MicroCool IBEX Series Mode d’emploi

IBEX 8 Nozzle SMALL FRAME_June 2020 June 20 Page 1 of 41

IBEX SERIES 1-3 GPM

2020 Installation & Maintenance Manual Version 06.20

MicroCool

72216 Northshore Street #103-104, Thousand Palms, CA 92276, USA

www.microcool.com

Phone:

+1-760-322-1111

[email protected]

Fax:

+1-760-343-1820

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Table of Contents

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

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

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

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

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

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

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

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

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

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

TOTAL DISSOLVED SOLIDS COUNT ...................................................................................................................................... 6

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

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

ULTRAVIOLET WATER PURIFIERS ........................................................................................................................................ 6

REVERSE OSMOSIS WATER TREATMENT ............................................................................................................................ 6

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

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

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

DRAINAGE FROM THE PUMP.............................................................................................................................................. 7

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

CAUTION! ........................................................................................................................................................................... 8

INSURE ELECTRICAL SPECIFICATION ................................................................................................................................... 8

ELECTRICAL CONTROLS ....................................................................................................................................................... 8

ELECTRICAL CONNECTIONS/ HIGH VOLTAGE...................................................................................................................... 8

24V DC VOLTAGE FROM PUMP CONTROLLER .................................................................................................................... 9

5. Standard wiring diagrams for MicroCool



IBEX pump modules .................................................. 9

6. Principle of the VFD system on the IBEX pump unit..................................................................... 9

VARIABLE FREQUENCY DRIVE ............................................................................................................................................. 9

7. MicroCool IBEX - STARTING THE SYSTEM...................................................................................10

START UP .......................................................................................................................................................................... 10

8. PRESSURIZING THE SYSTEM ......................................................................................................11

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9. System Operation .....................................................................................................................12

Time Clock................................................................................................................................................................................. 13

Setting Date & Time.......................................................................................................................................................... 13

Setting Auxiliary Parameters ............................................................................................................................................ 13

Drain/Pressure Relief Valve Time................................................................................................................................................ 13

Setting Drain Valve Time................................................................................................................................................... 13

24 Hour, 7 Day Clock Time........................................................................................................................................................ 14

9.4 Setting 24 Hour, 7 Day Clock Timers................................................................................................................................. 14

Setting Cycle/Pulse Timer ................................................................................................................................................. 14

Disabling F1 “Manual Run ................................................................................................................................................ 14

Setting Internal Temperature and Humidity Controls (Optional Upgrade)....................................................................... 15

Setting for Humidity control only:..................................................................................................................................... 15

Setting for Temperature control only: .............................................................................................................................. 15

Setting for Humidity control with Temperature override: ................................................................................................ 15

Setting for Temperature control with Humidity override: ................................................................................................ 15

To view the VFD fault code: .............................................................................................................................................. 15

10. SYSTEM MAINTENANCE ............................................................................................................22

CRANKCASE OIL................................................................................................................................................................. 22

SYNTHETIC 75w-90 GEAR OIL IS RECCOMENDED FOR ALL APPLICATIONS (Mobil One or Equal).............................................. 22

ELECTRICAL MOTOR SERVICE............................................................................................................................................ 22

INLET WATER FILTERS ....................................................................................................................................................... 23

ATOMIZATION LINES/MANIFOLD HOSES.......................................................................................................................... 23

SYSTEM FLUSH – SHUT DOWN - WINTERIZING................................................................................................................. 23

INLET WATER PRESSURE SWITCH ..................................................................................................................................... 23

OPTIONAL EXTRAS ............................................................................................................................................................ 24

11. TROUBLE SHOOTING.................................................................................................................25

PUMP MODULE HAS STOPPED RUNNING......................................................................................................................... 25

INLET WATER PRESSURE FAULT:....................................................................................................................................... 25

VARIABLE FREQUENCY DRIVE (VFD) FAULT CODES .......................................................................................................... 26

12. WARRANTY ..............................................................................................................................28

13. UL Certification.........................................................................................................................29

14. IBEX 1-3 Gallon Illustrations......................................................................................................30

IBEX 1-3 GALLON FRONT VIEW ......................................................................................................................................... 30

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IBEX 1-3 GALLON REAR VIEW............................................................................................................................................ 31

IBEX 1-3 GALLON RIGHT SIDE VIEW.................................................................................................................................. 32

IBEX 1-3 GALLON LEFT SIDE VIEW..................................................................................................................................... 33

IBEX 1-3 GALLON TOP VIEW.............................................................................................................................................. 34

IBEX 1-3 GALLON INTERNAL TOP VIEW ............................................................................................................................ 35

IBEX 1-3 GALLON BOTTOM VIEW ..................................................................................................................................... 36

IBEX 1-3 GALLON 240V CONTROL PANEL.......................................................................................................................... 37

IBEX 1-3 GALLON 480V CONTROL PANEL.......................................................................................................................... 38

IBEX 1-3 GALLON NOTES 1 ............................................................................................................................................ 39

IBEX 1-3 GALLON NOTES 2 ............................................................................................................................................ 40

IBEX 1-3 GALLON 208-240V ELECTRICAL DIAGRAM...................................................................................................... 41

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WARNING!!

