Frick FPHE Penthouse Evaporators Installation Operation and Maintenance Guide

Brand: Frick

Model: FPHE Penthouse Evaporators

Type: Installation Operation and Maintenance Guide

This manual contains installation, operation, and maintenance

instructions. Read thoroughly before you begin installing. Failure

to follow these instructions may result in personal injury or death,

damage to the unit, or incorrect operation.

FPHE

Frick Penthouse Evaporators

Form 200.110-IOM (FEB 2023)

Installation – Operation – Maintenance

File: Service Manual – Section 200

Replaces: None

Distribution: 3, 3a, 3b, 3c

Check www.FrickCold.com for the latest version of this publication.

200.110-IOM (FEB 23)

Page 2

FPHE Frick Penthouse Evaporators

Installation - Operation - Maintenance

Indicates an imminently hazardous situation that, if not avoided, results in death or serious in-

jury.

Indicates a potentially hazardous situation or practice that, if not avoided, results in death or

serious injury.

Safety precaution denitions

Indicates a potentially hazardous situation or practice that, if not avoided, results in damage to

equipment and/or minor injury.

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

DANGER

WARNING

CAUTION

NOTICE

Contents

Read before proceeding .................................................... 3

Changeability of this document ........................................ 3

General information

Receiving the shipment .....................................................4

Inspecting the shipment ............................................... 4

Checking for a leak .......................................................4

Transit damage and shortage claim .............................. 4

Safety ................................................................................4

Warranty and technical support ........................................ 5

Pre-installation requirements ............................................5

Training and safety considerations .............................. 5

Preliminary site layout considerations .......................... 5

Preliminary eld piping design considerations ............. 6

Electrical power ............................................................6

Refrigeration ................................................................ 6

Condensate drain .........................................................6

Installation

Installation safety guidelines .............................................8

Electric ......................................................................... 8

Fans ..............................................................................8

Vibration and noise ......................................................8

Support structure information .......................................... 8

FPHE supported by roof curb ............................................ 9

Suggested roof to curb nish ............................................ 9

Roof curb ........................................................................10

Preparing the roof curb .............................................. 10

Rigging the roof curb..................................................10

Setting the roof curb ..................................................10

FPHE unit ....................................................................... 11

Preparing the FPHE unit .............................................11

Rigging and lifting the FPHE unit ................................ 11

Setting the FPHE unit ................................................. 12

Setting the FPHE unit without a roof curb .................. 12

Installing optional sloped roof paneling ......................13

Installing the roof membrane ..................................... 13

Sealing the FPHE enclosure ........................................ 15

Discharge air plenum ...................................................... 16

Preparing the discharge plenum ................................. 16

Installing the discharge plenum .................................. 16

Electrical ......................................................................... 17

120 V service power ..................................................17

Refrigeration ................................................................... 20

Refrigerant piping ...................................................... 20

Flooded surge vessels support ................................... 20

Evaporator condensate drain piping ........................... 20

Operation

Start-up ..........................................................................21

Before start-up ........................................................... 21

Maintenance

Unit exterior ...................................................................22

Door heater replacement ................................................ 22

Coil maintenance ............................................................ 23

200.110-IOM (FEB 23)

Page 3

FPHE Frick Penthouse Evaporators

Installation - Operation - Maintenance

Read before proceeding

Use the information in this manual to safely and correctly

install, operate, and maintain the Frick Penthouse Evapo-

rator (FPHE).

Frick strongly suggests that personnel become fully fa-

miliar with this manual before operating or working on a

FPHE unit.

After installing the unit, the relevant personnel must

correctly connect it to an appropriately designed and

installed refrigeration system. The engineering plans, pip-

ing layouts, and any other relevant design and installation

material must be detailed in accordance with local codes

and applicable industry standards and practices.

Rig and install units as outlined in this manual. Review

these procedures in detail before the actual rigging

operation to acquaint all personnel with the procedures.

If you have any questions or comments about this manual,

call your sales representative.

NOTICE

This manual, in combination with the applicable

cooling coil data, unit G&A drawing, unit electrical

drawing, roof curb drawing, and discharge plenum

drawing, provides the information necessary to safely

install and start up a Frick FPHE unit. Due to the

possibility of customization associated with the FPHE

product line, there may be areas beyond the scope

of this manual. If there are any questions about a

special application lacking the required information,

contact the installing contractor or your local Frick

sales ofce.

Changeability of this document

In complying with Johnson Controls® policy for continu-

ous product improvement, the information contained in

this document is subject to change without notice. While

Frick makes no commitment to update or provide current

information automatically to the manual owner, that in-

formation, if applicable, can be obtained by contacting the

nearest Frick Factor or the nearest Frick Sales ofce.

It is the responsibility of operating or service personnel to

verify the applicability of these documents to the equip-

ment in question. In case of doubt as to the applicability of

these documents, then before working on the equipment,

they need to verify with the owner whether the equipment

has been modied and if current literature is available.

WARNING

External wiring is not to be connected inside an

FPHE factory mounted electrical panel unless spe-

cically indicated as required eld wiring on the

Frick electrical drawings provided. Devices such as

relays, switches, transducers and controls may not

be installed inside the Frick FPHE electrical panel.

