INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS MAINTENANCE INSTRUCTIONS … · 2019. 2....

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Adiabatic Cooling Systems

INSTALLATION, OPERATION AND INSTALLATION, OPERATION AND INSTALLATION, OPERATION AND INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONS

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Rev. Tarihi:20.09.2017 Rev.No:1 Dok. No: KLV.008.ENG

İÇİNDEKİLER

1. ABOUT THIS MANUAL/ GENERAL .............................................................................................. 3

1.1 Examining the operating manual .......................................................................................................... 3

1.2 Responsibilities ...................................................................................................................................... 3

1.2.1 Manufacturer’s Responsibilities ..................................................................................................... 3

1.2.2 Contractor’s Responsibilities (Installation, Commissioning) .......................................................... 4

1.2.3 Operator’s or Owner’s Responsibilities (Operation and Maintenance) ......................................... 4

1.3 Warranty ................................................................................................................................................ 5

2. SAFETY REGULATIONS .............................................................................................................. 6

2.1 Symbols and warning signs.................................................................................................................... 6

2.2 Personal protection ............................................................................................................................... 7

2.2.1 Personal protection signs ............................................................................................................... 7

2.2.2 Warning signs ................................................................................................................................. 8

2.3 Warnings................................................................................................................................................ 8

2.4 Improper Use ......................................................................................................................................... 9

2.4.1 Hazardous rotating machinery ....................................................................................................... 9

2.4.2 Hazardous voltage .......................................................................................................................... 9

2.4.3 Hazardous thermal ....................................................................................................................... 10

2.5 Environmental protection ................................................................................................................... 10

3. SPRAY SYSTEM DEFINITION ..................................................................................................... 10

3.1 Ecomesh water spray system .............................................................................................................. 10

3.2 Direct Adiabatic Water Spray System.................................................................................................. 13

3.3 Adiabatic Cooling Pad System ............................................................................................................. 14

3.3.1. Recirculated Adiabatic Cooling Pad System .......................................................................... 15

3.3.2. Uncirculated Adiabatic Cooling Pad System .......................................................................... 15

4. TRANSPORT AND STORAGE ................................................................................................... 16

4.1 Check for completeness and transport damage ................................................................................. 16

4.2 Transport ............................................................................................................................................. 16

5. INSTALLATION ....................................................................................................................... 17

5.1 Location ............................................................................................................................................... 17

5.2 Requirements at the set up point ....................................................................................................... 18

5.2.1 Horizontal types set up side by side ............................................................................................. 18

5.2.2 Vertical types set up next to wall ................................................................................................. 18

5.2.3 Vertical types set up in pit-hallow ................................................................................................ 19

5.2.4Horizontal types set up in pit-hallow ............................................................................................ 20

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5.2.5Horizontal types set up next to wall .............................................................................................. 21

6. COMPONENTS OF ADIABATIC COOLING SYSTEM ..................................................................... 22

6.1 Water Spraying System ....................................................................................................................... 22

6.1.1 Fitting group ................................................................................................................................. 23

6.1.2 Nozzles .......................................................................................................................................... 23

6.1.3 Water spraying pipes .................................................................................................................... 25

6.2 Meshes ................................................................................................................................................ 25

6.3 Cooling Pad .......................................................................................................................................... 26

6.4 Fittings, Tighten elements and system installation ............................................................................. 26

6.4.1 Installation for vertical and horizontal type units ........................................................................ 27

6.4.2 Installation for V type units .......................................................................................................... 29

6.4 Controller and Electric connection ...................................................................................................... 41

6.4.1 Direct adiabatic water spray system controller ........................................................................... 41

6.4.2 Ecomesh spray system controller ................................................................................................. 41

6.4.3 Controller Working Principle and Definition ................................................................................ 42

6.4.4 Electric connection system ........................................................................................................... 43

6.5.5 Adiabatic cooling pad system controller ...................................................................................... 45

7. OPERATION ........................................................................................................................ 45

7.1 Initial commissioning ........................................................................................................................... 47

7.2 Regular commissioning........................................................................................................................ 47

7.2.1 Spraying system water characteristics ......................................................................................... 47

7.3 Shutting down ..................................................................................................................................... 48

8. MAINTENANCE ....................................................................................................................... 48

8.1 Maintenance intervals ......................................................................................................................... 48

8.3 Periodical Controls (Once a year) ........................................................................................................ 49

8.4 Cleaning ............................................................................................................................................... 49

9. TROUBLESHOOTING .............................................................................................................. 50

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1. ABOUT THIS MANUAL/ GENERAL

This document specifies the instructions for installation, operating and maintenance of the

products which have water spry system (FDH, FDV, FDW, FCH, FCV, FCW, NCH and NCV

models) manufactured by FRITERM A.Ş., Turkey.

The instructions below must be followed strictly for the labor health and safety reasons during

installation and maintenance of products.

Upon receipt, the product should be visually inspected, and in case of any damage or fault, the

supplier must be notified within 7 days.

The manufacturer will not accept any responsibility in these situations;

• Damages caused by persons,

• Damages product due to the disregarding of the recommendations indicated in this handbook.

