Frick IDC2 Evaporative Condenser Installation Operation and Maintenance Guide
- Type
- Installation Operation and Maintenance Guide
Please check www.jci.com/frick for the latest version of this publication.
Check Unit Before Rigging ....................................................3
Unit Weights.........................................................................3
Anchoring .............................................................................3
Leveling ................................................................................3
Safety ...................................................................................3
Freeze Protection .................................................................3
Location ...............................................................................3
Warranties ............................................................................3
Rigging .................................................................................3
Positive Closure Plate Option ...............................................6
Positive Closure Plate Installation .........................................6
Water Bafes .......................................................................7
Water Bafe Installation .......................................................7
Motor Installation for IDC2-x-7409-x and IDC2-x-7418-x .....7
Sloped Ladder Installation ....................................................8
Installation of the Side Outlet Depressed Sump Box ............8
Platform and Ladder Installation ...........................................8
General ............................................................................... 11
Cleaning ............................................................................. 11
Inspection ........................................................................... 11
Start-up ............................................................................. 11
Water Levels ...................................................................... 13
Inspection & Maintenance .................................................. 13
Inspection & Maintenance .................................................. 13
Fortitude™ Power Train ...................................................... 13
Inspection & Maintenance .................................................. 13
Model Specic Fan Drive System Descriptions ................... 15
Inspection and Maintenance ............................................... 15
Adjustable Motor Base ....................................................... 15
Inspection & Maintenance .................................................. 15
Mechanical Makeup Valve Assembly .................................. 16
Optional Electric Water Level Control Package ...................16
When 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.
Before 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.
must
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.
The 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.
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.
These 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.
All 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.
Please 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.
Refer to 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.
Model Number
H (distance from lift point to
lifting device in feet)
Lower Section
Upper Section/
Single Piece Lift
IDC2-X-0406-X 14 9
IDC2-X-0412-X 16 9
IDC2-X-7409-X 14 10
IDC2-X-7418-X 16 15
IDC2-X-1012-X 16 15
IDC2-X-1212-X 16 13
IDC2-X-1218-X 18 15
Most IDC2 Evaporative Condensers (Except Models IDC2-x-
1218-x) are designed to be lifted in one assembled piece as
shown in . The multipiece lift is shown in and .
• 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
, 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
, 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 ().
• 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
, 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
insert 3/8” self-tapping screws in each hole from the
mechanical section into the middle section and tighten.
• Position the lower section on the unit support and bolt in
place. , and shows the proper rigging and
assembly of units that ship in three-sections.
• Remove any motors or accessories shipped in the cold water
basin.
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.
• 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 .
• 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 , insert 3/8” self-tapping screws in
each hole from the flume box into the basin wall and tighten.
The 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.
• 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.
Lower Bafe
Lower Bafe
Side
Bafe
Side
Bafe
3/8”
3/8” Screw
For multi-cell IDC2 Evaporative Condensers, water baffles join
the air louver sections to prevent leaks. To install the water
baffles, follow the steps below.
• 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.
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.
1/2" Washer
1/2" Lock Washer
1/2" Nut
•
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.
Remove platform and ladder assembly from cold water basin.
Hang preassembled platform by inserting top guide pins into the
fan deck notches as shown in . Secure with
tappers. Assemble lower platform clamps and secure to side of
tower, tightening nuts and bolts as shown in , .
Remove 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.
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.
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:
• 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.
• 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
for more details.
Axial Fan
Fan Guard
Large Access
Door
Motor
Motor Removal
Davit (Optional)
Louvers
Fan Cowl
Coil Connection:
Refrigerant In
Coil
Coil Connection:
Refrigerant Out
Secondary
Pump (Optional)
Primary Pump
Inclined Ladder
(Optional)
Cold Water
Basin
IBC Cross
Bracing (Optional)
Terminal Box
(Optional)
Adjustable
Float
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.
• 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.
• 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
• Prior to seasonal start-up, lubricate the motor base adjusting
screw(s) (see and) 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.
- Initiate the
biocide water treatment program at this time. Refer to
“Biological Control” in the Common Operation & Main-
tenance Manual for more details.
-
: 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.
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.
• 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.
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.
Model Number At Overflow
Level (in.)
At Operating
Level (in.)
All IDC2 models except
IDC2-x-1218-x 11¾” 9”
IDC2-x-1218-x 13½” 10½”
• The makeup valve controls the operating level, which is
maintained at the levels shown in .
• 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.
• 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
.
The IDC2 Evaporative Condenser uses axial fan(s). Thoroughly
inspect the fan for damaged or deteriorated fan blades and
replace the fan as required.
• 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.
• : Check the clearance between the tip of the
blade and the fan cowl. The clearance should be between
1/8” and 1/2”.
• : On hollow blades, the drain hole in the blade
tip should be unobstructed. Tip: Use a piece of wire to probe
the hole.
• : 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°.
• : 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.
• : 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.
• : On initial start-up, run the fan in the manual
position for several minutes and check for any unusual noises
or vibration.
The 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.
Fortitude™ Power Train requires a periodic check of the belt
condition and, when necessary, tension adjustment. The recom-
mended service intervals are as follows:
:
- 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]
- 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 .
- The straight edge should contact all four points as shown
in 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.
- 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]
• : Readjust the tension on the belt.
• : 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.
•
- Place a straight edge along the belt from sheave to sheave
as shown in , or use a tape measure as shown
in 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 and .
Driven Sheave
Driven Sheave Belt
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
Driven Sheave
Driven Sheave Belt
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
- 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 ( and
) 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.
Motor
Adjusting
Bolt
Motor
Adjusting
Bolt
(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. ()
(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. ()
• 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.
Coat the motor base slides and adjusting screws (refer to
and ) twice a year using good quality corrosion inhibiting
grease such as one of those recommended for lubricating the
fan shaft bearings below.
Two 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.
• 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™
• Lubricate the bearings as follows:
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.
: Purge both bearings with new grease
prior to start-up.
: Purge bearings every 2,000 hours of operation
or once every three months, whichever occurs first.
: Purge bearings with new grease
prior to any prolonged storage or downtime.
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.
• 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 .
A 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 .
• 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 . 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.
As 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.
• Mechanical makeup valve assembly
• Optional electric water level control package
Inspect general condition of the unit(2) and check unit for
unusual noise or vibration X X
Inspect cold water basin X X X
Inspect spray nozzles X X X
Drain basin and piping X
Check and adjust water level in basin X X
Check operation of makeup valve X X
Check and adjust bleed rate X X
Inspect unit Finish X
Check belt condition X X
Adjust belt tension(3) X X
Lubricate fan shaft bearings X X X
Lubricate motor base adjusting screw X X X
Check drive alignment X
Check motor voltage and current X X
Clean fan motor exterior X X
Check fan motors for proper rotation X
Check fans for rotation without obstruction X X
Check general condition of the fan X
Check and unplug fan drain holes (hollow blade fans) X
Check fan for uniform pitch X
Check and recoat steel shafts with RUST VETO®XXX
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.
JOHNSON CONTROLS
100 CV Avenue
Waynesboro, PA 17268-1206 USA
Phone: 717-762-2121 • FAX: 717-762-8624
www.jci.com/frick
Form 140.940-IOM (2013-12)
Supersedes: 140.940-IOM (2013-02)
Subject to change without notice
Published in USA • 01/15 PDF
© 2015 Johnson Controls Inc. - ALL RIGHTS RESERVED
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Frick IDC2 Evaporative Condenser Installation Operation and Maintenance Guide
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- Installation Operation and Maintenance Guide
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