No external wiring is allowed to be run through the

Frick FPHE electrical panel. All wiring must be in

accordance with Frick published specications and

must be performed only by qualied Frick person-

nel. Frick will not be responsible for damages or

problems resulting from improper connections to the

controls or application of improper control signals.

Failure to follow this will void the manufacturer’s

warranty and may cause serious damage to property

or injury to persons.

200.110-IOM (FEB 23)

Page 4

FPHE Frick Penthouse Evaporators

Installation - Operation - Maintenance

General information

Receiving the shipment

Inspecting the shipment

Do not accept the delivery until you inspect the shipment

on arrival. This is to ensure that all required parts are

present and free of shipping damage. Unpack all items and

compare them with the shipping lists. Contact your sales

representative to report any missing items.

Signature acceptance of equipment implies that the FPHE

unit and all loose components are complete and free from

defects.

Inspect the following parts:

• Roof curb

• Discharge plenum

• Enclosure plugs for the lifting lug locations

• Transition ducts

• Roof ashing

• Miscellaneous hardware

• Weatherproof membrane

• Trim pieces

In addition, check the motor supports, fan, and fan guard

fasteners for tightness. Some fasteners may have loosened

during transportation.

Checking for a leak

Check the coil to verify that the internal gas holding

charge remains intact (15 psi to 25 psi). Maintain this

charge until connecting the refrigerant piping to the unit.

A coil that does not have a charge may have been dam-

aged during transit.

If the charge is not present when the unit is received, you

must pressure test the coil with dry nitrogen gas to con-

rm that it is free of leaks. To leak check the unit, com-

plete the following steps:

1. Install a pressure gauge with a range of 200 psi to

400 psi.

2. Apply a 100 psi to 150 psi charge of dry nitrogen.

3. Hold the charge for 24 hr and observe any signicant

changes in pressure.

Note: The nitrogen charge may change 1 psi to 2 psi for

each 10°F change in temperature.

Transit damage and shortage claim

The consignee must make all damaged freight claims. This

is an ICC requirement. Request immediate inspection by

the agent of the carrier and ensure that all the correct

documentation is completed. Send a copy of the damage

claim to the Frick Service and Warranty department.

Send shortage claims directly to the Frick sales represen-

tative and the Frick factory sales department.

For either claim, include the FPHE unit model number, the

serial number, and the Frick sales order number. Refer to

the FPHE unit nameplate for all of this information.

Safety

Because penthouse evaporator installation, operation, and

maintenance involves operating at high speed and high

voltage, safety is a top priority.

The customer is responsible for providing qualied and

trained personnel to install and operate the equipment.

Consult all local building, occupational safety, electrical,

gas, and other codes applicable to the installation.

A variety of optional safety features are available from

the manufacturer. It is the responsibility of the owner to

determine if the unit is equipped with all of the safety

devices required for the particular application.

Be aware of the following safety considerations:

• Accessibility of the equipment to non-service

personnel.

• The provision of electrical lockout switches.

• Maintenance procedures.

• Automatic control sequences.

CAUTION

Users and installers of this equipment should be aware

of all recommended safety procedures and information

such as AMCA publication 410-90 Safety Practices.

CAUTION

Never open an access door while air unit is in operation.

CAUTION

A fan, even though locked out electrically, can rotate

in a seemingly insignicant air ow. During mainte-

nance the fan blades should be secured to restrict

rotation. Verify that the restrictive device is removed

before putting the fan back into service.

CAUTION

Equipment wired to automatic control devices may

start without warning, resulting in personal injury or

property damage. In many instances, a unit will have

multiple elec trical connection points. To prevent un-

foreseen start-up before beginning work on an FPHE

unit, always lock out all power supplies.

CAUTION

Always replace any protective covers removed for

servicing.

CAUTION

Always replace bolts or locks on latches of access

doors that provide access to areas with moving

parts. This mechanical protection from moving parts

is required by UL 1995.

200.110-IOM (FEB 23)

Page 5

FPHE Frick Penthouse Evaporators

Installation - Operation - Maintenance

CAUTION

A number of additional safety issues are discussed

throughout the manual. Read the complete manual

before installing, operating, or servicing the equipment.

Warranty and technical support

NOTICE

For warranty support with the Frick FPHE unit, con-

tact Frick Service at 717-762-2121 and choose Option

4 for Tech Services, or visit www.frickservice.com.

Pre-installation requirements

Training and safety considerations

The Frick FPHE evaporator design uses the nest materi-

als and corrosion protection to deliver dependable and

consistent cooling for coolers and freezers. To ensure the

longest possible system life and dependable, consistent

performance, follow the instructions and guidelines in this

manual.

CAUTION

Frick suggests that only experienced industrial re-

frigeration contractors, operators, and maintenance

technicians be used to install, operate and maintain

the FPHE unit. Before working on the FPHE unit, it is

further recommended that they be provided formal

training on the FPHE’s design and features that in-

corporates reading and understanding this manual.

Installing, operating, and maintaining the Frick FPHE unit

involves rotating machinery operating at high speed and

high voltage. Normal operations and maintenance pro-

cedures may require working at elevations, entry into

enclosed spaces, and the use of hand and power tools. As

a result, safety is the top priority.

Frick suggests that every site installing an FPHE unit ana-

lyze and develop an installation-specic safety regime that

takes into account specic site and unit features, person-

nel qualications, hazard identication, and other safety-

related considerations.

