat Tracing:

 Heat trace and insulate all exposed water 

piping including pump piping below the overflow level and 
make-up water lines with electrical heater tape.

NOTICE

For remote sump applications, the water level in the basin 
of the equipment is a function of the design flow rate, the 
quantity, size and location of the remote sump connection 
and the pipe design between the cooling tower and the 
remote sump. Units installed on remote sump applications 

are supplied without a make-up connection.

COIL FREEZE PROTECTION

For protection against coil freeze-up, recommended solutions are 
an industrial grade inhibited ethylene glycol or propylene glycol 
solution. When the use of glycol is not practical, the system 
must be designed to meet both minimum flow and minimum 
temperature requirements.

Coil volumes for the XLP3 Evaporative Condenser using liquid 
cooling circuits is job specific.

Minimum Operation

When utilizing an auxiliary cooling circuit with water as the 
cooling media, the system must be operated to meet minimum 
flow and temperature requirements. Maintain a minimum heat 
load so that the temperature of the fluid leaving the coil is not 
less than 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 and adjust the flow to ensure 
that fluid leaving the coil maintains the minimum required tem-
perature. Otherwise, a glycol solution can be used as the cooling 
media to prevent freezing.

OPERATION CONSIDERATIONS 

FOR ACCESSORIES

Basin Heater (Optional)

One or more electric immersion heaters prevent the cold water 
basin from completely freezing over and damaging the unit dur-
ing shutdown or standby. The heaters are sized for the specific 
unit. The heating element has an enclosure that is suitable for 
outdoor use. Annually, inspect the basin heater prior to the risk 
of reaching freezing operating conditions.

Operation

Ensure that the heating element is completely submerged be-
fore energizing the main disconnect. For installations that have 
a Frick Controls Enclosure, please consult the submittal packet 
provided with the unit and contact your local Frick Representa-
tive for support. For installations that use a stand alone heater 
control panel, see below.

NOTICE

The basin heater is not designed to prevent icing during 
unit operation.

Stand Alone Frick Heater Control Panel (Optional)

The heater control system consists of a heater control panel 
and a combination temperature/water level sensor. The stainless 
steel sensor probe with 1/2” NPT mounting fitting has an on/off 
relay output that de-energizes the heaters whenever the basin 
water temperature is above 45°F (7.2°C), or whenever the sen-
sor probe is not fully submersed. The control panel enclosure is 
suitable for outdoor use.

The control system utilizes a combination temperature/low 
water level control sensor, which is powered by a transformer 
in the control panel. When the sensor provides a signal to the 
control panel, the panel sends a control voltage to the magnetic 
contactors. When energized, the magnetic contactors supply 
line voltage to the heaters. Annually inspect the heater control 
system prior to the risk of reaching freezing operating conditions.

NOTICE

The heater control panel temperature/low level control can 
only be used with the supplied combination temperature/

water level sensor probe. Please contact your local Frick 

Representative for replacement parts.

Operation

Ensure that the element is completely submerged before ener-
gizing the main disconnect. The combination temperature/low 
level control is preset to energize the heater at 40°F (4.5°C), 
but will not energize if the water level is too low or if the water 
temperature is above 45°F (7.2°C).

Testing the heater when water temperatures are above 
45°F (7.2°C):

•  Disconnect the heater control panel and tag out the circuit.
•  Remove the heater control panel cover.
•  Remove the sensor wires connected to terminals T1 and 

T2 on the combination temperature/low level control and 
isolate them.

Figure 18 - Basin Heater

Summary of Contents for XLP3

Page 1: ...ive 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 INJU...

Page 2: ...TIONS 14 START UP PROCEDURE 15 Considerations for Initial Start Up 15 General 15 Cleaning 15 Inspection 15 Start up 15 EXTENDED SHUTDOWN 16 PROLONGED OUTDOOR STORAGE 16 Storage Preparation 16 Motor Re...

Page 3: ...afety Cage Optional Coil Connection Refrigerant Vapor In Coil Connection Refrig erant Liquid Out Terminal Box Pump Factory Pre Assembled Platforms with Perimeter Handrails Optional BranchLokTM Removal...

Page 4: ...ellaneous parts are included with the shipment and where they are packed This envelope will be attached to the side of the unit or located in a box inside the unit INSTALLATION Unit Weights Before rig...

Page 5: ...to ensure an airtight seal between the top and bottom section Install flat butyl sealer tape Frick part 554000 supplied with the unit on the mating flanges of the lower section in a continuous line A...

Page 6: ...basin section sealer tape must be applied to both cross flanges see Figure 3 10 On units operating with a remote sump tank install a bleed line with valve between the system circulating pump discharg...

Page 7: ...lease ensure that the correct voltage is supplied to the unit If unsure check your unit s submittal to verify that the provided power matches your unit On the factory terminal box remove the NEMA plug...

Page 8: ...nd Figure 9 Detail A Check your submittal for the ladder orientation ordered Attach the ladder to the platform and fasten the lower and intermediate brackets to the ladder side rails as shown in Figur...

