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Form 140.960-IOM (JUN 2016)

 INSTALLATION - OPERATION - MAINTENANCE

File: 

SERVICE MANUAL - Section 140

Replaces: 

NOTHING

Dist: 

3, 3a, 3b, 3c

IDCF & IDC3 Evaporative Condensers

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.

Содержание IDC3-0406

Страница 1: ...rative Condensers 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 ...

Страница 2: ...aning 35 Inspection 35 Start up 35 EXTENDED SHUTDOWN 36 COLD WEATHER OPERATION 36 Fan Section Icing Protection 36 BASIN WATER FREEZE PROTECTION 37 Water Basin Protection 37 CORROSION PROTECTION 37 Water Treatment 37 Gray Water and Reclaimed Water 37 Corrosion and Scale Control 37 Table 5 Quality Guidelines for Chemically Treated Circulating Water 38 Chemical Treatment Requirements 38 Passivation 3...

Страница 3: ...ed to the side of the unit marked Customer Information Packet indicates what miscellaneous 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 rigging any unit the weight of each section should be verified from the unit submittal drawing Unit print weights include ...

Страница 4: ...the rigging contractor CAUTION Before an actual lift is undertaken ensure no water snow ice or debris has collected in the basin or elsewhere in the unit Such accumulations will add substantially to the equipment s lifting weight NOTICE For weight information refer to the submittal drawing package Section Assembly of Two piece Cells 1 Figures 2 and 3 show the proper rigging of sections for units t...

Страница 5: ...rift pin per Figure 5 Start at the corner hole and skip every 3 or 4 holes along the length of the unit Repeat this process on the other side 10 Lower the upper section the remaining distance using the alignment pins and drift pins to align the coil casing section and lower section holes 11 Fasten the hardware between the coil casing and lower sec tion per Figure 6 12 Position the hose connecting ...

Страница 6: ...ring 2 6 above the lower section 9 When necessary insert drift pin per Figure 5 on page 6 Start at the corner hole and skip every 3 or 4 holes along the length of the unit Repeat this process on the other side 10 Lower the upper section the remaining distance using the alignment pins and drift pins to align the coil casing section and lower section holes 11 Fasten the hardware between the coil cas...

Страница 7: ...ion from the lower section 3 Remove any motors or accessories shipped in the lower section 4 Install rigging alignment pins on the water basin in the loca tions shown in Figure 4 Secure the alignment pins using the 1 2 hardware provided 5 Position the lower section on the unit support and bolt into place 6 Follow steps 6 11 on previous page 7 The motor for containerized units ships loose Attach th...

Страница 8: ...the supplied flat butyl sealer tape Part BAC554000 and 5 16 self tapping screws after the final cell is in place and the lift shackles are removed NOTICE On quad cell installations it is suggested that the cells subsequent to the first cell have the upper and lower sections assembled on the support foundation adjacent to the final mounting locations This will allow space for securing the upper and...

Страница 9: ...s shown in Table 2 Figure 12 Two Piece Fan Guard Assembly Detail A Detail B Detail C X 3 8 x 1 1 2 Bolt 3 8 x 1 1 2 Bolt U Bolt Assembly 3 8 Flatwasher 3 8 Locknut 3 8 Flatwasher 3 8 Locknut Y 2 Mount the fan guard to unit as illustrated in Figure 12 Detail A for the seams where the two halves join together and Detail C for all others FAN DIAMETER X Y 9 10 17 10 10 20 11 10 23 TABLE 2 U BOLT SPACI...

Страница 10: ... The bottom connection seal Figure 13 is typical for all bot tom remote sump outlets and bypasses Flange mounting hardware and gasket to be supplied by others 2 Bottom connection seal kit s ship in plastic tubs NOTICE Some parts that ship loose are labeled with unique three key codes for identification purposes These three key codes are referenced throughout this guide to identify parts to be asse...

Страница 11: ...024 2012 1212 2412 1224 2424 1218 1236 2418 AND 2436 AND IDC3 1220 1 Verify the davit support is factory installed next to the access door If not installed remove the bolts next to the access door refer to Figure 18b DO NOT REMOVE TAPPERS Secure the davit support by re installing the bolts 2 Rotate the davit assembly to align the bolt head on the davit with the keyway in the upper support channel ...

