IDC2 Evaporative Condenser

Form 140.940-IOM (DEC 2013) INSTALLATION - OPERATION - MAINTENANCE

File: SERVICE MANUAL - Section 140Replaces: 140.940-IOM (FEB 2013)Dist: 3, 3a, 3b, 3c

IDC2 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.jci.com/frick for the latest version of this publication.

IDC2 EVAPORATIVE CONDENSERSINSTALLATION - OPERATION - MAINTENANCE

140.940-IOM DEC 13)Page 2

CONTENTS

INSTALLATION

RIGGING AND ASSEMBLY INSTRUCTIONS ............... 3Check Unit Before Rigging ....................................................3Unit Weights.........................................................................3Anchoring .............................................................................3Leveling ................................................................................3Safety ...................................................................................3Freeze Protection .................................................................3Location ...............................................................................3Warranties ............................................................................3Rigging .................................................................................3

SECTION ASSEMBLY OF TWO-PIECE CELLS ............4SECTION ASSEMBLY OF OPTIONAL THREE-PIECE CELLS .................................................4ASSEMBLY OF MULTI-CELL UNITS .......................... 5IDC2 FLUME BOx INSTALLATION ............................. 6

Positive Closure Plate Option ...............................................6Positive Closure Plate Installation .........................................6Water Baffles .......................................................................7Water Baffle Installation .......................................................7Motor Installation for IDC2-x-7409-x and IDC2-x-7418-x .....7Sloped Ladder Installation ....................................................8Installation of the Side Outlet Depressed Sump Box ............8Platform and Ladder Installation ...........................................8

OPERATION

WARNINGS .............................................................. 9WARRANTIES .......................................................... 9CAUTIONS ............................................................... 9

GENERAL MAINTENANCE INFORMATION ............... 10INITIAL & SEASONAL START-UP ............................11

General ............................................................................... 11Cleaning ............................................................................. 11Inspection ........................................................................... 11Start-up ............................................................................. 11

ExTENDED SHUTDOWN ..........................................12MAINTENANCE

COLD WATER BASIN ..............................................13Water Levels ...................................................................... 13Inspection & Maintenance .................................................. 13

FAN ........................................................................13Inspection & Maintenance .................................................. 13

FAN DRIVE SYSTEM ...............................................13Fortitude™ Power Train ...................................................... 13Inspection & Maintenance .................................................. 13

FAN MOTORS ........................................................ 15Model Specific Fan Drive System Descriptions ................... 15Inspection and Maintenance ............................................... 15Adjustable Motor Base ....................................................... 15

FAN SHAFT BEARINGS ........................................... 15Inspection & Maintenance .................................................. 15

WATER DISTRIBUTION SYSTEM AND HEAT TRANSFER SECTION ............................................ 15WATER LEVEL CONTROL ....................................... 16

Mechanical Makeup Valve Assembly .................................. 16Optional Electric Water Level Control Package ................... 16

RECOMMENDED MAINTENANCE SERVICES .............17

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

IDC2 EVAPORATIVE CONDENSERSINSTALLATION

140.940-IOM (DEC 13)Page 3

INSTALLATION

RIGGING AND ASSEMBLY INSTRUCTIONS

Check Unit Before RiggingWhen the unit is delivered to the jobsite, check it thoroughly to ensure all required items have been received and are free of any shipping damage before signing the bill of lading. The following parts should be inspected:

Sheaves and Belts Interior Surfaces Bearings Exterior Surfaces Bearing Supports Float Valve Assembly(s) Fan Motor(s) Cold Water Basin Accessories Fan Guards(s) Spray Water Pumps Fan(s) and Fan Shaft(s) Water Distribution System Coil Surface Louvers Mating Surfaces Between Sections/Modules Miscellaneous Items: All bolts, nuts, washers, and sealer tape

required to assemble sections or component parts are furnished by Frick and shipped with the unit. A checklist inside the envelope attached to the side of the unit marked “Contractor’s Installation Instructions” indicates what miscellaneous parts are included with the shipment and where they are packed.

Unit WeightsBefore rigging any unit, the weight of each section should be verified from the unit certified drawing. Unit print weights include the final assembled condenser with all accessories. Accessory weights (found on the respective drawing) can be deducted from the total weight.

WARNINGThese weights are approximate only and should be con-firmed by weighing before lifting when available hoisting capacity provides little margin for safety. In preparing for a lift, individuals responsible for rigging Frick units must inspect the equipment before the lift to make certain that all water or other liquids have been drained from the unit and any debris removed.

During cold weather, the pre-lift procedure must include a check for and removal of accumulations of ice and snow, which will not naturally drain from the equipment and would add substantially to the equipment’s lifting weight.

Anchoring

CAUTIONUnit must be properly anchored in place before operation begins.

Bolt holes, 7/8 in. diameter, are provided in the bottom flange of the basin section for bolting the unit to the support beams. Refer to the suggested support details on the certified drawing for loca-tions of the mounting holes. Anchor bolts are supplied by others.

LevelingThe support beams and unit must be level for proper operation. Shims should not be used between the basin and support beams to level the unit.

WARNINGOperation, maintenance, and repair of this equipment should be undertaken only by personnel qualified to do so. Proper care, procedures and tools must be used in handling, lifting, installing, operating, maintaining and repairing this equipment to prevent personal injury and/or property damage.