PLEASE TAKE NOTE OF THE FOLLOWING

1. BEFORE STARTING

PLEASE READ THIS GUIDE ENTIRELY BEFORE BEGINNING INSTALLATION

ALSO, READ SUPPLEMENTAL INFORMATION RELATING TO OPTIONAL CONTROL EQUIPMENT

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.

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.

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. (6.20BAR)

•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

9SYSTEM OPERATION FOR FUTHER INFORMATION.

OIL CHANGE INTERVAL

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

•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)

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. Extreme caution should always be exercised when working with high pressure water. Always wear safety glass

when working around fog equipment.

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.

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.

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. For more information about Water Quality, consult a MicroCool specialist.

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

TOTAL 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 6.7 and above 7.5 may not be satisfactory and could

lead to excessive nozzle blockage and the need for nozzle maintenance.

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 (SLI) 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.

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 undesirables’ proper treatments are

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

details.

ULTRAVIOLET WATER PURIFIERS

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.

REVERSE OSMOSIS WATER TREATMENT

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 odors

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

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 - Zone Controllers, Temperature/Humidity Controllers, Reverse

Osmosis, UV sterilizers, etc...

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 upon it.

A concrete floor or a concrete slab is ideal. Attach the supplied adjustable feet and plugs

to the legs of the pump as shown in the photograph (right). Using a level, make sure that

the IBEX unit sits as level and plumb as possible.

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

MIN Flow rate

(USGPM)

MIN Flow Rate (LPM)

MIN Pressure psi /

bars

IBEX 1000 (1.00gpm)

1.00

3.79

20 / 1.40

IBEX 2000 (2.00gpm)

3.00

11.40

20 / 1.40

IBEX 3000 (2.50gpm)

3.75

14.25

20 / 1.40

Correct water pressure and flow 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 a low

pressure inlet water fault delay timer, which allows small drops in pressure, but will ultimately “fault off” if low pressure

is present for more than a few seconds.

Ensure that either copper or PVC pipe is used to provide the

correct water supply to the IBEX unit. Never use steel or

galvanized steel fittings. Always use the largest diameter pipe

practical.

DRAINAGE FROM THE PUMP

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

and through the end of the atomization lines on some 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 tube is provided for this purpose. 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.

CAUTION!

If the pump unit will be powerd by a generator at any time, a properly sized line reactor needs to be installed prior to

the pump unit to eliminate voltage spikes. If this is not done, the Variable Frequency Drive (VFD) & procesor could

be damaged and warranty may be voided.

INSURE 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 IBEX electrical specification can be found on the serial number label or from the electrical wiring

diagram adhered to the inside cover of the electrical enclosure on the pump module.

4.2.1 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 MicroCoolEngineering Manual or electrical data plate on the

motor to determine the amperage draw of the Ibex pump module.

4.2.2 The power supply to the pump module must be hard wired directly to a fused disconnect box. If the power

supply cannot be directly wired to a disconnect box, then it should be hard wired, using a junction box, into a

suitable circuit with a disconnect box located elsewhere. This applies to either single phase or three phase

applications.

4.2.3 After verifying all of the above, power should be taken from the disconnect box/junction box to the terminal

strip located inside the 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.

ELECTRICAL CONTROLS

The high voltage motor electrical supply must be connected to the pump module inside the control box. The low

voltage control wiring must also be connected inside the control box. We recommend that a LICENSED

ELECTRICIAN IS USED FOR ELECTRICAL CONNECTIONS.

ELECTRICAL CONNECTIONS/ HIGH VOLTAGE

Open front cover to connect the high voltage wiring to pump controls. Connect high voltage to TB1(terminal block

1) electrical strip in the control box. There is a conduit connector provided for connecting conduit to the side of the

control box.