NOTICE

Congure all power switches and controls to provide

an open, safe circuit before and during maintenance

pro cedures, until the system is cleared by manage-

ment for normal online operations. For extended

shutdowns, it is recommended that a qualied tech-

nician remove fuses from fused-disconnect panels

or otherwise open the circuit in an accepted, secure

manner.

Frick suggests incorporating the following operational-

safety elements into every client's FPHE safety require-

ments and safety program.

Fans: all fan covers, guards, and shaft retainers, if any,

must be in place before applying power to an FPHE unit.

Always disengage and lock out power before allowing

interior inspections. To prevent foreign objects from being

sucked into rotating fan blades, never allow operation with

the doors open.

Enclosed space inspections: the inspection of coils, drain

pans, guards, or other components in an enclosed space,

requires machinery lockout and another colleague to look

out, at a minimum. Consult your internal safety policy and

OSHA requirements for additional safety procedures.

Vibration and noise: discontinue or stop machinery that

emits unusual vibration and noise. Investigate and identify

the source of the disturbance and correct before testing or

placing the system back in operation.

Wet surface precautions: poorly maintained and wetted

machinery requires care to avoid electrical shocks from

inadequate or loose eld wiring and connections. All per-

sonnel must lock out and tag machinery before working on

the unit. Correct safety precautions such as using insulat-

ing soles and gloves and a trained colleague to look out

are indispensable.

Ice formation in cold weather can present slip and fall

hazards around a penthouse unit. Ensure ice-related safety

procedures are mandatory when the daily ambient tem-

perature falls below 40°F.

FPHE units operates in a continuous-duty capacity so it is

important that unit installers correctly locate, install, and

connect the units in the eld. It is also imperative to ad-

equately size and correctly install the electrical power and

control wiring, refrigerant lines, and air duct.

Preliminary site layout considerations

Locate all FPHE units for accessibility on the roof and

adequate air ow in and out of the cold space. The Frick

FPHE enclosure has two access doors, one on either side

of the unit. Ensure there is access for service and mainte-

nance to both of these locations.

Air is drawn into the FPHE unit along one side, enter-

ing upward through the bottom of the unit. Colder air is

discharged downward along the opposite side of the unit.

Adequate free ow area must be available for returning air

to enter the bottom of the FPHE unit. Excessive restriction

reduces air ow and in turn the cooling capacity of the

FPHE unit.

It is the owner’s responsibility to correctly locate the FPHE

unit in consultation with a qualied engineer before laying

out structural supports and installing the penthouse unit.

Ensure Frick FPHE units are uniformly supported around

the perimeter either by roof curb or building structural

steel under roof decking.

200.110-IOM (FEB 23)

Page 6

FPHE Frick Penthouse Evaporators

Installation - Operation - Maintenance

Preliminary eld piping design considerations

Before nalizing the refrigerant piping plans for the new

FPHE unit, discuss related plans for potential expansion of

the refrigeration system and building with your refrigera-

tion system designer and Frick sales representative. Incor-

porating appropriate pipe and opening sizes now, in light

of existing and future needs, is often the most economical

long-term strategy.

CAUTION

Avoid hydraulic lockup caused by trapped liquid.

When there is an increase in ambient temperature

and liquid refrigerant conned in rooftop piping, the

resulting expansion pressure has the potential to

cause refrigerant lines to burst.

CAUTION

All Frick FPHE units require strongly supported and

properly anchored eld piping. NO eld piping is to

be supported by the FPHE unit enclosure itself. Wind

loading, and temperature variation must be consid-

ered to allow for movement between the rooftop

unit, adjoining building, and eld piping. A qualied

cooling system design engineer should provide nal

eld-piping plans and specications.

Electrical power

Frick FPHE units usually require both 120 V/single-

phase/60 Hz and three-phase electrical power.

• The 3-phase power drives the evaporator fans. Frick

may or may not supply factory-installed switch gear

and disconnects. Consult the specic order details when

designing the electrical power system.

• Separate 120 V single-phase power is required to both

sides of the FPHE unit for internal service light, GFI

convenience outlet, and heated freezer door seals.

• An additional 120 V power circuit may be required to

heat trace the condensate drain pan outlet and p-trap.

• The refrigeration system design engineer must provide

separate electrical controls and instrumentation infor-

mation.

Refrigeration

Frick equips the FPHE unit with a cooling coil based on a

specied refrigerant and a specied type of liquid feed.

Each cooling coil is shipped with a low-pressure nitrogen

charge to prevent moisture from collecting inside the

circuits.

It is the refrigeration design engineer’s responsibility to lay

out the refrigerant piping and control valves to service the

FPHE cooling coil. Do not use the FPHE unit or the cooling

coil pipe stubs to support the refrigerant piping system.

The FPHE insulated enclosure is not designed to support

concentrated roof loads. If the cooling coil is serviced by a

ooded surge drum, unit installers must provide separate

supports to transmit the weight of the vessel and piping to

the foundational structure.

Condensate drain

Each FPHE unit is designed with a condensate drain pan

under the cooling coil. The drain pan is internally sloped

to channel the water to the connection end of the FPHE

unit. A threaded male pipe stub is run to the outside of the

FPHE enclosure. Pipe this stub with a p-trap to prevent air

migration through the drain line. In addition, environmen-

tal conditions may make it necessary to heat trace this

drain line.

