S140-500 IOM/DEC 2001

Replaces: NOTHING: New Information

Dist: 3, 3a, 3b, 3c

INSTALLATION - OPERATION - MAINTENANCE

IDC
INDUCED DRAFT
EVAPORATIVE CONDENSERS
S140-500 IOM IDC EVAPORATIVE CONDENSERS
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TABLE OF CONTENTS
Section 1.0 Pre-Installation ................................................................................... 4
1.1 Preface ................................................................................................... 4
1.2 Shipment Inspection ................................................................................ 4
1.3 Transit Damage Claims ............................................................................ 4
1.4 Unit Identification .................................................................................... 4
1.5 Safety Requirements ............................................................................... 4
1.6 Placement of IDC Units ........................................................................... 5
1.7 Field Piping Considerations for IDC Unit Installation ................................ 5
Section 2.0 Installation Procedures ....................................................................... 8
2.1 Installation Tools ...................................................................................... 8
2.2 Foundation Information ............................................................................ 8
2.3 Eliminator Placement ............................................................................ 12
2.4 Inlet Louver Installation ......................................................................... 12
2.5 Erecting the IDC Unit ............................................................................. 12
2.6 Optional Vibration Isolator ...................................................................... 12
Section 3.0 Startup & Operation .......................................................................... 16
3.1 Initial Startup (for new IDC Units) .......................................................... 16
3.2 Initial and Seasonal Start-Up ................................................................. 16
3.3 24-Hour Run In ...................................................................................... 17
3.4 Daily Operation ...................................................................................... 17
3.5 Seasonal Start up & Shutdown .............................................................. 18
3.6 Winter Operations .................................................................................. 18
Section 4.0 Maintenance ..................................................................................... 18
4.1 Maintenance Intervals ........................................................................... 18
4.2 Spare Parts Recommendations ............................................................. 20
4.3 Lubrication ............................................................................................. 21
4.4 Drivetrain ............................................................................................... 21
4.5 Sump Drainage ...................................................................................... 21
4.6 Belt Replacement and Tensioning .......................................................... 22
4.7 New Belt Run-in ..................................................................................... 22
4.8 Coil Assembly ....................................................................................... 22
4.9 Water Makeup Requirements ................................................................. 23
4.10 Water Treatment ................................................................................... 23
4.11 Protective Finish ................................................................................. 23
Section 5.0 Troubleshooting ................................................................................. 26
5.1 Condition: High Condensing Pressure .................................................... 26
5.2 Condition: Excessive Deposits, Scale, Or Turbidity ................................ 27
5.3 Condition: Excessive Slime Plugging Water/Air Passages ..................... 27
5.4 Condition: Low or High Water Level ........................................................ 27
5.5 Condition: Excessive Noise or Vibration ................................................ 27
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FIGURES
Figure 1-1. ID Plate Information ............................................................................. 4
Figure 1-2. IDC Unit-to-Unit Spacing Requirements ............................................... 6
Figure 1-3. IDC Unit-to-Wall Spacing Requirements ............................................... 7
Figure 2-1a. 12' x 12' Foundation Layout ................................................................ 9
Figure 2-1b. 12' x 18' Foundation Layout .............................................................. 10
Figure 2-1c. 12' x 20' Foundation Layout .............................................................. 11
Figure 2-2. Eliminator Orientation Cross Section ................................................. 12
Figure 2-3a. Assembly and Placement ................................................................ 13
Figure 2-3b. Assembly and Placement ................................................................ 14
Figure 2-4a. Vibration Isolator Feet ...................................................................... 15
Figure 2-4b. Vibration Isolator Rails ...................................................................... 15
Figure 4-1. Recommended Maintenance Intervals ............................................... 18
Figure 4-2. Recommended Spare Parts List ........................................................ 20
Figure 4-3. Sheave Alignment .............................................................................. 21
Figure 4-4. Sump Drain Location .......................................................................... 21
Figure 4-5. Belt Tensioning Schematic ................................................................. 22
Figure 4-6. Nozzle Orientation ............................................................................. 24
Figure 5-1. Standard IDC Series Unit Specifications ............................................ 30
Figure 5-2. Standard IDC Series Unit Dimensions ................................................ 31
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Section 1.0 Pre-Installation

