MicroCool BIGHORN Series Mode d’emploi

BIGHORN_March 2020.docx March 26, 2020 Page 1 of 36

Fog System

2020 Installation & Maintenance Manual Version 3 26

BIGHORN Series

MicroCool

Web site: www.microcool.com

Email: [email protected]

72216 Northshore St. #103-104

Thousand Palms, CA 92276, USA

Phone: +1-760-322-1111

Fax: +1-760-343-1820

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Table of Contents

1. BEFORE STARTING .................................................................................................................... 5

1.1 CRANKCASE OIL PLUG ......................................................................................................................................................... 5

1.2 OIL LEVEL ............................................................................................................................................................................. 5

1.3 INLET WATER SUPPLY PRESSURE. ....................................................................................................................................... 5

1.4 OIL CHANGE INTERVAL........................................................................................................................................................ 5

1.5 HIGH PRESSURE FITTINGS ................................................................................................................................................... 5

1.6INLET WATER SUPPLY PLUMBING MATERIAL..................................................................................................................... 5

1.7 FLUSHING THE SYSTEM ....................................................................................................................................................... 5

1.8 TEFLON TAPE ....................................................................................................................................................................... 5

2. WATER QUALITY ....................................................................................................................... 6

2.1 TOTALLY DISSOLVED SOLIDS COUNT .................................................................................................................................. 6

2.2 WATER ANALYSIS ................................................................................................................................................................ 6

2.3 WATER TREATMENT............................................................................................................................................................ 6

2.4 ULTRAVIOLET WATER PURIFIERS (OPTIONAL).................................................................................................................... 6

2.5 REVERSE OSMOSIS WATER TREATMENT (OPTIONAL)........................................................................................................ 6

3. INSTALLATION OF THE PUMP MODULE ..................................................................................... 7

3.1 PRE-INSTALLATION PROCEDURE......................................................................................................................................... 7

3.2 POSITIONING THE PUMP MODULE..................................................................................................................................... 7

3.3 WATER SUPPLY AND CONNECTION .................................................................................................................................... 7

3.4 INLET WATER HOSE............................................................................................................................................................. 7

3.5 PUMP DRAINAGE ................................................................................................................................................................ 7

4. PUMP MODULE POWER SUPPLY ............................................................................................... 8

4.1 ELECTRICAL SPECIFICATION................................................................................................................................................. 8

4.2 ELECTRICAL CIRCUIT ............................................................................................................................................................ 8

4.3 ELECTRICAL POWER SUPPLY ............................................................................................................................................... 8

4.4 TERMINAL STRIP - POWER .................................................................................................................................................. 8

4.5 ELECTRICAL CONNECTIONS- LOW VOLTAGE ...................................................................................................................... 8

5. BIGHORN – VFD BASICS............................................................................................................. 9

6. MICROCOOL BIGHORN - STARTING THE SYSTEM ...................................................................... 9

6.1 SYSTEM FLUSH..................................................................................................................................................................... 9

6.2 WATER & DRAIN VALVES .................................................................................................................................................... 9

6.3 TURN ON POWER ................................................................................................................................................................ 9

6.4 PUMP IS RUNNING.............................................................................................................................................................. 9

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6.5 LOW WATER PRESSURE .................................................................................................................................................... 10

6.6 SYSTEM RUN...................................................................................................................................................................... 10

7. PRESSURIZING THE SYSTEM .................................................................................................... 10

7.1 INSTALL DRAIN VALVES ..................................................................................................................................................... 10

7.2 MAN/OFF/AUTO SWITCH.................................................................................................................................................. 10

7.3 PRESSURE REGULATOR ..................................................................................................................................................... 10

8. DRAIN VALVE SEQUENCE ........................................................................................................ 11

8.1 SYSTEM ON/OFF................................................................................................................................................................ 11

8.2 RAMP DOWN..................................................................................................................................................................... 11

8.3 LOW SYSTEM SHOCK ......................................................................................................................................................... 11

9. SYSTEM OPERATION ............................................................................................................... 11

9.1 EXTERNAL CONTROLS........................................................................................................................................................ 11

9.2 TROUBLE SHOOTING CHART............................................................................................................................................. 12

10.SYSTEM MAINTENANCE .......................................................................................................... 12

10.1 CRANKCASE OIL ................................................................................................................................................................. 12

10.2 TYPE OF CRANKCASE OIL................................................................................................................................................... 12