When planning the installation of the penthouse unit, the

elevation of this drain connection and the need for a drain

trap are often important when determining the unit sup-

port and the possible benets of a roof curb.

200.110-IOM (FEB 23)

Page 7

FPHE Frick Penthouse Evaporators

Installation - Operation - Maintenance

Figure 1: Standard FPHE arrangement

Callout Description Callout Description

A Field junction box power connection next to

each door for 120 V/1 ph/60 Hz

F Lifting lug opening removable plug, Type 4.

Four in total

B Canopy over each door G 110 V duplex GFI outlet next to each door

C Termination bar for roof membrane H Light switch next to each door

DRefrigerant connection, order specic I Solid service door

E Approximately 9.75 in. - -

200.110-IOM (FEB 23)

Page 8

FPHE Frick Penthouse Evaporators

Installation

Installation safety guidelines

Electric

Check the unit nameplate to verify that the power be-

ing provided corresponds with the requirements of the

equipment.

Ensure

that only qualied electricians install

the power supply and xtures, and that they conduct all

electrical work in accordance with local codes.

All electrical conduits entering the FPHE enclosure walls

must be non-metalic inside the wall to minimize heat

transfer. After the electrical conductors are run inside

those conduits, thoroughly seal the inside of the conduits

with electrical putty or caulk to prevent moisture migra-

tion. Failure to follow these guidelines may result in the

accumulation of water or ice in the electrical boxes and

conduits inside the FPHE.

It is important to congure all power switches and controls

to provide a safe circuit. Poorly installed, maintained, or

wetted machinery could lead to electrical shocks.

Fans

Ensure all fan covers, guards, and shaft retainers, if any, are

in place before applying power to the unit. Always turn off

electrical power and use lock-out/tag-out procedures be-

fore interior inspections, testing, or starting the FPHE unit.

Vibration and noise

Immediately stop machinery that emits unusual vibra-

tion or noise. Investigate the source and resolve the issue

before placing the unit back in operation.

Support structure information

The Frick FPHE unit consists of the penthouse enclosure

assembly and possibly a roof curb for mounting. You must

anchor these components to a suitable support structure

such as building structural steel or roof decking. Ensure

the structure is capable of supporting the dry shipping

weight of the unit plus any refrigerant within the coil; any

frost or ice that may accumulate on the coil, the weight

of any ancillary items attached to the unit enclosure, such

as electrical panels, and any live loads imposed due to

operating fans and moving air. The weight that the sup-

port structure must support and the associated anchoring

requirements also varies as a result of externally imposed

loads, such as expected snow or ice buildup, seismic, and

wind loading.

Ensure the structure is designed for at least 110% of the

operating weight of the FPHE unit distributed as a uni-

form load around the perimeter of the enclosure support

surface.

Ensure the support structure where you are locating the

FPHE units is rigid and level, and shim if necessary. Place

shims, as required, at intervals no greater than 3 ft apart

and do not use them to compensate for signicant surface

slope. Ensure the sum total of any individual stack of shims

does not exceed 1/2 in. and only use them to compensate

for surface irregularities.

Secure the FPHE unit to the support structure. It is the

installer’s responsibility to ensure the unit is secured in

accordance with applicable building and earthquake codes.

If the support structure is in the form of parallel steel

beams, size the beams in accordance with standard engi-

neering practices.

Figure 2: FPHE supported directly on building steel

Callout Description Callout Description

A FPHE unit D Supporting steel

B Steel base E Roof or insulation, existing

C Load bearing location F Roof ashing and insulation, completed by unit

installers

200.110-IOM (FEB 23)

Page 9

FPHE Frick Penthouse Evaporators

Installation

FPHE supported by roof curb

Figure 3: FPHE supported by roof curb

Callout Description Callout Description

A Penthouse panels C Roof curb upper lip

B Gasket material provided with the roof curb D Roof curb height

Suggested roof to curb nish

Figure 4: Suggested roof to curb nish

Callout Description

A FPHE base frame

B Roof curb

C Building steel or roof deck

D Roof insulation, completed by unit installers

ERoof ashing and insulation, completed by

unit installers

F Seal strip, completed by unit installers

Note: Roof ashing to extend up to the seal strip covering

the FPHE enclosure to the roof curb joint.

Figure 5: FPHE support layout dimensions, in.

Table 1: FPHE support layout dimensions, in.

Model A AA B BB

R-201 88 96 89.5 9 7.5

R-302 144 152 89.5 9 7.5

R-422 144 152 93.5 101.5

R-453 168 176 89.5 9 7.5

R-603 168 176 99.5 107.5

R-703 168 176 99.5 107.5

R-604 216 224 89.5 97.5

R-734 216 224 93.5 101.5

R-904 216 224 99.5 107.5

R-755 243 251 93.5 101.5

R-905 243 251 99.5 107.5

R-1005 249.5 257.5 99.5 107.5

R-1155 249.5 257.5 99.5 107.5

R-1245 249.5 257.5 99.5 107.5

Note: Dimensions assume 4 in. thick insulated enclo-

sure panels. Add 2 3/4 in. to the above AA and BB

dimensions if 5 3/8 in. thick panels are used.

200.110-IOM (FEB 23)

Page 10

FPHE Frick Penthouse Evaporators

Installation

Roof curb

Preparing the roof curb

Unless specifically indicated on the project drawings, Frick

provides the roof curbs for use with the FPHE unit fully

assembled.

