S140-600IOM/FEB2000File: SERVICE MANUAL - Section 140Replaces: S140-600/AUG96Dist: 3, 3a, 3b, 3cXLEVAPORATIVE COOLING PRODUCTSXLEVAPORATIVECOOLINGPRODUCTSTABLEOFCONTENTSS140-600IOMPage 2TABLEOFCONTENTSPreface ................................................................................................................. 3Job Inspection....................................................................................................... 3Transit Damage Claims.......................................................................................... 3Unit Identification .................................................................................................. 3Installation Tools .................................................................................................... 4General Information ............................................................................................... 4Installation Instructions ......................................................................................... 4Optional Vibration Isolator - Mounting Instructions ................................................. 9Final Assembly Details........................................................................................ 10Operating Instructions ......................................................................................... 11Maintenance Instructions .................................................................................... 12Chemical Treatment ......................................................................................... 12Suggested Maintenance Intervals .................................................................... 12Fans ................................................................................................................ 14Operation and Maintenance ................................................................................. 14Operation and Maintenance Schedule ................................................................. 16Recommended Spare Parts................................................................................. 17FIGURESFigure 1a. XLC I-Beam Location ............................................................................ 4Figure 1b. XLP I-Beam Location ............................................................................ 4Figure 2. Platform Layout ...................................................................................... 5Figure 3a. XLC Pan Coil Section Rigging ............................................................... 5Figure 3b. XLC Fan Section Rigging....................................................................... 5Figure 4a. Mastic Placement For Blower Mounting ................................................ 6Figure 4b. Blower Assembly Mounting Instructions ................................................ 6Figure 5. XLC Unit Assembly with Desuperheater .................................................. 6Figure 6. Platform Layour ...................................................................................... 7Figure 7a. XLP Fan Section Rigging ...................................................................... 7Figure 7b. XLP Coil Section Rigging ...................................................................... 8Figure 8. XLP Mastic Location and Unit Assembly ................................................ 8Figure 9. Vibration Isolator Feet ............................................................................. 9Figure 10. Vibration Isolator Rails ........................................................................ 10Figure 11. Eliminator ............................................................................................ 10Figure 12. SprayHeader Nozzle Orientation ....................................................... 12Figure 13. Sheave Alignment ............................................................................... 13TABLESTable 1. XLC Foundation Layout Dimensions ......................................................... 5Table 2. XLP Foundation Layout Dimensions ......................................................... 7Table 3. Rigging Cable Lengths .............................................................................. 8NOTE: Installation, operation, maintenance, and repair of this equipmentshould only be accomplished by qualified personnel. Failure to follow thisnote may result in improper installation and operation of the equipment andpersonal injury.Frick XL Condensers are designed to ensure energy efficient operation and yearsof dependable, trouble-free service. To maximize service life, it is important tofollow the recommended installation, operation, and maintenance proceduresoutlined in this manual. Be sure to follow the Recommended Maintenance Tableand read the detailed instructions of each procedure. Care taken to follow theseinstructions will directly affect the satisfactory operation and reliability of thesystem.XLEVAPORATIVECOOLINGPRODUCTSGENERALINFORMATIONS140-600IOMPage 3PREFACEThismanualhasbeenpreparedtoadvisetheownerandservicepersonnelofrecommendedINSTALLATION,OP-ERATION, AND MAINTENANCE procedures recommendedbyFrickforXLEvaporativeCoolingEquipment.Readthefollowing instructions completely prior to installation. Theseinstructionsprovideyouwiththeinformationneededforsafe, proper installation, operation, and maintenance of yournew product. Care taken during the