10.3 ELECTRICAL MOTOR MAINTENANCE ................................................................................................................................ 12

10.4 INLET WATER FILTER ......................................................................................................................................................... 12

10.5 ATOMIZATION HOSE AND MANIFOLD.............................................................................................................................. 13

10.6 SYSTEM FLUSH – SHUT DOWN - WINTERIZING ................................................................................................................ 13

11. GUIDELINES FOR LOCATION AND INSTALLATION OF ATOMIZATION LINE ................................ 13

11.1 AIRFLOW............................................................................................................................................................................ 13

11.2 SUPPORTS & ALIGNMENT................................................................................................................................................. 13

11.3 NOZZLE ANGLE .................................................................................................................................................................. 13

11.4 NOZZLE DIRECTION ........................................................................................................................................................... 13

11.5 CEILINGS & SHADE SCREENS ............................................................................................................................................. 13

11.6 HOT SURFACES .................................................................................................................................................................. 13

11.7 DRAINAGE.......................................................................................................................................................................... 13

11.8 VENTING............................................................................................................................................................................ 13

11.9 TWISTS & KINKS................................................................................................................................................................. 14

11.10 SUPPORT & ROUTING ................................................................................................................................................... 14

12. INSTALLATION OF FLEXIBLE ATOMIZATION & MANIFOLD LINE FITTINGS ................................. 14

12.1 USE OF REUSABLE HOSE FITTINGS.................................................................................................................................... 14

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13. INSTALLATION OF REUSABLE HOSE FITTINGS........................................................................... 15

13.1 WARNING:......................................................................................................................................................................... 16

14. INSTALLATION OF STAINLESS STEEL LINE FITTINGS .................................................................. 16

14.1 INSTALLATION INSTRUCTIONS—TUBE FITTINGS .............................................................................................................. 17

14.2 INSTALLATION INSTRUCTIONS-TUBE BENDING................................................................................................................ 17

15. INSTALLATION OF ATOMIZATION LINE .................................................................................... 18

15.1 METHODS OF SUSPENDING ATOMIZATION LINES ........................................................................................................... 18

15.2 USE OF AIRCRAFT CABLE ................................................................................................................................................... 18

15.3 AIRCRAFT CABLE INSTALLATION TECHNIQUE................................................................................................................... 18

15.4 SPECIAL CONSIDERATIONS:............................................................................................................................................... 20

16. HOSE CLAMP INSTALLATION TECHNIQUE ................................................................................ 21

16.1 SPECIAL CONSIDERATIONS:............................................................................................................................................... 21

16.2 FLEXIBLE MANIFOLD OR FLEXIBLE NOZZLE LINE RELIEF ROUTING................................................................................... 22

17. ORIENTATION OF ATOMIZATION NOZZLES.............................................................................. 22

17.1 NOZZLE ANGLE .................................................................................................................................................................. 23

18. ATOMIZATION LINE/MANIFOLD HOSE DRAINAGE................................................................... 23

19. ATOMIZATION NOZZLES.......................................................................................................... 24

20. UL CERTIFICATE....................................................................................................................... 26

21. WARRANTY............................................................................................................................. 27

22. BIGHORN ILLUSTRATIONS ....................................................................................................... 28

22.1 BIGHORN FRONT EXTERNAL VIEW.................................................................................................................................... 29

22.2 BIGHORN BACK EXTERNAL VIEW ...................................................................................................................................... 30

22.3 BIGHORN RIGHT EXTERNAL VIEW..................................................................................................................................... 31

22.4 BIGHORN LEFT EXTERNAL VIEW ....................................................................................................................................... 32

22.5 BIGHORN TOP EXTERNAL VIEW ........................................................................................................................................ 33

22.6 BIGHORN TOP INTERNAL VIEW......................................................................................................................................... 34

22.7 BIGHORN CONTROL PANEL VIEW ..................................................................................................................................... 35

22.8 NOTES................................................................................................................................................................................ 36

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1. BEFORE STARTING

PLEASE READ THIS GUIDE ENTIRELY BEFORE BEGINNING INSTALLATION

ALSO, READ SUPPLEMENTAL INFORMATION RELATING

TO OPTIONAL CONTROL EQUIPMENT

1.1 CRANKCASE OIL PLUG

The pump module crankcase vent has been plugged to prevent accidental oil leakage during shipment. Remove the

plug and replace with the supplied vent cap before operating pump unit. Failure to do so will cause oil leaks.