WARNINGAdequate precautions, appropriate for the installation and location of these products, should be taken to safeguard the public from possible injury and the equipment and the premises from damage.

Safety Adequate precautions appropriate for the installation and location of these products should be taken to safeguard the equipment and the premises from damage and the public from possible injury.

When the fan speed of the unit is to be changed from the factory set speed, including the use of a variable speed device, steps must be taken to avoid operating at or near the fan’s “critical speed” which could result in fan failure and possible injury or damage. Consult with your local Frick Representative on any such applications.

Freeze ProtectionThese products must be protected by mechanical and operational methods against damage and/or reduced effectiveness due to possible freeze-up. Please refer to the Common Operation and Maintenance Manual on www.johnsoncontrols.com/frick or contact your local Frick Representative for recommended protection alternatives.

LocationAll evaporative cooling equipment must be located to ensure an adequate supply of fresh air to the fans. When units are located adjacent to walls or in enclosures, care must be taken to ensure the warm, saturated, discharge air is not deflected and short-circuited back to the air intakes.

Each unit must be located and positioned to prevent the introduc-tion of discharge air into the ventilation systems of the building on which the unit is located and of adjacent buildings. For detailed recommendation on Frick equipment layout, see our website at www.johnsoncontrols.com/frick or contact your local Repre-sentative.

WarrantiesPlease refer to the Limitation of Warranties (located in the submittal package) applicable to and in effect at the time of the sale/purchase of these products.

RiggingRefer to Table 1 for the recommended vertical dimension “H” from the lifting device to the spreader bar. In the event of ex-tended lifts or where hazards exist, the lifting devices should be used in conjunction with safety slings placed under the unit.


140.940-IOM (DEC 13)Page 4

Figure 2 - Upper Section Multi-piece Lift

NOTICEFor weight information, refer to submittal drawing package.

NOTICEAny motors or accessories shipped in the cold water basin must be removed prior to installing the upper section.

WARNINGIn the event of extended lifts or where hazards exist, the lifting devices should be used in conjunction with safety slings placed under the unit.

Model Number

H (distance from lift point to lifting device in feet)

Lower SectionUpper Section/Single Piece Lift

IDC2-X-0406-X 14 9IDC2-X-0412-X 16 9IDC2-X-7409-X 14 10IDC2-X-7418-X 16 15IDC2-X-1012-X 16 15IDC2-X-1212-X 16 13IDC2-X-1218-X 18 15

Table 1 - Recommended Vertical Dimension

Most IDC2 Evaporative Condensers (Except Models IDC2-x-1218-x) are designed to be lifted in one assembled piece as shown in Figure 1. The multipiece lift is shown in Figures 2 and 3.

SECTION ASSEMBLY OF TWO-PIECE CELLS

• Position the lower section on the supports and bolt in place.

• Wipe moisture and dirt from the perimeter flange.

• Remove any motors or accessories shipped in the cold water basin.

• Install sealer tape supplied with the unit, as illustrated in Figure 4 - Mechanical Section Bolt Assembly, on the mat-ing flanges of the lower section in a continuous line. At each corner, allow 1” overlap.

• Using drift pins in the bolt holes provided, as shown in Figure 5, guide the upper section onto the lower section starting with the bolt hole at one corner and follow down the flange.

• Screw in place using the self-tapping screws, supplied with the unit, to ensure leak-free operation (Figure 5a).

SECTION ASSEMBLY OF OPTIONAL THREE-PIECE CELLS

NOTICEIBC Rating is void if section assembly is not performed as described in this manual.

NOTICEAll piping must be restrained to ensure no vertical or horizontal movement. All piping and supports are to be furnished by others. Refer to the certified drawing for details on the connection size, etc.

Figure 1 - Single Piece Lift


140.940-IOM (DEC 13)Page 5

Figure 3 - Lower Section Multi-piece Lift Figure 3a. Middle Section Lift Figure 3b. Mechanical Section Lift

• Using drift pins in the bolt holes provided, as shown in Figure 5, guide the middle section onto the lower section. Match marks must line up.

• Bolt the middle section in place as illustrated in Figure 4 - Middle/Coil Bolt Assembly, using a 1/2” bolt and flat washer. Remove disposable middle section lifting ears and discard.

• Next, wipe down the mating surface of the mechanical section to remove any dirt or moisture that may have accumulated during shipment

• On one end, apply a layer of 1/8” x 1” foam tape around the face of the flange over the centerline of the holes.

• As illustrated in Figure 4 - Typical/Standard Bolt Assem-bly, insert 3/8” self-tapping screws in each hole from the mechanical section into the middle section and tighten.

ASSEMBLY OF MULTI-CELL UNITS

NOTICEOn quad cell installations, it is suggested that cells sub-sequent to the first 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 lower sections of each cell. Slide the subsequent cell(s) to their final position using the lifting devices at the top of the cell(s). Refer to the “Assembly of Multiple-Cell Units” section for details. All multi-cell units have the cell number and “face” identified on each section as well as match marks to show how the cells are to be mated.

Figure 5a - Typical Bolting

Figure 5 - Drift Pin Alignment

Figure 4 - Mechanical Section Bolt Assembly

• Position the lower section on the unit support and bolt in place. Figures 3, 3a and 3b shows the proper rigging and assembly of units that ship in three-sections.