1. Check the roof curb for any damage that may have oc-

curred during shipment: corner welds, bottom resting

surfaces, upper FPHE unit mating surfaces, and anges.

2. Check the roof curb for square by comparing the two

diagonal measurements.

3. Check that the rooftop mounting surface and any

opening in decking and insulation is adequate for ac-

cepting the curb dimensions.

4. Locate the gasket material that is shipped loose with

the curb. Apply this to the curb just before setting the

FPHE unit on the curb.

Rigging the roof curb

The roof curb is provided with an interior perimeter ange

that contains slotted holes for attaching the FPHE unit to

the roof curb, in addition to a number of circular holes

near each corner. Use these circular holes to attach rig-

ging clevises for lifting the curb into place as shown in

Figure 6.

Figure 6: Lifting holes in roof curb

Callout Description

A Lifting hole

Figure 7: Roof curb load bearing region

Callout Description

A Insulated panels

B Potential stitch weld location

C Support structure

D Load bearing point

NOTICE

If you are not setting the FPHE on a roof curb, pro-

ceed to Rigging and lifting the FPHE unit.

Setting the roof curb

The roof curb is designed to set directly on support steel.

The load bearing region of the roof curb is the interior

perimeter of the curb as indicated on Figure 7.

The roof curb must be supported uniformly around the

entire interior perimeter. Apply shims as necessary. Space

shim packs no more than 36 in. apart and do not exceed

1/2 in. thickness. Do not use shims and blocking to adapt a

curb to roof pitch.

It is the responsibility of the installing contractor to secure

the roof curb to the supporting structure in accordance

with local building codes. If welding is used, place the

light stitch welds along the outside perimeter of the 11

gauge lip as shown in Figure 7. Welding along the inside

perimeter may result in damage to the thermal barrier and

insulation.

200.110-IOM (FEB 23)

Page 11

FPHE Frick Penthouse Evaporators

Installation

WARNING

When lifting the FPHE unit, weight may not be

evenly distributed causing the unit to be unbalanced

or top heavy. See Figure 10 for recommended lifting

procedure.

Rigging and lifting the FPHE unit

1. Using the lifting lugs provided, attach spreader bars

and rigging as shown in Figure 10. Spreader bars are

required to prevent damage to the cabinet and pro-

truding components during a lift.

2. Cooling coil is not centered inside the enclosure and is

likely offset the center of mass. Adjust the tension in

each line for the correct load distribution.

Figure 10: Standard rigging conguration

Callout Description

A Lifting point

B Fan side

C Center of gravity, approximate location

D Spreader bar

Lift the air unit only in an upright position. Never lift or

move a unit on its side or upside-down.

3. After the FPHE unit can be lifted, remove the protective

sheet metal angles under the perimeter of the enclo-

sure. If mounting the unit on a roof curb, keep the bolts

and nuts because these are required to secure the

FPHE unit to the roof curb. See Figure 11. If mounting

the FPHE unit directly on structural steel proceed to

Setting the FPHE unit without a roof curb.

FPHE unit

Preparing the FPHE unit

The FPHE unit arrives fully assembled as a single unit.

1. Inspect the FPHE unit enclosure for any visible damage.

2. The FPHE unit is shipped with lifting lugs in place.

These lugs may be used to secure the unit during

transport as well. Ensure that all of the lug mounting

bolts are in place and secure before attempting to lift

the unit onto the roof. See the following gure.

Figure 8: Standard lifting lug for mounting bolts

Callout Description

A Standard mounting bolt for the lifting lugs (4)

WARNING

When lifting, use all lifting lugs to avoid damage and/

or personal injury. Lifting lugs are shown in Figure 8.

There are a number of items that may be shipped loose

inside the FPHE unit. Identify and inspect these items be-

fore lifting the unit into place. See the following gure.

Figure 9: Ship loose items placed in fan side of FPHE

200.110-IOM (FEB 23)

Page 12

FPHE Frick Penthouse Evaporators

Installation

Figure 11: Enclosure protective perimeter base

Callout Description

A Protective base

B Base

Note: Store attachment bolts and nuts inside the base

CAUTION

If you do not rig or lift the unit carefully, you could

damage the unit, hurt yourself or others.

Setting the FPHE unit

1. When setting the FPHE unit on a roof curb, rst apply

two strips of 1 7⁄8 in. wide neoprene gasket material

around the top surface of the roof curb. Position the

inside strip of gasket material a third of the way inside

the load bearing point of the mating surface. Ensure

the outside strip is approximately 1/4 in. from the out-

side edge of the curb nailer. See the following gure.

Figure 12: Applying roof curb gasket

Callout Description

A Two 1 7/8 in. x 1/2 in. neoprene gaskets

B Support structure

C Load bearing point

2. As the FPHE unit is being positioned overhead, it may

be benecial to spray the neoprene gasket with a light

mist of water. This allows slight adjustments while

the FPHE unit is aligned for nal positioning. The use

of drift pins also facilitates positioning the FPHE unit

on the roof curb so that the attachment bolts can be

installed easily.

3. Install the ange bolts around the inside perimeter

ange. Insert the bolts downward with the nuts being

installed on the bottom side of the ange. Space the

attachment bolts uniformly around the inside perim-

eter ange with no more than 14 in. between adjacent

bolts. See Figure 3 and Figure 6.