1.2 OIL LEVEL

Check that the oil level appears 1/2 way in the sight gauge or within range on the dipstick in the pump head.

1.3 INLET WATER SUPPLY PRESSURE.

When the pump module is running, it must be supplied with an inlet water supply of

NEVER LESS THAN 20 P.S.I. (1.40 BAR) and NEVER MORE THAN 90 P.S.I. (6.20 BAR)

•Inlet water supply pressure should be steady and should not be allowed to fluctuate outside of these ranges.

Failure to do so can result in damage to equipment and is not covered by warranty.

•IF WATER PRESSURE DROPS BELOW 20 PSI, THE PUMP WILL SHUT OFF AND THE FAULT LIGHT

WILL COME ON. SEE SECTION 9 SYSTEM OPERATION FOR FUTHER INFORMATION.

1.4 OIL CHANGE INTERVAL

The crankcase oil must be changed after the first 50 hours of operation and from then on, once every 500 hours or

every 6 months, whichever comes first.

•synthetic 75w-90 gear oil is recommended for all applications (mobile one or equal)

•Secondary choice synthetic 15w-50 motor oil may be used for all applications (mobile one or equal)

1.5 HIGH PRESSURE FITTINGS

The system operates at 1,000 P.S.I. (70 bar) and should always be shut down when working on fittings or manifold

line. When adjusting the orientation of the nozzles, follow the procedures. Extreme caution should always be

exercised when working with high pressure water. Always wear safety glasses when working around fog equipment.

1.6 INLET WATER SUPPLY PLUMBING MATERIAL

Only rated and approved brass fittings or stainless steel fittings should be used to make plumbing connections. The

use of galvanized or steel pipe fittings can cause system failure, nozzle blockage and pump damage.

1.7 FLUSHING THE SYSTEM

Before pressurizing the system, flush all plumbing and atomization lines thoroughly to purge any residual debris.

Please refer to the startup section 7 of this manual.

1.8 TEFLON TAPE

When using Teflon tape on NPT threads, leave 1 or 2 of the starting threads showing. This will prevent pieces of

Teflon tape from entering the system, which could cause blockage or damage.

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WATER QUALITY

2. WATER QUALITY

To obtain the best performance, special consideration should be given to the quality of water used in a MicroCool

fog system.

MicroCoolIS NOT RESPONSIBLE FOR NOZZLE BLOCKAGE DUE TO POOR WATER QUALITY.

2.1 TOTALLY DISSOLVED SOLIDS COUNT

Water with total dissolved solids (TDS) counts of greater than 500 parts per million (PPM); water with high calcium

and magnesium carbonate levels, or water with pH levels below 6.5 and above 7.5 may not be satisfactory and could

lead to excessive nozzle blockage and nozzle maintenance.

2.2 WATER ANALYSIS

If there is any doubt about water quality, a water analysis is recommended. Of major interest is the water’s Langelier

Saturation Index (LSI) together with other items such as hardness and TDS. A slightly negative, or neutral, Langelier

index is preferred, whereas a positive index may indicate a tendency to form calcium carbonate deposits in the lines

and nozzles.If using city water, an analysis should be available from the city/town water department. If in any doubt,

please contact your MicroCool representative for further information.

2.3 WATER TREATMENT

Generally speaking most municipal water is suitable for atomization. Well water, river water and the like should be

tested before atomizing. If an analysis indicates any unusually high levels of undesirable elements proper treatments

are available. MicroCoolcan supply a variety of water treatment systems. Please contact MicroCoolfor further

details.

2.4 ULTRAVIOLET WATER PURIFIERS (OPTIONAL)

Optional ULTRAVIOLET high intensity light purifiers can also be installed on the inlet water supply to sterilize the

system water. By bombarding the water with UV light, dangerous pathogens, spores and germs are destroyed. UV

systems must be regularly serviced to maintain the correct high intensity output.

2.5 REVERSE OSMOSIS WATER TREATMENT (OPTIONAL)

MicroCool offers optional comprehensive reverse osmosis packages for all applications. Units are available for large

scale industrial as well as domestic installations.

Reverse Osmosis units incorporate a semi-permeable membrane that micro filters the water to 0.0001 microns

removing bacteria, viruses, aqueous salts and metal ions. By eliminating these from the supply water, MicroCool

ensures that clean, hygienic water is used in each system. Clean water will also reduce nozzle blockage, foul

smelling water and white “chalky” deposits on material close to the fog spray.