• Remove any motors or accessories shipped in the cold water basin.


140.940-IOM (DEC 13)Page 6

Refer to the certified unit print for the proper orientation of each cell. The cell number and “face” are stenciled on the outer basin wall. Multi-cell unit installations may use flume boxes to equalize the water level in the basin of each cell.

Follow directions below for details on their installation:

• First, attach the first cell’s lower section to the support and then fasten the first cell’s upper section to the first cell’s secured bottom section.

• Each subsequent cell should be assembled just adjacent to its final location, and then properly positioned next to the previous cell.

• Use the flume box installation procedure to connect the basins of multi-cell units.

IDC2 FLUME BOx INSTALLATION

NOTICEFlume boxes furnished with units constructed with stainless steel basins and the TripleGuard™ Corrosion Protection System are assembled with stainless steel bolts, washers and nuts in lieu of self-tapping screws.

NOTICEFor units equipped with the positive closure plate option, skip last step on this page and go to the positive closure plate section of this manual.

• Position Cell #1 on the unit support and bolt in place.

• Wipe down the mating surface by the flume opening to re-move any dirt or moisture that may have accumulated during shipment.

• Wipe down the flanges on both ends of the flume box. On one end, apply a layer of 1/8” x 1” butyl sealer tape around the face of the flange over the centerline of the holes. Do not overlap or stretch too thinly at the corners. When it is necessary to splice the sealer, be sure to press the two ends together to form a smooth, continuous strip. Apply a second layer of sealer tape over the first layer following the same procedure.

• Using drift pins to align the bolt holes, place the flume box over the opening in the basin of Cell #1 and fasten into place. Insert the 3/8” self-tapping screws or bolts from the flume box into the basin wall as illustrated in Figure 6.

• Apply sealer to the other end of the flume box as described in bullet 3 above.

• Position Cell #2 on the unit supports. Wipe down the mating surface by the flume opening to remove any dirt or moisture.

• Using drift pins to ensure alignment, draw Cell #2 tight against the flume box.

• As illustrated in Figure 6, insert 3/8” self-tapping screws in each hole from the flume box into the basin wall and tighten.

Positive Closure Plate OptionThe optional positive closure plate and gasket can be furnished on multi-cell units to allow individual cells to be isolated for cleaning and routine maintenance. For IDC2 Evaporative Con-densers, the plate ships loose inside the basin. To install the Positive Closure Plate and gasket, follow the “Positive Closure Plate Installation” then complete the installation of your specific type of unit using the instructions listed.

Positive Closure Plate Installation (Figures 7, 7a & 7b)• Thread 3/8” self-tapping screws from the flume box into the

basin wall with the positive closure plate as shown.

• Position the neoprene gasket and positive closure plate over the bolts and fasten in place with 3/8” wing nut and flat washers.

PCPPCP Gasket

Ring

Small Backing Ring

Flume -InstalledBetween

Cells

Large Backing Ring

Figure 7 - Flume Box Layout

Figure 7a - Positive Closure Figure 7b - Self Aligning Plate Assembly Butterfly Bolt PatternFigure 6 - Self Tapping Bolt Pattern for Flume Box


140.940-IOM (DEC 13)Page 7

Figure 8c - Step 3

Figure 8a - Step 1 Figure 8b - Step 2

Lower BaffleLower Baffle

SideBaffleSide Baffle

3/8”3/8” Screw

Water BafflesFor multi-cell IDC2 Evaporative Condensers, water baffles join the air louver sections to prevent leaks. To install the water baffles, follow the steps below.

Water Baffle Installation (Figures 8a, b and c)• Slide lower water baffle into place.

• Install left and right side water baffles by first aligning top notches and then sliding bottom into place.

• Install 3/8” self-tapping screws in each hole provided.

Motor Installation for IDC2-x-7409-x and IDC2-x-7418-x (Figures 9a and 9b)

WARNINGEnsure that the fan guard is properly installed prior to com-mencing operation.

NOTICEAll other IDC2 models have the fan motor mounted and tensioned at the factory.

Attach lifting strap to the motor base eyelet and remove the motor and motor base assembly from the cold water basin ship-ping location. The motor assembly remains vertical to maintain proper alignment during installation. Lift assembly into position next to access door. Attach the assembly to the unit using the six supplied studs and hardware. Install power band and check sheave alignment. Finally, tension the power band. For correct tensioning specifications and procedures, refer to the MAINTE-NANCE/Fan Drive System section in this manual.

Figure 9a - External Motor Mount Assembly Instruction

Figure 9b - External Motor Mount Assembly Pattern

1/2" Washer

1/2" Lock Washer

1/2" Nut

Figure 10 - Side Outlet Depressed Sump Box Assembly


140.940-IOM (DEC 13)Page 8

Installation of the Side Outlet Depressed Sump BoxTo install the side outlet depressed sump box, follow these steps:

• Wipe the edges around the opening in the cold water basin to remove any dirt or moisture that may have accumulated during shipment. Apply a layer of 1/8” x 1” butyl sealer tape around the opening in the basin over the centerline of the holes. Do not stretch the sealer too thinly or overlap at the corners. When it is necessary to splice the sealer, be sure to press the two ends together to form a smooth continuous strip. Apply a second layer of sealer tape over the first layer following the same procedure. Refer to Figure 10 for more details.