Страница 12: ...0 2420 2440 Detail B Detail A MECHANICAL ACCESS PLATFORM NOTICE 1 Platforms ladders and safety cages can be added at the time of order or as an aftermarket item 2 Safety gates are provided for all guardrail openings All components are designed to meet OSHA requirements REFER TO FIGURES FOR YOUR PARTICULAR UNIT 1 Lift the platform module s into place and secure to the unit at the locations indicate...

Страница 13: ... and 2436 install the preassembled mid platform support s using the 3 8 x 1 1 4 bolts provided See Figure 22 Details C to G Mechanical Access Platform for Multi cell Units Optional Figure 21 Mechanical Access Platform IDCF IDC3 1218 two fan 2418 two fan Detail B Detail C Detail E Detail D Detail A Detail G Detail F ...

Страница 14: ...m 2 For the two fan IDCF IDC3 1236 and 2436 the Mechanical Access platform spans two cells See Figure below Details A to D for the bridging components 3 Secure the toe board PGP using the 5 16 self tapping screws provided See Detail D 4 Secure the grating bridge plate PCC using the 1 4 x 2 self drilling screws provided 5 Install the gap cover channels PIP using the 3 8 x 1 1 4 bolts provided See D...

Страница 15: ...adder assembly to the platform using the 3 8 x 1 1 4 bolts provided See Figure below Detail B 2 Secure the ladder flares to the platform railing posts using the 5 16 x 3 1 3 bolts provided See Detail A 3 Install the mid and lower ladder supports per Figure below as follows Secure the standoff channels PDI to the factory installed support channels using the 3 8 x 1 1 4 bolts provided Secure the sta...

Страница 16: ...ladder assembly to the platform using the 3 8 x 1 1 4 bolts provided See Detail B 2 Secure the ladder flares to the platform railing posts using the 5 16 x 3 1 2 bolts provided See Detail A 3 Install the mid and lower ladder supports per Detail C as follows Loosely assemble the support channels PHE PHF PHG and PHD using the 3 8 x 1 1 4 bolts provided and then loosely attach this assembly to the fa...

Страница 17: ...IT 1 For 18 long platforms first secure the bolt plates PHN to the factory installed brackets on the casing frame using the 5 16 self tapping screws provided See Figures 27 and 28 Detail F Detail C Figure 25 Fill Access Platform with Side Ladder IDCF 0709 1012 2012 1212 2412 Detail B Toe board PHA Detail A Platform frame Detail D PHK PHL other end PHA ...

Страница 18: ...units use the 1 2 x 1 1 4 bolts provided to secure the platform frame to the end supports See Detail B Detail A PEK Detail B Toe board Platform frame Detail C PHA Detail D PHA PHK PHL other end Figure 26 Fill Access Platform with End Ladder IDCF 0709 1012 2012 1212 2412 3 Secure the support channels PHA to the platform frame using the 1 2 x 1 1 4 bolts provided See Detail C 4 Secure the support ch...

Страница 19: ... Side Ladder IDCF 0718 1218 2418 1220 2420 1 For 18 and 20 long platforms secure the support channels PHA to the basin at the center locations using the adapter brackets PHM See Detail E Detail A Detail B Toe board Platform frame Detail E PHA PHM Detail F PHN Detail G Detail D PHK PHL other end PHA Detail C PHA ...

Страница 20: ...ackets on the casing using the 3 8 x 2 1 2 bolts provided See Detail A For plat forms with an end ladder the end rail assembly PEK ships loose Secure this rail assembly to the casing using the 3 8 x 2 1 2 bolts provided See Detail A below Figure 28 Fill Access Platform with End Ladder IDCF 0718 1218 2418 1220 2420 Detail E PHA PHM Detail F PHN Detail G Detail D PHK PHL other end PHA Detail C PHA D...

