Frick XLP3 Installation Operation & Maintenance Download Page 29

140.925-IOM (APR 2019) 

Page 29

XLP3 EVAPORATIVE CONDENSERS

MAINTENANCE

Gray Water and Reclaimed Water

The use of water reclaimed from another process as a source 
of makeup water for evaporative cooling equipment can be 
considered as long as the resultant recirculating water chemistry 
conforms to the parameters noted in Table 5. It should be noted 
that using water reclaimed form other processes may increase 
the potential of corrosion, microbiological fouling, or scale for-
mation. Gray water or reclaimed water should be avoided unless 
all the associated risks are understood and documented as part 
of the site specific treatment plan.

NOTICE

1. Galvanized steel units require passivation in order to 

prevent white rust (refer to “Passivation”).

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).
4. DuraTest™ Construction units have a TripleGuard® 

Corrosion Protection System basin.
5. The guidelines above refer to the materials used in 

construction. Different combinations of materials may be 

used on the same unit.
6. 

Water chemistry will change with operating 

temperatures. The recommended guidelines listed in 

Table 2 refers to water temperature at 95˚F.

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.).

•  Frick discourages acid dosing as means of scale control 

except for open circuit cooling towers with remote sump 
applications or towers constructed from stainless steel. 
This should be done at a point in the system where total 
mixing and dilution occur before reaching the evaporative 

Table 5 — Quality Guidelines for Treated Circulated Water

Property of Water

Recommended Levels for Various Materials of Construction

Galvanized

Steel

Thermosetting

Hybrid Polymer

Type 304

Stainless Steel

TripleGuard®  

Corrosion Protection 

System or Type 316 

Stainless Steel

pH

6.5 to 9.0[1]

6.5 to 9.2[1]

6.5 to 9.2[1]

6.5 to 9.5[1]

Total Suspended Solids

25 ppm

25 ppm

25 ppm

25 ppm

Total 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]

600 ppm[2]

Calcium Hardness as CaCO3

50 to 600 ppm[2]

50 to 750 ppm[2]

50 to 750 ppm[2]

50 to 750 ppm[2]

Chlorides (CL)

250 ppm

300 ppm

300 ppm

750 ppm

Sulfates

250 ppm

350 ppm

350 ppm

750 ppm

Silica

150 ppm

150 ppm

150 ppm

150 ppm

cooling equipment. The preferred injection point for 
chemical scale and corrosion inhibitors is on the discharge 
side of the system circulating pump(s). These chemicals 
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 on Page 15. Exceeding this limit 
may accelerate corrosion.

Passivation

When new systems are first commissioned, special measures 
should be taken to ensure that galvanized steel surfaces are 
properly passivated to provide maximum protection from corro-
sion. Passivation is the formation of a protective, passive, oxide 
layer on galvanized steel surfaces. To ensure the galvanized steel 
surfaces are passivated, the pH of circulating water should be 
kept between 6.5 and 8.2 and calcium hardness between 50 and 
600 ppm (as CaCO

3

) 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. In case the pH can’t be kept below 8.2, a secondary 
approach is to conduct a chemical passivation using inorganic 
phosphate or film-forming passivation agents. Consult your water 
treatment specialist for specific recommendation.

NOTICE

Stainless steel cold water basins and basins protected by 

the TripleGuard® Corrosion Protection System or 

thermosetting hybrid polymer do not require passivation. 

However, if the upper structure is galvanized steel, 

passivation is required on the galvanized area including 

any Hot Dip Galvanized After Fabrication (HDGAF) coil(s).

Biological Control

•  The warm, oxygen and nutrient rich environment 

inside evaporative cooling equipment provides an ideal 
environment conducive to the growth of algae, slime, and 
other micro-organisms. Uncontrolled, this can reduce heat 

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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