• Insert the sump box assembly into the opening in the cold water basin and attach it to the basin with 3/8” x 1” bolts, nuts, flat washers, and lock washers as shown in Figure 10, Detail A.

• Place the suction strainer over the opening.

Platform and Ladder InstallationRemove platform and ladder assembly from cold water basin. Hang preassembled platform by inserting top guide pins into the fan deck notches as shown in Figure 11, Detail A. Secure with tappers. Assemble lower platform clamps and secure to side of tower, tightening nuts and bolts as shown in Figure 11, Detail B.

Figure 11 - External Platform Assembly

Detail A

Detail B

Sloped Ladder InstallationRemove ladder from cold water basin. Slide the ladder bracket assembly (attached to side of ladder) into the ladder mounting guides located on the side of the condenser (Figure 12). Align the bolt holes and install the hardware through the ladder mounting bracket and ladder mounting guides; tighten.

Sloped Ladder Installation

Figure 12 - Ladder Installation

IDC2 EVAPORATIVE CONDENSERSOPERATION

140.940-IOM (DEC 13)Page 9

OPERATION

WARNINGS

Do not perform any service on or near the fans, motors, and drives, or inside the unit without first ensuring that the fans and pumps are disconnected, locked out, and tagged out.

WARNINGCheck 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.

WARNINGOpenings and/or submerged obstructions may exist in the bottom of the cold water basin. Use caution when walking inside the equipment.

WARNINGThe top horizontal surface of the unit is not intended to be used as a walking surface or working platform. If access to the top of the unit is desired, the purchaser/end-user is cautioned to use appropriate means complying with applicable safety standards of governmental authorities.

WARNINGTop combined inlet shields on IDC2 units are not designed to support the weight of a person or to be used as a storage or work surface for any equipment or tools. Use of these top combined inlet shields as walking, working or storage surfaces may result in injury to personnel or damage to equipment. Units with top combined inlet shields should not be covered with a plastic tarpaulin.

WARNINGWhen the fan speed of the unit is to be changed from the factory set speed, including changes achieved by the use of a variable fan speed device, steps must be taken to avoid operation at or near the fan’s “critical speed” which could result in fan failure and possible personal injury or dam-age. Contact your local Frick Representative regarding any such applications. Additionally, inverter duty motors are required on installations that are to be controlled by VFDs. See “Variable Frequency Drive Operation” in the Common Operation & Maintenance Manual for more details.

WARNINGThe recirculating water system may contain chemicals or biological contaminants, including Legionella, which could be harmful if inhaled or ingested. Personnel exposed directly to the discharge airstream and the associated drift mists, generated during operation of the water distribution sys-tem and/or fans, or mists produced by high pressure water jets or compressed air (if used to clean components of the recirculating water system), must wear respiratory protec-tion equipment approved for such use by governmental occupational safety and health authorities.

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

WARRANTIES

Please refer to the Limitation of Warranties in the submit-tal packet applicable to and in effect at the time of the sale/purchase of these products. Described in this manual are the recommended services for start-up, operation, and shutdown, and the approximate frequency of each.

CAUTIONS

CAUTIONFrick units are typically installed immediately after shipment and many operate year round. However, if the unit is to be stored for a prolonged period of time either before or after installation, certain precautions should be observed. For in-stance, covering the unit with a clear plastic tarpaulin during storage can trap heat inside the unit, potentially causing damage to the fill and other plastic components. If units must be covered during storage, an opaque, reflective tarp should be used. Consult with your local Frick Representa-tive for additional recommendations on long-term storage. For normal seasonal shutdowns, refer to the OPERATION/Extended Shutdown section in this manual.

CAUTIONAll electrical, mechanical, and rotating machinery are potential hazards, particularly for those not familiar with their design, construction, and operation. Accordingly, use appropriate lockout procedures. Adequate safeguards (in-cluding the use of protective enclosures where necessary) should be taken with this equipment both to safeguard the public from injury and to prevent damage to the equipment, its associated system, and the premises.

CAUTIONWhen reversing the direction of rotation, allow the fan to come to a complete stop before restarting the motor.

CAUTIONDo not use oils containing detergents for bearing lubrica-tion. Detergent oils will remove the graphite in the bearing sleeve and cause bearing failure. Also, do not disturb bearing alignment by tightening the bearing cap adjustment on a new unit as it is torque-adjusted at the factory.

CAUTIONThis equipment should never be operated without all fan screens, access panels, and access doors in place. For the protection of authorized service and maintenance person-nel, install a lockable disconnect switch located within sight of the unit on each fan and pump motor associated with this equipment.


140.940-IOM (DEC 13)Page 10

Figure 13 - IDC2 Evaporative Condenser

CAUTIONMechanical and operational methods must be employed to protect these products against damage and/or reduced effectiveness due to possible freeze-up. Please refer to www.johnsoncontrols.com/frick or contact your local Frick Representative for recommended protection alternatives.

CAUTIONPressure greater than 10.0 psig may cause damage to the distribution system.