1.1 Preface
The Imeco evaporative-cooled, Induced Draft Condenser
(IDC) you have purchased utilizes the finest in engineered
design, materials, and corrosion protection to provide a
rugged, long-lasting unit. This manual provides the infor-
mation needed for safe installation, operation, and mainte-
nance. Close attention to the instructions and guidelines
provided in this manual will ensure a long satisfactory unit
life and dependable operation and performance.
Before rigging or beginning work on the unit, Imeco recom-
mends that experienced Refrigeration contractors, opera-
tors, and maintenance technicians be formally trained on
the IDC design and features - with this manual’s reading as
a minimum requirement. After installation, the unit (as se-
lected) must also be properly connected to appropriately
designed and installed refrigeration and water treatment
systems. The engineering plans, piping layouts, etc. for the
Figure 1-1. ID Plate Information
IDC and associated system components must be detailed
in accordance with local/governing codes and the best in- 1.5 Safety Requirements
dustry standards and practices such as those outlined in IDC unit installation, operation, and maintenance – involves
up-to-date industry literature. heavy rotating machinery operating at high speed and high
Should you have any comments or questions regarding voltage. Normal operations and maintenance procedures
this manual or the IDC unit, you are urged to call your local may require working at elevations, enclosed space entry,
sales representative. or use of hand and power tools. With these considerations,
1.2 Shipment Inspection safety must be the top priority in all activities with this evapo-
rative cooling product.
Upon arrival of the IDC condenser at the job site, the unit
Imeco recommends that every client analyze and develop
should not be signed for until it is inspected to ensure that
an installation-specific safety regime that takes into account
all required parts have been received and are free of ship-
such variables as specific site/system features, personnel
ping damage. Unpack all items and check against shipping
qualifications, hazard identification, etc. The following ele-
lists - any items that appears to be missing should be noted
ments of operational safety are recommended for inclusion
on the shipping papers and reported to an Imeco represen-
in every client’s IDC condenser safety plan/requirements:
tative. The following parts should be inspected:
Electric: Configure all power switches and controls to pro-
·Sheaves, belts, bearings/supports vide an open, safe circuit before and during maintenance
·Fan blades, shaft, and motor/hood procedures, until the unit is cleared by management for
normal on-line operations. For extended shutdowns it is
·Coil/s and water distribution spray header, pump, recommended that a qualified technician remove fuses from
strainers, and float assembly “fused-disconnect panels” or otherwise open the circuit in
·Drift eliminators and inlet louvers an accepted, secure manner.
·Parts shipped loose in pan section Fans - All fan covers, guards, and shaft retainers (if any)
must be in place before applying power to an IDC con-
Parts shipped loose include fan guard, inlet louvers, as- denser. Always disengage and lock out power before al-
sorted nuts, bolts, washers, and mastic strip (a flexible joint lowing interior inspections. To prevent foreign objects from
seal stored on a continuous paper-backed roll). Accessory being drawn into rotating fan blades, never allow opera-
items will likely be shipped “loose” in a sealed box that is tion with hatch off/open.
secured in the pan section.
Enclosed space inspections – Inspections of condenser
1.3 Transit Damage Claims coil, drift eliminators, etc., requires machinery lockout and
The IDC unit owner’s authorized agent who signs for the the use of a “lookout buddy” at a minimum. Consult your
shipment is responsible for making damage claims (per internal safety policy and OSHA requirements for additional
ICC requirement). Request immediate inspection and form safety rules/procedures.
execution by the agent of the carrier. Contact Imeco (Tel. Vibration and noise – Discontinue or stop machinery that
815-946-2351) to report damage or shortage claims. emits unusual vibration and noise. The source must be in-
1.4 Unit Identification vestigated (and apparent discrepancies corrected) before
testing or placing the unit back in operation.
All IDC units are identified by a nameplate permanently
attached to the pan section. Figure 1-1. ID Plate Informa- Wet Surface Precautions – Poorly maintained/wetted ma-
tion shows the information provided. Imeco recommends chinery requires care to avoid electrical shocks from inad-
that the name plate data be copied onto the graphic for equate/loose field wiring/connections. All personnel must
ease of reference ordering parts. lock out and tag machinery before working on the con-
denser. Proper safety precautions such as the use of insu-
Note: When inquiring about the unit or ordering repair lating soles/gloves and a trained “lookout buddy” are indis-
parts, provide the MODEL and SERIAL NUMBERS from pensable. Ice formation in cold weather can present fall/slip
the data plates. hazards. Icing safety procedures should be mandatory when
the daily ambient temperature falls below 40°F (4.4°C).
 IDC EVAPORATIVE CONDENSERS S140-500 IOM
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Water Chemistry – All evaporative-cooled condensers In general, IDC unit/s should always be located/elevated
operate on principles that encourage biological growth in on concrete pads, piers or structural steel so that exhaust
the recirculating water unless effective treatment is applied. air discharge of the fan orifice is at or above the elevation of
Recirculating water must be periodically analyzed for bio- nearby walls or structures/equipment.
logical culture plate counts. IDC units should not be oper- For other minimum spacing requirements see Figure 1-3.
ated without an effective biological treatment program. (IDC Unit/s to Wall Spacing Requirements) for examples
Note: Emergency “shock” treatment with chemical bio- showing (2) IDC condensers installed next to a single wall
cides may upset the unit’s appropriate pH range (creat- and next to a double wall; and, (1) multiple-cell IDC con-
ing an excessively corrosive environment for the mate- denser installed next to a double wall.
rials of construction) and may expose operators to strong 1.7 Field Piping Considerations for IDC Unit
chemicals that are corrosive or otherwise dangerous if
mishandled (see water treatment page in Section 4.0). Installation
1.6 Placement of IDC Units All IDC units require strongly supported and anchored field
piping. No field piping is to be supported by the IDC itself.
All IDC units must be located to minimize the effect of ex- Wind loading, temperature variation, etc., must be consid-
haust air recirculation. This can significantly derate an evapo- ered to allow for movement between the tower, building,
rative-cooled IDC’s capacity due to the exhaust air’s rela- optional vibration isolator/rails, and field piping. A qualified
tively higher heat and moisture (gained from evaporation of cooling system design engineer should provide final field-
tower water). piping plans and specifications.
In some worst case scenarios, up to 30% heat removal Before finalizing piping installation plans, it is recommended
capacity can be lost if a cooling tower is improperly located that related plans for cooling system/plant expansion be
or oriented. It is the owner’s responsibility to properly locate discussed with your field piping/system designer and Imeco
each unit and/or consult with a qualified engineer before sales representative. Incorporating pipe openings/sizes now
laying out structural/foundation supports and installing the allows for easier installation in the future.
IDC condenser.
Adequate space must be continuously available to allow
adequate airflow to the IDC inlet louvers to prevent dis-
charge air recirculation. Figure 1-2. IDC (Unit to Unit Spac-
ing Requirements) shows IDC condensers on an open
roof with the minimum required distance between the units.
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Figure 1-2. IDC Unit-to-Unit Spacing Requirements

