140.020-IOM IDSC2 Stainless Steel Evaporative Condenser

This manual contains installation, operation, 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 incorrect operation.

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

IDSC2Stainless Steel Evaporative Condenser

Form 140.020-IOM (JUN 2021) Installation - Operation - Maintenance

File: Service Manual - Section 140Replaces: 140.020-IOM (OCT 2020)Dist: 3, 3a, 3b, 3c

140.020-IOM (JUN 2021)Page 2

IDSC2 Evaporative CondensersInstallation - Operation - Maintenance

Contents

General informationSafety instructions ............................................................ 3Warranty statement .......................................................... 3Terminology ...................................................................... 4

InstallationLocation layout .................................................................. 7Equipment layout .............................................................. 7

Single/multiple unit layouts .......................................... 8Support structure ....................................................... 10

Receiving and inspection................................................. 11 Rigging and hardware .................................................... 11

Rigging the basin section ........................................... 12Rigging the upper casing section ................................ 15

Offloading and assembly ................................................. 18Installing the basin...................................................... 18Fitting the upper casing section ................................. 18Connection joint ......................................................... 19Installing the riser pipe coupling ................................. 19Inlet louvers ................................................................ 19Installing inlet louvers ................................................. 20Removing inlet louvers ............................................... 20

Piping .............................................................................. 21Storage ........................................................................... 21Electrical ......................................................................... 21

Field wiring ................................................................ 21Electrical data ............................................................. 22

Water distribution pump ......................................... 22Basin heaters .......................................................... 22Electronic water level controller ............................. 22Electrical enclosures ............................................... 22Fan motors ............................................................. 22EC motors ............................................................... 22

OperationPre-start up inspection ................................................... 25

General ....................................................................... 25Cleaning ..................................................................... 25Pre-start checks ......................................................... 25Start-up ...................................................................... 25

Cold weather operation................................................... 26Extended shutdown ......................................................... 27Capacity control .............................................................. 27

Normal operation ....................................................... 27Cold weather operation .............................................. 27

MaintenanceMaintenance requirements .............................................. 30

Removing the inlet louver .......................................... 30Removing the drift eliminators ................................... 30Cold water basin ........................................................ 31

Cleaning ................................................................. 31General maintenance ............................................. 31Electronic water level controller ............................ 31

Stainless steel casing and panels ............................... 31Water distribution system .......................................... 32

Maintaining the water distribution system ............ 32Water distribution pump ............................................. 32EC motors................................................................... 32

Water quality and water treatment guidelines ................ 32Bleed or blow down rate ........................................... 32Water treatment guidelines ........................................ 33

Indicates an imminently hazardous situation, which if not avoided results in death or serious injury.

Indicates a potentially hazardous situation or practice, which if not avoided results in death or serious injury.

Safety precaution definitions

Indicates a potentially hazardous situation or practice, which if not avoided results in damage to equipment and/or minor injury.

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

WARNING CAUTION

DANGER

NOTICE

140.020-IOM (JUN 2021)Page 3


General information IDSC2 units are designed to provide optimum efficiency and an extended life when correctly installed, operated and maintained. As a result, it is highly recommended that a comprehensive maintenance schedule be developed and undertaken on a regular pre-determined basis. This manual assists the owner – operator in developing such a schedule.

This equipment is relatively complicated and the instal-lation, operation, maintenance, and servicing must only be carried out by suitable individuals who are qualified to carry out these functions. These individuals must also be familiar with and comply with all applicable governmental standards and regulations pertaining to the function(s).

NOTICEThe type of refrigerant must comply with what is indicated on the submittal drawings and/or unit’s nameplate. Design operating pressures, as indicated on the nameplate, must never be exceeded.

NOTICEEvaporative condensers and fluid coolers and all piping systems must be correctly evacuated before charging the system with refrigerant, to ensure the complete removal of moisture and non – condens-ables from the entire refrigerant circuit.

NOTICEFor evaporative condenser and fluid coolers instal-lations that are installed at or near coastal areas, speak to your Frick representative to confirm the material combination compatibility.

NOTICEIn locations where the fluid within the evaporative fluid cooler could possibly freeze due to ambient temperatures dropping below freezing, drain the fluid from the coil when the ambient temperature is at or below 40˚F.

WARNINGFailure to comply with any of these requirements could result in serious damage to the equipment and/or the property where it is installed, as well as personal injury and/or death to themselves and/or people at the specific location.

Warranty statementFrick warrants the product to be free from defects in workmanship and materials under normal usage for a peri-od of 24 months from the date of purchase (the “Warranty Period”), provided that the product is correctly installed and operated within the recommended limits of Frick’s technical documentation. This warranty is only valid if the product is given normal and proper use and complies with Frick‘s installation and maintenance instructions.

Safety instructions• Only qualified personnel who are familiar with this type

of equipment must carry out installation and mainte-nance.

• Always wear safety glasses, gloves, and head protec-tion when working on the equipment.

• Avoid contact with sharp edges as these can cause painful lacerations.

• All units must be correctly evacuated before charging the system.

• Before undertaking any work, verify that the power is switched off and that the unit is correctly disconnected, locked out, and tagged out.

• Never apply heat to a sealed refrigeration system.

• Keep hands away from fans when the unit is running.

• Ensure all mounting bolts are tight and are the correct length for the specific application.

• Do not remove any of the safety labels from the unit.

• Maintain all safety labels on the unit in good condition. If required replace with new.

WARNINGAlthough halocarbon refrigerants are classified as safe refrigerants, certain precautions must be observed when handling them. Refrigerants can be harmful if inhaled. When released to the atmosphere in the liquid state, refrigerants evaporate rapidly, freezing anything they contact. Use and recover refrigerants responsibly.

Failure to follow this warning may result in personal injury or death.

DANGERAnhydrous Ammonia (NH3):Specific precaution must be adhered to when people are working with or are exposed to Anhydrous Am-monia.

Ammonia is considered a high health hazard because it is corrosive to the skin, eyes, and lungs. Exposure to 300 parts per million (ppm) is life threatening. Am-monia is also flammable at concentrations of approxi-mately 15% to 28% by volume in air. When mixed with lubricating oils, its flammable concentration range is increased. It can explode if released in an enclosed space with a source of ignition present, or if a vessel containing anhydrous ammonia is exposed to fire.

Personal protective equipment must be worn at all times when working with Ammonia. For systems that have an operating charge greater than 10,000 lb a pro-cess safety management program is mandatory. More information on this topic is available from OSHA.

Failure to follow this warning may result in personal injury or death.

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Frick assumes no responsibility for repairs to a product sustaining damages resulting from user modifications, at-tachments to the product, misuse, alteration or negligent use.

Frick, at its option, shall repair or replace, free of charge to the buyer, all components of the product which are, or become, defective during the Warranty Period because of defects in design, workmanship or materials, ordinary wear and tear excluded, provided however, that:

• The product is applied correctly.

• All operating and installation instructions for the prod-uct are complied with.

• System component and piping design is in accordance with state-of–the-art HVAC practice.

• Nitrogen or an inert gas is introduced into the piping during the brazing of the piping installation.

In all instances, industry standard refrigeration practices must be observed and followed by certified refrigeration technicians, mechanics, pipe fitters, design engineers, and any other personnel involved in installing and servicing FRICK products. This warranty shall not include ordinary maintenance or cleaning of the product, defects in the installation of the product or defects in turning and moving parts. This warranty also does not cover physical damage to the product, during transit or otherwise, after purchase of the product but before installation.

The buyer must request repair or replacement of the defective component through a written notice delivered to Frick no later than two business days after the buyer becomes aware of the defect. The buyer must provide Frick with the time and opportunity to make repairs or re-placement. Otherwise, Frick will be released from liability for the defect. Under no circumstances will Frick make any repair or replacement without Frick’s prior written consent, except to the limited extent permitted by Frick’s Service Policy.