installation will directlyaffectthesatisfactoryoperationandreliabilityofthesys-tem.To ensure correct installation and application, the units mustbeproperlyselectedandconnectedtoanappropriatelydesigned and installed system. The engineering plans, pip-inglayouts,etc.mustbedetailedinaccordancewiththebestpracticesandlocalcodes,suchasthoseoutlinedinASHRAEliterature.Allunitsshouldberiggedandinstalledasoutlinedinthismanual. These procedures should be thoroughly reviewedprior to the actual rigging operation to acquaint all person-nel with the procedures to be followed. It is also importantthattheseunitsbeappliedtoaproperlycontrolledrefrig-eration system. Your authorized Frick representative shouldbeconsultedforexpertguidanceonquestionspertainingtoinstallationandapplication.If at any time during the review of this document or installa-tion/operationyourequireassistance,pleasecallyourlo-cal Frick representative.JOBINSPECTIONPLEASE RECORDTHE FOLLOWING INFORMATION FORFUTUREREFERENCE:Model No.Serial No.DateReceivedImmediately upon arrival at the job site, the unit should beinspected to ensure all required parts have been receivedand are free of shipping damage prior to signing the Bill ofLading.Unpackallitemsandcheckagainstshippinglistsfor any possible shortages. If any part appears to be miss-ing,contactyourFrickrepresentative. Thefollowingpartsshouldbeinspected: Sheaves & Belts Spray Water Pump(s)Bearings Strainer(s) Bearing Supports Float Valve Assembly(ies) Fan Motor(s) Eliminators Fan(s) and Shaft(s) Interior and Exterior Surfaces Coils Belt Guard(s) Water Distribution Motor Hood(s)System(s) Miscellaneous Items:Ifrequiredforfieldassembly,thefollowingpartswillbepackaged and usually placed inside the pan section: Mas-tic, Bolts, Nuts, Washers, and any accessory items.TRANSITDAMAGECLAIMSAll claims must be made by the consignee. This is an ICCrequirement. Request immediate inspection by the agent ofthe carrier and be sure the proper forms are executed.ContactPartsandWarrantyDepartment-Fricktoreportdamage or shortage claims.UNITIDENTIFICATIONNOTE: When inquiring about the unit or ordering repairparts, provide the MODEL and SERIAL NUMBERS fromthe data plates.XLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 4INSTALLATION TOOLSTocompletetheinstallationoftheXLEvaporativeCon-densers, the following tools are needed: Drift pins 8-foot straight edge Level Assortedopen-endwrenches Socket set Belttensiongage TapemeasureGENERALINFORMATIONAllXLCandXLPmodelsshouldbeanchoreddirectlytoconcretepadsorconcretepiers. Theseunitsmayalsobesupported on structural I beams as outlined below.TheCentrifugalFanXLCunitsaredesignedtobesup-ported by two structural I beams, one located under eachendoftheunitandrunningthefullwidthoftheunit(SeeFigure1a).The Vane Axial Fan XLP units are designed to be supportedby two structural I beams, one located under the front andone under the rear of the unit, running the full length of theunit (Figure 1b).Asanalternate,thestructuralIbeamsmayrunthefullwidth of the unit. Please refer to the unit foundation draw-ings furnished by Frick for each specific sales order for com-pletedetails.Eachbeamshouldbesizedinaccordancewithstandardengineeringpractices,55%oftheoperatingweightoftheunit as a uniform load on the beam, allowing for a maximumdeflection of 1/360 of the length, not to exceed 1/2 inch.Figure 1b.XLP I-BEAM LOCATION ON UNITAllunitshave13/16inchdiametermountingholesformounting to the beams. The beams should be supported sothat the unit is level. Shims between the beams and theunit should not be used, as this will not provide adequatesupport.If vibration isolation is required, whether furnished by Frickor by others, the isolators must always be mounted belowthe structural I beams. Continuous support of unit, as de-scribed above, must be provided.INSTALLATIONINSTRUCTIONSFOUNDATION LAYOUT INFORMATION FOR XLC UNITSBeamsand/orpiersshouldbesizedinaccordancewithstandard engineering practices, 55% of the operating weightas a uniform load. Beam deflection should not exceed thelarger of 1/360 of span or 1/2 inch. In Figure 2, A repre-sents the overall length of one cell and B represents thecenter lines of the mounting holes in the unit. The dashedlines show the location of the structural beams to which theunit is mounted.Figure 1a.XLC I-BEAM LOCATION ON UNITXLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 5XLC CENTRIFUGAL FAN UNITSXLCunitsareshippedintwopieces:thepan/coilsectionandthefansection. Thefirststepoftheinstallationistomount the pan/coil section on the structural beams and boltittothebeams. TheriggingofthetwopiecesisshowninFigures 3a and 3b. For minimum cable length, see Table 1.Figure 2.PLATFORM LAYOUTTable 1.XLC FOUNDATION LAYOUT DIMENSIONSMIN.CABLEMODEL A B C D LENGTHXLC 25 through XLC 40 57 54 27.25 6 ft.XLC 43 through XLC 55 57 54 38.75 6 ft.XLC 58 through XLC 90 117 114 27.25 11 ft.XLC 95 through XLC 128 117 114 38.75 11 ft.XLC 130 through XLC 185 117 114 57.25 11 ft.XLC 195 through XLC 250 117 114 80.25 12 ft.XLC 285 through XLC 385 177 174 80.25 17 ft.XLC 410-2 through XLC 500-2 117 114 80.25 258 12 ft.XLC 570-2through XLC 770-2 177 174 80.25 378 17 ft.Figure 3a.XLC PAN/COIL SECTION RIGGINGFigure 3b.XLC FAN SECTION RIGGINGXLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 6The second step of installation is to mount the fan section tothe pan/coil section as follows:1. Remove guards from both ends and remove the verticalguard