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Figure 1-3. IDC Unit-to-Wall Spacing Requirements (Multiple Cell and Multiple Unit Installation)
S140-500 IOM IDC EVAPORATIVE CONDENSERS
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Section 2.0 Installation Procedures 2.2 Foundation Information

Installation of an IDC unit involves constructing heavy foun- IDC units are shipped in two pieces, a pan section and the
dations and/or structural steel supports as well as erecting fan/coil section. As the unit’s base, the pan section must first
and anchoring the unit. Imeco strongly recommends that a be anchored to suitable “footings”: concrete pads; concrete
qualified, bonded, and insured mechanical general con- piers; or structural steel capable of supporting the total unit
tractor be used to perform this heavy structural work. operating weight plus a significant safety margin as de-
As a crane is generally required, it is advisable to clear the termined by a qualified structural engineer. Support “foot-
access area a day in advance to ensure smooth and safe ing” requirements will vary with live loads (expected snow/
operations the day of the lift. Once the IDC unit is set in ice buildup) as will related anchoring requirements for re-
position and the crane drops its hook, it is the client’s re- sisting seismic and wind loads.
sponsibility to ensure that the IDC is made safe with perma- Two IDC units support “foundation footings” are required,
nent anchoring to a solid foundation. one located under each end of the unit with both running
The project site should be surveyed periodically to ensure the full width of the unit - reference Figure 2-1. Foundation
that no unattended IDC components or contractor materi- Layout.
als/tools remain unsecured. Electrical work should also be If the support “footings” are in the form of two steel beams,
made safe against unauthorized site visitors, vandalism, or each should be sized in accordance with standard engi-
weather. neering practices. Structural design should account for 55%
of the operating weight of the unit as a uniform load on the
2.1 Installation Tools beam, allowing for a maximum deflection of 1/360 of the
To complete the installation of Induced Draft Condenser length, not to exceed 1/2 inch.
(IDC) evaporative cooling unit/s, the following tools are All units have holes for the use of appropriate beam “foot-
needed at a minimum: ing” anchors/connections such as epoxy-bolts, metal con-
·Drift pins crete fasteners, or direct welds to structural steel beams.
Structural beams need to be shimmed level before final
·8-foot straight edge anchoring.
·Level Note: Shims between the beams and the unit should not
·Assorted open-end wrenches be used, as this will not provide adequate support.
·Socket set
·Belt tension gage
·Tape measure
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Figure 2-1a. 12' x 12' Foundation Layout