MicroCool reverse osmosis systems are designed specifically for each application – please consult with MicroCool

specialists for more details.

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3. INSTALLATION OF THE PUMP MODULE

3.1 PRE-INSTALLATION PROCEDURE

•Determine pump module location

•Identify water supply/connection for the system

•Determine routing of the high pressure manifold from the pump.

•Establish drainage location from the pump.

•Verify correct electrical power supply to the pump.

•Determine all of the above for optional Equipment - Sectioning Controllers, Temperature/Humidity

Controllers, Reverse Osmosis, UV sterilizers, etc...

3.2 POSITIONING THE PUMP MODULE

The pump module requires a flat, level surface. Position selection will largely depend on the availability of power and

water, but remember the points outlined on the previous pages as the terms of the pump warranty depend on it.

A concrete floor or a concrete slab is ideal. Using a level, ensure that the BIGHORN unit sits as level and plumb as

possible.

3.3 WATER SUPPLY AND CONNECTION

The water supply should be capable of 1.5 times the maximum flow of the pump as shown in the table below.

Pump Model & Flow

Minimum Flow Rate

USGPM

MIN Flow Rate

(LPM)

MIN Pressure psi /

bars

BIGHORN 1000

1.50

6.00

20 / 1.40

BIGHORN 2000

3.00

12.00

20 / 1.40

Correct water pressure and supply rate are essential to pump operation. All pump modules require a minimum of 20

P.S.I. (1.40 BAR) and a maximum of 90 P.S.I. (6.20 BAR) while in operation. The pressure should always be constant

and not fluctuate outside these ranges, especially on system start up. All pump modules are equipped with an inlet

water fault delay timer that tolerates small drops in pressure, but will ultimately “fault off” if low pressure is present

for more than a few seconds.

Ensure that either rubber hose, copper or PVC pipe is used

to provide the correct water supply to the BIGHORN unit.

Never use steel or galvanized steel fittings. Always use the

largest diameter pipe possible.

The inlet hose connection is 3/8” Female NPT Thread

The outlet hose connection is ¼” Male thread NPT

Use care and do not over tighten.

3.4 INLET WATER HOSE

MicroCool can supply an inlet hose connection kit for your

BIGHORN pump – call your MicroCool specialist and ask for

item number IHK0001.

3.5 PUMP DRAINAGE

After the pump module shuts down, the water remaining in the manifold lines will drain out through the pump module

and the end of the atomization lines. Ensure that the drain outlet is routed to a suitable drainage point to avoid

flooding.A 6 foot (1.8 M) low pressure drain hose is provided from the drain solenoid. This hose can be extended

as necessary.

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4. PUMP MODULE POWER SUPPLY

After all water and plumbing connections have been completed, a licensed, qualified electrician should connect the

power supply to the pump. It is important to follow the National Electrical Code (NEC), as well as any local codes to

ensure a safe installation.

4.1 ELECTRICAL SPECIFICATION

Establish that the circuit to be used to power the pump module is of the same electrical specification as the pump

module. The BIGHORN electrical specification can be found on the serial number data plate on the pump module

(inside the pump control box).

4.2 ELECTRICAL CIRCUIT

The circuit to the pump module must be dedicated and properly sized to carry the electrical load placed upon it by

the pump motor. Please refer to the serial number data plate on the pump module for more details.

4.3 ELECTRICAL POWER SUPPLY

The power supply to the pump module must be hard wired to a correctly rated fuse protected circuit complying with

NEC guidelines. NOTE: This pump unit has a frequency inverter. If local electrical code requires a GFCI (Ground

Fault Circuit Interrupted), this pump will require a special GFCI unit. Please contact MicroCool for details.

4.4 TERMINAL STRIP - POWER

After verifying all of the above, power should be on to the terminal strip located inside the NEMA 3R electrical

enclosure mounted on the pump module. We recommended that the correct sized wiring be in conduit (preferably

liquid tight); make the final connection to the high voltage terminal strip.

4.5 ELECTRICAL CONNECTIONS- LOW VOLTAGE

NOTE:All control wiring such as remote start must be SHIELDED cable of suitable size, for this application.

a. Resets VFD Drive

b. Open to Disable Manual ON/OFF

Enclosure

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5. BIGHORN – VFD BASICS

•The VFD (Variable Frequency Drive) controls the speed of the electrical motor (and subsequently the pump

head) by changing the Frequency (Hertz).