Any transport and exchange costs for the repair or re-placement shall be borne by the buyer. Frick shall also not be liable for costs incurred in dismantling or fitting replacement parts or for any independent inspection un-dertaken by the buyer. The buyer shall return any allegedly defective goods, postage or freight paid, to Frick at the address below. Upon receipt of the goods and inspection thereof, Frick shall repair or replace, at Frick’s discretion, the defective components and shall return the same to the buyer, return postage and freight paid. This shall constitute full compliance with Frick’s warranty obligations here-under. Frick accepts no liability for the direct or indirect consequences of any modifications of or repairs to the product made by the buyer or by a third party without the prior consent of Frick. Frick reserves the right to inspect the product for customer abuse during the warranty pe-riod if abnormal claims against the equipment arise.

This warranty shall not apply to Frick products which have been improperly installed or repaired, or altered in any way outside of the manufacturer’s factory or have been subject to misuse, negligence, or accident. Equipment or component parts such as valves, electric motors, electric heaters, and electric accessories manufactured by others

and used as part of or in connection with Frick products, carry only the warranty of the manufacturer thereof. This warranty shall be void if equipment has been subjected to negligence, abuse, misuse, low voltage, corrosive chemi-cals, excessive pressure, accident, outward damage, or hidden damage while in transit, or if operated contrary to the manufacturer’s recommendations.

This warranty applies only to the repair or replacement of the product and/or its components and expressly excludes responsibility for damages not occurring to the product and/or its components themselves and for consequential damages. This warranty is the buyer‘s exclusive remedy, and any implied warranty of merchantability or fitness is excluded. FRICK shall not be liable to the buyer or to any customer of the buyer under any circumstances for any direct or indirect damages, injury to persons or property or any consequential or incidental damages or loss of profits, including, without limitation, loss of refrigerant, loss of stored goods, lost sales, orders, profits or income, either gross or net, arising, directly or indirectly, from defective goods or workmanship or from any other cause whatsoever.

NOTICEFailure to comply with the water guidelines laid out in the water quality and treatment section of this manual voids all related warranty consideration.

TerminologyThe following descriptions are provided to ensure all per-sons working with the IDSC2 equipment are familiar with the terminologies used.

Basin: An assembly located at the base of the unit de-signed to hold a volume of recirculated water while pro-viding connections for the water recirculation pump, drain, and overflow. It is also known as a pan or sump.

Water recirculation pump: Closed-coupled, centrifugal type impeller, with mechanical seal required to circulate a specified flow rate of water over the heat exchange coil(s).

Basin section (induced draft unit): An assembly com-prised of the basin, support columns, air inlet louvers, make-up water connection, and other small parts required for correct unit operation in the field. The basin section is usually shipped separate from the rest of the unit.

Basin section (forced draft unit): An assembly comprised of the basin, support columns, axial motors/fans, enclosure panels, make-up water connection, and other small parts required for correct unit operation in the field. The basin section is usually shipped separate from the rest of the evaporative unit.

Inlet louvers: Enables ambient air to enter the unit at the basin section, while preventing water from splashing out and direct line of sight into the basin during unit operation. There are many different profiles, sizes, and materials of construction.

Sump/strainer connection: Appropriately sized cross-sec-tional area, box or pipe, that is greater than or equal to the suction connection size of the water recirculation pump.

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Strainer: An assembly used to catch large suspended par-ticles in the recirculating water before entering the water recirculation pump. Periodic maintenance is required to keep the strainer clean.

Drain connection: Appropriate sized pipe, usually MPT, extending from the lowest point of the basin to facilitate basin drainage.

Overflow connection: Appropriate sized pipe, usually MPT, extending from the highest point of the basin, con-nection end to prevent spill out from the air inlet louver section and bleed off.

Casing: Perimeter panels of the fan and/or coil section of the unit that house all interior components.

Coil section: An assembly comprised of the heat exchange coil(s), tube sheets (IDSC2 only), casing, and any other structural members required.

Condensing coil: An assembly comprised of tubes, head-ers, connections, and framing, in a specific serpentine arrangement such that circulating refrigerant is condensed when operating with other unit components. It is also known as the heat transfer coil.

Axial fan section: An assembly comprised of the fan(s), fan motor(s), fan nozzle(s), fan motor mount(s), framing, casing, drift eliminators, and water distribution system.

Fan motor mount: An assembly comprised of heavy gauge sheet metal, or structure, to rigidly support a single motor and fan coupled together.

Drift eliminators: Located above the water distribution system to remove entrained water droplets in the leaving air stream.

Water distribution system: An assembly comprised of a water distribution box (or header), water distribution branches (or pipes), water spray nozzles and other minor parts to fasten, seal, and secure all parts in place.

Riser pipe: Water pipe that connects the discharge side of the water recirculation pump to the water distribution box (header) entrance.

Bleed valve: Located on the lower portion of the riser pipe where the discharge side of the valve connects to the top of the overflow drain connection (basin). It is necessary to set the appropriate amount of water “bleed” from the unit to maintain the appropriate cycles of concentration. Also known as a blowdown valve.

Lifting lug: Heavy gauge or multiple heavy gauge plates, joined together, with a large hole to accommodate the attachment of an industrial lifting connection, for example, screw pin shackle. Also called a lifting ear.

Mechanical float make-up assembly: Make-up water valve with armature and circular or pancake type float for basin water level adjustment.

Make-up water connection: Appropriate sized pipe, usually MPT, extending from the vertical louver support at the connection end. This connects to the mechanical float make-up assembly located inside the basin section to facilitate make-up water feed.

The following are possible accessories available for IDSC2 units.

External service walkway package: OSHA approved, self –supporting, external walkway assembly, which includes a vertical access ladder, connected to the unit. This enables access to the unit fan section, eliminators, and water nozzles.

Remote sump: A separate basin, or water tank, located inside a structure that must be kept above freezing tem-peratures. It is used to hold/circulate the water used by the unit instead of the standard basin with pump supplied. A remote sump connection in the unit basin is provided for this option.

Electric heaters: Electric immersion heaters to ensure the basin water does not freeze. Basin water temperature maintained is approximately +40°F.

Electronic water level control: External stand pipe with level sensor elements to control a separate solenoid valve to provide make-up water to the basin.

Motor davit: An assembly connected to the unit used to facilitate lifting the fan and/or motor from the fan motor mount.

Water silencers: Located in the basin above the operating water level. This option reduces the overall noise level of the unit.

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140.020-IOM (JUN 2021)Page 7

IDSC2 Evaporative CondensersInstallation

Installation • Ensure that there is sufficient space for maintenance.

• Ensure that all liquid-carrying components, connec-tions, lines, and all electrical connections and lines are easy to access.

• Ensure that the pipe connection points are visible.

NOTICEFrick suggests using lightning protection rods beside the unit.

If you intend to put the units into a dual or quad position, increase the height of the louver section in the single box sizes to ensure sufficient air intake. See Figure 1 to Figure 4 and Table 1.

WARNINGRefer to the submittal package for specific unit infor-mation.

Equipment layout

Location layoutEnsuring optimum performance of the unit with unobstruct-ed airflow is the responsibility of the installing contractor. In order not to compromise the performance of the unit, loca-tions on open rooftops or at ground level with no obstruc-tions such as walls or adjacent buildings are optimal.

When optimal locations are not possible, position units so that the discharge air is either level or higher than these adjacent obstacles. It is imperative that the location allows for unrestricted airflow into each unit and that there is no recirculation of the saturated discharge air. It is also advis-able that the discharge air is not in the direction of, or in close proximity to, any air intake location for the building’s ventilation system.

The following points are also important to consider when selecting the installation location:

• Place the unit so that you can monitor and control it from all sides at all times.

HL

HL

Figure 1: Single unit

Figure 2: Dual unit, end to end

Figure 3: Dual units, side by side Figure 4: Quad units

HL

HL

140.020-IOM (JUN 2021)Page 8


The IDSC2 is an induced-draft, counter-flow, evaporative-cooled product line consisting of a four-sided air entry configuration. Correctly evaluating equipment location leads to a successful installation, and subsequently, correct operation. This manual provides suggestions for vari-ous layout scenarios including placing equipment in close proximity to an obstruction, such as a wall. In addition, Frick offers both dual and quad unit configurations, which increase the air inlet openings appropriately in comparison to a single unit, to enable the absolute minimum clearance between units. See Figure 5 to Figure 10 for details.

