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140.925-IOM (APR 2019)

Page 2

XLP3 EVAPORATIVE CONDENSERS

INSTALLATION - OPERATION - MAINTENANCE

Table of Contents

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.

SAFETY PRECAUTION DEFINITIONS

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage 

to equipment and/or minor injury.

Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.

WARNING

 

CAUTION

 

DANGER

NOTICE

INSTALLATION

INTRODUCTION ............................................................... 4

Safety .................................................................................4
Shipping..............................................................................4
Pre-Rigging Checks ............................................................4
Cold Weather Operation .....................................................4
Location ..............................................................................4
Warranties ..........................................................................4
Unit Operation .................................................................... 5

RIGGING & ASSEMBLY ......................................................5

Rigging ............................................................................... 5
Section Assembly ............................................................... 5
Table 1 - Recommended Vertical Dimension and Spreader 

Bar Length ..................................................................... 5

Wiring the Factory Terminal Box (EC Fan System Only) ......7

OPTIONAL ACCESSORY INSTALLATION ............................8

Bottom Water Outlet (Optional) .........................................8
Offset Access Platform, Perimeter Guardrail and Ladder ....8
Ladder Safety Cage (Optional) ..........................................10
Table 2 - Ladder Safety Cage Bolting Location and  

Quantities ....................................................................10

Automatic Bearing Greasers (Optional for Belt Drive Fan 

System Units Only) ...................................................... 11

Heater Control Panel (Optional) ........................................ 11

FIELD CONNECTIONS ......................................................13

Table 3 - Supplies for Installing Field Connections ............ 13

OPERATION

SAFETY PRECAUTIONS ...................................................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 Recommendations ................................................. 17
Electronically Commutated (EC) Motors ............................ 17
Belt Drive Fan System ...................................................... 17
Maintenance Requirements During Storage...................... 18
Start-Up Preparation After Prolonged Storage ................. 18

COLD WEATHER OPERATION ..........................................18

Inspection and Maintenance ............................................. 18
Fan Section Icing Protection ............................................. 18

BASIN WATER AND INTERNAL PIPING  
FREEZE PROTECTION ......................................................18

Cold Water Basin Protection ............................................. 18

COIL FREEZE PROTECTION ..............................................19

Minimum Operation .......................................................... 19

OPERATION CONSIDERATIONS 
FOR ACCESSORIES .........................................................19

Basin Heater (Optional) .................................................... 19
Stand Alone Frick Heater Control Panel (Optional) ........... 19
Operation ......................................................................... 19

VIBRATION CUTOUT SWITCH (VCOS) ............................20

Mechanical Vibration Cutout Switch (Standard) ................20
Electronic Vibration Cutout Switch (Optional) ..................20

FAN CONTROL ................................................................ 22

EC Fan System Fan Control ............................................... 22
Independent Fan Control (Optional) .................................. 22

MAINTENANCE

DETAILED COMPONENT  
MAINTENANCE PROCEDURES .........................................24

Cold Water Basin ..............................................................24
Table 4 - Cold Water Basin Water Levels .........................24
EC Fan System ..................................................................24
Belt Drive Fan System ......................................................24
Water Distribution System and Heat Transfer Section ...... 26
Water Level Control .......................................................... 27

CORROSION PROTECTION ..............................................28

Water Treatment .............................................................. 28
Corrosion and Scale Control ............................................. 28
Gray Water and Reclaimed Water..................................... 29
Chemical Treatment Requirements ................................... 29
Table 5 – Quality Guidelines for Treated Circulated Water 29
Passivation ....................................................................... 29
Biological Control ............................................................. 29
Long Term Care of Stainless Steel ....................................30
Jobsite Considerations ......................................................30
System Cleaning ...............................................................30

BLEED RATE ....................................................................30
RECOMMENDED MAINTENANCE INTERVALS ..................32

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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