Страница 21: ...rackets on the casing using the 3 8 bolts provided See Detail B 3 Install the toe board PCE using the 5 16 self tapping screws provided See Detail D 4 Secure the grating bridge plate PCC to the platform using the 1 4 x 2 self drilling screws provided Then secure the grating bridge plate PCC to the bottom of the vertical gap cover PHH using the 5 16 self tapping screws provided NOTICE The screws pa...

Страница 22: ...e platform railing posts using the 5 16 x 3 1 2 bolts provided See Detail A 3 Install the lower ladder support per Detail C as follows Secure the standoff channels PDI to the factory installed support channel using the 3 8 x 1 1 4 bolts provided Secure the standoff channels PDI to the ladder with the ladder clamps PDC using the 3 8 x 1 1 4 bolts provided Install the cross brace using the 3 8 x 1 1...

Страница 23: ...ts using the 5 16 x 3 1 2 bolts provided See Detail A 3 Install the lower ladder supports per Detail C as follows Loosely assemble the support channels PHE PHF PHG and PHD using the 3 8 x 1 1 4 bolts provided and then loosely attach this assembly to the factory installed channel Attach the support assembly to the ladder with the ladder clamps PDC and PDB using the 3 8 x 1 1 4 bolts provided Tighte...

Страница 24: ...ded See Figure 33 Figure 33 Top Perimeter Guardrail Segment Attachment 5 16 Lockwasher 5 16 Nut 5 16 Flatwasher 5 16 Flatwasher 5 16 x 3 3 4 Bolt 3 For multi cell units install the gap plates Secure plates on one side by re using the 5 16 self tapping screws from the fan deck Secure on the other side using the 1 4 self drilling screws provided See Figure 34 4 Install the toe boards using the 5 16 ...

Страница 25: ...3 1212 28 3 4 53 42 PIX RAIL C PIS RAIL A RAIL B RAIL B RAIL B RAIL B PIS RAIL C PIX PJB Safety Gate Figure 38 Top Perimeter Guardrails IDCF IDC3 1218 1220 Detail A IDCF IDC3 1218 1220 GUARDRAIL LENGTHS IN Model Number Rail A Rail B Rail C Rail D IDCF IDC3 1218 28 3 4 48 5 8 53 42 IDCF IDC3 1220 28 3 4 53 53 42 PIX RAIL D RAIL A RAIL B RAIL C PIS RAIL B RAIL A RAIL B RAIL C RAIL B PIS RAIL D PIX P...

Страница 26: ... RAIL B RAIL B RAIL A RAIL B RAIL B Detail B PJT IDCF IDC3 1224 GUARDRAIL LENGTHS IN Model Number Rail A Rail B Rail C IDCF IDC3 1224 28 3 4 53 42 PJB Safety Gate Figure 39 Top Perimeter Guardrails IDCF IDC3 2412 PIX RAIL C PIS RAIL C RAIL B RAIL B PIX RAIL C RAIL C PIS IDC3 IDCF 2412 GUARDRAIL LENGTHS IN Model Number Rail A Rail B Rail C IDCF IDC3 2412 28 3 4 53 42 Detail B PJP Detail A Safety Ga...

Страница 27: ...NGTHS IN Model Number Rail A Rail B Rail C Rail D IDCF IDC3 2418 28 3 4 48 5 8 53 42 IDCF IDC3 2420 28 3 4 53 53 42 Figure 42 Top Perimeter Guardrails IDCF IDC3 1236 1240 Detail A PIX RAIL D PIS RAIL A RAIL B RAIL C RAIL B RAIL A RAIL A RAIL B RAIL C RAIL B RAIL A RAIL B RAIL C RAIL B RAIL A RAIL B RAIL C RAIL B PJT PIX PIS RAIL D Detail A Safety Gate IDCF IDC3 1236 1240 GUARDRAIL LENGTHS IN Model...