•The VFD is shipped with a minimum factory setting of 30 Hz. This will produce the minimum speed at which

the pump is still capable of adequate oil distribution within the crankcase.This minimum setting will ensure

reduced motor and pump wear.

•The VFD is factory set at a maximum of 60 Hz. This will produce the maximum designed water flow of the

pump at 1000 psi / 70 Bar.

•For more details on the VFD drive, the readings and fault status refer to the WEG Drive supplement which

is enclosed.

6. MICROCOOL BIGHORN - STARTING THE SYSTEM

6.1 SYSTEM FLUSH

The system must be flushed before pressurization. This removes any contaminants such as dirt, brass filings or

Teflon tape that have found their way into the system. At the end of each atomization line, there is a plug or an

automatic drain valve. Do not install plugs or automatic drain valves until the system has been completely flushed.

6.2 WATER & DRAIN VALVES

Turn on the water supply to the pump module. Ensure that the drain valves or plugs at the end of lines are not

installed.

6.3 TURN ON POWER

1. Turn on the power supply to the BIGHORN module, and then

turn the circuit breaker switch mounted inside the electrical

enclosure to the on position. Ensure the VFD reads “RDY”.

2. To start the pump, switch the “MAN/OFF/AUTO” switch to the

MAN position.

6.4 PUMP IS RUNNING

The pump system is now in operation. The VFD will increase the

speed of the motor / pump to maximum speed (60 Hz) to fill the

manifold and nozzle lines.

Switch to Manual ‘MAN’ Position

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6.5 LOW WATER PRESSURE

If the inlet water pressure gauge drops below 20 P.S.I. (1.4 BAR) (or out of the green zone) when the pump starts,

the pump will go into fault mode and will not start.

There must be between 20 PSI (1.4 BAR) and 90 PSI (6.2 BAR) of pressure available to the pump at all times

NOTE: should the water pressure drop below the factory preset of 20 psi, the system goes to E06 “FAULT”. The

system will automatically try to restart after a 30 second delay. If the water pressure has been restored, the

system will continue running normally.

The BIGHORN pump incorporates a delay timer on the water pressure switch that allows the system to run for a

few seconds before going to alarm.

If the water pressure has not been restored, the system will attempt to start a further two times at 30 second

intervals. If the water pressure has still not been restored, the system will remain in fault and will need to be

manually reset.

To reset the unit; turn the MAN/OFF/AUTO switch to the “OFF” position and press the “Red/Green Button” on the

VFD panel one time and release. The system is now reset.

The setting on the water pressure-sensing switch is factory preset at 20 PSI / 1.4 Bar and does not require any

further adjustment.

6.6 SYSTEM RUN

Let the module run for five minutes making sure that there is a good flow of water running out the end of each

atomization line. Lines may have to be flushed in groups with a large system. The system is now ready for

pressurization.

7. PRESSURIZING THE SYSTEM

Safety glasses must be worn when adjusting pressure. Always keep guards and covers in place.

7.1 INSTALL DRAIN VALVES

Install the automatic drain valves, or plugs, into the open ends of the atomization lines. Use Teflon tape on NPT

threads and tighten each fitting firmly. Do not apply tape to compression fittings.

7.2 MAN/OFF/AUTO SWITCH

Select the MAN (ON) position on the main switch. Select AUTO if using external controllers or switches. The VFD

will now adjust the speed of the motor / pump so that the system pressure is steady at 1,000 psi / 70 bar. Depending

on the number of nozzles running in the system at any particular time,

7.3 PRESSURE REGULATOR

DO NOT ADJUST THE PRESSURE REGULATOR.The regulator is installed as a safety valve only

and is factory set at 1200 psi / 84 Bar. Should the regulator be taken apart for any reason, the correct reassembly

sequence is shown below.

NEVER DISSASSEMBLE THE REGULATOR UNDER PRESSURE!

JAM NUT

ADJUSTABLE KNOB

SPRING

BRASS THRUST PLATE

STAINLESS BALL

PRESSURE RELIEF

POPPET

WASHER

O-RING

INLET PORT

SEAT

O-RING O-RING

BYPASS OUTLET

Ce manuel convient aux modèles suivants

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