GENERAL MAINTENANCE INFORMATION

The services required to maintain a piece of evaporative cooling equipment are primarily a function of the quality of the air and water in the locality of the installation:

• Air: The most harmful atmospheric conditions are those with unusual quantities of industrial smoke, chemical fumes, salt or heavy dust. Such airborne impurities are carried into the equipment and absorbed by the recirculating water to form a corrosive solution.

• Water: The most harmful conditions develop as water evaporates from the equipment, leaving behind the dissolved solids originally contained in the makeup water. These dis-solved solids may be either alkaline or acidic and, as they are concentrated in the circulating water, can produce scaling or accelerated corrosion.

The extent of impurities in the air and water determines the frequency of most maintenance services and also governs the extent of water treatment which can vary from a simple continu-ous bleed and biological control to a sophisticated treatment sys-tem. Refer to “Water Treatment” and “Biological Control” in the Common Operation & Maintenance Manual for more details.

AxialFan

FanGuard

LargeAccessDoor

Motor

MotorRemovalDavit(Optional)

Louvers

FanCowl

CoilConnection:RefrigerantIn

Coil

CoilConnection:RefrigerantOut

SecondaryPump(Optional)

PrimaryPump

InclinedLadder(Optional)

ColdWaterBasin

IBCCrossBracing(Optional)

TerminalBox(Optional)

AdjustableFloat


140.940-IOM (DEC 13)Page 11

INITIAL & SEASONAL START-UP

WARNINGDo not perform any service on or near the fans, motors, and drives, or inside the unit without first ensuring that the fans and pumps are disconnected, locked out, and tagged out.


General• If the unit is mounted on vibration isolators or isolation rails

(by others), refer to the vibration isolation manufacturer’s guidelines before loading/unloading weight from the unit.

• Verify fan and unit pump motors are disconnected and locked out.

• Conduct external inspection of the equipment. Check for leaks, corrosion, and any structural damage.

• Inspect piping and connections.

Cleaning• Drain the cold water basin with the strainer in place.

• Flush the water distribution system by removing the cleanout cap. Inspect and clean all spray nozzles.

• Clean all of the mechanical components, such as the fan and motor.

• Flush the cold water basin to remove any accumulated dirt and debris.

• Remove, clean, and replace the basin strainer.

• Remove all dirt and debris from the fan guard.

Inspection• Thoroughly inspect the fan(s) for any mechanical or physical

damage.

• At seasonal start-up or after prolonged shutdown, check the motor insulation with an insulation tester prior to the motor start-up.

• Prior to seasonal start-up, check and adjust the belt tension. At initial start-up, the belt tension may not require adjust-ment as the drive will be properly tensioned at the factory prior to shipment.

• Start the fan motor(s) and check for proper fan rotation. The fan should rotate in the direction indicated by the arrow on the fan cowl.

• Run the fan in manual mode for several minutes to check for any unusual noise or vibrations.

• For a 2-speed motor, check to ensure the starter includes 15 second time delay when switching from high speed to low speed.

• Check that the float operated makeup valve is operating freely.

Start-up


WARNINGPressure greater than 10.0 psig may cause damage to the distribution system.

• Prior to seasonal start-up, lubricate the motor base adjusting screw(s) (see Figures 3a and 3b) and fan shaft bearings. At initial start-up, no bearing lubrication is required since the bearings are factory lubricated prior to the shipment.

• Fill the cold water basin with fresh water up to the overflow level via the makeup valve.

- Water Treatment for New Installations: Initiate the biocide water treatment program at this time. Refer to “Biological Control” in the Common Operation & Main-tenance Manual for more details.

- Water Treatment for Seasonal Start-up or after a Shut-down period in excess of three days: Resume the biocide treatment program or administer a shock treatment of appropriate biocides prior to operating the evporative condenser fans. This will eliminate accumulated biological contaminants. Refer to “Biological Control” in the Com-mon Operation & Maintenance Manual for more details.

• Set the makeup valve float so the water shuts off at the overflow.

• Start the unit pump and check for proper rotation indicated by the arrow on the pump cover.

• On installations where the unit pump was not furnished by Frick, a globe valve should be installed in the pump discharge line and the pump flow rate adjusted to the correct water flow and pressure (2 psig at spray header connection).

• Open the supply valve slowly until the design flow is reached based on the pressure in the distribution system. Refer to “Water Distribution and Heat Transfer System” section for more details.

• For systems with a manual bleed, open the valve in the unit bleed line, and adjust the bleed by closing or opening the valve. See “Water Treatment” in the Common Operation & Maintenance Manual for more details.

• Once the unit is operating, check the current and the voltage of all three phases (legs) of the fan motor with a heat load on the unit under warm ambient conditions. The current must not exceed the nameplate ratings.

• Check the operation of the optional vibration cutout switch.


140.940-IOM (DEC 13)Page 12

NOTICEAfter 24 hours of operation under thermal load, perform the following services:

ü Check the unit for any unusual noise or vibrations.

ü Check the operating water level in the cold water basins.

ü Adjust makeup valve if necessary.

ü Check the belt tension and readjust if necessary.

ü Inspect the spray nozzles and heat transfer section.

ExTENDED SHUTDOWN


Perform the following services whenever the unit is shut down in excess of three days:

• If the unit is mounted on vibration isolators or isolation rails (by others), refer to the manufacturer’s guidelines before loading/unloading weight from the unit.