The list of minimum clearances between an obstruction and the air inlet side or end is a guideline only. There are always circumstances, for example prevailing winds, coupled with field experience, which lead to alternate lay-outs that would increase a minimum clearance presented in this manual to achieve correct operation.

It is best practice to place the equipment in a free-field environment when possible, to ensure the required ambi-ent airflow and prevent recirculation of the saturated discharge air. Units on open rooftops or at ground level with no obstructions, such as walls or adjacent buildings, are the optimum location. However, in many instances this is not possible. Positioning in wells, next to high walls, adjacent buildings, occupied areas, or specific enclosures all pose a risk of recirculating the saturated discharge air. This increases the wet bulb temperature of the intake air and compromises the performance of the condenser, which can result in higher condensing temperatures. Use discharge hoods or duct extensions in such instances.

Single and multiple unit layoutsAll minimum clearance values indicated are for IDSC2 induced draft units only. In addition, overall nominal unit lengths are also indicated. A unit is a specific model num-ber that consists of a single nominal box size or multiple, single boxes arranged in very close proximity. See Table 1 for model dimensions. There are three different unit configurations available: single, dual, and quad. A dual unit, for example, can be two, 12 ft x 12 ft single boxes positioned end-to-end that is designated as one model number and is considered one unit. Figure 5 to Figure 10 highlight different potential layouts in which you can cor-rectly locate a unit or units on-site.

Figure 5: No obstruction/two units

Table 2: No obstruction/two units

Unit configuration Unit length (ft)

C3 and C4 (ft)

Single 9 3

Single 12 6.5

Single 18 6.5

Dual (end-to-end) All 8.5

Dual (side-to-side) All 13

Quad All 13

Table 1: IDSC2 configurations and air inlet and basin heights (in.)Unitsize (ft)

Single unit Dual end-to-end Dual side-by-side Quad unitInlet louver height (L)

Basin height (H)

Inlet louver height (L)

Basin height (H)


Basin height (H)


Basin height (H)

8.5 x 12 30 57.5 — — — — — —10 x 12 36 63.5 48 75.5 — — — —12 x 12 36 63.5 48 75.5 78 105.5 78 105.510 x 18 48 75.5 48 75.5 — — — —12 x 18 48 75.5 78 105.5 78 105.5 78 105.5Note: Consult factory for additional information. This is for reference only; use certified drawings for design purposes.

C4

C3

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Figure 8: Two walls/two units

Table 5: One wall/two units (ft)

Unit configuration Unit length

C1 and C2

C3 and C4

Single 9 3 6

Single 12 3.5 7

Single 18 4.5 9

Dual (end-to-end) All 4.5 9

Dual (side-to-side) All 7 14

Quad All 7 14

Figure 9: Two walls (corner)/single and multiple units

Table 6: Two walls (corner)/single and multiple units (ft)


C5, C6, C7, and C2

C3 and C4

Single 9 3 6

Single 12 3.5 7

Single 18 4.5 9



Quad All 7 14

Figure 6: One wall/one unit

Table 3: One wall/one unit (ft)


C1 and C2

Single 9 3

Single 12 3.5

Single 18 4.5



Quad All 7

Figure 7: Two walls/one unit

Table 4: Two walls/one unit (ft)


C1 and C2

Single 9 3

Single 12 3.5

Single 18 4.5



Quad All 7

C2

C1

C2

C2

C1 C1

C2

C2 C2

C2

C2

C6

C5C4

C8 C8

C7

C7

C4C3

C3

C4 C4

C3C2

C1 C1

C1

C1 C1

C1

140.020-IOM (JUN 2021)Page 10


Figure 10: Three walls/single and multiple units

Table 7: Three walls/single and multiple units (ft)


C7 and C7

C3 and C4

Single 9 3 6

Single 12 3.5 7

Single 18 4.5 9



Quad All 7 14

Support structureUse two parallel I-beams traversing the entire length of the unit to structurally support the units. See Figure 11.

Figure 11: IDSC2 steel support dimensions

B2

B1

B4

B3

A1 A2 A3 A4

NOTICERefer to the submittal package for specific unit infor-mation.

Use Neoprene gasketing between the I-beams and the base of the unit.

NOTICEIf Neoprene gasketing is not used, corrosion may oc-cur between the dissimilar materials.

I-beams must be level, with no deviance greater than 1/8 in. over a 6 ft span. Do not use shims to level the unit as this compromises the load bearing surface.

Use the mounting holes of 13/16 in. diameter at the base of the basin section, in the side panel flanges, for securing each unit to the support structure using 3/4 in. diameter bolts. Refer to the Frick unit certified drawing for the bolt hole locations.

The installing contractor, the building contractor, or some other relevant party must provide all support beams and anchoring bolts, which you must select in accordance with sound structural engineering standards. When select-ing the support beams, calculate deflection by using 55% of the unit’s operating weight as a uniform load on each beam.

NOTICEThe support beams must be level at the top and meet industry acceptable tolerance related to the overall length of the unit installed. Do not level any unit with shims.

Table 8: IDSC2 steel support dimensions, single cell arrangements

Model A1 B1

IDSC2 0812... 8 ft, 5 1/2 in. 11 ft, 11 3/4 in.

IDSC2 1012... 9 ft, 9 3/4 in. 11 ft, 11 3/4 in.

IDSC2 1018... 9 ft, 9 3/4 in. 18 ft, 4 in.

IDSC2 1212... 11 ft, 10 in. 11 ft, 11 3/4 in

IDSC2 1218... 11 ft, 10 in. 18 ft, 4 in.

Table 9: IDSC2 steel support dimensions, dual cell arrangements (end-to-end)

Model A1 B1

IDSC2 0812... — —

IDSC2 1024... 9 ft, 9 3/4 in. 24 ft, 1 1/2 in.

IDSC2 1036... 9 ft, 9 3/4 in. 36 ft, 10 in.

IDSC2 1224... 11 ft, 10 in. 24 ft, 1 1/2 in.

IDSC2 1226... 11 ft, 10 in. 36 ft, 10 in.

C7 C7

C7 C7

C7C7C4 C4

C3

C3

C8

C8 C8

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Table 10: IDSC2 steel support dimensions, dual cell arrangements (side-to-side)

Model A1 B1

IDSC2 0812... — —

IDSC2 2412... 23 ft, 10 in. 11 ft, 11 3/4 in.

IDSC2 2418... 23 ft, 10 in. 18 ft, 4 in.

Table 11: IDSC2 steel support dimensions, quad cell arrangements

Model A1 B1

IDSC2 2424... 23 ft, 10 in. 24 ft, 1 1/2 in.

IDSC2 2436... 23 ft, 10 in. 36 ft, 10 in.

Figure 12: End view dimension, in. (mm)

Receiving and inspectionAll units are packaged so that you can remove them from a truck using a crane.

All units are factory-tested to ensure safe operation and quality assembly. Units are packaged and shipped in two pieces or more, depending on options ordered, for easy handling and storage at the job site, if necessary.

NOTICERecord any unit damage or shortages on the Bill of Lading and report to the carrier and factory im-mediately. Shipping and handling damages are not warranty items.

Take photos of all damaged equipment if possible. Dam-aged equipment is the responsibility of the designated carrier. Do not return to the manufacturer unless prior approval is given to do so. Confirm that you have received all items listed on bill of lading.

C/L of unit load

Mounting hole

1 5/8 (41)

13/16 (21)

Unit


NOTICEWhen lifting the unit use only the designated lifting lugs as detailed on the rigging drawing attached to the unit at the time of shipping. Always ensure that the lifting points are balanced so that the unit is level during lifting.

Rigging and hardware

Figure 13: Rigging and hardware parts

C

D

BA

Callout Description

A Lifting lugs

B Screw pin shackles. A minimum capacity of 3 tons

C Spreader bars. A minimum capacity of 10 tons

D Straps or chains. A minimum capacity of 3 tons

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Figure 14: Upper casing section rigged

Figure 15: Basin section rigged

Figure 16: Rigging connections

Rigging the basin section1. Remove the nuts from the shipping support so that

when lifting the units the shipping support detaches, allowing you to remove the basin section.