208-240 volt 1 phase 50/60 Hz systems connect to:

Connections:

1: Zero Voltage Remote Start (cable must be shielded)

2: Zero Voltage Remote Start (cable must be shielded)

3: Zero Voltage Fault output

4: Zero Voltage Fault output

5: 208-240 Volt 1 phase 50/60 Hz power supply- L1

6: 208-240 Volt 1 phase 50/60 Hz power supply- L2

Ground grnd(grn/yel)

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208-240 volt 3 phase 50/60 Hz systems connect to:

Connections:

1: Zero Voltage Remote Start (cable must be shielded)

2: Zero Voltage Remote Start (cable must be shielded)

3: Zero Voltage Fault output

4: Zero Voltage Fault output

5: 208-240 Volt 3 phase 50/60 Hz power supply- L1

6: 208-240 Volt 3 phase 50/60 Hz power supply- L2

7: 208-240 Volt 3 phase 50/60 Hz power supply- L3

Ground grnd(grn/yel)

See note 4.5

380-575 volt 3 phase systems connect to:

PD1 - Connections:

L1: 380-575 Volt 3 phase 50/60 Hz power supply- L1

L2: 380-575 Volt 3 phase 50/60 Hz power supply- L2

L3: 380-575 Volt 3 phase 50/60 Hz power supply- L3

TB1 - Connections:

1: Zero Voltage Remote Start (cable must be shielded)

2: Zero Voltage Remote Start (cable must be shielded)

3: Zero Voltage Fault output

4: Zero Voltage Fault output

Ground grnd(grn/yel)

24V DC VOLTAGE FROM PUMP CONTROLLER

External (remote) start connections must be made to TB1 Terminals 1 & 2. Note that this connection is powered by

a 24V DC voltage from the pump controller. Adequate care must be taken NOT to connect a different or separate

power supply to these terminals as serious damage could occur. If in doubt – please contact the factory for a

suitable relay or conditioner.

WARNING: The control box is completely wired for immediate operation. After high voltage wiring is connected

and the unit is supplied with proper water pressure, pressing F1 will immediately

activate the pump operation.

5. Standard wiring diagrams for MicroCoolIBEX pump modules

An as-built wiring diagram has been added to the back of this manual.

6. Principle of the VFD system on the IBEX pump unit

VARIABLE FREQUENCY DRIVE

6.1.1 A VFD (Variable Frequency Drive) controls the speed of the electrical motor (and subsequently the pump

head) by changing the Frequency (Hertz). The IBEX pump module has a Pressure Transducer unit mounted on the

high-pressure (discharge) side of the pump that transmits the water pressure back to the control unit.

6.1.2 The controller is pre-set to maintain a pressure of 1,000 psi (70 Bar) at the discharge of the pump.

6.1.3 As the water flow rate of the system changes (for example with more or less nozzles in operation) the

controller will increase or decrease the motor speed to maintain the required pressure (1,000 psi / 70 Bar).

IBEX 8 Nozzle SMALL FRAME_June 2020 June 20 Page 10 of 41

The controller is capable of increasing the speed (frequency) to a maximum of 50 Hz. The rate of change is

governed by programming within the drive to reduce motor, pump, and equipment wear.

6.1.4 The minimum speed of the motor is also regulated by the controller. At very low rpm, the pump may be

moving too slowly to adequately distribute the oil in the pump reservoir. Damage to the pump may occur.

The minimum speed (frequency) is set at 15 Hz to protect the pump unit from oil starvation.

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

end of this manual.

7. MicroCool IBEX - STARTING THE SYSTEM

START UP

7.1.1 Install UV bulb prior to start up. (If UV is provided)

7.1.2 The system must be primed and flushed before pressurization.

This removes any contaminants such as dirt, brass filings or

Teflon tape that have found their way into the system.

7.1.3 Turn on the water supply to the pump module. The inlet or low

pressure gauge should read at the very least 20 PSI (1.4 BAR)

indicated by the green area of the dial. If the water pressure is

not sufficient, do not try to start the pump. The water pressure

problem must be corrected first.

7.1.4 To prime the pump module turn on the power supply to the IBEX module, open the electrical enclosure,

switch the circuit breaker to the on position. Once the VFD indicates “RDY” and the PLC is illuminated,

press F3 and F4 simultaneously. This will start the prime sequence of 30 seconds. The pump is now ready

to be started.

7.1.5 To start the IBEX module press F1 (run in Manual). The pump module will now run, 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, there is a 3 second delay before the system goes to

“FAULT”. Refer to section 9 to reset.

7.1.6 The pump motor RPM will ramp (increase) up to the maximum speed (50 Hz) to fill the system. Do not worry

if the pressure does NOT reach 1,000 PSI (70 BAR) at this time (during flush sequence).

7.1.7 Let the module run for 2-3 minutes making sure that there is a good flow of water running out the end of the

atomization lines. Lines may have to be flushed in groups, with larger systems, to ensure adequate system

flush.

7.1.8 When finished flushing, press F3 (Stop) to stop the pump module.

7.1.9 The system is now flushed and ready for the pressurization procedure.

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