SPX RECOLD LC Manuel utilisateur
LC evaporative condenser
INSTALLATION - OPERATION - MAINTENANCE
Z1053717_B ISSUED 4/2019 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT
user manual
2
contents
Overview .......................................................................................................................3
Safety First....................................................................................................................3
Location.........................................................................................................................4
Shipment.......................................................................................................................4
Receiving ......................................................................................................................4
Hoisting.........................................................................................................................5
Installation.....................................................................................................................6
Control Panel ...............................................................................................................7
Mechanical Equipment ..............................................................................................8
Startup...........................................................................................................................8
Operation...................................................................................................................10
Dry Operation ...........................................................................................................11
Freezing Weather Operation.................................................................................11
Water Quality and Blowdown...............................................................................13
Evaporative Condenser Inspection and Maintenance.....................................15
Water Collection Basin Access/ Air Inlet Louver Removal ............................15
Access Doors ...........................................................................................................16
Fill Removal and Replacement..............................................................................16
Drift Eliminator Removal and Replacement ....................................................... 17
Distribution System Maintenance ........................................................................ 17
Routine Maintenance ..............................................................................................18
Seasonal Shutdown Instructions .........................................................................20
Long Term Storage Procedures ...........................................................................21
This manual contains vital information for the proper installation and
operation of your evaporative condenser. Carefully read the manual
before installation or operation of the evaporative condenser and
follow all instructions. Save this manual for future reference.
Note
Indicates presence of a hazard which can cause severe personal
injury, death or substantial property damage if ignored.
Indicates presence of a hazard which will or can cause personal
injury or property damage if ignored.
Indicates special instructions on installation, operation or mainte-
nance which are important but not related to personal injury hazards.
Warning
Caution
Note
The following defined terms are used throughout this manual to
bring attention to the presence of hazards of various risk levels, or
to important information concerning the life of the product. Also,
please observe all Caution and Warning labels on the tower.
3
overview
This User Manual, as well as those offered separately on motors, float valves,
pumps, etc., is intended to assure that this evaporative condenser serves you
properly for the maximum possible time. Since product warrantability may well
depend upon your actions, please read this User Manual thoroughly prior to
operation.
This User Manual provides information regarding general equipment installation
and operation. Any deviation from, change or modification to, the User Manual,
the original design conditions or the original intended use of the equipment
may result in improper installation and/or operation.
Any such deviation, change or modification shall be the responsibility of the
party or parties making such deviation, change or modification. SPX Cool-
ing Technologies, Inc. expressly disclaims all liability for any such deviation,
change or modification. The equipment shall be warranted in accordance with
the applicable SPX Cooling Technologies Certification of Limited Warranty.
If you have questions about the operation and/or maintenance of this evapora-
tive condenser, and you don’t find the answers in this manual, please contact
your sales representative. When writing for information, or when ordering
parts, please include the serial number shown on the equipment nameplate.
Safety First
The location and orientation of the evaporative condenser can affect the safety
of those responsible for installation, operation or maintenance. However, since
SPX Cooling Technologies does not determine the evaporative condenser
location or orientation, we cannot be responsible for addressing those safety
issues that are affected by evaporative condenser location or orientation.
The following safety issues should be considered by those
responsible for designing the evaporative condenser installation.
• Access to and from the collection basin
• Access to and from access doors
• The possible need for ladders (either portable or permanent) to
gain access to the access doors
• Access issues due to obstructions surrounding the evaporative
condenser
• Lockout of mechanical equipment
• The need to avoid exposing maintenance personnel to the
potentially unsafe environment inside the evaporative condenser
Warning
4
Those are only some of the safety issues that may arise in the design
process. SPX strongly recommends that you consult a safety engi-
neer to be sure that all safety considerations have been addressed.
Location
Space available around the evaporative condenser should be as generous
as possible to promote ease of maintenance and to permit freedom of airflow
into and through the evaporative condenser. If you have questions about the
adequacy of the available space or the intended configuration of the equip-
ment, please contact your Recold sales representative for guidance.
Prepare a stable, level support foundation for the evaporative condenser, utiliz-
ing weight, wind load, and dimensional information appearing on appropriate
Recold submittal drawings. Supports must be level to insure proper operation
of the evaporative condenser.
The evaporative condenser must be located at such distance and
direction to avoid the possibility of contaminated discharge air
being drawn into building fresh air intake ducts. The purchaser
should obtain the services of a Licensed Professional Engineer or
Registered Architect to certify that the location of the equipment is
in compliance with applicable air pollution, fire and clean air codes.
Shipment
Unless otherwise specified, evaporative condensers ship by truck (on trailer(s)),
which lets you receive, hoist, and install in one continuous operation.
Responsibility for the condition of the evaporative condenser upon its arrival
belongs to the carrier as does the coordination of multiple shipments, if required.
Receiving
Prior to unloading the evaporative condenser from the delivering carrier, in-
spect the shipment for evidence of damage in transit. If damage is apparent,
note the freight bill accordingly. This will support your future recovery claim.