2. Dispose of the shipping support after lifting the basin section.

Figure 17: Nuts on shipping support

3. Secure four screw pin shackles through each of the 4 lifting lugs.

Figure 18: Basin shipping support nut removal

Figure 19: Pin shackles at the lifting lugs

Liftinglugs

WARNINGDo not use hooks to lift the unit.

4. Use the straps or chains to attach the spreader bar to the basin section of the unit.

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Figure 21: Lower section of the unit - lifting guidelines

8.5' WIDE UNITS

43°120.0"10'-0"

94.9"7'-10.9"

12' LONG UNITS

120.0"10'-0"

44°

99.4"8'-3.4"

10' WIDE UNITS

120"10'-0"

49°

111.1"9'-3.1"

12' WIDE UNITS

58°

135.4"11'-3.4"

120"10'-0"

18' LONG UNITS

120"10'-0"

117.5"9'-9.5"

52°

FRONT VIEW SIDE VIEW

8.5' WIDE UNITS

43°120.0"10'-0"

94.9"7'-10.9"

12' LONG UNITS

120.0"10'-0"

44°

99.4"8'-3.4"

10' WIDE UNITS

120"10'-0"

49°

111.1"9'-3.1"

12' WIDE UNITS

58°

135.4"11'-3.4"

120"10'-0"

18' LONG UNITS

120"10'-0"

117.5"9'-9.5"

52°


8.5' WIDE UNITS

43°120.0"10'-0"

94.9"7'-10.9"

12' LONG UNITS

120.0"10'-0"

44°

99.4"8'-3.4"

10' WIDE UNITS

120"10'-0"

49°

111.1"9'-3.1"

12' WIDE UNITS

58°

135.4"11'-3.4"

120"10'-0"

18' LONG UNITS

120"10'-0"

117.5"9'-9.5"

52°


8.5' WIDE UNITS

43°120.0"10'-0"

94.9"7'-10.9"

12' LONG UNITS

120.0"10'-0"

44°

99.4"8'-3.4"

10' WIDE UNITS

120"10'-0"

49°

111.1"9'-3.1"

12' WIDE UNITS

58°

135.4"11'-3.4"

120"10'-0"

18' LONG UNITS

120"10'-0"

117.5"9'-9.5"

52°


CAUTIONThe spreader bar must traverse the full width of the unit, not the length. Incorrect size and use of the spreader bar may result in equipment damage.

Figure 20: Lifting basin section with spreader bar

94.9 in.(7 ft, 10.9 in.)

120 in.(10 ft)

120 in.(10 ft)

120 in.(10 ft)

120 in.(10 ft)

120 in.(10 ft)

8.5 ft wide units10 ft wide units12 ft wide units

18 ft long units 12 ft long units

43°

49°58°

52°

44°

135.4 in (11 ft, 3.4 in.) 111.1 in

(9 ft, 3.1 in.)

117.5 in (9 ft, 9.5 in.)

99.4 in (8 ft, 3.4 in.)

140.020-IOM (JUN 2021)Page 14


10' WIDE UNITS

12' WIDE UNITS

18' LONG UNITS

12' LONG UNITS

60° 120.0( 10' )

48°

106.3(8' - 10.3")

138.2(11' - 6.2")

120.0( 10' )

113.9( 9' - 5.9")

51°

109.0(9' - 1")

120.0( 10' )

120.0( 10' )

49°

Figure 22: Upper section of the unit - lifting guidelines

120 in.(10 ft)

120 in.(10 ft)

120 in.(10 ft)

120 in.(10 ft)

18 ft long units10 ft wide units

12 ft wide units 12 ft long units

51°

60°48°

49°

113.9 in (9 ft, 5.9 in.)

138.2 in (11 ft, 6.2 in.)

106.3 in (8 ft, 10.3 in.)

109 in (9 ft, 1 in.)

140.020-IOM (JUN 2021)Page 15


Rigging the upper casing section1. Remove all four screws from each plate that holds the

shipping support structure to the unit. This way, when lifting the unit off the truck it also lifts off the shipping support structure.

Figure 23: Upper casing shipping support screw removal

Remove

2. Secure four screw pin shackles through each of the four lifting lugs.

Figure 24: Screw pin shackle attachment

WARNINGDo not use hooks to lift the unit.

Figure 25: Lifting upper casing with spreader bar

3. Use the straps or chains to attach the spreader bar to the upper section of the unit.

Figure 26: Screw pin shackle attachment

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See Figure 27 to Figure 31 for vertical dimension require-ments for lifting the top section of the unit with two spreader bars.

CAUTIONCompromising the vertical dimensions indicated in Figure 27 to Figure 31 may result in equipment dam-age.

Figure 27: 12 ft long unit

Figure 28: 18 ft long unit

NOTICERefer to the submittal package for specific installation instructions.

46°Ref.

106.3 in. (8 ft, 10.3 in.)

Spreader bars

Minimum sling length 10 ft long


Spreader bar drop leg

20 in. minimum

Spreader bars

109 in. (9 ft, 1 in.)

49°Ref.



Spreader bar drop leg

20 in. minimum

140.020-IOM (JUN 2021)Page 17


Figure 29: 8.5 ft wide unit

Figure 30: 10 ft wide unit

57°Ref.

114.4 in. (9 ft, 6.4 in.)



20 in. minimum

Spreader bars

Spreader bars drop leg

Figure 31: 12 ft wide unit

57°Ref.

138.7 in. (11 ft, 6.7 in.)



20 in. minimum

Spreader bars



48°Ref.

98.2 in. (8 ft, 2.2 in.)

Spreader bars




20 in. minimum

140.020-IOM (JUN 2021)Page 18


Offloading and assemblyCompare the data on the nameplate of the unit with the submittal information to verify you received the correct unit. Verify the model nomenclature and electrical data with the original order.

NOTICERemove any loose parts that were shipped in the basin section of the unit before installation, when applicable.

Installing the basin1. See Rigging and Hardware for instructions on rigging

the basin.

2. Slowly lift the basin section from the shipping support structure, move to the installation location, and set on the support structure.

CAUTIONTake care when lifting the basin section so that it is lifted level with little or no tilt. This ensures the drain connection pipe does not come in contact with the ground or any objects in order to prevent damage.

3. Check the position of the basin on the support struc-ture to ensure correct positioning and that it conforms to the information provided in Support Structure.

4. Secure the basin section of unit to the support struc-ture with suitable 3/4 in. diameter bolts. These bolts are not provided

• Use all of the bolt holes to secure the unit to the support structure. For bolt hole locations, refer to the Frick unit certified drawing.

5. Prevent stresses on the unit:

• Check that all mounting bolts are tightened equally to ensure balanced load distribution.

See Riser Pipe Coupling Installation before rigging the up-per casing section.

Fitting the upper casing section1. See Rigging and Hardware for instructions on rigging

the upper section.

2. Slowly lift the upper section and move to the installa-tion location to fit the upper section on top of the basin section.

Figure 32: Lifting the top section of the unit

3. Align the upper casing section with the basin section.

Figure 33: Aligning top and bottom sections

4. Appropriately guide the upper section safely into the recess and ensure it is free from pinch points.

Figure 34: Positioning the top section of the unit

140.020-IOM (JUN 2021)Page 19


CAUTIONThere is already a clearance gap designed between the polyvinyl chloride (PVC) riser pipe in the basin section and upper section. Take care when lifting the upper section such that it is lifted level with little or no tilt, to ensure the PVC riser pipe does not come in contact with the ground, any objects, or the basin section in order to prevent damage.

Connection jointBolt the upper casing section and the basin section to-gether using the connection joint.

Installing the riser pipe coupling1. Align the casing to the basin then proceed with tight-

ening the union nut.

Figure 35: Casing

2. Install the cover with M6 x 20 (10x) screws and wash-ers.

Figure 36: Casing installed


Inlet louvers• The narrower inlet louvers fit into the inlet louver

openings on the front and back of the unit.

• The wider inlet louvers fit into the inlet louver openings on the sides of the unit.

• Position inlet louvers so that the louver pattern points downward into the basin section. See Figure 37.

Figure 37: Positioning louver

• After installing the inlet louvers, the top is held in place by the inlet louver front supports. See Figure 38.