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Figure 2-1b. 12' x 18' Foundation Layout

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Figure 2-1c. 12' x 20' Foundation Layout

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2.3 Eliminator Placement 2.6 Optional Vibration Isolator

Check the placement of the eliminator sections for proper Vibration isolators minimize transfer of forces due to vibra-
interlock and eliminate openings, which will allow the es- tion/dynamic loading to or from IDC unit/s. This IDC unit
cape of water droplets. Check the orientation of the elimina- option requires additional field installation measures.
tor sections to ensure “RIGHT SIDE UP” as shown in Figure If vibration isolation is provided (whether furnished by Imeco
2-2. Eliminator Orientation Cross Section. Eliminator or by others) the isolators must always be mounted below
placement is described in greater detail in Section 4 - Main- the condenser unit structural “I” beam supports (such that
tenance. continuous support of unit, as described above, is provided).
Refer to Figures 2-5 (a-b) Vibration Isolator Installation
THIS SIDE FACES UP WHEN INSTALLED ON UNIT and the following instructions:
ISOLATOR FEET INSTALLATION:
·Refer to the submitted foundation layout drawing
for the correct location of each isolator and sup-
port beams.
·Place the isolators in their proper location and
attach the bottom plate to the building support
steel by means of bolting or welding.
THIS SIDE RESTS ON ELIMINATOR SUPPORTS OF ·Set the unit support beams on top of the isolators
UNIT and attach them to the top plate by means of
bolting or welding.
Figure 2-2. Eliminator Orientation Cross Section ·Lower the first section of the unit onto the beams,
taking care not to overload any one corner.
2.4 Inlet Louver Installation
·Attach the unit to the beam by means of bolting or
Install inlet air louvers so that water drains into unit. Louvers
welding.
are shipped within the drain pan. Orient the louvers as shown
in Figure 2-3 Louver Installation. A slotted holding bracket ·Continue to attach the remaining unit sections
slides up to install the louver. The bracket then slides down per the instructions on the previous pages and
to be tightened. It will hold the louvers in place. complete piping, wiring, etc.
·Loosen the vertical restraint jam nuts to the end
of the restraint bolts.
·When the unit is completely installed and operat-
ing, turn the leveling bolts counterclockwise sev-
eral complete turns on each isolator until the
blocking channel can be removed by hand. In
order to raise the unit uniformly, it will be neces-
sary to alternate between isolators. Do not at-
tempt to place all the weight on any one isolator,
but distribute the load proportionally.
·After the unit is level, tighten the vertical restrain-
ing nuts finger tight, then back off one half turn.
Lock each nut with the jam nuts provided.
Figure 2-3. Louver Installation ISOLATOR RAIL INSTALLATION
2.5 Erecting the IDC Unit ·Refer to the submitted foundation layout drawing
As mentioned above, the pan section is first hoisted into for the correct location of each isolator rail.
place and secured to prepared “foundation beams” with ·Place the isolator rail assemblies in their proper
appropriate anchoring hardware. Following this procedure, location and attach the bottom plate to the build-
the Coil/fan Section is hoisted into position and bolted to ing support steel by means of bolting or welding.
the Pan Section’s support posts.
·Lower the first section of the unit onto the rails,
Note: lifting-cable length is critical as shown in the rig- taking care not to overload any one corner.
ging of the two sections in Figure 2-4 (a-b). Assembly
and Placement. ·Attach the unit to the isolator rail by means of
bolting or welding.
ERECTION NOTES:
·Continue to attach the remaining unit sections
·For extended lifts, use all lifting points and safety
per the instructions on the following pages and
slings. For final placement, use all lifting points.
complete piping, wiring, etc.
·Use spreaders and blocking to protect the flanges ·Temporarily remove all vertical lock nuts from
of the casing and prevent caving in sides.
hold-down bolt.
·All safety precautions should be vigilantly en-
·When the unit is completely installed and operat-
forced while crane is on site. Only properly trained
ing, turn the leveling nuts clockwise several com-
members of the crane’s crew should handle hook
plete turns on each isolator until the shim can be
cables, slings, spreaders, etc. removed by hand. It will be necessary to alter-
 IDC EVAPORATIVE CONDENSERS S140-500 IOM
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Figure 2-4a. Assembly and Placement