1.1 Examining the operating manual

To follow the instructions defined in this document is a prerequisite for safety of the staff and for

the products to be operated in a fault-free and safe manner.

• The operating manual must always be available. In case of absence of this manual another

copy could be obtained from the manufacturers’ web page. It should be printed out and kept

in an accessible place to everyone whoever should carry out any work regarding the product.

(http://www.friterm.com/tr-TR/catalogue/4 )

• All persons who are responsible for the transport, assembly, initial commissioning, operating,

maintenance or repair of the component must be acquainted with the operating manual. The

operator should accept in written form that they are acquainted with the operating manual.

• Whenever you have difficulty in understanding and/or comprehend and description or

definition given/expressed in this manual, please immediately ask for help from an expert

or from then manufacturer. It is of great importance to understand this manual completely and

correctly for the sake of labor health and safety.

1.2 Responsibilities

1.2.1 Manufacturer’s Responsibilities

• The manufacturer is strictly responsible for supplying a manual accompanying the product

which comprises the necessary and enough detailed information regarding the

installation/mounting and operation of the product. Besides, the product is expected to fulfill

the requirements and satisfy with the anticipated functioning.

• The construction of the product should comply with the presumed operational conditions. The

product is expected to be robust enough and resistive against all the mechanical, thermal

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and chemical challenges. The material used to produce should be compatible with the fluid

and the mixture of fluids used as heat transfer media.

• All the materials and components used in constructing the product should be resistive

against all the stress and pressure that the product will be subjected to.

1.2.2 Contractor’s Responsibilities (Installation, Commissioning)

• Should follow all the instructions and provide all the conditions stated in this manual.

• All the documentation accompanying the product is complementary to this manual. The safety

instructions and all other information stated in this manual should be considered.

• The national regulations regarding the protection of environment and labor safety should be

strictly followed besides the instructions for safe and correct operation.

• In case of any problem encountered during the installation, FRITERM A.Ş. should be

informed and asked for technical assistance if necessary.

• Emergency instructions and the required infrastructure should be prepared and ready for use

in any case.

• The regular maintenance/servicing periods and instructions should be determined and

defined.

• The additive in order to prevent the freezing of the operating fluid should be feed as requires

and as much as required.

• If storage of the product for a long period is needed, a clean, non-hazardous and low humidity

environment is recommended.

• The fans of the products that are stored horizontally are recommended to be run for 4-5 hours

a week. In case of difficulty of running the fans, then they should be covered and protected

from rain and excess humidity.

• In case of storing vertically, it is not recommended to store more than 1 month.

1.2.3 Operator’s or Owner’s Responsibilities (Operation and Maintenance)

• The director is the responsible person who employs the adequate staff for servicing

operating and monitoring the system.

• All requirements and instructions in this operating manual must be complied with.

• The documentation of purchased products is a constituent part of this operating manual. All

safety information in this operating manual and all other information must be observed.

• All relevant regulations concerning accident prevention and environmental protection must be

complied as well as the confirmed technical regulations for safe and proper working.

• Personal ineligibility. All the work should be conducted by authorized and trained personnel.

• Any defect/damage/malfunction caused by disregarding the instructions given in this manual

is the responsibility of the operator.

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• Any defect/damage/malfunction caused by the misuse of the product is the responsibility of

the operator.

• The product should not be put in operation without the completion of the installation and

commissioning.

• The personnel who is responsible for the operation/servicing/maintenance of the product

should be provided with all the necessary documentation including this manual.

1.3 Warranty

• The manufacturer warrants that the equipment delivered to the client shows no defects

caused by failure of design, material, manufacturing and/or workmanship within the warranty

period.

• The client must notify in written form within 10 days from the receipt of the goods, any

perceptible defects including transport damages. For hidden defects, he must notify and

explain in details the defect in written form within 10 days from observation time.

• Unless otherwise agreed, the warranty period shall be 24 months starting from the date of

delivery.

• The warranty does not cover defects in the product’s operation stemming from a fault in

materials or parts provided by the client, nor shall it cover an installation that has not been

assembled according to the manufacturer’s instructions and according to professional

practice. The products or parts that the costs are not paid to the producer are out of

manufacturer’s warranty.

• The warranty shall not cover equipment and/or its accessories if they have been modified by

the client without manufacturer’s written consent.

• The warranty clause can only be invoked by the client if the equipment is used normally and

in conformity with its purpose and manufacturer’s instructions.

• The manufacturer’s liability hereunder shall be limited to repair, modify or replace the parts or

equipment that shows defect within the limitation of the items under this article.

• The warranty period of the repaired or modified or replaced parts or equipment shall in no

way extend the warranty period of the original ones.

• The works resulting from the warranty conditions shall be carried out in the manufacturer’s

workshop after the client has sent the defective equipment or parts for repair or replacement.

• The manufacturer’s responsibility is strictly limited to the obligations as stipulated herein and it

is expressly agreed that he shall not be found to make any other indemnity. In particular, he

shall in no case be liable to compensate loss caused directly or indirectly by a defect in the

equipment delivered.