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Figure 38: Louvers and supports

Installing inlet louvers1. Pick up the inlet louver by holding the louver pattern.

2. Angle the inlet louver to place the top end into the inlet louver space and slide it all the way up under the squared inlet louver front supports.

Figure 39: Angling the louver

3. While the inlet louver is slid as far up as it can go into the inlet louver opening, put the bottom of the inlet louver into place.

4. Set the inlet louver down so that it rests in the bottom of the inlet louver opening.

Figure 40: Setting the louver

Removing inlet louvers1. Grab the inlet louver pattern.

2. Slide the inlet louver straight up to release the bottom of the inlet louver from the inlet louver opening.

Figure 41: Detaching the louver

3. Pull the bottom of the inlet louver out to remove it.

4. Slide the inlet louver down to release the top of the inlet louver from the inlet louver front supports.

Figure 42: Removing the louver

140.020-IOM (JUN 2021)Page 21


Figure 43: Ladder and external service walkway package


PipingYou must support and anchor all field piping external to the IDSC2 unit separately. Do not place any external loads on the unit connections. Do not anchor piping supports to any part of the cooler’s panels or frame.

CAUTIONFailure to comply with this results in damage to the IDSC2 product and voids all warranties.

Install pressure or temperature sensors in the field at the appropriate locations in the system and in accordance with your local refrigerant guidelines for piping installation best practices.

When mounting the equipment on vibration rails or springs, all connecting piping must incorporate compen-sators to eradicate any vibrations travelling through the connecting pipework to the IDSC2 unit.

Heat trace and insulate the external water distribution pip-ing when exposed to subfreezing ambient conditions.

The design and installation of evaporative condenser refrigerant piping must be in accordance with generally accepted condenser piping and good engineering practice in compliance with ASME B31.5 - Refrigerant Piping.

StorageThe unit is intended only for outdoor use. To protect the unit from environmental damage, store in a clean, dry location and away from areas with excessive traffic. Ensure that the unit is in a well-ventilated area at all times during storage.

Do not store units for longer than necessary, and make sure the original packaging is kept intact.

Only remove the basin or the coil sections from their re-spective shipping support in the following circumstances:

• After mounting and fastening the basin section to a support structure.

• After correctly positioning and fastening the upper cas-ing to the basin section.

During extended storage or downtime periods, run the fans for at least 2 h to 4 h each month. At an absolute minimum, rotate the motors a minimum of 10 revolutions a month.

ElectricalField wiring The IDSC2 unit ships with all motors pre-wired to indi-vidual terminals within a NEMA 4X enclosure. A Modbus communication cable from each electronically commutated (EC) motor is wired to the optional GMM controller housed within a NEMA 4X enclosure. The water distribution pump is not factory-wired.

The selected electrical options determine what field wiring is necessary. The selected motor power supply needs to be run to the unit. A power supply for each motor is nec-essary in the event of a non-fused disconnect and motor starter protectors (MSPs) not being selected. When a non-fused disconnect and MSPs are supplied, one main power cable needs to be run to the non-fused disconnect.

NOTICERefer to the submittal package for each unit supplied to verify all electrical field wiring requirements.

Only qualified personnel must undertake the wiring, and in accordance with national and local electrical codes and standards.

140.020-IOM (JUN 2021)Page 22


Electrical dataWater distribution pumpThe water distribution pump is not factory-wired and requires field wiring.

NOTICEDo not use VFDs on water distribution pump motors. Failure to comply with this results in reduced cooler performance due to insufficient wetting of the coil bundle. Design water flow over the coil bundle is re-quired at all times, especially with regard to capacity control.

NOTICESpecific installation information is available on our website or upon request.

Basin heatersBasin heaters are copper, through the wall immersion heater elements with an integral thermostat. Frick does not supply the wiring, disconnects, contactors, and over-load protection with the condenser. Other suppliers must provide this. Other suppliers can also provide an MSP for each heater element to provide overload protection, short circuit protection, and a manual on/off switch for each element, and a main non-fused disconnect and contactors to energize heater elements. See Figure 44 for heaters control panel wiring diagram.

Electronic water level controllerA conductance-type electronic level control package comes with probes located in a PVC standpipe external to the basin with a prewired control panel that mounts on the unit. Suitable for 115 V/1 Ph/60 Hz.

Electrical enclosuresAll electrical enclosures are NEMA 4X constructed for ei-ther indoor or outdoor use. This provides protection from the following hazards:

• To personnel against access to hazardous parts

• To the equipment inside the enclosure against ingress of solid foreign objects, such as windblown dust

• Against harmful effects on the equipment due to the ingress of water, such as rain, sleet, snow, splashing water, and hose directed water

• Additional level of protection against corrosion

• Against the external formation of ice on the enclosure

NEMA 4X is equivalent to IP66 protection classification. As standard the enclosures are of FRP construction, but a stainless steel enclosure is optional.

Fan motors

NOTICESpecific operation and maintenance information is available upon request.

NOTICESee Figure 44 and Figure 45 for generic schematics for EC Motors.

EC motorsA GMM controller comes as standard on all models that have EC motors. The GMM comes with either a pressure or temperature transducer, which requires field placement. This functionality enables you to set the GMM to auto-matically control the primary cell fan motors in accordance with the system and ambient conditions.

Alternatively, the GMM can be supplied with a 0 VDC to 10 VDC or 4 mA to 20 mA signal from the PLC and oper-ate in a slave mode according to system requirements. This allows for the motors to receive a 0 VDC to 10 VDC and function automatically. Alternatively, the motors can be controlled through a communication protocol such as Modbus or Profibus.

As such, the following operating modes are possible with EC motors:

• Automatic control using the internal set point of the GMM (temperature or pressure control point)

• Automatic control using external analog input (0 VDC to 10 VDC)

• Automatic control using communication protocol (Modbus, Profibus)

• Slave mode using external analog input (0 VDC to 10 VDC)

• Slave mode using external communication protocol (Modbus, Profibus)

See Figure 45 for EC motor control panel wiring diagram.

140.020-IOM (JUN 2021)Page 23


Figure 44: Basin heaters - generic schematic

140.020-IOM (JUN 2021)Page 24


Figure 45: Electrical schematic for EC motor (generic)

140.020-IOM (JUN 2021)Page 25

IDSC2 Evaporative CondensersOperation

Pre-start up inspectionGeneral• Only trained, experienced, and qualified personnel

must install, operate, maintain, and repair the IDSC2 units. Failure to comply with this may result in damage to the IDSC2 product and voids all warranties.

• Confirm the power supply matches the electrical rating on the nameplate.

• Before undertaking any work, verify that the power is switched off and that the unit is correctly disconnected, locked out, and tagged out.

• If the unit is mounted on vibration isolators or isolation rails, check the manufacturers’ ratings before loading or unloading the unit.

• Check that all safety interlocks are working and fully functional.

• Confirm that the installation of the unit is in accordance with the guidelines. See Location layout.

• Confirm that a water treatment program has already been applied.

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

remove all dirt and sediment and flush with clean water to have the basin 100% clean and ready for operation.

• Remove and clean the basin strainer. Ensure that this is reinstalled correctly so as to not allow any bypass during operation.

• Ensure that inlet louvers are free of any dirt, leaves, and debris. Pressure clean if required.

• Inspect drift eliminators and confirm that they are free of any dirt, leaves, and debris. Pressure clean if required.

• Ensure that all drift eliminators are firmly in place and correctly oriented.

• Remove all dirt, leaves, and debris from fan guards.

• Inspect all water spray nozzles and clean if required.

Pre-start checks• Confirm that all impellers can rotate freely and are not

obstructed in any way.

• Ensure that all electrical connections and terminals are tight.

• Conduct a visual inspection of the entire unit and verify that there are no structural or component damages.

• Bump, or jog, and verify the correct rotation of all fan motors and water distribution pump, when supplied.

• Confirm the mechanical float valve is operating cor-rectly and that there is no obstruction in any way.

Start-up1. Fill the cold water basin with clean fresh water to the

correct level using the make-up valve.

2. Ensure that the float valve is set to maintain the cor-rect water level. Monitor this level over the initial 24 h of operation.

