SPX RECOLD LC Manual de usuario

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

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.

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

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

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

receiving and hoisting

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

Caution

installation

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

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

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.

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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