between the blowers to provide access to mountingholes. Also, remove the motor housing access panel.2. Take mastic from parts box and place on coil section unitbody as shown in Figure 4a.3. Lowerfansectiontopan/coilsectionunitbodysothatthe blower support on the fan section rests on the flangededge of the top fan mounting panel on the pan/coil sectionunit body. Move the fan section to the pan/coil section unitbody until all mounting flanges are touching. (Figure 4b)4. Oneachblower,installboltswithaflatwasherunderboth the bolt and nut.5. Tightenallboltsconnectingfanandpan/coilSectionstogetherbeforeremovingrigging.6. Align the V-belt drive and check tension in the belts us-ing the procedures in the section labeled "Fan Drives andBelts" in this manual.7. Replace all guards and the motor hood access panel.Notes: When provided, mount desuperheater on top ofunit using holes provided in the mounting bracket. Notethat some units are shipped with the desuperheater fac-torymounted.Assemblegaspipingbetweendesuperheater and condensing coils after final position-ing of the desuperheater. Inter-gaspiping is to be fur-nished by others.Figure 4b.BLOWER ASSEMBLY MOUNTING INSTRUCTIONSFigure 4a.MASTIC PLACEMENT FOR BLOWER MOUNTINGFigure 5.XLC UNIT ASSEMBLY WITH DESUPERHEATERXLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 7FOUNDATION LAYOUT INFORMATION FOR XLP UNITSBeamsand/orpiersshouldbesizedinaccordancewithstandardengineeringpractices,55%oftheoperatingweight as a uniform load. Beam deflection should not ex-ceed 1/360 of span, or maximum of 1/2 inch. In Figure 6,A represents the overall length of one cell and B repre-sentsthecenterlinesofthemountingholesintheunit.The dashed lines show the location of the structural beamsto which the unit is mounted.MODEL A B C DS90 through S175S185,S190,S200,S205 145 141 57.5 S180, S195S210 through S270 145 141 68.5 M155 through M280 121.87 117.87 92 M285 through M430 177 173 92 M810-2throughM960-2 177 173 92 378ML235throughML345 145 141 92 L350 through ML520 211 207 92 ML820-2throughML1040-2 211 207 92 446L290 through L415 145 141 112 L435 through L635 211 207 112 L810-2throughL830-2 145 141 112 314L870-2throughL1270-2 211 207 112 446XL355 through XL530 145 141 137 XL535 through XL805 211 207 137 XL830-2throughXL1060-2 145 141 137 314XL1070-2throughXL1610-2 211 207 137 446Table 2.XLP FOUNDATION LAYOUT DIMENSIONSFigure 6.PLATFORM LAYOUTINSTALLING XLP SINGLE LENGTH UNITXLPunitsareshippedintwopieces; Thepan/fansectionandthecoilsection. Thefirststepoftheinstallationistomount the fan/pan section on the structural beams with bolts.The rigging of the two pieces is shown below in Figures 7aand 7b. For cable lengths, see Table 3.Figure 7a.XLP FAN SECTION RIGGINGXLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 8Thesecondstepoftheinstallationistomountthecoilsection as follows:1. Some units are shipped with the fan guards in the pansection for shipping purposes. In these cases, remove fanguards from pan section and install on the front of the unitbefore joining fan and coil sections.2. Take mastic from parts box and place on the top of the fan& pan section as shown in Figure 8. Be sure to apply twolayers of mastic across each end of the unit as shown.3. Lower the coil section to the fan & pan section with rig-ging attached to all eight lifters. For extended lifts, use liftersand safety slings (Figure 7b). Use drift pins in bolt holes toensure proper alignment. See Figure 8.4. Remove rigging and install four 1/2" bolts with flat wash-ers under both the bolt and nut.NOTES:1. Use spreaders and blocking to protect casing frompossible damage caused by slings.2. Remove eliminator tie straps and eliminators as nec-essary to access lifters.3. Mount coil connection toward access door unlessspecified differently on product drawing.4. When provided, mount desuperheater on top of unitusing the holes provided in the mounting bracket.As-semblepipingbetweendesuperheaterandcoilafterfinal positioning of desuperheater.Figure 7b.XLP COIL SECTION RIGGING XLPModel Min.CableLengthS 14 ftM - 2 Fan 13 ftM - 3 Fan 17 ftML - 2 Fan 15 ftML - 3 Fan 20 ftL - 2 Fan 16 ftL - 3 Fan 21 ftXL - 2 Fan 17 ftXL - 3 Fan 22 ftTable 3.RIGGING CABLE LENGTHSFigure 8.XLP MASTIC LOCATION AND UNIT ASSEMBLYXLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 9OPTIONAL VIBRATIONISOLATOR-MOUNTINGINSTRUCTIONSVibrationisolators,purchasedasanoption,areusedtominimize transfer of forces due to vibration/dynamic load-ing to or from unit. To install the isolator feet and rails, refertoFigure9andFigure10respectivelyandfollowtheseinstructions:ISOLATOR FEET1. Refer to the submitted foundation layout drawing for thecorrect location of each isolator and support beams.2.Placetheisolatorsintheirproperlocationandattachthe bottom plate to the building support steel by means ofboltingorwelding.3. Set the unit support beams on top of the isolators andattach them to the top plate by means of bolting or weld-ing.4. Lower the first section of the unit onto the beams, takingcare not to overload any one corner.Do not attempt to move the unit lat-erally with the weight on the isola-tors. If it is necessary to move theunit, remove the weight from the isolators by raising theunit before moving. Failure to follow this procedure couldresult in damage to the isolator.5. Attach the unit to the beam by means of bolting or weld-ing.6.Continuetoattachtheremainingunitsectionspertheinstructionsonthepreviouspagesandcompletepiping,wiring,etc.Note: Ridged connections between the unit and buildingstructure shall not be permitted when vibration isola-tors are used. Use flexible connections that allow forvibration and noise isolation.7. Loosen the vertical restraint jam nuts to the end of therestraint bolts.8.Whentheunitiscompletelyinstalledandoperating,turn the leveling bolts counterclockwise several completeturnsoneachisolatoruntiltheblockingchannelcanberemoved by hand. It will be necessary to alternate betweenisolators in order to uniformly raise the unit. Do not attempttoplacealltheweightonanyoneisolator,butdistributetheloadproportionally.9. After the unit is level, tighten the vertical restraining nutsfinger tight, then back off one half turn. Lock each nut withthe jam nuts provided.Figure 9.VIBRATIONISOLATORFEETISOLATOR RAILS1. Refer to the submitted foundation layout drawing for thecorrect location of each isolator rail.2.Placetheisolatorrailassembliesintheirproperloca-tionandattachthebottomplatetothebuildingsupportsteel by means of bolting or welding.3. Lower the first section of the unit onto the rails, takingcare not to overload any one corner.Do not attempt to move the unit lat-erally with the weight on the isola-tors. If it is necessary to move theunit, remove the weight from the isolators by raising theunit before moving. Failure to follow this procedure couldresult in damage to the isolator.4. Attach the unit to the isolator rail by means of bolting orwelding.5.Continuetoattachtheremainingunitsectionspertheinstructionsonthefollowingpagesandcompletepiping,wiring, etc.Note:Ridged connections between the unit and build-ing structure shall not be permitted when vibration iso-lators are used. Use flexible connections that allow forvibration and noise isolation.6. Temporarily remove all vertical locknuts from hold-downbolt.7. When the unit is completely installed and operating,turnthe leveling nuts clockwise several complete turns on eachisolatoruntiltheshimcanberemovedbyhand.Itwillbenecessary to alternate on each isolator in order to uniformlyraise the unit. Do not attempt to place all the weight on anyone isolator, but distribute the load proportionally.8.Aftertheunitislevel,replaceallverticallocknutsonhold-down bolts and fasten finger tight.XLEVAPORATIVECOOLINGPRODUCTSINSTALLATIONS140-600IOMPage 10Figure 10.VIBRATIONISOLATORRAILSFINALASSEMBLYDETAILS1. ELIMINATOR PLACEMENTCheck the placement of the eliminator sections on the topof the unit to ensure that all eliminator sections are properlyinterlockedandthattherearenoopeningspresentwhichwill allow the escape of water droplets. Eliminator tie-downstraps can be removed after assembly is complete. Checkthe orientation of the eliminator sections to ensure "RIGHTSIDE UP" as shown in Figure 11.2. INSPECTION *Prior to start-up, the following services, which are describedindetailintheoperatingandmaintenancemanual,mustbeperformed:A) Inspect general condition of unit.B) Inspect fan, motors, bearings, drives, and locking collarsforconditionandalignment.C)Checkbelttensionandconditionperthemaintenancemanualinstructions.D)Lubricateallbearings.E) Inspect spray headers and heat transfer section.F) Check makeup valve and sump water level.G) Check fans and guards for obstructions.H) Clean and flush pan and strainer.I) Rotate fan(s) by hand to ensure rotation without obstruc-tion.J) Check fans and pumps for correct rotation and electricalhook-up.K) SeetheOperationandMaintenanceManualfornewbeltrun-inprocedures.3. BREAKING IN THE GALVANIZED SURFACESAproperbreak-inprocedureshouldbefollowedforwatertreatmenttoallowthegalvanizedsurfacestobreakinorpassivate.Thisallowsthegalvanizedsurfacestoformaself-protecting zinc carbonate layer. A qualified water treat-mentspecialistcanprovidespecificdetails,butfollowingaresomeguidelines. Clean all wetted surfaces. Touchupscratchesinthegalvanizingwithcoldgal-vanizedpaint. Keep the water moderately hard. AvoidcleaningchemicalsinpHrangesabove8.0andbelow6.0.Particularlyanythingwhichwillraisethe pH level to 8.3 or above. Afterabreak-inperiod,typically30-45days,beginregularwatertreatmentprocedures.Again,localwatertreatmentprofessionalswillbebestequipped to create a water treatment program designed tomeet the specific needs of the installation.Properstart-upproceduresandscheduledperiodicmain-tenancewillprolongthelifeoftheequipmentandensuretrouble-free performance for which the unit is designed.DONOTATTEMPTANYINSPEC-TION AND/OR MAINTENANCE UN-LESS THEELECTRICALSUPPLYHASBEENCOMPLETELYDISCONNECTEDANDLOCKED OUT.Figure 11.ELIMINATORXLEVAPORATIVECOOLINGPRODUCTSOPERATIONS140-600IOMPage 11OPERATINGINSTRUCTIONSEvaporative Condensers remove heat from the fluid circu-latinginthecoilbyrecirculatingwaterovertheoutsideofthecoilandblowingairupthroughthewettedcoil.Thewater that is recirculated over the outside of the coil is storedin the pan section at the bottom of the unit, and is pumpedoverthecoilthroughspraynozzlesbythespraypumpmounted on the end of the unit. The fans are located on theside of the XLC Centrifugal Fan Units in the dry entering airstream and are driven by a motor that is mounted on top ofthe fan section. The fans on the XLP Vane Axial Fan Unitsare located above the pan in the pan/fan section in the dryenteringairstreamandaredrivenbymotorsthatarelo-cated below the fans.Thecoolersaredesignedtoprovidemaximumcapacitywhen both the spray system and the fans are running, andonlypartialcapacitywheneitherthespraysystemorthefans