Setting the FPHE unit without a roof curb

1. When setting the FPHE unit without a roof curb it is

unnecessary to apply a sealing gasket. The FPHE base

structure may be set directly on supporting steel.

2. The FPHE base needs to be supported uniformly around

the entire interior perimeter. Apply shims as necessary.

Space shim packs no more than 36 in. apart and do not

exceed 1/2 in. thickness. Do not use shims and blocking

to adapt the FPHE base to a pitched roof.

Figure 13: FPHE set directly on site structural steel

Callout Description

A Factory-supplied bolt holes

B Insulated panels

C Load bearing point

D Support structure

E Potential weld location

3. It is the responsibility of the installing contractor to se-

cure the FPHE unit base to the supporting structure in

accordance with local building codes. If welding, place

light stitch welds along the inside perimeter of the base

lip as shown in Figure 13. Alternatively, the interior

base lip also has factory-supplied holes through which

bolts may be used to secure the unit.

200.110-IOM (FEB 23)

Page 13

FPHE Frick Penthouse Evaporators

Installation

Installing optional sloped roof paneling

For sloped roof applications, refer to the suppliers

instructions for installing sloped roof paneling. Install the

paneling before the roof membrane.

Installing the roof membrane

You must protect the FPHE units with a membrane roof

cover, which consists of the following components:

• Membrane roof cover

• Termination trim, plastic

• Black Phillips head metal screws

• 2 in. truss plates

• Caulking

Before you install the membrane, keep the following points

in mind:

CAUTION

The membrane is very slippery when wet.

• Keep sharp objects such as nails or screws off the

roof. Someone stepping on them could puncture the

membrane.

• Do not allow hot objects to touch the membrane.

• You can temporarily repair any punctures or holes that

occur during installation with duct tape or caulking.

However, you need to make any nal repairs using a

heat gun.

For correct weather protection, complete the following

steps:

1. Unpack the membrane roll, being careful not to cut the

membrane.

2. Unroll the membrane over the roof area, ensuring the

tabs are on the underside and that the roof area is free

of debris.

3. Maneuver or shift the membrane so it ts squarely over

the roof area, allowing equal amounts of membrane

to overhang at least 6 in. on the edges of the roof. In

windy conditions, place a heavy object, such as con-

crete blocks or tires, around the perimeter to keep the

wind from lifting the membrane.

4. After centering the membrane on the roof, either fold

or roll the membrane back towards the center of the

roof so the underside tabs are exposed. The roll or fold

must be parallel to the factory seam and tab.

5. Stop rolling or folding when you reach the tab going in

the opposite direction.

6. Begin to roll or fold the membrane back until a tab is

exposed and the tab is at on the roof deck.

7. Install the 2 in. truss plates along the fastening tab us-

ing the Black Philips screws, keeping them spaced 12

in. O.C.

Note: Do not screw directly over a ceiling panel seam.

Stay 6 in. away from any of these seams.

8. Continue to roll the membrane until the next tab is

exposed and in place, ready for fastening.

9. Pull the tab tightly to reduce any wrinkle that may oc-

cur. After pulling the tab, hold it in position until you

can secure it with a couple of fasteners.

10. Install the fasteners along the tab 12 in. O.C.

11. Complete steps 9 and 10 for every tab.

12. Hold the membrane that is overhanging the edge of the

roof tight and install the termination bar at least 5 in.

below the horizontal roof. If the termination bar has a

caulking lip, ensure the lip is on the upside.

13. Fasten the termination bar using the pilot holes with

the Black Philips head screws.

Figure 14: Fastening the termination trim

14. After attaching all termination bars, trim any excess

membrane that is exposed under the termination bar

with a sharp knife, using the bottom edge of the bar as

a cutting guide.

15. Caulk the top edge of the termination bar.

200.110-IOM (FEB 23)

Page 14

FPHE Frick Penthouse Evaporators

Installation

Callout Description Callout Description

A Fastening tab F Factory welds, staggered equidistant

between factory welds of adjacent roles

27 in. O.C.

B Approved fastener with barbed stress plate G Approved fastener with barbed stress plate

approximately 27 in. O.C.

C Factory weld H Side lap roll to roll minimum 4 1/2 in.

D Paneled roll I Side lap

E Factory tab - -

Figure 15: Membrane roll out and fastener placement

200.110-IOM (FEB 23)

Page 15

FPHE Frick Penthouse Evaporators

Installation

Sealing the FPHE enclosure

The FPHE enclosure insulated panels may have shifted

during transit. It is important to inspect all panel seams

and reset the cam-locks as necessary.

1. Inspect all panel seams to ensure that the sealing gas-

ket is visibly compressed. If it is not, remove the snap

plugs at the cam-lock, use an allen wrench to com-

pletely unlock the cam latch and then reset and relock

it. Reinstall the snap plugs.

2. Inspect all panel corners to be sure that adjacent pan-

els are not racked; loosen the required cams, adjust the

panels then reset and relock the cam-locks.

3. Although the FPHE enclosure is completely sealed

when assembled at the factory, additional caulk may be

required on either interior and exterior panel seams.

Frick suggests the use of a silicone DOW RTV-732 food

grade caulk for any interior seams. Use rainbuster 1200

for resealing any external seams.