• Drain the cold water basin and all the piping that will be exposed to freezing temperatures. Heat trace and insulate all exposed piping.

• Clean all the debris, such as leaves and dirt, from the interior and exterior of the unit.

• Leave the cold water basin drain open so rain and melting snow will drain from the unit.

• Clean the basin strainer and reinstall.

• Cover the fan discharge to keep out dirt and debris.

• Lubricate the fan shaft bearings, motor base, and motor base adjusting screw.

• Close the shutoff valve in the makeup water line (supplied by others) and drain all exposed makeup water piping. Heat trace and insulate all exposed piping.

• Inspect the protective finish on the unit. Clean and refinish as required. Refer to “Corrosion Protection” in the Common Operation & Maintenance Manual for more details.

• Secure the fan motor starting device in the “OFF” position to ensure personal safety in the case of future inspection or service.

IDC2 EVAPORATIVE CONDENSERSMAINTENANCE

140.940-IOM (DEC 13)Page 13

MAINTENANCE

COLD WATER BASIN

The refrigerant to be condensed is circulated inside the tubes of the unit’s heat exchanger. Heat flows from the refrigerant through the coil to the spray water outside which is cascading over the tubes. The spray water collects in the cold water basin, passes the suction strainer and is pumped back to the distribution sys-tem. The cold water basin is constructed from galvanized steel.

Water Levels

Model NumberAt Overflow Level (in.)

At Operating Level (in.)

AllIDC2modelsexceptIDC2-x-1218-x

11¾” 9”

IDC2-x-1218-x 13½” 10½”

Table 2 - Cold Water Basin Water Levels

• The makeup valve controls the operating level, which is maintained at the levels shown in Table 2.

• The operating water level in the cold water basin will vary with system thermal load (evaporation rate), the bleed rate employed, and the makeup water supply pressure.

• Check the operating water level monthly, and readjust the float when necessary to maintain the recommended operat-ing level.

Inspection & Maintenance

WARNINGOpenings and/or submerged obstructions may exist in the bottom of the cold water basin. Use caution when walking inside the equipment.

• Inspect the cold water basin regularly. Remove trash or debris accumulated in the basin or on the strainer.

• Quarterly or more often if necessary, drain, clean, and flush the entire cold water basin with fresh water. This will remove the sediment, which can collect in the basin during operation. If not removed, sediment can become corrosive and cause deterioration of the protective finish of metallic basins.

• When flushing the basin, leave the strainer in place to prevent the sediment from re-entering the system.

• Remove the strainer after the basin has been flushed.

• Clean and replace the strainer before refilling the basin with fresh water.

• Adjust the float to maintain the design operating level. See Table 1.

FAN

The IDC2 Evaporative Condenser uses axial fan(s). Thoroughly inspect the fan for damaged or deteriorated fan blades and replace the fan as required.

Inspection & Maintenance• If the unit is already in operation, while the fan is running,

check for any unusual noise or vibration.

• With the fan off and the motor locked out and tagged, check the general condition of the fan:

- Inspect for any loose or missing bolts in the fan shaft bushing, the fan hub, and the fan shaft bearing(s).

- Check the fan blades for looseness, first by twisting the blade by hand, and then by moving the blade tip up and down. There should be no play or slippage.

- Inspect each blade for excessive scale build-up that could cause vibration.

- Check each blade in the area of the shank for any signs of cracking. If cracking is found, the fan motor should be locked out immediately. Contact Johnson Controls-Frick or your local Frick Factor for assistance.

• Tip Clearance: Check the clearance between the tip of the blade and the fan cowl. The clearance should be between 1/8” and 1/2”.

• Drain Holes: On hollow blades, the drain hole in the blade tip should be unobstructed. Tip: Use a piece of wire to probe the hole.

• Blade Pitch: Check to ensure that the blades are all at the same pitch. If uncertain, measure the pitch with an inclinom-eter. All blades should be within +/-1/2°.

• Rotation: Turn the fan by hand to ensure that it moves freely with no rough spots, binding or other malfunctions that could cause vibration or fan motor overload. While rotating the fan, check the blade tracking. All blades should track within a 1/2” band at any single point around the cowl.

• Direction of Rotation: On initial start-up, or if the fan motor has been rewired, bump the fan motor and note the direction of rotation. It should rotate in the direction indicated by the arrow on the fan cowl.

• Operation: On initial start-up, run the fan in the manual position for several minutes and check for any unusual noises or vibration.

FAN DRIVE SYSTEM

Fortitude™ Power TrainThe Fortitude™ Power Train consists of a solid-backed, multi-groove, neoprene/polyester belt rated for evaporative condenser service, and corrosion-resistant sheaves. These components provide high reliability with low maintenance requirements.

Inspection & MaintenanceFortitude™ Power Train requires a periodic check of the belt condition and, when necessary, tension adjustment. The recom-mended service intervals are as follows:

• Initial Start-Up:

- No servicing is required prior to initial start-up since the drive has been tensioned and aligned at the factory. [IDC2-x-1212-x and IDC2-x-1218-x]


140.940-IOM (DEC 13)Page 14

- When the belt is properly tensioned, align the adjustment bolt to facilitate replacement of the locking wrench. Re-place the locking wrench and tighten the plastic thumb-screw to secure.Alignment

• Check the drive alignment annually to ensure maximum belt life.