Страница 28: ...etail B PJP Detail C PJT PJB Safety Gate IDCF IDC3 2436 2440 GUARDRAIL LENGTHS IN Model Number Rail A Rail B Rail C Rail D IDCF IDC3 2436 28 3 4 48 5 8 53 42 IDCF IDC3 2440 28 3 4 53 53 42 Figure 43 Top Perimeter Guardrails IDCF IDC3 2424 Detail A Detail A PIX RAIL C PIS RAIL B RAIL A RAIL B RAIL C PIX RAIL C RAIL C PIS RAIL B RAIL B RAIL A PJP Detail C PJT PJB Safety Gate IDCF IDC3 2424 GUARDRAIL...

Страница 29: ...he railing posts using the 5 16 x 3 1 2 bolts provided See Detail A 3 Install the lower Mechanical section ladder supports PJG using the 3 8 x 1 1 4 bolts provided Secure to the ladder s using ladder clamps PDC See Detail C 4 Install the coil casing section supports PJW or PJG using the 3 8 x 1 1 4 bolts provided Secure to the ladder s using ladder clamps PDC See Detail D 5 Install the basin level...

Страница 30: ...JUN 2016 Page 30 IDCF IDC3 EVAPORATIVE CONDENSERS INSTALLATION Figure 46 Top Perimeter Guardrail Ladder IDC3 1220 1240 2420 2440 Detail C Detail E Detail A PJG PDC PJG Detail B PJF PJF PJG PDC Detail D PJG PDC PJG ...

Страница 31: ...l the lower Mechanical section ladder supports PJG using the 3 8 bolts provided Secure to the ladder s using ladder clamps PDC See Detail C 4 Secure the ladder s to the factory installed bracket s on the Fill Platform with the ladder clamps PDC and PDB Use the 3 8 bolts provided See Detail D NOTICE Not all units receive supports at this location NOTICE The total quantity of ladders depends on the ...

Страница 32: ...to Table 4 for the quan tity of bolting locations for different safety cage heights Figure 48 Safety Cage NOTICE Safety gates are provided for all guardrail openings and all components are designed to meet OSHA requirements TABLE 4 LADDER SAFETY CAGE BOLTING LOCATION AND QUANTITIES CAGE HEIGHT FT BOLTING LOCATION CAGE HEIGHT FT BOLTING LOCATION CAGE HEIGHT FT BOLTING LOCATION A B C D A B C D A B C...

Страница 33: ...are sized for wires based on the total nameplate kW and voltage The actual load for a particular installation may be less Either compute the actual load on the heater control panel the total kW of all the heaters connected to it or use the nameplate rating to determine the wire size required The field supplied branch circuit disconnect switch and the branch circuit protective de vices fusing or ci...

Страница 34: ...sket 150 lb flange weld any piping to the flange prior to installation Vulkem Caulk Gasket for the outside of the water basin For field installed outlet connections adding a flange connection is recommended Order the recommended supplies prior to shutdown Field Connection Instructions 1 Use the template provided with the accessory to layout and mark the hole pattern on the exterior of the water ba...

Страница 35: ...rt up no bearing lubrication is required since the bearings are factory lubricated prior to shipment Apply RUST VETO to steel shafts Fill the water basin with fresh water to the overflow level via the make up valve Set the make up valve float so the water shuts off at the operating level see Table 1 Execute one of the following biocide treatment programs while operating the circulating pump and pr...

Страница 36: ...f applicable Apply RUST VETO to steel shafts Inspect the protective finish on the unit Clean and refinish as required Refer to Corrosion Protection for more details Lockout the fan motor starting device in the OFF position to ensure personal safety in case of future inspection or service Verify combined inlet shield retainers are compressed COLD WEATHER OPERATION Frick condensers can be operated a...

Страница 37: ...revalent contact your local Frick Representative TripleGuard Corrosion Protection System Inspect compo nents protected with the TripleGuard Corrosion Protection System for signs of deep scratches or blemishes especially in areas with field penetrations Touch these up with 3M Windo Weld Super Fast Urethane Part RK1015 Water Treatment A proper water treatment program administered under the supervisi...

Страница 38: ...nd basins protected by the TripleGuard Corrosion Protection System do not require passivation However if the upper structure is galvanized steel passivation is required on the galvanized areas in cluding any Hot Dip Galv After Fabrication HDGAF coils BIOLOGICAL CONTROL The warm oxygen and nutrient rich environment inside evaporative cooling equipment provides an ideal environment conducive to the ...