3. The make-up water valve with armature and circular float for basin water level adjustment is delivered pre- assembled. Set the circular float height to a maximum water level of 14 1/4 in. above the lowest point in the basin before the water distribution pump is in opera-tion. After the water distribution pump is in operation, set the water level so that the maximum water level is no more than 15 1/2 in.

Figure 46: Circular float

4. After the unit has been operational for a couple of hours, record the voltage and amp draw on all three phases of the fan motors and water distribution pump. These currents must not exceed the nameplate FLA ratings.

5. Open the bleed valve located in the bleed line of the pump discharge and set according to the bleed rate required. It may be necessary for your qualified water treatment specialist to set or verify this.

Operation

140.020-IOM (JUN 2021)Page 26


Figure 47: Bleed valve location

6. Confirm an even water distribution over the plan area of the condenser coil from the water spray nozzles.

7. For remote sump applications, and when Frick does not supply the water distribution pump, install a globe valve in the water pump discharge line. Adjust the wa-ter flow rate between 6 psig and 8 psig at the inlet of the supplied riser pipe to ensure sufficient water flow to all the water spray nozzles.


8. After 24 h of operation:

• Check the water level in the cold water basin.

• Adjust the water level control valve if required.

• Check all water spray nozzles and confirm that each has a uniform, full-spray pattern over the condenser coil.

You must adequately protect units that are subject to sub-freezing climates to protect against damage and reduced thermal performance. Use, and correctly set up, mechani-cal (basin heaters) and operational controls to prevent any freeze damage occurring to the unit.

Cold weather operationThe operation of evaporative-cooled equipment at, or close to, full load conditions prevents the recirculating water from freezing. However, during periods of reduced load and especially when pumps or fan motors are shut down, consider freeze protection. When using the IDSC2 evaporative-cooling equipment in subfreezing ambient conditions, conisder the following items:

• Unobstructed unit location and layout. Recirculated air entering the cooler causes icing on the inlet louvers.

• Protection against the water in the basin from freezing. Basin heaters are available as an accessory. All cold water basin heaters are designed to maintain a water temperature of 40°F (4.4°C) when the water distribu-tion pump and fan motors are shut down.

• When the equipment is run dry, drain the cold water basin, even if there are basin heaters.

• During dry operation, ensure that the drain line for the basin is left open to prevent the accumulation of rain water or snow.

• Heat trace and insulate the following components:

– All external water lines, the pump, and external wa-ter distribution piping to the unit, when operating at subfreezing conditions. Access the riser piping using removable profile covers.

– The supply line for make-up water, overflow, and drain lines.

– All connections and accessories at or below the wa-ter level, such as an electronic water level controller.

• For fluid coolers protection against the fluid from freezing in the coil, consider the use of glycol or alter-nate antifreeze solutions.

– These solutions, and the concentration thereof, have an impact on the thermal performance of the cooler, which you must consider when selecting the equip-ment.

• Increase visual inspections and maintenance frequen-cies during subfreezing conditions.

• Check all operating controls for freeze protection and capacity control on a regular basis during subfreezing operation.

An indoor remote sump is the best form of protection for outdoor freezing ambient operating conditions. Placing the remote sump indoors prevents freezing in the cold water basin during low ambient temperature, low load condi-tions, or when operating dry. With the sump indoors and the pump not running, the water in the basin and all asso-ciated water distribution piping gravity drains to an above freezing holding location.

NOTICENote any instruction labels on the unit.

140.020-IOM (JUN 2021)Page 27


NOTICEImmersion basin heaters do not prevent the residual water in the pump and recirculated water piping from freezing. These components must be heat traced and insulated.

Extended shutdownWhen it is necessary to shut down a unit for an extended period of time, perform the following steps:

• Disconnect, lock out, and tag any electrical motors for fans and pumps.

• Drain the cold water basin and ensure that the make-up water line is shut off.

• Draining all water from the units minimizes the possible risk of biological contamination during the shut-down period.

• Flush cold water basin and clean, with strainers in place.

• Clean and replace the strainers.

• Drain all exposed water piping.

• Leave cold water basin drain line open.

• Heat trace and insulate all exposed piping, water distri-bution pump, and piping up to overflow level.

• Clean all dirt and debris from the exterior and interior of the units.

• Clean and replace inlet louvers.

• Cover the fan discharge outlets to prevent the ingress of dirt and debris.

• During periods of extended shutdown or prolonged storage rotate all impellers each month at least 10 revolutions.

Capacity controlNormal operationThe EC motor option incorporates fan speed control within the motor’s electronic controller without the need for any external VFDs. Fan cycling requires the use of contactors controlled through a feed from either the PLC or a pres-sure or temperature sensor. Fan cycling is not suggested for evaporative units due to the elevated power input requirements associated with fan cycling versus variable fan speed technology. When cycling individuals fan off and on there is the possibility that moist air may condense and freeze on the impellers or fan orifices of the motors that are not running. As such, during these low ambient condi-tions cycle all fan motors to prevent extended idle times for each motor.

Automatic control of the motors using an internal set point on the GMM, external analogue input (0 VDC to 10 VDC) or external communication protocol (Modbus, Profibus) is the most energy efficient option available.

Cold weather operationWhen operating the IDSC2 unit at low ambient tempera-tures above freezing, the control logic matches that of the summer operation. The water distribution pump runs continuously during operation, and as the condensing temperature for evaporative condensers decreases or increases, you must increase or decrease the fan motor speed respectively.

However, when ambient conditions drop below freezing, additional precautionary measures are required to pre-vent the potential for damage to the equipment from ice formation.

NOTICEWhile spring and fall daytime ambient temperatures may be above freezing there is always the possibility that night time temperatures can drop below freez-ing. Operators of this equipment must take this into consideration.

The EC motors are an excellent solution for condenser fan speed control. All IDSC2 condensers come with a mounted and wired GMM motor management controller that modulates the fan speed dependent on the condens-ing temperature setpoint. It is also possible to provide an independent analog signal, 0 V to 10 V or 4 mA to 20 mA feed, to the controller to regulate motor speed. This unit mounted GMM controller ramps all fan motors together.

NOTICEVarying the recirculated water flow rate across the heat exchange coil is not suggested as a means of capacity control in low load or low ambient condi-tions, because this may increase scale buildup on the coil surface.

140.020-IOM (JUN 2021)Page 28



140.020-IOM (JUN 2021)Page 29

IDSC2 Evaporative CondensersMaintenance

Maintenance

Table 12: Inspection and maintenance frequencies

Type of action

Action step Start-up

Monthly Quarterly Annually Shutdown

Inspect and clean as required

Inspect the general condition of units X X XClean the basin strainer X X XClean and flush the cold water basin X X XDrain the cold water basin and all water piping XFlush the water distribution system X XInspect water spray nozzles and confirm a uniform distribution X X

Inspect inlet louvers X X XInspect bleed rate and adjust if required X XCheck the operating level of water in the basin and adjust if necessary

X X

Inspect drift eliminators X XInspect the coil X XInspect fan guards for any dirt or debris X X XClean the exterior of unit X XTest water quality to ensure there is no biological contamination

X X X X

Confirm water treatment specialist has a fixed program in place

X X X X

Inspect mechanical components as required

Inspect fan motors and impellers for any noise or vibration X X

Confirm correct rotation of impellers X XConfirm impellers rotate freely and have no obstructions X X

Confirm correct rotation of water distribution pump X XCheck all motor amperages against nameplate amps (FLA) X X

Check all voltages X XInspect all electrical junction boxes for loose wiring and moisture X X X

Options and accessories

Inspect the basin heater thermostat operation and set point X X

Inspect for scale buildup on basin heater elements X XInspect the electronic water level controller and clean probe ends X X

Clean the internal portion of the stand pipe X X XInspect and clean the water make-up solenoid valve X X XInspect all electrical junction boxes for loose wiring and moisture

X X X

Check that the water purge valve is free of any obstructions

X X

Note: Maintenance frequencies suggestions are for installations with normal operating conditions. Aggressive or severe envi-ronmental conditions may require an increase in maintenance frequencies. Industrial or chemical fumes, salt, dust, and any unusual airborne contaminates are absorbed into the recirculated water system, which could form solutions and deposits that can be harmful to the unit.