are running alone. A practical method of capacity con-trol is to cycle the fan and spray pump motors with a thermo-stat or pressure switch that senses the fluid leaving the unit.Care must be taken, however, to cycle the fans off first, thenthespraypump. Thisenablesthesolidsleftbehindtobewashed into the pan, by the spray water, where they can bebled off to the drain.Whenprovided,capacitycontroldampersaremountedinthe discharge throat of the fans on the XLC units or on theair discharge of the XLP units for closer control of fluid tem-peratureorpressure.Thesedampersarecontrolledbyamodulatingdamperactuatorandaremotebulb-typetem-perature or pressure controller. The sensing bulb of the con-troller should be installed in the fluid piping leaving the unit,and the controller should be wired to the damper actuatorasshownontheappropriatewiringdiagram. Thedamperactuator contains an end switch that should be used to turnoff the fan motor when the dampers are fully closed.Unitsprovidedwithpositiveclosuredischargedampersare designed to reduce heat loss from the unit when it is notinoperationbyeliminatingthechimneyeffect. Thedamp-ers are operated by an On-Off damper actuator, and arepositionedclosedwhenthespraypumpmotorisoff,andopen when the spray pump motor is on. The actuator shouldbe wired as shown on the appropriate wiring diagram.COLD WEATHER OPERATIONEvaporative Condensers are suitable for most cold weatherapplicationswhensuppliedwithpropercapacitycontroland freeze protection.Acommonapplicationfor VaneAxialunitsistocycletheoperatingfanstoachievecapacitycontrol.Typically,thefans are cycled off as capacity drops and finally, the pump isshut off. In cold weather operation, Frick recommends thatthe pump should be the first item shut off to achieve capac-ity control. By running the unit dry in cold applications, theunits drive is protected from ice formation. Ice forms whenthe spray water causes moist air to migrate out of idle fanswhere it condenses and freezes on cold metal surfaces.AslongastheEvaporativeCondensersareinoperationwith a load, with capacity control dampers, the recirculatingpan water will not freeze. However, the pan water must beprotectedwhenEvaporativeCondensersareunderanoloadconditionwithfansandspraypumpsoff.Anindoorremote sump and pump is the best means of avoiding panwater freezing in an idle Evaporative Condenser. With thisremotesumpsystem,thepanwaterisalwaysdrainedtotheindoorremotesumpwhenevertherecirculatingwaterpump is stopped.BecauseoftheEvaporativeCondenserlocationorspacelimitations, a remote sump installation may be impractical.In such cases, supplementary heat must be supplied to thepan water. The Evaporative Condenser will then need to befurnishedwithanelectricpanheater. Thisheaterwillpro-vide sufficient heat to keep the spray water in the pan fromfreezingwhentheunitisnotrunning.Theheateriscon-trolled by a thermostat that senses the pan water tempera-ture, and is factory set at 42F. The heater is protected by alow water cutout switch that prevents the heater from oper-ating if the pan water level is below the heater element. Inaddition to protecting the pan water, all exposed water pip-ing, including the pump suction line, pump, pump dischargepiping(uptotheoverflowconnection),andthemake-upwater lines, should be traced with electrical heat tape andinsulated.SomeEvaporativeCondenserinstallationswillpermitallspraywatertobedrainedfromthepanduringcoldweatheroperation. ThispermitsdryoperationoftheEvaporativeCoolerorCondenserwhentheloadandam-bient temperatures are low.Unitsthatrequireyear-roundoperationinafreezingcli-mateshouldbeequippedwithanelectricpanwaterlevelcontrolpackage.Thispackageensuresaconstantwaterlevel without adjustment and also maintains very close con-trol of the pan water level. The system consists of a weather-protected electric float switch with stilling chamber mountedon the pan section and a weather-protected solenoid valvemounted on the water makeup connection. When this sys-temisused,itreplacesthestandardmechanicalwatermakeupvalve.XLEVAPORATIVECOOLINGPRODUCTSMAINTENANCES140-600IOMPage 12MAINTENANCEINSTRUCTIONSEvaporative Condensers accomplish condensing by evapo-rating water from the spray water system at the rate of twogallons per minute per one million BTUs per hour of heatremoved, or three GPM per 100 tons of refrigeration. Whenthis water evaporates, however, the solid impurities remainandmustbeflushedfromthesystemtopreventascalebuild up on the coil and casing. This is accomplished by ableed-offvalvelocatedonthespraypumpdischargelinewhich bleeds off an equal amount of water to that which isevaporated.Forconditionswheretheoriginalwaterhardnessisveryhigh or a large number of airborne contaminants may enterthespraywater,ahigherbleed-offrateorchemicaltreat-ment may be required to prevent scale buildup on the coil.Consult your local water treatment company for recommen-dations.CHEMICAL TREATMENTIf the condition of the water is such that constant bleed-offwill not control scale or corrosion, chemical treatment maybe necessary. If a water treatment program is used it mustmeetthefollowingrequirements:1. The chemicals must be compatible with zinc.2. The pH of the circulating water must be maintained be-tween 6.5 and 10.3. Chemicals should be fed into the recirculated water, butnot into the cold water sump, on a continuous metered ba-sis to avoid localized high concentrations which may causecorrosion. These