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• The product should be installed and commissioned in accordance with the

national/international regulations and rules.

• For the fans having thermal protection, the related wiring should be definitely done and it is

considered as contractor’s and/or owners’ responsibility. Any defect caused by misconnection

of the thermal protection wiring in accordance to the circuit diagrams given in this manual

would be out of manufacturer’s warranty.

• The power supply which the product is supplies should not deviate 10% from the values given

on the label.

2. SAFETY REGULATIONS

2.1 Symbols and warning signs

The following terms and/or symbols are used in the operating manual for particularly important

information.

Safety messages and symbols are quoted at the relevant positions in the operating manual if

there is danger such as death, personal injury and environmental damage. These safety

warnings must be strictly adhered to.

Indicates a hazardous situation which, if not avoided, may

result in death or serious injury

Indicates a hazardous situation which, if not avoided, may result

in serious injury.

Indicates a hazardous situation which, if not avoided, may result

in moderate or minor injury.

Additional notes, information and tips.

Rev. Tarihi:20.09.2017

IN CASE OF DANGER

• Switch off the power

• Switch off the main

• Please ask assistance from an authorized

• Please do not try to resolve any problem by trial and error.

2.2 Personal protection

While working on and standing by the product, protective clothing must be worn.

• Safety shoes

• Safety helmet

• Protective gloves for fitting and rep

• Chemical-resistant clothing and protective gloves for cleaning work, especially when

handling solvents

• Safety goggles for cleaning work, especially while handling solvents or using compressed

air for cleaning

• Hearing protection

2.2.1 Personal protection signs

Head Protection

Foot Protection

Rev.No:1 Dok. No: KLV.008.ENG

IN CASE OF DANGER!

Please ask assistance from an authorized technician or expert.

Please do not try to resolve any problem by trial and error.

Personal protection


Protective gloves for fitting and repair work

resistant clothing and protective gloves for cleaning work, especially when

Safety goggles for cleaning work, especially while handling solvents or using compressed

Personal protection signs

Head Protection Eye Protection

Foot Protection High Visibility Clothing

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resistant clothing and protective gloves for cleaning work, especially when

Safety goggles for cleaning work, especially while handling solvents or using compressed

Eye Protection

Clothing


Protective Clothing

Respiratory Protection

2.2.2 Warning signs

No SmokingFlammable

High Voltage

Hand Injuries

Fire Risk

2.3 Warnings

• In an unexpected situation use the emergency stop button which is set up on an easily

accessible place.


Protective Clothing Hand Protection

Respiratory Protection

No SmokingFlammable

High Voltage Hot Surfaces

Hand Injuries Poisoning Danger

Fire Risk Frostbite Hazard

unexpected situation use the emergency stop button which is set up on an easily

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Hot Surfaces

Poisoning Danger

Frostbite Hazard

unexpected situation use the emergency stop button which is set up on an easily


• Do not exceed maximum operating pressure given on the unit’s type plate.

• Unless the advised safety devices available or fully active the unit must not be

• Set up the unit with extreme cleanliness.

• The unit must not be operated if it is damaged. FR

damages.

• The unit must be installed, operated and maintained by authorized/qualified personnel

only.

• No modification is allowed on the product without written permission from the

manufacturer.

• Operational conditions are limited within the specified range by the manufacturer. In case

of need to operate the product out of the range, a confirmation should be asked from

FRITERM A.Ş.

2.4 Improper Use

Danger of injuries in improper using;

2.4.1 Hazardous rotating machinery

Danger of cutting hands and fingers. Lids should be unscrewed by an authorized

technician.

Use hand protection.

2.4.2 Hazardous voltage

Electrical voltage can cause serious injuries or death. Do not contact with

voltage direct or indirect. Do not forget to power off the unit before you begin

maintenance work.


Do not exceed maximum operating pressure given on the unit’s type plate.

Unless the advised safety devices available or fully active the unit must not be

Set up the unit with extreme cleanliness.

The unit must not be operated if it is damaged. FRİTERM A.Ş. must be informed about all

The unit must be installed, operated and maintained by authorized/qualified personnel

is allowed on the product without written permission from the

Operational conditions are limited within the specified range by the manufacturer. In case


Danger of injuries in improper using;

Hazardous rotating machinery


Use hand protection.



maintenance work.

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Do not exceed maximum operating pressure given on the unit’s type plate.

Unless the advised safety devices available or fully active the unit must not be operated.

. must be informed about all

The unit must be installed, operated and maintained by authorized/qualified personnel

is allowed on the product without written permission from the

Operational conditions are limited within the specified range by the manufacturer. In case






2.4.3 Hazardous thermal

Danger of burns and frostbites.

Adiabatic cooling systems are design to work at summer season when the

temperature is high.

the system is full drained.

The danger of frostbite can occur if there is insufficient frost

the unit cannot be drained completely, frostbite hazard occurs after draining.

2.5 Environmental protection

While handling the product, it has to be ensured that materials which can endanger the

environment are disposed of properly. Service materials must not be allowed to enter the

sewerage system and the ground water system.