Find and remove the installation instructions accompanying the evaporative
condenser. This information should be kept for future reference and mainte-
nance purposes.
Warning
receiving and hoisting
5
Hoisting
All LC evaporative condenser models use reinforced hoisting clips located
near the air inlet (bottom section) of the equipment for overhead lifting and
handling of assembled shipping modules. A spreader bar should always be
used at the top of the unit to help balance the load and prevent damage to
the top section — consult the applicable hoisting instructions drawing. Never
use hoisting clips located near the top of the equipment to lift the entire
unit, as these are intended for lifting subassemblies only during factory
assembly. If a forklift is used to lift from the base of the equipment, ensure
forks extend completely underneath the unit and past the basin flange on the
opposite side. Remove evaporative condenser from the trailer and hoist into
place according to the instructions.
Evaporative condensers must be hoisted and set according to in-
structions. Under no circumstances should you use hoisting clips
located near the top of the equipment to lift the entire unit.
Hoisting clips are provided for ease of unloading and positioning
the evaporative condenser. For overhead lifts or where additional
hazards exist, safety slings should also be placed under the unit.
Warning
Warning
receiving and hoisting
6
Installation
These installation instructions are intended to help you prepare
before your evaporative condenser arrives. If discrepancies exist
between these instructions and those shipped with the evaporative
condenser, the instructions shipped with the evaporative condenser
will govern.
1. Prior to placement of the evaporative condenser, confirm that the support-
ing platform is level, and that the anchor bolt holes are correctly located
in accordance with Recold drawings. If your installation uses vibration
isolators to dampen vibration, they must be mounted below the support-
ing steel. See support drawings for further information.
2. Place the evaporative condenser on your prepared supports, aligning
anchor bolt holes with those in your supporting steel. Make sure that
the orientation agrees with your intended piping arrangement. Attach to
supporting steel with bolts and flat washers (by others) — see support
drawing for size, location and quantity. Position flat washers between the
bolt head and the evaporative condenser basin flange.
3. Attach makeup water supply piping to appropriately-sized float valve
connection. Attach the drain and overflow piping according to drawings
shipped with your evaporative condenser.
Fasteners and components provided by others that are to be at-
tached to the evaporative condenser must be compatible with the
evaporative condenser materials — i.e. fasteners in a stainless steel
cold water basin must be stainless steel.
4. Attach the refrigerant supply and return piping to the evaporative con-
denser coil copper pipe stubs by field soldering/brazing. Protect adjacent
areas from excessive heat and sparks or damage may occur. Wrapping
a large wet rag around piping near braze joints is one method for limiting
the conduction of heat through the piping.
Except for the horizontal components of piping, do not support your
piping from the evaporative condenser inlet / outlet connections —
support it externally.
Note
Note
Caution
installation
7
Protect adjacent areas from excessive heat and sparks or damage
may occur.
5. Conduct a visual inspection of the control panel and wiring for loose con-
nections or other damage. Connect electrical supply wiring to the main
control panel inaccordance with wiringdiagram(s) and instructions included
with the control panel.
For maintenance/safety purposes, SPX recommends a lockout type
disconnect switch for all mechanical equipment. Branch circuit
protection must be provided for control panels and must meet or
exceed all NEC and local codes.
Control Panel
Variable speed operation of fan motors in cooling applications offers advan-
tages over traditional single or two-speed motor control. Variable speed fan
operation can reduce the cost of electrical energy being used and provide
better temperature control. In addition, it reduces the mechanical and electri-
cal stress on the motor and mechanical equipment. Electrical savings can be
large during periods of low ambient temperature when the cooling require-
ment can be satisfied at reduced speeds. LC evaporative condensers use EC
(electronically commutated) fan motors with integral variable speed capability.
Multiple-fan units are designed for synchronous variable speed operation of all
fans. Fan speed and other operating parameters of LC evaporative condensers
are typically controlled with a factory mounted starter control panel.
The basic starter control panel enables programmable setpoint fan speed
control and pump starter control, and is factory wired and tested. The exte-
rior cover of the panel includes a main disconnect switch, mode selection
switches for fans and pump, and a PID controller with clear lockable cover
to control fan speed based on a programmable setpoint and signal from a
pressure transducer in the refrigerant piping or RTD temperature sensor in the
recirculating water loop. Also included are a control transformer, fuses for all
fans and the pump, disconnect switches for individual fans, pump overcurrent
protection, and a T-stat sensor for pump control (and fan control in bypass
mode). Basin heaters and electric water level packages, when selected, are
contained within separate panels, but are wired to the main control panel to
provide a single point power connection for power supply.
Caution
Warning
installation
8
Mechanical Equipment
Always use caution when working near electrical and mechanical
components. Always shut off electrical power to the evaporative
condenser fan motor prior to performing any maintenance on the
evaporative condenser. Any electrical switches should be locked out
and tagged out to prevent others from turning the power back on.