chemicals are normally fed into the pumpdischargeline.Batchfeedingofchemicalsdoesnotpro-videadequatecontrolorwaterqualityandisnotrecom-mended.4. Acid water treatment is not recommended.5.Theuseofsimplebleed-offorchemicaltreatmentforcontrol of scale or corrosion does not preclude the need tocontrol biological contamination. Treatment with biocides isa necessary portion of required water treatment!For specific recommendations on water treatment, contacta competent water treatment supplier.SUGGESTEDMAINTENANCEINTERVALSBLEED-OFFVALVEThe bleed-off valve should be checked monthly to ensurethat it is not blocked and that water is flowing as required.Thevalveshouldbesetsothatthebleed-offrateistwoGPM per one million BTUs/hour of heat removed (or per 83tonsofrefrigeration).Thebleedvalveshouldalwaysbeopen,unlesstheunitiscontrolledbyawatertreatmentsystem.STRAINERThe pan water strainer is located at the bottom of the pansectionatthesuctionconnectionofthespraypump. Thestrainershouldbecleanedmonthly,orasconditionsre-quire,tokeepitclean.Thestraineriseasilyaccessiblethrough the access door. Do not operate the unit withoutthe strainer.MAKEUPVALVEThe pan water level is controlled by a float-actuated valvethat is accessible through the access door. This valve shouldbecheckedmonthlyforproperoperationandwaterlevel.The pan water level should be even with the centerline ofthe overflow when the unit is not running. This will preventthe pump from cavitating when the spray system is in op-eration. The water level is easily adjusted by loosening thewingnutonthevalveandraisingorloweringtheballtomaintain the proper level. The recommended operating pres-sure for the water makeup valve is 15 to 20 PSI.MOISTURE ELIMINATORSThe moisture eliminators are located on top of the unit andpreventlossesofthespraywaterduetowaterbeingen-trained in the air stream as it passes through the unit. Theeliminators should be checked monthly to remove any ob-structions that may be trapped between the blades and toensureproperpositioning.WATER DISTRIBUTION SYSTEMThespraynozzlesareaccessiblebymovingtheelimina-tors in sections from the top of the unit (DO NOT OPERATEUNITWITHOUTELIMINATORS).Thespraynozzlesarelarge orifice, cleanable type. The nozzles should be checkedmonthly to see that the spray pattern is complete and even.Figure 12 shows the nozzle orientation in the spray head-ers and the spray direction.Figure 12SPRAY HEADER NOZZLE ORIENTATIONXLEVAPORATIVECOOLINGPRODUCTSMAINTENANCES140-600IOMPage 13Ifthenozzlesarenotoperatingproperly,checkthatthestrainer in the pan or that the water distribution pipes do nothave accumulated dirt or debris. Also, check the nozzles byremoving them and clean any that may need cleaning. Thenozzlesarevirtuallynoncloggingandshouldseldomre-quirecleaningorattention.NOTE: When cleaning the nozzles and distribution sys-tem,alwaysensurethattheinitialorientationofthenozzles is maintained.HEAT TRANSFER SECTIONThecoilshouldbeexaminedmonthlyforsignsofscalebuildup, and any obstructions between the tubes should beremoved. If there is evidence of scale buildup on the coil,check the bleed valve for adequate bleed-off. If the bleed-offvalveisfunctioningproperly,contactyourlocalwatertreatment company for recommendations.FAN MOTOR AND SPRAY PUMP MOTORThe motors should be checked and/or lubricated every sixmonths according to the motor manufacturers recommen-dations.FAN BEARINGSThefanbeari ngsshoul dbecheckedmonthl yandrelubricated.Thebearingsshouldbelubricatedwhileinoperation, and the grease should be pumped in slowly untilaslightbeadformsaroundtheseals. Thegreasewillin-creaseintemperatureapproximately30Fduringtherelubrication.Iftherelubricationmustbedonewhilethebearings are not in operation, the grease capacity of eachbearing on the XLC units is 7/8 ounce.The capacity on theXLP units is 3/8 ounce. The grease should conform to NLGIGrade Two consistency and should be free of any chemicalimpurities such as free acid or free alkali, dust, rust, metalparticles or abrasives. Bearings should be lubricated withhand grease guns only.FAN DRIVE AND BELTSThefanandmotorsheavesandbelttensionshouldbecheckedeverymonthusingtheprocedureoutlinedbelow.Thesheavesshouldbetightontheshaftsandshouldbealigned properly to minimize belt wear. The belts should becheckedforwearalongtheedgesasanyirregularitywillcause vibration. If the belts are not wearing evenly, the causecould be improper sheave alignment. Use the sheave align-mentprocedurebelowtocheckthesheavealignment.Ifanybeltrequiresreplacement,replaceallthebeltswithamatched set, never one at a time.Sheave InspectionCheck the sheaves for proper alignment, excessive corro-sion, and wear or damage. Also, check the belt for exces-sive heat. If the belt is too hot to touch, then the sheavesmaybedamagedorneedaligning.Ifthesheaveshaveexcessivecorrosionorarewornordamaged, they should be replaced. Check for sharp edgesfromwearorpittingofthegroovesfromcorrosion.Eitherconditionwillpromotebeltwearandincreaseturnover.Groove gauges are also available to make it easy to see ifthegroovesareworn.Ifmorethan1/32ofwearcanbeseen, the sheave should be replaced.Alignment of sheaves is extremely important for proper beltinstallation. The sheaves are aligned at the factory, but shouldbe rechecked when new belts are installed. Use a straightedgetocheckalignment.Misalignmentwillshowupasagapbetweentheoutsidefaceandthestraightedge. Twoconditionsformisalignmentexist,angularandparallel. Tocheck