All relevant national regulations

safe and proper working must be complied.

3. SPRAY SYSTEM DEFINITION

3 types of adiabatic cooling systems

direct,ecomesh and cool pad adiabatic cooling systems

3.1 Ecomeshwater spray system

Ecomesh Spray System concept is based on intermittently and efficiently evaporating water

on a large mesh area in front of the heat rejection surface of


Danger of burns and frostbites.


temperature is high. When the temperature is low at winter season; be sure that

the system is full drained.

The danger of frostbite can occur if there is insufficient frost


Environmental protection



sewerage system and the ground water system.

All relevant national regulations concerning environmental protection and the technical issues for

safe and proper working must be complied.

AY SYSTEM DEFINITION

3 types of adiabatic cooling systems can be applied to dry coolers and condenser of

adiabatic cooling systems.

water spray system


on a large mesh area in front of the heat rejection surface of Condensers

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When the temperature is low at winter season; be sure that

The danger of frostbite can occur if there is insufficient frost protection. Also if




concerning environmental protection and the technical issues for

dry coolers and condenser of Friterm A.Ş;


Condensers and Dry Coolers.

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Water spray provides an adiabatic cooling effect of till 25 °C for the incoming air stream and

it can be initiated via an ambient sensor or alternatively by external control override. As soon

as settings exceed, a pre-set level controller initiates water spray in order to make air

temperature lower during high ambient periods.

Advantages of Ecomesh Water Spray System:

• Running Cost: Lower condensing temperature provides reliable operation and lower

annual electricity running costs.

• Reduced Water Consumption:Water is used whenever it is required at significantly

reduced quantities.

• Flexible System:Sectional panel and coil clip design suits with any brand and model of

mini-splits, air cooled chillers, rooftop units, air cooled condensers and dry coolers on the

market.

• Lower Maintenance Cost:Reduced condenser pressure leads to reduced discharge

temperature which extends the compressor reliability and life.

• Quick Response:Large mesh surface area provides efficient adiabatic cooling surface

with minimum air flow reduction, hence, water evaporates very rapidly to cool the

incoming air.

• Eliminates Health Risks:It uses water directly without any water reservoir, hence, the

health risks associated with a still water reservoir are completely eliminated.

• Green Solution: Reduced energy consumption, hence, less indirect CO2 emission.

• Continuity of heat transfer efficiency:Since the water is not sprayed directly to the heat

exchanger fin surface, it is sprayed on the ecomeshsurface; no lime layer is formed on

the fins. Thus, the reduction of the thermal transfer efficiency is prevented.

Mois

ture

Co

nte

nt

Temperature

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Picture 1- Ecomesh water spray system at vertical type condensers

Picture 2- Ecomesh water spray system at V type condensers

Picture 3-Ecomesh water spray system at horizontal type condensers

Picture 4- Ecomesh water spray system at V type dry coolers

Picture 5-Ecomesh water spray system at horizontal type dry coolers

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3.2 Direct Adiabatic Water Spray System

Directadiabatic water spray system comprises a series of specialized water nozzles fitted

intermittently. The nozzles are designed to pulverize the water and provide a very fine mist of

atomized water droplets which are readily absorbed by the high temperature ambient air

approaching the coil.

It is necessary that the water used in this system must undergo for a strict water treatment regime

to reduce the risk of corrosion and prevent dirty water in the water circuit. Moreover the hardness

of the water should be taken and pass from high efficiency filtration system.Otherwise, the lime

and residue that accumulates on the heat exchanger fins will eventually reduce product capacity

and shorten its lifetime.

Epoxy coated fins can be used for dry coolers with spraying systems as an additional protection

due to the abrasive effects. The epoxy coating has a very high resistance to salt and acid in the

environment.It is preferred that the unit is made of epoxy-powder coated galvanized steel and

stainless steel in advanced corrosive environments.It is important to take these precautions to

ensure the dry coolers are long-lived, although they are much less exposed to the harmful effects

of water than the water towers.

The amount of water to be consumed in order to saturate the intake air, varies depending on the

sprayer used and the spraying pressure.The choice depends on the relative humidity of the

ambient air; It should be ensured that water is sprayed in sufficient quantity to bring the relative

humidity as close to 100% as possible.For this reason, some more water is sprayed from the

completely evaporating amount and the increased water remains as the liquid in the environment.

This measure also provides safety against the loss that can occur over time in the performance of

the spray system.

Picture 6-Horizontal type condenser with direct spraying system

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Picture 7-V type dry cooler with direct spraying system

3.3Adiabatic Cooling Pad System

In adiabatic cooling pad systems, coolpads are placed in special sheet metal assemblies which

are mounted in front of fin block. With the aid of the pump, water wets the pads from the upper

part of the pad system. The outside air, which is dry and hot, is pre-cooled by passing it through

wet cooling pads.The temperature of the air that contact with the wet cooling pads is

approximated to the wet thermometer temperature.

The water does not contact directly with the fins. Thusfins lifetime is longer than the direct

spraying systems.Also pads prevent contamination of fins.

Since the microorganisms, minerals and similar parts do not mix into the air during the

evaporation phase of water, the working principle is completely healthy.