140.020-IOM (JUN 2021)Page 30


Maintenance requirementsRemoving the inlet louverSee Inlet louvers for instructions on how to remove the inlet louvers in order to access the cold water basin and basin strainer.

Removing the drift eliminators1. Access the drift eliminators from the internal walkway

at the top of the unit.

Figure 48: Internal walkway

Figure 49: Drift eliminator pattern

2. Grab the drift eliminator pattern and pull up so that the edge towards the center of the opening below the hinged fans comes out first.

Figure 50: Detaching drift eliminator pattern

Figure 51: Removing drift eliminator pattern

3. After removing the drift eliminators, you can find the spray headers and water spray nozzles attached to the bottom of the PVC pipes.

Figure 52: Spray header and water spray nozzle

4. Inspect the water spray nozzles for debris and Clean as necessary.

140.020-IOM (JUN 2021)Page 31


Figure 53: Spray nozzle, side view

Figure 54: Spray nozzle, close-up

Cold water basinThe cold water basin is a fully-welded stainless steel 304L construction.

CleaningInspect the basin regularly to ensure cleanliness. When cleaning, complete the following steps:

1. Remove all debris from the basin and any accumulation on the strainers.

2. When required, completely drain the basin and thoroughly clean and flush with fresh clean water to remove any sediment that may accumulate within the lower portions of the basin.

• During this process the strainers must be left in place to prevent any carry-over of the sediment into the piping system, which would redistribute within the system.

3. After flushing the basin clean remove, clean, and replace the strainers, ensuring a tight fit between strainers and basin to prevent any debris bypassing the strainers.

4. Refill the basin with clean water.

General maintenance During operation the water level in the cold water basin varies depending on the thermal load, evaporation rate, and the bleed rate. For genearl maintence, complete the following steps:

• Inspect the water level on a regular basis and readjust the float valve when required to maintain the water level at the appropiate operating level of 14 1/4 in. from the base of the depressed basin.

• When the water distribution pump is off, ensure the water level in the basin is 17 in. from the base of the depressed basin before energizing the pump.

• Ensure the water make-up supply pressure is between 15 psig and 50 psig at all times, for correct operation of the make-up valve.

• Install a pressure regulating valve in the water make-up supply line when conditions exist where the water sup-ply pressure is greater than 50 psig.

Electronic water level controller The IDSC2 unit comes with a mechanical make-up valve, as standard, or an electronic water level controller, as an option. The electronic water level controller includes a factory-assembled standpipe incorporating electrodes that are factory-set at predetermined lengths to maintain the required water level. When cleaning, complete the follow-ing steps:

• Remove the electrodes from the stand pipe and clean to prevent the buildup of any scale accumulation or biological growth.

• Clean the internal section of the standpipe of any dirt or sludge accumulation using the supplied fittings.

The electronic water level controller includes low and high level alarm output functions and a low water level basin heater cut off function for added protection.

Stainless steel casing and panelsDuring normal operation, stainless steel is naturally self-passivating and as such does not require any field passivation. However, in order to maintain the corrosion resistance, clean the stainless steel on a regular basis. This also serves to maintain the aesthetics of the stainless steel surfaces.

• You can easily remove most dirt and soiling from the stainless steel surfaces simply by wiping with a clean cloth, with mild detergent, and warm water

• Remove more stubborn dirt with the addition of a mild dose of vinegar.

• In all instances, rinse these surfaces with warm water and wipe clean with a clean dry cloth after cleaning.

There are numerous commercial stainless steel wipes and solvents available that you can use to clean these stainless steel surfaces. Follow the instructions provided with these commercial products.

140.020-IOM (JUN 2021)Page 32


NOTICEChlorides or chlorine-based cleaning solutions, bleach or hydrochloric acid, must never be used to clean stainless steel surfaces.

Water distribution systemThe water distribution piping is made of polyvinyl chloride (PVC), which is corrosion resistant and requires no protec-tion against rust or degradation.

The water distribution header is an arrangement made of PVC and requires no corrosion protection, but does need maintenance such as cleaning or flushing when required to remove any sludge accumulations and retard any biological growth.

The drift eliminators are constructed from heavy duty PVC, are UV and corrosion resistant, and aerodynamically optimized to ensure zero moisture carryover from the saturated discharge airstream.

NOTICEBefore any inspection or maintenance of the wa-ter distribution system, ensure that all fan motors are shut off, locked out and tagged out. The water distribution pump must be left running in order to thoroughly inspect and evaluate the effectiveness of the water distribution system.

Maintaining the water distribution system 1. Remove the drift eliminator sections to gain access to

the water spray nozzles, which provides a clear view of the water spray distribution pattern from each nozzle.

2. Ensure that the spray pattern from the nozzles are uni-form and validate that the entire plan area of the heat exchange coil is being wetted.

3. Remove and clean any nozzles that do not produce a 360° spray pattern.

4. Investigate any excessive sludge buildup in the spray branches and nozzles. This could be due to the strain-ers not inserted correctly, or being damaged.

5. When required, clean drift eliminators and inlet louvers with a pressure washer, however do not use high pres-sure or steam.

NOTICEYou must never use high-pressure water or steam to clean the PVC components within the IDSC2 unit, for example the drift eliminators, inlet louvers, water distribution piping, and the spray nozzles. Never direct high-pressure water or steam at motors. Suit-ably wrap the motors if you are performing any high- pressure cleaning of the IDSC2 unit.

NOTICEBefore performing any maintenance, adjustment, or inspection of the electrical and mechanical compo-nents, ensure that all power has been switched off, locked out, and tagged out.

Water distribution pumpTo maintain the water distribution pump, consider the fol-lowing points:

• Record pressure readings from the pump discharge at the time of startup and use, if required, for future reference.

• When a remote sump comes with the unit, ensure that the pressure at the inlet to the supplied water pipe riser is between 6 psig and 8 psig.

• For electrical data, record voltage and amperage read-ings and verify against original installation data.

• Inspect the pumps on a regular basis for leaks and rectify if required.

• Inspect, lubricate, and maintain the pump and pump motor in accordance with the manufacturers’ recom-mendations, which are available upon request.

EC motorsEC motors are essentially maintenance free. However, ensure the following points:

• Before connecting the power supply, ensure that the supply voltage matches the operating voltage of the motors.

• Tightly secure and seal the terminal box on the motor and ensure to correctly tighten all cable glands.

• Condensate discharge holes must always be open. Ensure that these are not clogged with any debris and clean if necessary.

It is not necessary to lubricate bearings. Bearings are sealed and last the life of the motor.

Water quality and water treatment guidelines

NOTICEFrick strongly suggests to consult with a water treat-ment service company with full service capabilities before installation.

Bleed or blow down rate The thermodynamics behind evaporative cooling is such that a portion of the recirculated water passing over the heat exchange surface evaporates as it absorbs the heat from the fluid being cooled. This process provides the primary cooling effect. The heat is rejected into the atmosphere as relatively warm, saturated air discharged through the fan section.

However, only pure water evaporates, which means that any impurities in the makeup water remain in the recircu-lated water system. Depending on the location, it is also possible that airborne impurities could be absorbed into the recirculating water system.

140.020-IOM (JUN 2021)Page 33


The impurities and any airborne contaminants (dissolved solids) remain in the water system. If not effectively con-trolled, they can lead to sludge accumulations, biological growth, scale, fouling, and corrosion as their concentra-tion increases in the water distribution system.

To prevent these dissolved solids from overconcentrat-ing, a portion of the recirculating water system must be drained from the system as a bleed or blow down. The concentration level of these dissolved solids is referred to as the cycles of concentration within the water distribution system.

Cycles of Concentration

=Water Conductivity (in the evaporative unit)

Makeup Water Conductivity

The cycles of concentration equation reflects the degree to which the dissolved solids in the makeup water are al-lowed to concentrate in the recirculating water system.

The higher this ratio, the more the dissolved solids in the makeup water are allowed to concentrate in the water system, and the lower the bleed rate. To reduce the cycles of concentration, makeup water must be added to the recirculated water system.