S140-500 IOM IDC EVAPORATIVE CONDENSERS
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Figure 2-4b. Assembly and Placement

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Figure 2-5a. Vibration Isolator Feet

NOTE: Do not attempt to move the unit laterally with the weight on the isolators. If it is necessary to move the unit, remove the
weight from the isolators by raising the unit before moving. Failure to follow this procedure could result in damage to the isolator.
Do not use ridged connections between the unit and building structure when using vibration isolators. Use flexible connections
that allow for vibration and noise isolation.

Figure 2-5b. Vibration Isolator Rails

S140-500 IOM IDC EVAPORATIVE CONDENSERS
Page 16 INSTALLATION - OPERATION - MAINTENANCE
nate turns on each isolator to uniformly raise the •Confirm proper belt condition and tension. (See
unit. Do not attempt to place all the weight on any Maintenance Section 4.4)
one isolator, but distribute the load proportion- •Check condenser for any damage, or blockage
ally. that may impede water flow. Check all flow con-
·After the unit is level, replace all vertical lock nuts trols such as basin heaters, makeup valves, ther-
on hold-down bolts and fasten finger tight. mostats, etc.
Section 3.0 Startup & Operation •Confirm “sump” level is at proper level. (Section
3.2.8)
Before attempting to startup and operate any electrical cool-
•Check fans and guards for obstructions.
ing equipment such as an IDC condenser unit, it is essen-
tial that all personnel associated with have a basic knowl- •Clean and flush pan and strainer. (Section 4.5)
edge of how and why the unit operates in normal condi- •Check fan/s for correct rotation and electrical hook-
tions. The following description outlines a standard unit’s up.
general features, operation, and controls. •Understand and prepare for first 24 hour opera-
An IDC (Induced Draft Condenser) is an engineered heat tion measures e.g., new belt run-in procedures.
transfer device that uses a fine water spray and (Section 3.3)
counter-current airflow to evaporative-cool a “coil” (con-
Breaking In Galvanized Surfaces
tinuous tubing bundle). Heat is transferred to the spray’s
water film on the outside coil surface from a gas flowing A proper break-in procedure should be followed for water
inside the coil. The gas stream ultimately condenses when treatment based on allowing the galvanized surfaces to
its heat load is fully transferred. The transferred heat load break in (passivate). Properly executed, this allows galva-
evaporates a small part of the water stream before the re- nized surfaces to form a self-protecting zinc carbonate layer.
maining water is collected and recirculated. A qualified water treatment specialist can provide specific
details, but the following are minimum guidelines.
The water “film” that is sprayed over the outside of the coil -
gravity-feeds into a basin “pan section” located at the bot- •Clean all wetted surfaces.
tom of the IDC unit. A “recirculation” pump collects and dis- •Touch up scratches in the galvanizing with a zinc
charges the water at a given pressure to the spray distribu- rich compound.
tion piping header “tree” and nozzles - that are arranged in •Keep the water moderately hard.
an opposed flow arrangement for even spray coverage over
the coil assembly. •Avoid cleaning chemicals in pH ranges above
9.0 and below 6.5 (particularly anything which
Located on the top of the IDC unit is an induced-draft, will raise the pH level to 9.0 or above).
axial-flow fan that is indirectly driven by an electric motor
which uses sheaves and a multi-band belt for power reduc- Begin regular water treatment procedures after a break-in
tion/transmission. The fan draws fresh intake air through period, typically 30-45 days.
side louvers and up through the coil (counter-flow to the 3.2 Initial and Seasonal Start-Up
falling water stream).
Before initial start-up or after a long shutdown period, the
Heat and moisture-laden air is then passed through a unit should be thoroughly inspected and cleaned. The start-
drift eliminator to remove entrained droplets. Air then flows up sequence should be:
through the air plenum, fan, fan orifice, and fan guard –
before exhausting to atmosphere. 1. Clean any debris from guards, fans, eliminators, heat
transfer coil, and cold water basin.
Safeties and controls vary with each IDC installation and
may be interfaced with ancillary equipment or system con- 2. Flush the cold water sump (WITH STRAINERS IN
trols. Since all operators should be thoroughly trained in an PLACE) and drain to remove accumulated dirt. (Sec-
integrated cooling system’s sequence of operations – Imeco tion 4.5)