The system ensures that product efficiency can be increased with minimum water consumption.

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System can be built in two ways as recirculated and uncirculated.

3.3.1. Recirculated Adiabatic Cooling Pad System

In recirculated adiabatic systems, water that flow over the pads, collected at the drain pan. When

it reaches a certain level, it is pumped back to the upper part water spraying line by the circulation

pump.

3.3.2. Uncirculated Adiabatic Cooling Pad System

In uncirculated systems, the amount of water supplied through the cooling pads is provided by

the appropriate automation system, depending on the external air relative humidity.

A small amount of water collected in the pan under the pads is drained by a drainage line.

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Picture 8- V Type dry cooler with adiabatic cool pad system

4. TRANSPORT AND STORAGE

4.1 Check for completeness and transport damage

• Attention! May cause severe injuries or unrecoverable damages in case of uncontrolled

fall down.

• Instructions on lift and transportation should be strictly followed.

• Check if there is any damage on product or package. Immediately after receipt, the

delivery must be inspected for possible transport damage. Any damage must be reported

immediately to the shipping company. If it is to be expected that the transport damage

may affect proper operation, then the product must not be commissioned.

• Upon receipt, the product should be visually inspected, and in case of any damage or

shortage, the supplier should be notified within 7 days.

4.2 Transport

The product may only be lifted and moved by persons who:

1. Are authorised to operate crane systems,

2. Are authorised to drive motorised handling product

3. Also know the transport and lifting instructions according to the operating manual and the

assembly drawing.

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Suitable transport equipment must be used.

5. INSTALLATION

The system installer is responsible for the proper installation according to standards and

guidelines (DIN EN 292 / 294) which contains installation and security guidelines.

Before installing, it must be ensured that the technical specifications of the product are in

accordance with the desired working conditions.

5.1 Location

• The spraying system is designed only for permanent installation. It should be fixed to a

stable base.

• In recirculated or uncirculatedadiabatic cooling pad systems, excess water accumulating

in the drain pan and must be properly well trained. Product must be installed in such a

way that will not obstruct the drainage.

The working area should be well ventilated and should not be contained any hazardous

substances or explosives.

• Air motion should not be adversely affected by obstructions and inlet air should not be

undesirably heated or cooled by some other product.

• All the blind bolts and/or flanges should be removed right before the installation.

• The site where the installation process is being carried out should be provided as clean as

possible and low humidity.

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5.2 Requirements at the set up point

5.2.1 Horizontal types set up side by side

5.2.2 Vertical types set up next to wall

Smin ≥ H

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5.2.3 Vertical types set up in pit-hallow

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5.2.4Horizontal types set up in pit-hallow

� ≥ 0,5 ∗�

� = 450 − 600 mm

21


5.2.5Horizontal types set up next to wall

To avoid bypassing of the blowing air due to the side wall, a blocking accessory should be used.

Also a dry-cooler half-width lifting case or higher feet should be used to facilitate the suction from

down side. (700-1200 mm)

K ≥ W/2

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6. COMPONENTS OF ADIABATIC COOLING SYSTEM

Adiabatic cooling systems comprises of the following equipment;

1) Water spraying system

2) Meshes (for ecomesh systems)

3)Cool pads (for cool pad systems)

4) Fittings, tighten elements and system installation

5)Controller and electric connection

Quick change type plastic nozzles connected in series and parallel arrangement in order to

provide uniform coverage area for an effective evaporation process.

6.1Water Spraying System

Picture 9- Water spraying system

Water spray system comprises of the following equipment.

1) Fitting group

2) Nozzle

3) Water spraying pipes

Water spraying pipe

Water spraying pipe

Nozzle Nozzle

Nozzle Nozzle

Clamp Clamp Clamp

Clamp Clamp Clamp

Fitting Group

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6.1.1 Fitting group

The fitting group is provided to the customer as a whole fitted together. It comprises nipple,

solenoid valve, hydrometer, water strainer and globe valve.

At the entrance of the installation there is a water filter. There is also a wire filter inside the nozzle

to avoid dirt. Filters should be checked at periodic intervals.

6.1.2 Nozzles

Nozzles are sent to the customer with the utilities. Nozzle connections are made to the holes on

the utility.

While the pulverizes are working there should not be any leakage except from the nozzle if there

is a leakage, the connections should be checked and leakage must be prevented.

Nozzles are designed to operate with very low pressure and they can operate with normal city

mains water pressures 1.5 - 3 bar and above.

Water Filter

Hydrometer Selenoid Valve

Spraying line Globe valve

Water inlet line

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Nozzles should be mounted approximately the angle of 45° as shown above. The nozzles should

be placed in a way that the water will be sprayed widely and equally to the meshes.

For direct spraying systems the distance between nozzles and fins should be 400- 600 mm.

Picture 10- Nozzles mounting angle

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6.1.3 Water spraying pipes

Water spraying pipes are sent to the customer with the unit. It is mounted to the mounting holes

on the product with the help of the clamps.

Extra loading on the piping system may cause leakage on the piping.