• Drive alignment check and adjustment:

- Place a straight edge across the driver and the driven sheaves as shown in Figure 16.

- The straight edge should contact all four points as shown in Figure 16 indicating that the drives are properly aligned.

- There should be no more than 1/16” deviation from four points of contact.

- In case of realignment, loosen the motor sheave and align it with the fan sheave. Allow 1/4” for draw-up as the bushing screw is retightened.


Figure 16 - Drive Alignment

- The motor base assembly has been pre-aligned at the fac-tory. Mount the motor base assembly to the unit and verify alignment. Install the belt and follow the belt tensioning directions below. [IDC2-x-7409-x and IDC2-x-7418-x]

• Seasonal Start-Up: Readjust the tension on the belt.

• Operation: After the first 24 hours of operation, readjust the belt tension on a new unit start-up or installation of a new belt. Thereafter, check the belt condition monthly, and adjust tension as 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 14a, or use a tape measure as shown in Figure 14b to measure belt deflection.

- Apply a moderate force by hand (approximately 40 lb/275 kPa) evenly across the width of the belt in the center of the span between the sheaves.

- There is adequate belt tension if the belt deflects between 1/4” and 3/8” as shown in Figures 14a and 14b.

Driven SheaveDriven SheaveBelt

Driver Sheave

Straight Edge

1/4” to 3/8” Deflection = Proper Belt Tension 1/4” to 3/8” Deflection = Proper Belt Tension

Tape Measure

Belt

Driver Sheave

Figure 14a - Belt Tension with a Straight Edge

Driven SheaveDriven SheaveBelt

Driver Sheave

Straight Edge

1/4” to 3/8” Deflection = Proper Belt Tension 1/4” to 3/8” Deflection = Proper Belt Tension

Tape Measure

Belt

Driver Sheave

Figure 14b - Belt Tension with a Tape Measure

NOTICEThere should be no “chirp” or “squeal” when the fan mo-tor is started.

Belt tension adjustment (if required):

- Remove the locking wrench (wrench attached to casing near motor/door) by loosening the plastic thumbscrew.

- Using the supplied locking wrench, wrench or impact gun, turn the motor base adjusting bolt (Figures 15a and 15b) clockwise to tension the belt, or counterclockwise to relieve belt tension. During adjustment of belt tension, the drives should be rotated several times by hand to evenly distribute the tension throughout the belt.

MotorAdjustingBolt

Figure 15a - External Motor

Figure 15b - Internal Motor

MotorAdjustingBolt


140.940-IOM (DEC 13)Page 15

FAN MOTORS

Model Specific Fan Drive System DescriptionsExternally Mounted Motor (Models IDC2-x-7409-x and IDC2-x-7418-x): A belt drive system with a premium efficiency totally enclosed motor mounted outside the airstream is provided on these units. (Figure 17)

Figure 17 - Externally Mounted Motor

Internally Mounted Motor (Models IDC2-x-1212-x, and IDC2-1218-x): A belt drive system with a premium efficiency totally enclosed motor mounted inside the airstream is provided on these units. (Figure 15b)

Inspection and Maintenance• Clean the outside of the motor at least quarterly to ensure

proper motor cooling.

• After prolonged shutdowns, check the motor insulation with an insulation tester prior to restarting the motor.

Adjustable Motor BaseCoat the motor base slides and adjusting screws (refer to Figures 15a and 15b) twice a year using good quality corrosion inhibiting grease such as one of those recommended for lubricating the fan shaft bearings below.

FAN SHAFT BEARINGSTwo pillow block ball bearings support the fan shaft and are provided with extended lube lines as standard. Each bearing is equipped with a lubrication fitting and a slinger/locking collar to keep out moisture.

Inspection & Maintenance• Only lubricate the bearings with a manual grease gun. Do not

use high-pressure grease guns since they may rupture the bearing seals.

• Only ubricate the bearings with one of the following com-patible water resistant greases which are suitable for ambi-ent temperatures ranging from - 65°F (-53.9°C) to +250°F (121.1°C).

- Amoco - Rycon Premium #3 - Chevron - SRI - Citgo - Polyurea MP2™ - Conoco - Polyurea 2™ - Exxon - Polyrex® EM - Exxon - Unirex N™ - MobilGrease® - AW2 - Shell - Alvania RL3™ - Shell - Alvania #3 - Shell - Dolium “R” - SKF - LGHP2™ - Unocal 76 - Unilife Grease™

NOTICEList of brand names is for identification only and are not exclusive recommendations.

• Lubricate 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 evaporative condenser has been stored at the job site or more than 1 year, both bearings should be lubricated with new grease before initial operation. When lubricating, 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.

- Seasonal Start-up: Purge both bearings with new grease prior to start-up.

- Operation: Purge bearings every 2,000 hours of operation or once every three months, whichever occurs first.

- Extended Shutdown: Purge bearings with new grease prior to any prolonged storage or downtime.

WATER DISTRIBUTION SYSTEM AND HEAT TRANSFER SECTION

CAUTIONDo not use steam or high pressure water to clean PVC eliminators or materials other than steel.

The hot water is distributed through a corrosion resistant polyvi-nyl chloride (PVC) spray distribution system. The drift eliminators are made of PVC, which is impervious to rot, decay, rust, or biological attack. Inspect and clean the spray nozzles and heat transfer section each month.