both parallel and angular alignment, refer to the Fig-ure 13 below and follow these instructions:1. While placing a straight edge across the top of both motorand fan sheaves, check for four points of contact.2.Ifafour-pointcontactisachieved,skiptothebelttensioningsection.3.Toadjustforparallelmisalignment,adjustthemotororfan shaft sheave.4. To adjust for angular misalignment, adjust the motor mountadjustment nuts. This should also be done when tensioningthe belt.Figure 13SHEAVE ALIGNMENTXLEVAPORATIVECOOLINGPRODUCTSMAINTENANCES140-600IOMPage 14BeltReplacementWhen the decision is made to replace the belt, follow thesesteps:1. Lock and tag out the starter.2. After the power has been turned off and the motor guardremoved, loosen the motor mount adjustment nuts.3. Move the motor until there is enough slack in the belt soit can be removed without prying.4. Remove the old belts and inspect for unusual wear. Ex-cessivewearmayindicateproblemswithalignmentorsheavedamage.5. Order replacement belts from the factory to ensure a properbeltequivalent.6.Inspectotherdrivecomponentssuchasbearingsandsheaves for alignment, wear, lubrication, etc.7.Cleanthesheavesofdebrisbeforeinstallingthenewbelt.8. Install the new belts, align the drive, and tension the beltsaccordingtotheproceduresoutlinedhere.Belt TensioningPropertensionofabeltisveryimportanttoensuremaxi-mum belt life. If too little tension is applied, the belt will slip.Too much tension can reduce belt and bearing life. It is notrecommendedthatbeltdressingisusedwhenbeltslip-page occurs as this will damage the belt and cause prema-ture failure.1.Decreasethecenterdistancebetweenthesheavessothat the sheaves are somewhat loose.2. Arrange the belts so the top and bottom spans have thesame amount of sag. On vertical drives, arrange the beltsso that each side has about the same amount of slack.3.Applytensiontothebeltsbyincreasingthecenterdis-tance between the sheaves until the belts are snug.4. Operate the drive a few minutes to seat the belts in thesheave grooves. Observe the operation of the drive duringstart-up. A slight bowing of the slack side of the drive indi-cates proper tension. If the slack side remains taut duringthepeakload,thedriveistotight.Excessivebowingorslippage indicates insufficient tension. If the belts squeal asthemotorcomeson,theyarenottightenough. Thedriveshould be stopped and the belts tightened.Note: Do not overtighten the drive. If the above procedurestill results in the belts squealing, but the belts are still tauton the slack side, a more precise method of testing the belttensionmustbeused.Inthiscase,useabelttensioninggage available from V-belt drive manufacturers or from Im-eco.New Belt Run-InDuring initial startup of new belts, a belt run-in procedure isrecommended. During start-up, follow these instructions:1.Duringstart-up,lookandlistenforunusualnoiseorvi-bration.2. After shutting down and locking out the starter, check thebearings and motor. If they feel hot, the belt tension may betoo tight.3. Run the drive under full load for 24 hours of continuousoperation. Running the belts under full load allows them toseat themselves into the grooves.4.Afterrunningthedrive,checkthetensionofthebelts.Retensiontotherecommendedvalues.Thisrun-inprocedurewillreducethefutureneedforre-tensioning and will help extend the life of the belts.FANSThe fans should be checked monthly for any debris caughtintheblades.Anyforeignmaterialthathasaccumulatedbetweenthebladesshouldberemovedtopreventairca-pacityreductionoranimbalance,resultinginexcessivevibration.CASING FINISHThe casing finish should be checked annually for corrosionthat may have occurred due to the alternating wet and dryconditions. Any area that has corroded should be thoroughlycleaned and retouched with a zinc rich compound.DISCHARGECLOSUREDAMPERS/CAPACITYCONTROL DAMPERS/LINKAGESUnder normal operating conditions, all bearings and otherworking joints must be lubricated every three months with awater-resistant grease which is rated for satisfactory perfor-mance at an ambient temperature range of -65F to 250F.Alllinkagesshouldalsobeinspectedmonthlytoensureproper adjustment and flexibility. All linkage ball joints shouldbelubricatedeverythreemonthswiththesamegreasementionedabove.ELECTRICPANWATERLEVELCONTROLPACKAGESInspectStillingChamberforobstructionseverythreemonths.OPERATIONANDMAINTENANCEINITIAL AND SEASONAL START-UPBeforeinitialstart-uporafteralongshutdownperiod,theunit should be thoroughly inspected and cleaned. The start-upsequenceshouldbe:1.Cleananydebrisfromguards,fans,eliminators,heattransfer sections, and cold water sump.2. Flush the cold water sump (WITH STRAINERS IN PLACE)and drain to remove accumulated dirt.3. Remove, clean, and replace sump strainers.4.Turnthefan(s)byhandtoensurerotationwithoutob-struction.5. Check and, if necessary, adjust the fan belt tension.6.Priortoseasonalstart-up,lubricatethefanshaftandmotorbearings.Theballbearingsarefactorylubricated,but should be relubricated if the unit has been sitting on sitefor more than a year before start-up.7. On units furnished with discharge closure dampers and/or capacity control dampers, lubricate all bearings and otherworkingjointsandensureproperlinkageoperation.XLEVAPORATIVECOOLINGPRODUCTSMAINTENANCES140-600IOMPage 158. Check float-operated makeup valve to be sure it is oper-atingfreely.9. Fill cold water sump with fresh water to the overflow level.10. Adjust the float on the