6.2Meshes

Nonmetallic mesh provides an effective coverage area for an efficient evaporation surface with

minimal air pressure drop. Meshes are fixed in front of the heat rejection surface via spacer bars

and/or fixing brackets to suit the unit configuration. Various size sectional mesh panels are either

joined together to form a full mesh area or alternatively flexible mesh roll cut to fit to a required

size in front of the heat rejection surface.

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The dust on the meshes should be cleaned with pressurized air or water at least once in a week.

6.3 Cooling Pad

Cellulosic Media Pad

It is a cellulosic paper impregnated with chemicals that provide easy wettability and durability.

The wavy and cross-channel structure expands the surface area, facilitating air to water contact

and minimizing air resistance.

The pad materials are flammable.

6.4Fittings, Tighten elements and system installation

Installation and electrical connections must only be carried out by qualified personnel.

During installation, the product should not be connected to an electrical source.

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6.4.1Installation for vertical and horizontal type units

The installation pipes on which the nozzles are mounted, are mounted with the clamps to the

plate.

Once the installation pipes have been installed in place, the clamping assembly is fastened

with M8 bolts to the nut rivets previously punched.

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Then the fitting group is installed at the end of the installation pipe.

The mesh is attached to the special rails on the product with the clips sent alongside the

product. (For ecomesh installation)

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After all the meshes are mounted, the tensioning devices are set and fixed. (For network

connection)

6.4.2Installation for V type units

6.4.2.1 Installation of ecomesh system

First, the mesh tensioning assembly is connected to the mounting holes on the unit with

M16 studs. Clamps are mounted on the net tensioning device and on the sheet metal at

the collector side.

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The straight pipe on which the spraying nozzles are located arefitted with the clamps

connected to the net tensioning device.

After the straight pipe installation is completed on both sides, the U pipe connecting both

pipes is installed.

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The fitting group installed to the end of the U pipe.

The mesh is attached to the special rails on the product with the clips sent alongside the

product.

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After all the meshes are mounted, the tensioning devices are set and fixed. (For network

connection)

6.4.2.2 Installation of direct spraying system

First of all, the installation support sheet is mounted on the mirrors shown in the technical

drawing. Then we will use it when connecting to the installation, clamps are mounted by

adding the studs prepared to the back.

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Then the flat installation pipes are attached to the clamps and mounted on the product.

After the installation of the flat pipes, the installation of the U pipe connecting these pipes

is carried out.

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Finally, fitting group is installed at the end of the U pipe.


6.4.2.3 Adiabatic cooling pad system installation

In the standard assembly of the unit, firstly, the side cover plates which are prepared with

the necessary fasteners

Additional shhet parts are mounted underneath the side cover sheets which overlap with

the middle plates.


cooling pad system installation


fasteners are mounted.


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Then the bottom cover plates are mounted.

Pre-assembled cooling pad modules are mounted on the nuts on the side cover plates.


Then the bottom cover plates are mounted.

assembled cooling pad modules are mounted on the nuts on the side cover plates.

36


assembled cooling pad modules are mounted on the nuts on the side cover plates.


After the assembly of the sheet metals

pads are pushed in from the outside as shown below, until they reach the upright position.

When the pads are in the upright position

Make sure that the pads are correctly positioned and there are no visible gaps between

them.

When all the pads have been settled, the pad retaining parts are

retaining screws.


the assembly of the sheet metals is completed, the cooling pads can be placed. The

pushed in from the outside as shown below, until they reach the upright position.

When the pads are in the upright position, they will fit well on the side plates.


When all the pads have been settled, the pad retaining parts are mounted

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is completed, the cooling pads can be placed. The

pushed in from the outside as shown below, until they reach the upright position.

fit well on the side plates.


mounted with the help of


After the assembly of the pad modules is completed,

the pump system is assembled. The coarse partic

pump is installed.


After the assembly of the pad modules is completed, is the system is recirculated system,

the pump system is assembled. The coarse particle filter must be installed before the

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is the system is recirculated system,

le filter must be installed before the


After the pump installation is done , the

modules, is mounted between two drainage outlets.

Pump and cool pad water supply will be done as

required for this installation.)


After the pump installation is done , the PVC pipe which connects the two cooling pad

is mounted between two drainage outlets.

Pump and cool pad water supply will be done as follows. (PVC pipe welding machine is

required for this installation.)

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the two cooling pad

follows. (PVC pipe welding machine is


The system feed is made from the nipple input shown below.


The system feed is made from the nipple input shown below.

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6.4Controller and Electric connection

6.4.1Direct adiabatic water spray system controller

The system is controlled by a thermostat. The stepped thermostat on the product controls the cut-

in and cut-out of the fans and it commands in an integrated manner to the turn on/off of the

solenoid valve. If fan control is not to be done, only the solenoid valve is switched on and off with

a single-stage thermostat.

6.4.2Ecomeshspray system controller

A custom-made intelligent PLC based controller records the ambient conditions and at a pre-set

value, which is adjustable by the operator, initiates inline solenoid valve(s).