However, in order to add water to the system, an equal amount must be removed from the system. This is what is referred to as the bleed or blow down. Regulating the bleed rate maintains a specific cycle of concentration. A regulating valve is located on the discharge side of the water pump on all IDSC2 units. Use an automatic con-ductivity controller to reduce water waste and maximize water usage efficiency.

The cycles of concentration equation above can be ex-pressed in terms of water flow by the following equation:

Cycles of Concentration = MU / BD

MU = Total makeup water [ sum of evaporation + bleed (gpm) ]

BD = Bleed flow rate (gpm)

MU in this equation can be replaced with the value (E + BD), where E is the evaporation rate that can be rear-ranged to yield the following relationship:

BD = E/(Cycles of Concentration - 1)

The evaporation rate is always dependent on the location, wet bulb temperature, and the heat load.

There are two methods to control the blow down/bleed rate:

1. Constant blow down - manually setting the bleed regu-lating valve at the pump discharge, based on periodic analysis of the concentration of dissolved solids (water hardness), at peak loads. This is a simple method, but due to the blow down being constant, the loss of water and water treatment chemicals is high, expensive, and certainly not efficient.

2. Controlled blow down - the IDSC2 unit mounted conductivity controller monitors the dissolved solids (water hardness) as indicated by the conductivity of the water. Automated control minimizes water and chemical waste by bleeding water off only when necessary and

is the preferred method of concentration control. When selecting the IDSC2 conductivity controller, the com-ponents are factory-supplied. The factory configures the controller to the correct parameters. Ensure only a qualified water treatment specialist changes these parameters, to maintain the appropriate concentration.

Water treatment guidelinesWater related problems that may occur in an evaporative condenser can be broadly classified as:

• Scale deposits• Corrosion• Microbiological fouling

Scale deposits are a serious concern in evaporative heat transfer products. When dissolved solids become overly concentrated, an adherent deposit termed scale forms on the tubes of the heat exchanger, severely impacting the thermal performance of the heat exchanger. Evaporative cooled deposits may also include dust scrubbed from the air, corrosion by-products, and microbiological contami-nants (slime). Regardless of the source, the end result is reduced thermal performance, increased operating costs and eventually, equipment failure.

Corrosion in water is usually an electrochemical reaction initiated by the presence of naturally occurring impuri-ties in water or microbiological growth. Corrosion is the destructive reaction of a metal with its immediate envi-ronment, resulting in metal loss and ultimately equipment failure.

Metal corrosion occurs as a result of galvanic action at a negatively charged pole, or site on the metal surface. Both anodes and cathodes can be created on metal surfaces due to impurities in the metal, localized stress, metal grain size, or composition differences. The difference in charges between anodes and cathodes creates an electrical po-tential between them that results in an electrical charge flowing from anodes to cathodes, using the surrounding water was a conductor. General corrosion is widespread and normally caused by impurities in the metal or charac-teristics of the metal or its environment that results in an overall fouling of the metal surface. Localized corrosion results from stress or localized environment.

Having a consistent maintenance program in place and maintaining the equipment in a clean state all ascribe to the longevity of IDSC2 units.

Microbiological fouling results from bacteria, fungi, zoo-plankton, and algae introduced into the system through makeup water or filtered from the air. Fouling results when these microorganisms grow in open systems rich in oxygen and form slime on the surfaces of the equipment. Slime is an aggregate of both biological and nonbiological materials.

The best method of controlling biological fouling in evapo-rative units is to keep them clean. At least twice during the cooling season, drain and scrub the unit clean and allow to dry fully before refilling. Thereafter, a chemical treatment completes the process.

Uncontrolled microbiological fouling can cause major cor-rosion and deposit problems in evaporative units. Microbi-

140.020-IOM (JUN 2021)Page 34


als in condenser water systems can become resistant to a single method of treatment; because of this, use both oxidizing and nonoxidizing types of chemical treatment, either blended together or in alternating treatment pat-terns, as indicated by periodic water test results. The key to a successful biological treatment program is maintaining adequate chemical treatment levels at all times through continuous feed of antimicrobials in the water distribution system.

In order to maintain a continuous natural passivation of the stainless steel surface and maximize the unit life, it is essential to keep the stainless steel surface clean and free of foreign materials. Otherwise, the corrosion resistance that natural passivation provides can be interrupted or stopped resulting in premature material failure.

Legionella thrives in water temperatures between 68°F (20°C) and 122°F (50°C), with optimum growth occurring between 95°F (35°C) and 115°F (46°C). Low pH and high levels of aquatic growth enhance bacteria growth. Water temperatures above 140°F (60°C) kills the bacteria.

The normal operating temperature of evaporative units range from 85°F to 100°F, which makes the equipment an ideal habitat for Legionella. The major mechanism for infection by Legionella is through the inhalation of aero-solized water droplets or particles containing the bacteria. The spray nozzles introduce aerosolized water droplets, which represent prime mechanisms for infecting humans. Drinking water with the bacteria in it does not cause dis-ease, nor can the disease be passed by human-to-human contact.

WARNINGTest evaporative units for Legionella within the water distribution system. This testing must be specific for Legionella. “Total bacteria” testing, promoted by some water treatment companies is inadequate be-cause there is no correlation between total bacteria and Legionella concentrations. At a minimum, con-duct these tests at least once a year, however, twice a year is suggested.

As such a water treatment program, undertaken by a wa-ter treatment service company with full service capabili-ties, is a mandatory requirement for all IDSC2 units, and must be included in the maintenance schedule. The water treatment program must be compatible with the unit’s materials construction. In systems with mixed metallurgy, the water treatment expert must devise a program to ensure adequate protection for all components within the recirculated water loop. A system with a remote sump and carbon steel interconnecting piping coupled to the stain-less steel heat exchanger is an example of mixed metal-lurgy.

The water treatment service company must have sufficient expertise and experience to completely address all aspects of water related issues. Incorporate proven technology in the proposed approach to water treatment. This does not exclude new technologies, products, or methods, but does mean that the company can demonstrate that their proposed technology has been successfully applied at other locations with similar water treatment conditions and requirements.

Frick also suggests to send water samples from the units to an independent laboratory for analysis at least twice a year and compare the results with the water treatment company's most recent monthly reports.

An effective water treatment program for IDSC2 units is integral to water and energy efficiency, and helps ensure the longevity of the units.

The water treatment and water quality guidelines present-ed here has been compiled from sources believed to be reliable. No guarantee is implied or expressly stated here and the data given is intended as a guideline only.

Table 13: Recirculated water quality guidelines

Property Suggested value

Total bacteria (cfu/ml) < 1,000

pH (at 90°F) 6.0 - 9.0

Chlorides as Cl- < 400 ppm (maximum Cl)

Manganese < 50 ppb

Sulfates as SO42- < 500 ppm

Silica < 150 ppm

Hardness as CaCO3 < 500 ppm

Alkalinity as CaCO3 < 600 ppm (as CaCO3)

Total dissolved solids (TDS) < 1,500 ppm

Total suspended solids < 40 ppm

Conductivity < 3,000

Free chlorine <2.0 ppm

Note:

• The water quality guidelines listed above are for clean surfaces. Correct and periodic equipment maintenance is required to prevent tube fouling, surface deposit, scale, microbial deposit, or other issues, which in turn can reduce the range of the guidelines provided above.

• Keep water distribution nozzles clean at all times to ensure complete wetting of the coil. Failure to do so can result in war-ranty being voided.

• Only use non-chlorinated biocides for biological control.• Anaerobic dip slide: Sessile bacteria sampling must be con-

ducted along with bulk water (planktonic) sampling

NOTICEFailure to comply with the water guidelines as laid out above voids all warranties.

140.020-IOM (JUN 2021)Page 35



Johnson Controls100 Cumberland Valley AvenueWaynesboro, PA 17268-1206 USAPhone: 717-762-2121 • FAX: 717-762-8624www.johnsoncontrols.com/Frick

Form 140.020-IOM (2021-06)Supersedes: 140.020-IOM (2020-10)

Subject to change without noticePublished in USA • 06/21 • PDF

© 2021 Johnson Controls - All Rights Reserved

June 2021 revisions

Page 25 – Updated Pre-start up inspection section

Date post:	30-Dec-2021
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140.020-IOM IDSC2 Stainless Steel Evaporative Condenser

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