makeup valve to shut off the valvewhenthefloatisapproximately1.0"to1.5"belowthecenterline of the overflow.11. Start spray pump and check for the proper rotation asindicatedbystickeronpumpmotor.On Remoteinstalla-tions where the unit pump was not furnished by the factory,aglobevalveshouldbeinstalledinthepumpdischargelineandthepumpflowrateadjustedtothecorrectwaterflow.12. Inspect spray nozzles and heat transfer section.13. Check the locking collar on each fan shaft bearing andtighten if necessary.14.Startthefan(s)andcheckforproperrotationasindi-cated by sticker on unit.15. Check the voltage and current of all three legs of the fanand pump motors. The current should not exceed the ratedservice factor. After prolonged shutdowns, the motor insula-tionshouldbecheckedwithaMeggerInsulationTesterprior to restarting the motors.16. Open the bleed line valve and adjust bleed to the rec-ommendedrate.17. On units furnished with electric water level control pack-ages,ensurethatthestillingchamberisfreeofobstruc-tions.AFTER 24 HOURSAfter24hoursofoperationunderload,thefollowingser-vices should be performed:1. Check unit for any unusual noise or vibration.2. Check the operating water level in the cold water sump.Adjust if necessary.3. Readjust fan belt tension if required.4. Inspect spray nozzles and heat transfer section.OPERATIONDuringoperation,theunitshouldbeinspected,cleanedandlubricatedonaregularbasis.Therequiredservicesandrecommendedfrequencyforeacharesummarizedinthe Operation and Maintenance Schedule in this manual.SEASONAL SHUTDOWNThe following services should be performed when the unitis to be shutdown for a prolonged period:1.Drainthecoldwatersumpandallpipingthatwillbeexposed to freezing temperatures.2. Clean and flush the cold water sump with sump strainerinplace.Leavethedrainopensorainandmeltingsnowwill drain from the unit.3. Clean the sump strainers and reinstall.4. Lubricate the fan shaft and motor bearings, motor baseand motor base adjusting screws.5. Close shut-off valve in water make-up line and drain allexposedmake-uppiping.6. Inspect the protective finish on the unit. Clean and refin-ish as required.7. On units furnished with discharge closure dampers and/or capacity control dampers, lubricate all bearings and otherworkingjoints.8. On units equipped with electric water level control pack-ages,inspectstillingchambertoensureitisfreeofanyobstructions.XLEVAPORATIVECOOLINGPRODUCTSMAINTENANCES140-600IOMPage 16OPERATIONANDMAINTENANCESCHEDULEEVERY 3 EVERY 6TYPE OF SERVICE START-UP MONTHLY MONTHS MONTHS SHUTDOWN ANNUALLYInspect General Condition of Unit X XClean debris from unit X X XClean and flush sump X X XCleansumpstrainer X X XCheckandadjustsumpwaterlevel X XInspectheattransfersection X XInspectspraynozzles X XCheck and adjust fan belt tension X XCheck and adjust bleed rate X XCheckoperationofmake-upvalve X XCheck unit for unusual noise or vibration X XCheckfanbearinglockingcollars X XCheckmotorvoltagecurrent X XLubricatefanshaftbearings X X XLubricatemotorbaseadjustingscrews X X XLubricate the fan and pump motors XCheckfanforrotationwithoutobstruction X XCheck fan and pump motor for proper rotation XDrain sump and piping XInspectprotectivefinish X XLubricatecapacitycontroland/ordischarge X X XclosuredamperbearingsandworkingjointsInspect/adjustdamperlinkage X X XInspectelectricpanwaterlevelcontrol X X X"stillingchamber"SAFETYAdequateprecautionsshouldbetakentosafeguardtheequipmentandthepremisesfromdamageandthepublicfrom possible injury as appropriate for the installation andlocation of these products.Before performing any maintenance or inspection, make certain that all power has been discon-nected.FREEZE PROTECTIONThese products must be protected against damage and/orreducedeffectivenessduetopossiblefreeze-upbyme-chanicalandoperatingmethods.PleaserefertotheColdWeatherOperationguidelinesXLEVAPORATIVECOOLINGPRODUCTSMAINTENANCES140-600IOMPage 17SPAREPARTSFrick recommends that the customer maintain the followingsparepartsinstockfortheEvaporativeCondenser.Bymaintainingthisinventoryofspareparts,continuousunitoperationwillbeensured.Contact your local Frick representative for pricing.Thetypeandrecommendedstocklevelforeachpartislistedbelow.MODEL SERIALNUMBERPARTNUMBER RECOMMENDED STOCK LEVEL*FAN BELTS - ____________________________________________________ One Set*FAN BEARINGS - ________________________________________________ One SetFAN BUSHING - __________________________________________________ One SetMOTOR BUSHING - _______________________________________________ One SetFAN SHEAVE - ___________________________________________________ One SetMOTOR SHEAVE - ________________________________________________ One SetFLOAT VALVE ASSEMBLY - _________________________________________ OneSPRAY NOZZLES - ________________________________________________ One Set*FAN MOTOR - ___________________________________________________ One Set*SPRAY PUMP - __________________________________________________ OneFAN SHAFT - ____________________________________________________ One* Parts noted to be considered as critical components to be stocked by customers to ensure continuous unit operation.XL/EFCEVAPORATIVECOOLINGPRODUCTSS140-600IOMPage 18Thispageleftblankintentionally.XL/EFCEVAPORATIVECOOLINGPRODUCTSS140-600IOMPage 19Thispageleftblankintentionally.York Refrigeration3820 Highway 26 Polo, IL USA 61064Phone: 815-946-2351 Fax: 815-946-2034Subject To Change Without Notice PrintedinUSA