Water is sprayed intermittently to wet the meshes. The spray rate and duration are adjusted by

the controller to suit the ambient conditions, hence, minimal water consumption. Water usage is

based on total waste principle, hence, no health risk.

Ecomesh controller is provided with internal override terminals for a volt-free input which

overrides the temperature set limit and initiates intermittent spray as soon as this terminal is

linked. This facility can be used to provide head pressure or manual remote override flexibility.

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Picture 11- Ecomesh Controller

6.4.3 Controller Working Principle and Definition

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Picture 12- Ecomesh Controller Working Principle and Definition

6.4.4Electric connection system

Ecomesh Temperature AND Time Controller Block Diagram

The operator panel consists of two Printed Circuit Boards (PCB) which house the power supply,

sensor input conditioning circuitry, microcontroller, 7-segment Light Emitting diode (LED) display

for temperature and timer indication, status indicating LED, control and setting push buttons, and

output circuitry. The PCB is mounted inside a plastic enclosure. Both the display and the push

buttons are protected by the transparent cover. All the connections to the controller are via plug-

in screw terminals.

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Power supply

The control panel requires 110 or 240Vac 5VA max. 50/60Hz supply. Please specify the supply

voltage when order.

Sensor input

A platinum resistance thermometer PT100 temperature sensor is supplied as standard.

External override input

An optional volt-free contact can be connected to the external override input to force the

controller output to maximum when the contact is closed.

Control output

Opto-triac outputs are used for the control output. The ratings are 240Vac 1A max and 110Vac

2.1 A.

User interface

The user interface comprises of 3 digits 7-segment green LED display, 1 status indicating LED

and 3 push buttons.

The 7-segment display is used to indicate measured temperature, low set point temperature, high

set point temperature, and 3 sets of ON time setting and OFF time setting.

One red LED is used to show the output status of the controller.

One push button is used to scroll the parameter display. The two adjustment push buttons "UP"

and "DOWN" enable the temperature and time setting to be incremented and decremented.

Please note the display will revert to showing measured temperature after 1 minute of inactivity

on the push buttons.

6.4.4.1 Electrical installation

The Ecomesh controller can be wall mounted using the mounting kit provided. Please see

dimensional drawing for fixing holes arrangement.

All the electrical connections are via plug-in screw terminals. There are 4 sets of connections:

The sensor input (PRT100 sensor) is connected to a 2 way connector IN+ and IN- of the RT input

on the PCB. The sensor is not polarity sensitive.

The optional external override input (volt-free contact) is connected to a 2 way connector OVR+

and OVR- on the PCB. The external override input is not polarity sensitive.

The controller output is connected to a 2 way connector LINE and LOAD of the OUTPUT 1 on the

PCB. Please note from release 2.1 onwards, the LINE and LOAD should connect directly to the

external solenoid valve.

The mains supply is connected to a 2 way connector L and N of the mains input on the PCB.

Controller’s electrical connections can be check with the connection diagram below;

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Picture 13- Electric connection diagram

6.5.5 Adiabatic cooling pad system controller

The control device (thermostat) adjusted according to the applied system goes into operation with

the operation of the domestic line pump if the ambient conditions rise above the set values.

Water is conveyed from the top through the cooling pads, with the aid of the pump. Part of the

water flowing through the pads is collected in the pan, the reduced water is removed from the

network by means of a ballcock.

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7. OPERATION

All the parameters in the Ecomesh controller can be accessed by pressing the scroll button. Apart from the measured temperature, all the

parameters can be set within their limits using the UP and DOWN button.The following are the list of parameters:

ECOMESH CONTROLLER SETTING DESCRIPTION

Menu Description

Controller

Minimum

Limit

Controller

Maximum

Limit

Initial factory setup

Units Moderate

Climate *

Hot

Climate *

Pressure

Control

*

t Ambient Dry Bulb Reading Sensor Sensor Sensor Sensor Sensor ºC

L Minimum (Set) Temperature 10 60 20 25 20 ºC

H Maximum (Set) Temperature 10 60 35 50 40 ºC

1 T1 - Spray Duration (1-99 Second) at L 1 99 5 10 15 Second

2 T2 - Spray Frequency y(1-99x10 Seconds) at L 0,5 99 1 0,5 0,5 Minute

3 T3 - Spray Duration (1-99 Second) at H 1 99 15 30 30 Second

4 T4 - Spray Frequency(1-99x10 Seconds) at H 0,5 99 45 30 18 Second

5 T5 - Flash Cycle ON Time (Sec) (Duration) 0 99 0 0 0 Second

6 T6 - Flash Cycle OFF Time (h) (Frequency) 0 99 0 0 0 Hour

* The initial setup values can be changed to its desire values according to the device installation environment by the operator.

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Ecomesh water spray system controller can be operated in 3 different conditions.

1) "t" Ambient temperature is between L (Minimum temperature) and H (Maximum temperature)

2) "t" Ambient temperature is above H (Maximum temperature) and

3) Independent of temperature

The detailed information are given below table.