LC evaporative condensers use EC fan motors to directly drive the evapora-
tive condenser fans. The fan, motor, cylinder, guard and mounting plate are
combined into one assembly, eliminating installation and maintenance steps
typically required with belt or gear-driven fan drive systems. Multiple fan units
are designed for synchronous variable speed operation of all fans.
1. Spin the fans manually to assure that all fan blades properly clear the
inside of the fan cylinders.
2. Momentarily bump (energize) the motors and observe rotation of the fans.
3. Run the motors and observe the operation of the mechanical equipment.
Operation should be stable.
Startup
Microorganisms including Legionella bacteria can exist in premise
plumbing including cooling towers. The development of an effective
water management plan (WMP) and implementation of maintenance
procedures are essential to prevent the presence, dissemination and
amplification of Legionella bacteria and other waterborne contami-
nants throughout premise plumbing. Before operating the cooling
tower, the water management plan and maintenance procedures
must be in place and regularly practiced.
Water System:
1. Consult a knowledgeable water treatment professional to clean and treat
your new cooling tower prior to startup. Cooling towers must be cleaned
and disinfected regularly in accordance with ASHRAE Standard 188 and
Guideline 12.
The water conditions during initial evaporative condenser operation are
crucial in preventing premature corrosion of galvanized steel (white rust).
For at least the first eight weeks of operation, pH should be controlled
between 6.5 and 8.0 with hardness and alkalinity levels between 100 and
300 ppm (expressed as CaCO3).
Warning
Warning
operation
9
operation
2. Do NOT attempt any service unless the fan motor is locked out.
3. Remove any and all accumulated debris from the evaporative condenser.
Pay particular attention to inside areas of collection water basin, distribution
water system, louvers and drift eliminators. Make sure that recirculating
water suction screens are clear and properly installed.
4. Fill the collection basin water system to a level approximately 1⁄8" below
the lip of the overflow.
5. Start your pump(s) and check for proper rotation as indicated by the ar-
row on the pump cover, observe system operation. A certain amount of
“pump-down” of the basin water level will occur before water completes
the circuit and begins to fall from the coil. The water makeup valve is fac-
tory set to keep the water level in the basin at approximately 7" of depth
during operation. The amount of initial pump-down may be insufficient to
open the float valve. However, its operation can be checked by pressing
down on the operating lever to which the stem of the float valve is attached.
The float valve is set so that the water level after pump start-up is deep
enough to assure positive suction, but not overflow at pump shutdown.
6. Open the valve on the evaporative condenser bleed line and adjust bleed
to the recommended rate. See the Water Quality and Blowdown section.
7. Continue pump operation for about 15 minutes, after which it is recom-
mended that the water system be drained, flushed and refilled.
8. While operating the recirculating water pump(s) and prior to operating the
evaporative condenser fans, execute one of the two alternative biocidal
treatment programs described in the following:
• Resume treatment with the biocide which had been used prior to shut-
down. Utilize the services of the water treatment supplier. Maintain the
maximum recommended biocide residual (for the specific biocide) for
a sufficient period of time (residual and time will vary with the biocide)
to bring the system under good biological control. or
• Treat the system with sodium hypochlorite to a level of 4 to 5 ppm free
chlorine residual at a pH of 7.0 to 7.6. The chlorine residual must be
held at 4 to 5 ppm for six hours, measurable with standard commercial
water test kits.
If the evaporative condenser has been in operation and then shut down
for a duration of time and not drained, perform one of the two previous
biocidal treatment programs directly to the recirculating water storage
vessel (collection basin, drain down tank, etc.) without circulating stagnant
water over the coil or operating the fans.
10
operation
After biocidal pretreatment has been successfully completed, cooling
water may be circulated over the coil with the fan off.
When biocidal treatment has been maintained at a satisfactory level for
at least six hours, the fan may be turned on and the system returned to
service. Resume the standard water treatment program, including biocidal
treatment.
Operation
General:
The refrigerant condensing temperature obtained from an operating evapora-
tive condenser will vary with the following influences:
1. Heat load With the fan in full operation, if the heat load increases, the
condensing temperature will rise. If the heat load reduces, the condensing
temperature will reduce.
The fluid cooler establishes only the condensing temperature attainable
under any operating circumstance.
2. Air wet-bulb temperature Condensing temperature will also vary with
the wet-bulb temperature of the air entering the condenser. Reduced wet-
bulb temperatures will result in lower condensing temperatures. However,
the condensing temperature will not vary linearly with the wet-bulb. For
example, a 20°F reduction in wet-bulb may result in only a 15°F reduction
in condensing temperature.
3. Air flow rate Reducing air flow through the condenser causes the con-
densing temperature to rise. This is the recommended method by which
to control condensing temperature.
Pump Cycling Limits:
Cycling the recirculating water pump(s) to control condensing temperature
is not typically recommended. If the recirculating water pumps(s) are cycled
as part of normal system operation, care must be exercised — frequent wet/
dry cycles may lead to premature scaling of the coil surface. Motor cycling
limits apply.
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