4. Use caulking or insulating sealant to nish the exterior

joint between the FPHE enclosure and the roof curb

before the surrounding roong is sealed to the unit

5. Inspect each of the FPHE enclosure freezer door rain

hoods. Tighten any loose attachment screws and caulk

as necessary.

6. Remove all of the lifting lugs by removing the mounting

bolts in each one. Discard the lifting lugs and bolts.

7. Insert the lifting lug plug into the opening. Take care

not to damage the inner and outer seal strips. Attach

the plug into place using the screws provided. Plug all

of the factory-drilled screw holes.

8. Seal the building roof insulation to the FPHE enclo-

sure or the roof curb. Use a cant or radius around the

perimeter of the enclosure or curb.

For installations involving a roof curb, it is necessary to

use roof membrane or ashing to cover the exterior of the

curb including the curb to FPHE enclosure joint. Ensure the

nal nish includes a caulked seal strip as shown in Figure

If you are not using a roof curb, the location of the seal

strip is subject to the discretion of the installer that installs

and seals the roof.

Figure 16: Lifting lug enclosure plug

11 in.

1 1/2 in.

9 1/2 in. max

Callout Description

A1/8 in. pre-drilled holes for eld mounting

B Acrylume stucco cover plate

C Double-beaded gasket

D High-density urethane perimeter

200.110-IOM (FEB 23)

Page 16

FPHE Frick Penthouse Evaporators

Installation

Discharge air plenum

The discharge air plenum and interconnecting circular

ducts components ship separately from the FPHE unit.

It is intended that the FPHE discharge air plenum be sup-

ported independently of the FPHE unit or its supporting

roof curb.

Preparing the discharge plenum

1. Inspect the air discharge plenum for any obvious ship-

ping damage.

2. Install a prefabricated circular duct transition to each

plenum air inlet orice using tapper screws. The FPHE

fans are provided with a transition duct attachment.

See Figure 18.

Figure 17: Fan discharge nozzle integral to module

3. The interconnecting duct material is provided as pieces

of at stock. Take one piece of at stock, roll it into a tube

that is approximately 33 in. in diameter. Secure it with a

strap to prevent it from unrolling. Stand the roll inside one

of the plenum air inlet openings. Repeat this process for

each fan discharge duct.

Installing the discharge plenum

1. Lift the plenum into position taking care that the coiled

duct material does not get damaged. Mount the

plenum using support rods as indicated on the Frick

FPHE plenum drawing. See Figure 19 for an example.

Note that each plenum hanger rod must pass through

the upper alignment bracket and support the assem-

bly by the lower bracket. Use the double nuts jammed

together to secure the nal adjustment.

2. Each fan discharge must be connected to the plenum

using the coiled at stock material. Carefully measure

the distance between the FPHE fan discharge nozzle

and the plenum transition duct inlet. Mark the outside

of the coiled duct at stock so that approximately 50%

of the excess is available for insertion and attachment

into the fan discharge nozzle. Ensure that the remaining

50% is available to extend into the plenum transition

for attachment.

3. Carefully lift the coiled duct material and insert it into

the fan discharge nozzle. Allow it to uncoil and attach

it to the fan nozzle using tapper screws. Install screws

spaced approximately 18 in. apart.

4. Attach the coiled duct material to the lower plenum

duct transition assembly using tapper screws, again

spaced approximately 18 in. apart.

5. Secure the vertical duct seam using tapper screws

spaced a maximum of 12 in. apart.

Figure 18: Discharge plenum assembly

Callout Description

A Transition duct assembly

B Discharge plenum

200.110-IOM (FEB 23)

Page 17

FPHE Frick Penthouse Evaporators

Installation

Electrical

The Frick FPHE as standard does not provide high voltage

power wiring to fan motors.

An optional feature that is provided: Individual motors

wired to the unit exterior and placed in a NEMA 3R or 4

power distribution panel.

Other options are available, please refer to order-specic

wiring diagrams.

See Figure 23 and Figure 24 for standard suggestions

for wiring multiple parallel fans. When power wiring the

fans on the installation site, it is the installing contrac-

tor’s responsibility to ensure that the electrical design and

installation meet the applicable codes.

For FPHE units with factory wired motors, refer to the

order-specic wiring drawings provided.

120 V service power

Each Frick FPHE units is provided with internal lights,

exterior light switches and external convenience outlets

located by each access door. For FPHE units designed to

operate below 32°F, the access door seals are also heat

traced. Each access door and associated components are

internally wired and require 120 V eld supplied power to

an external electrical junction box. See Figure 20.

Figure 19: Standard FPHE 120 V factory-installed ser-

vice wiring diagram

BRONZE TERMINAL

(120 VAC/60 Hz/1Ø POWER)

(GROUND FAULT

CIRCUIT INTERRUPTER)

DOOR

HEAT ER

BACK VIEW

LOAD

GREEN

GRAY

DOOR

FRAME

HEAT ER

SILVER TERMINAL

(NEUTRAL)

LINE

GFCI

BLACK

WHITE

SINGLE

EXTERIOR

SWITCH

RED

WHITE

BLACK

GREEN

VAPOR PROOF

LIGHTON

DOOR FRAME

BLACK

GREEN

WHITE

GREEN

TAN

RED

GREEN

WHITE

BLACK

GREEN GREEN

BLACK

WHITE

FIELD CONNECT

120VAC/60 Hz/1Ø

#12 AWGTHHN STRANDED Cu

GRAY

FIELD CONNECTION BOX

Note: Two independent circuits for each FPHE unit, stan-

dard

NOTICE

The electrical specications information provided

here is standard for each of two tie-in points, one for

each side of the FPHE enclosure.