ECOMESH KONTROLLER WORKING CONDITIONS

1.Condition:

"t" Ambient temperature is between L (Minimum

temperature) and H (Maximum temperature)

2.Condition:

"t" Ambient temperature is above H (Maximum

temperature)

L < t < H t > H

1

Water spraying period in seconds when the ambient

temperature (t) is between lower limit (L) and upper limit

(H)

3 Water spraying period in seconds when the ambient

temperature (t) is above the upper limit (H)

2

Off period (Value x 60 seconds) between two spraying

when the ambient temperature (t) is between lower limit

(L) and upper limit (H)

4

Off period (Value x 60 seconds) between two spraying

when the ambient temperature (t) is above the upper limit

(H)

3.Condition:

Independent of temperature values

5 Water spraying period in seconds when the system is independent of temperature values

6 Off period (Value x 60 seconds) between two spraying when the system is independent of temperature values


7.1 Initial commissioning

Before running the unit for the first time, the following facts should be checked.

1. Check the input/output electric connections. If the connection is not done in correct way,

the value of the temperature will be appeared incorrectly.

2. Make sure that the sensor is working correctly. If there is any failure in function, the

value of the temperature will be appeared incorrectly.

3. The current ampere of the solenoid valve should not be over the

4. The screws of the control apparatus must be fastened tightly.

After the spray system is installed properly, the water system connection should be done

to the fitting group. The water system must be operated by the qualified

In order for the system to function proficient

fundamental requirement for optimum performance.

7.2 Regular commissioning

Material damage due to freezing hazard may occur.


temperature is high. When the temperature is low at winter season; be sure

that the system is full drained.

7.2.1 Spraying system water

UNI 8884 "Characteristics and

suggests that evaporative humidifiers be supplied with fresh water (as indicated in directive

98/83/EC) having the following characteristics:


Initial commissioning



temperature will be appeared incorrectly.


value of the temperature will be appeared incorrectly.

3. The current ampere of the solenoid valve should not be over the recommended values.

4. The screws of the control apparatus must be fastened tightly.


to the fitting group. The water system must be operated by the qualified

In order for the system to function proficiently, the complete wetting of the

fundamental requirement for optimum performance.

Regular commissioning

Material damage due to freezing hazard may occur.



that the system is full drained.

Spraying system water characteristics

Characteristics and treatment of water for cooling and humidification circuits” ”


98/83/EC) having the following characteristics:

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recommended values.


to the fitting group. The water system must be operated by the qualified operator only.

ly, the complete wetting of the media pads is a



treatment of water for cooling and humidification circuits” ”


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Electrical conductivity

<100 µS/ cm

Total hardness 2< x< 5° fH (50 ppm

CaCO3)

pH 6.5<pH<8.5

Chloride content < 20 mg/l

Silica content < 5 mg/ l

Demineralized or osmos water is not required.

7.3 Shutting down

To close the water sprinkler system completely, the electrical connection must be cut off and

the fluid circulation pump in the system must be switched off.

8. MAINTENANCE

8.1 Maintenance intervals

1. Maintenance operation is to be performed by qualified personnel only.

2. Ecomesh should be cleaned regularly once in week.

3. The system pipes and fitting group must be controlled regularly in order not to be

blocked of the flow line.

4. The connection of the meshes and the fitting should be controlled in order to prevent

from loosening any connection elements.

5. The electric and the sensor connections should be checked regularly.

Follow the instructions in the 'Initial Operation' section to operate the appliance after

maintenance and repair.

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8.3 Periodical Controls (Once a year)

• Check the fins and pipes for corrosion that will occur in case of water coming into

contact with the coil block in the spraying systems. If the pipes are worn, they can

cause leakage.

• In adiabatic cooling pad systems pads can clogged due to external contaminants and

cause pressure loss and this may reduce the efficiency. Checks must be done.

8.4 Cleaning

Ecomesh Cleaning

• Ecomesh should be cleaned once per week.

Cooling Pad Cleaning

• Where necessary, the pads should be cleaned with a soft bristle brush and low-

pressure water. Dirt, rust, smoke and hard cleaners should be avoided. Soft cleaners

compatible with pads materials should be used.

• Clean and flush distribution headers on a regular basis to prevent buildup of deposits or

microbiological growth.

The dust on the ecomesh or cooling pad surface must be cleaned with compressed air or

water at least once a week.

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9.TROUBLESHOOTING

Faults Possible Causes Remedy

Unit capacity

not achieved

Fans are not running properly Repair or change fans

Polluted coils Clean

Different brine working

pressure

Adjust brine pressurising values to

reference values

Heat exchanger is very dirty,

frosted, iced on the air side

Clean, defrost heat exchanger

Fan motor is

not working

Fan blade stuck Enable fan to rotate freely

Power supply cut off Fix power supply

Unusual noise Defective Fan bearing Replace bearing or fans

Vibration

Defective fan blades Modify or change fan blades

Fan fixtures loosened Tighten the fixtures

Working fluid

escaping

Unit working fluid-carrying

components leaking

Switch off working fluid feed and fans,

close leak

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS MAINTENANCE INSTRUCTIONS … · 2019. 2....

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Transcript of INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS MAINTENANCE INSTRUCTIONS … · 2019. 2....