Page 9: ...DENSERS INSTALLATION Figure 9 End Ladder Installation Detail A End Ladder Bracket Detail A Perimeter Guardrail Installation Detail B Corner Guardrail Installation Detail C Perimeter Guardrail Installa...

Page 10: ...are provided for all handrail openings and all components are designed to meet OSHA requirements Share two lower fasteners on upper ladder bracket Upper ladder bracket Hoop Detail D Figure 11 Safety...

Page 11: ...per the control panel wiring diagram 5 Connect the heater power wire conduit s to the heater power wire hub s provided on the control panel Make sure the con nection is watertight and secure Pull the...

Page 12: ...Control Panel L1 L2 L3 Controller Liquid Level Temperature Combination Series TL Solitech CT N C NO NC T1 T2 G1 G2 Shielded Cable Assembly Sensor Probe Cord G2 G1 T2 T1 SH No 1 Heater 40 24 16 12 8 1...

Page 13: ...ter basin a For connections 3 or less score the TripleGuard Corrosion Protection System with a hole saw as shown in Figure 14 b For connections 3 or greater proceed to step 4 4 Cut the hole from the o...

Page 14: ...fan screens access panels and access doors in place CAUTION All electrical mechanical and rotating machinery are potential hazards particularly for those not familiar with their design construction an...

Page 15: ...locked out and tagged out Inspection Conduct external inspection of the equipment Check for leaks corrosion and any structural damage Conduct internal inspection of the equipment Check for anything u...

Page 16: ...fer to the manufacturer s guidelines before loading unloading weight from the unit Disconnect lock out and tag out the fans pump and motors Close the shut off valve in the make up water line supplied...

Page 17: ...ump motors are disconnected locked out and tagged out Belt Drive Fan System Frick standard motors are designed for storage at ambient temperatures of 20 F to 104 F 28 9 C to 40 C Prolonged periods of...

Page 18: ...system performance or create a safety hazard Fan Section Icing Protection There are three basic operational methods which can be used to provide the system s required cooling temperature setting fan...

Page 19: ...heaters are sized for the specific unit The heating element has an enclosure that is suitable for outdoor use Annually inspect the basin heater prior to the risk of reaching freezing operating condit...

Page 20: ...bration cutout switch is not needed Mechanical Vibration Cutout Switch Standard Set Point Adjustment When Installed 1 For safety turn off then lock and tag out the electrical supply to the fan motor s...

Page 21: ...Control Panel L1 L2 L3 Controller Liquid Level Temperature Combination Series TL Solitech CT N C NO NC T1 T2 G1 G2 Shielded Cable Assembly Sensor Probe Cord G2 G1 T2 T1 SH No 1 Heater 40 24 16 12 8 10...

Page 22: ...ent Staging Down Turn off the fan motor No need for delays NOTICE For a unit with a VFD with a switching frequency of 2 5 kHz the line lead length cannot exceed 100 feet If the switching frequency is...

Page 23: ...the VFD on and verify that the fan is turning in the correct direction Using the VFD slowly about 1 RPM increase every five to ten seconds adjust the motor speed from the lowest limit to full speed wh...

Page 24: ...tors are disconnected locked out and tagged out 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...

Page 25: ...s necessary Readjust tension at least once every three months Belt tension check Place a straight edge along the belt from sheave to sheave as shown in Figure 22a or use a tape measure as shown in Fig...

Page 26: ...the bearings as follows Initial Start Up Normally no lubrication is required since the bearings have been lubricated at the factory prior to shipment However if the unit has been stored at the job si...

Page 27: ...the valve seat if necessary Maintain the make up water supply pressure between 15 psig and 50 psig for proper operation Frick recommends a pressure regulator valve provided by others for pressures ove...

Page 28: ...tection System for signs of deep scratches or blemishes especially in areas with field penetrations Touch these up with 3M Windo Weld Super Fast Urethane which is available through your local Frick Re...

Page 29: ...Dissolved Solids TDS 1 500 ppm 2 050 ppm 2 050 ppm 2 500 ppm Conductivity 2 400 micromhos cm 3 300 micromhos cm 3 300 micromhos cm 4 000 micromhos cm Alkalinity as CaCO3 500 ppm 2 600 ppm 2 600 ppm 2...

Page 30: ...methyl or ethyl alcohol or mineral spirits Stainless steel wipes or glass cleaners commonly available in stores may also be used NOTICE Never use chloride or chlorine based solvents such as bleach or...

Page 31: ...reatment expert Bleed Line Calculations Bleed rate is determined by the fol lowing formula B E n 1 Where B Bleed Rate USGPM E Evaporation Rate USGPM Q USGPM x R F x 0 001 Q Process Fluid Flow Rate USG...

Page 32: ...for proper rotation X Check general condition of the fan X X Check fan for uniform pitch 4 X Check fan for rotation without obstruction X X Check and recoat steel shafts with RUST VETO 4 X X X Check...

Page 33: ...140 925 IOM APR 2019 Page 33 XLP3 EVAPORATIVE CONDENSERS MAINTENANCE NOTES...

Page 34: ...ynesboro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www johnsoncontrols com frick Form 140 925 IOM 2019 04 Supersedes Nothing Subject to change without notice Published in USA 04 19 PDF 201...

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