Figure 20: Electrical specications

Electrical Specifications

120VAC/60 Hz/1Ø

Light and heated door frame

FLA 2.4 amps

GFCI rating

20 amps

Factory-installed wire

#12 AWG THHN stranded Cu

200.110-IOM (FEB 23)

Page 18

FPHE Frick Penthouse Evaporators

Installation

Figure 22: Standard power wiring involving ATL starters

Figure 21: Standard FPHE enclosure indicating 120 V eld power connection

Callout Description Callout Description

A Field junction box power connection next to

each door for 120 V/1 ph/60 Hz

D Light switch next to each door

B Door canopy above each door E Solid service door

C 110 V duplex GFI outlet next to each door

200.110-IOM (FEB 23)

Page 19

FPHE Frick Penthouse Evaporators

Installation

Figure 23: Standard power wiring involving a VFD

200.110-IOM (FEB 23)

Page 20

FPHE Frick Penthouse Evaporators

Installation

Refrigeration

The Frick FPHE unit may be provided with a cooling coil

designed for any direct or secondary refrigerant. Refer to

the original order documentation for specic information.

The FPHE cooling coil is provided with a nitrogen charge.

This charge prevents moisture from migrating inside the

refrigerant circuits, collecting and contaminating the future

cooling system.

CAUTION

Care must be taken when initially opening the ends

of the refrigerant pipes to make eld connections

as injury could occur due to the positive nitrogen

charge.

NOTICE

Once the cooling coil refrigerant piping has been

opened, maintain a dry nitrogen charge in the pip-

ing system if the coil is not charged with refriger-

ant immediately. Failure to do so could result in the

collection of moisture inside the coil circuits and

the possible contamination of the future refrigerant

charge.

Refrigerant piping

CAUTION

The unit connections are not designed to support the

weight of piping, valves, or ttings.

The cooling coil refrigerant connections are weldable pipe

stubs, anges, or threaded pipe caps. The project submit-

tal drawings indicate the coil connections for a specic

unit. It is important to correctly size and orientate the

refrigerant lines servicing the cooling coil in order for the

coil to function correctly.

Refrigeration piping design and line size selection are the

responsibility of the unit installers. Conrm that the system

design parameters comply with the coil design parameters

stated on the certied submittal drawings. Before con-

necting the refrigerant lines to the coil, verify that the pip-

ing and control valves on the unit are correctly supported.

Design all piping to minimize the transfer of vibration to

the unit and allow for thermal expansion of piping.

CAUTION

Avoid hydraulic lockup caused by trapped liquid.

When there is an increase in ambient temperature

around conned liquid, the expansion pressure could

cause refrigerant lines to burst.

When the Frick FPHE unit is provided with hot gas drain

pan heat, the pan coils are not factory-piped to the

evaporator refrigeration piping. Design of the refrigerant

control valve group and the interconnecting pan and coil

piping must be done by a qualied refrigeration engineer.

The required refrigeration piping must be done in the eld

by qualied pipe tters.

CAUTION

Use of a refrigerant other than that stamped on the

nameplates may cause damage to the refrigeration

coils. Coils must not be subjected to higher pressure

than the design pressure stamped on the nameplate.

In ammonia systems, be sure to use refrigerant

grade, not agricultural grade ammonia.

Flooded surge vessels support

The FPHE unit is not designed for ooded operation. The

enclosure and pipe stubs are not designed to support a

ooded surge vessel.

Evaporator condensate drain piping

The cooling coil condensate drain pan is provided with a

male pipe thread (MPT) pipe stub out the end of the pan

and extending through the FPHE enclosure.

Although the height may vary slightly from model to

model, in general the bottom of the drain pan connection

is approximately 9.75 in. above the bottom of the FPHE en-

closure panels. If the unit is mounted on a roof curb, this is

approximately 9.75 in. above the top of the roof curb.

Due to static pressures inside the FPHE unit enclosure, it

is necessary to trap the condensate drain. This is generally

done with a P-trap. It is the responsibility of the installing

contractor to be sure that the condensate water is piped

according to applicable codes.

Figure 24: MPT condensate drain

Callout Description

A Drain pan drain connection

NOTICE

When mounting a Frick FPHE unit directly on building

steel, be sure to allow enough elevation to properly

trap the condensate drain pipe. See the project sub-

mittal drawings for available height.

FPHE units are designed for freezer applications and may

be installed in climates that have low outdoor tempera-

tures during the winter. If either of these conditions apply

it is advisable to provide heat trace of the condensate

drain piping. Consult a refrigeration design engineer for

selection and application of the heat trace product.

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Frick FPHE Penthouse Evaporators Installation Operation and Maintenance Guide

Brand: Frick

Model: FPHE Penthouse Evaporators

Type: Installation Operation and Maintenance Guide

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Frick FPHE Penthouse Evaporators Installation Operation and Maintenance Guide

Frick FPHE Penthouse Evaporators Installation Operation and Maintenance Guide

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