Страница 39: ...it with independent fan capabilities and no partitions idle fans tend to windmill in the reverse direction A windmilling fan poses no threat to the system while turning freely but can create a large shock load when the fan motor is suddenly powered up Proper staging of fans when starting from a windmilling condition will prevent excessive stresses on the drive system NOTICE With evaporative coolin...

Страница 40: ...nit and ensure that the drive system is all clear Remove the lockout from the motor circuit With the VFD off record the vibration level indicated on the vibration analyzer and confirm that it is very low only picking up ambient vibration Record this overall vibration level 0 peak in inches per second ips If the ambient vibration level is greater than 0 35 ips identify and correct the cause of the ...

Страница 41: ... the set point The unit can be periodically calibrated on line by turning the set point control down until the light comes on This setting is then compared with the vibration measured with a portable vibration meter thus providing a calibration check of the unit I f the trip setting is maintained trip will occur after the duration of the time delay Remote Reset Connection of between terminals 5 an...

Страница 42: ...140 960 IOM JUN 2016 Page 42 IDCF IDC3 EVAPORATIVE CONDENSERS INSTALLATION OPERATION MAINTENANCE NOTES ...

Страница 43: ...ts with independent fan motors check the rotation of each fan NOTICE Check to ensure the controls for the fan motor are set to allow a maximum of six on off cycles per hour to prevent motor overload Operation On initial start up run the fan in the manual position for several minutes and check for any unusual noises or vibration WATER BASIN The water basin is constructed from one of the following m...

Страница 44: ... between the sheaves will produce the deflection shown in Figures 15a and 15b 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 Th...

Страница 45: ...ubricating purge the old grease from the bearing by gradually adding grease until a bead of new grease appears at the seal on the underside of the bearing 2 Seasonal Start up Purge the bearings with new grease prior to start up 3 Operation Purge the bearings with new grease every three 3 months while in operation 4 Extended Shutdown Purge the bearings with new grease prior to any prolonged storage...

Страница 46: ... 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 bypass the control un...

Страница 47: ...yl or ethyl alcohol or mineral spirits Stainless steel wipes or glass cleaners commonly available in stores may also be used Occasionally the surface of stainless steel can get iron chips or shavings embedded in it from having galvanized steel machined or welded in the vicinity The iron chips can start to rust reducing the corrosion resistance of the stainless steel and stain the surface giving th...

Страница 48: ... Process Fluid Flow Rate GPM R Range n Number of Cycles of Concentration CR CM CR Concentration in Recirculating Water CM Concentration in Makeup Water The evaporation rate is dependent on the wet bulb temperature and load The equation above provides the maximum bleed rate on the design day Contact your Frick sales representative for an exact calculation based on specific site conditions The evapo...

Страница 49: ...area should be free from ambient vibration Excessive vibration can cause bearing damage Precautions should be taken to prevent rodents snakes birds or other small animals from nesting inside the motors In areas where they are prevalent precautions must also be taken to prevent insects from gaining access to the interior of the motor If not stored indoors in a controlled environment some form of he...

Страница 50: ...ng in ambient temperatures below freezing the evaporative condenser should be inspected more frequently Refer to the Cold Weather Operation section for more details 3 Tension on new belts must be readjusted after the first 24 hours of operation and quarterly thereafter RECOMMENDED SPARE PARTS Frick parts are the Perfect Fit for your condenser These parts are specifically designed engineered and ma...

Страница 51: ...140 960 IOM JUN 2016 Page 51 IDCF IDC3 EVAPORATIVE CONDENSERS INSTALLATION OPERATION MAINTENANCE NOTES ...

Страница 52: ...boro PA 17268 1206 USA Phone 717 762 2121 FAX 717 762 8624 www johnsoncontrols com frick Form 140 960 IOM 2016 06 Supersedes NOTHING Subject to change without notice Published in USA 06 16 PDF 2016 Johnson Controls Inc ALL RIGHTS RESERVED ...

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