The inspection procedure is as follows:

• Shut off the fan and lock out and tag out the fan motor. Leave the system pump running.

• Remove the drift eliminators to allow a clear view of the spray distribution system and nozzle patterns.

• Check to see if the nozzles are all spraying consistently and producing the spray pattern shown in Figure 18.


140.940-IOM (DEC 13)Page 16

Mechanical Makeup Valve AssemblyA float-operated mechanical water makeup assembly is fur-nished as standard equipment on the evaporative condenser. The standard makeup assembly consists of a corrosion resistant makeup valve connected to a float arm assembly actuated by a polystyrene-filled plastic float. The float is mounted on an all-thread rod held in place by wing nuts. The cold water basin operating water level can be adjusted by repositioning the float and all-thread rod using the wing nuts provided.

• Inspect the makeup valve assembly monthly and adjust if necessary.

• Inspect the valve annually for leakage. Replace the valve seat if necessary.

• Maintain the makeup water supply pressure between 15 psig and 50 psig for proper operation. Frick recommends a surge protector (provided by others) for pressures over 50 psig.

• Set the initial basin water level by adjusting the wing nuts so that the makeup valve is completely closed when the water level in the cold water basin is at the operating level.

• With the design thermal load and the average water pressure (15 to 50 psig) at the valve, the above setting will produce operating water levels as stated in Table 2.

• If the thermal load is less than the design load at the time of unit start-up, the procedure may produce operating levels greater than those shown in Table 1. If operating levels are higher than specified, readjust the float in order to attain the recommended operating level.

• Closely monitor the water level in the cold water basin and adjust the level if necessary during the first 24 hours of op-eration.

• Operating at the recommended water level will ensure that the unit basin contains sufficient water volume to prevent air entrainment in the circulating pump during system start-up and provides sufficient excess basin capacity to accept the total system pull-down volume.

Optional Electric Water Level Control PackageAs an option, an electric water level control package is avail-able in lieu of the mechanical makeup assembly. The package consists of a probe-type liquid level control assembly and a slow-closing solenoid valve. Stainless steel electrodes, factory-set at predetermined lengths, extend from an electrode holder into the cold water basin.

• Clean the stainless steel electrodes periodically to prevent ac-cumulations 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 unit in order to fill the unit to the overflow connection.

• Quarterly or more often as required, turn off the pump. Flush any dirt or debris from the water distribution system to prevent clogged nozzles. If necessary, remove the nozzle and the grommet for cleaning. To remove, grasp the nozzle and pull while twisting. Replace any damaged nozzles.

• Major fouling requires cleaning and flushing. Follow the procedure in “System Cleaning” in the Common Operation & Maintenance Manual.

Heat trace and insulate all exposed water piping including pump piping below the overflow level, external header cleanout and makeup water lines with electrical heater tape.

Figure 18 - Nozzle Spray Pattern

WATER LEVEL CONTROL

NOTICEIf the unit has been ordered with the optional electric wa-ter level control package or is intended for remote sump application, a mechanical water makeup valve will not be provided.

There are two types of water level controls used on Frick evaporative condensers:

• Mechanical makeup valve assembly

• Optional electric water level control package


140.940-IOM (DEC 13)Page 17

RECOMMENDED MAINTENANCE SERVICES(1)

Type Service Start-Up Monthly Quarterly Annually Shutdown

Inspect and clean as necessary:Inspect general condition of the unit(2) and check unit for unusual noise or vibration

X X

Inspect cold water basin X X XInspect spray nozzles X X XDrain basin and piping X

Inspect air inlet louvers/Combined inlet shieldsCheck and adjust water level in basin X XCheck operation of makeup valve X XCheck and adjust bleed rate X XInspect unit Finish X

Mechanical equipment system:Check belt condition X XAdjust belt tension(3) X XLubricate fan shaft bearings X X XLubricate motor base adjusting screw X X XCheck drive alignment XCheck motor voltage and current X XClean fan motor exterior X XCheck fan motors for proper rotation XCheck fans for rotation without obstruction X XCheck general condition of the fan XCheck and unplug fan drain holes (hollow blade fans) XCheck fan for uniform pitch XCheck and recoat steel shafts with RUST VETO® X X X

1. Recommended service intervals are for typical installations. Different environmental conditions may dictate more frequent servicing.2. When operating in ambient temperatures below freezing, the unit should be inspected more frequently. Refer to “Cold Weather Operation” in the

Common Operation and Maintenance Manual for more details.3. Tension on new belts must be readjusted after the first 24 hours of operation and quarterly, thereafter.


IDC2 EVAPORATIVE CONDENSERSNOTES

140.940-IOM (DEC 13)Page 18

IDC2 EVAPORATIVE CONDENSERSNOTES

140.940-IOM (DEC 13)Page 19

JOHNSON CONTROLS100 CV AvenueWaynesboro, PA 17268-1206 USAPhone: 717-762-2121 • FAX: 717-762-8624www.jci.com/frick

Form 140.940-IOM (2013-12)Supersedes: 140.940-IOM (2013-02)

Subject to change without noticePublished in USA • 01/15 PDF

© 2015 Johnson Controls Inc. - ALL RIGHTS RESERVED

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IDC2 Evaporative Condenser