recommends that each client develop its own control de- 3. Remove, clean, and replace sump strainers.
scription. 4. Turn the fan(s) by hand to ensure rotation without ob-
3.1 Initial Startup (for new IDC Units) struction.
After installation of the unit, controls, and necessary ancil- 5. Check and, if necessary, adjust the fan belt tension.
lary/auxiliary equipment, the entire cooling system should (Section 4.4)
be prepared before placing the unit on-line for the first time. 6. Prior to seasonal start-up, lubricate the fan shaft and
Specifically, the following prestart measures must be com- motor bearings. The ball bearings are factory lubricated,
pleted satisfactorily to ensure readiness of the IDC. but should be relubricated if the unit has been sitting on
Note: Do not attempt any inspection or maintenance un- site for more than a year before start-up.
less the electrical supply has been completely discon- 7. Check float-operated makeup valve to be sure it is op-
nected and locked out. erating freely.
Inspection 8. Fill cold water sump with fresh water to overflow level
Do not start the unit until the following inspections prove (start basin heater if necessary).
operational readiness. Avoid accidents or equipment fail- 9. Adjust the float on the makeup valve to shut off the
ure by rectifying any unsatisfactory condition. valve when the float is approximately even with the
•Inspect general condition of unit, e.g., structural centerline of the overflow.
integrity, anchors/supports, etc. 10. Start spray pump and check for the proper rotation as
•Confirm drive assembly condition and alignment indicated by sticker on pump motor. On “Remote” in-
of motor, bearings/collars, and fan/shaft. stallations where the unit pump was not furnished by
the factory, water flow must be at the flow rate and pres-
sure shown on submittal drawing.
 IDC EVAPORATIVE CONDENSERS S140-500 IOM
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11. Inspect spray nozzles and heat transfer section. 3.4 Daily Operation
12. Check the locking collar on each fan shaft bearing and The unit should be inspected, cleaned, and lubricated on a
tighten if necessary. periodic basis. The required services and recommended
13. Check the voltage and current of all three legs of the frequency for each are summarized in the Operation and
fan and pump motors. The current should not exceed Maintenance Schedule in this manual.
the rated service factor. After prolonged shutdowns, the A daily IDC operations log is a good method to assure that
motor insulation should be checked with a Megger no problems develop that may go unchecked. Entries to
Tester prior to restarting the motors. this “rough” log should be made once each shift. Any nota-
14. Start the fan(s) and check for proper rotation as indi- tions should be entered as they occur (or internal policy
cated by sticker on unit. dictates). It is essential that the maintenance manager ex-
15. Open the bleed line valve and adjust bleed to the rec- amine notations (from the previous 24 hours) on a daily
ommended rate. (Section 4.9). basis.
16. On units furnished with electric water level control pack- As safety/weather dictates, a visual check of the condenser
ages, ensure that the stilling chamber is free of ob- should be made once each shift (daily at a minimum) to
check operating conditions. Unusual leaks, noise, vibra-
structions.
tion, part damage/failures, or vandalism should be logged
3.3 24-Hour Run In immediately. Corrective action should be initiated immedi-
After 24 hours of operation under load, the following ser- ately as operations permit, or ensuing service scheduled.
vices should be performed: Associated equipment should also be part of the daily op-
1. Check unit for any unusual noise or vibration. erational checks for the IDC unit. In particular, filtration and
other water treatment equipment performance are impor-
2. Check the operating water level in the cold water sump. tant to satisfactory and problem-free unit operation.
Adjust if necessary.
3. Readjust fan belt tension if required.
4. Inspect spray nozzles and heat transfer section.
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3.5 Seasonal Start up & Shutdown 3.6 Winter Operations

Since the IDC is exposed to freezing conditions and other Evaporative condensers are suitable for most cold weather
natural stresses, it is mandatory that maintenance person- applications when supplied with proper capacity control
nel conduct a thorough shutdown and startup on a given and freeze protection. Ultimate freeze protection in harsh
date each year (before freezing or high heat loads cause climates means keeping the basin pan water heated and
problems for an unprepared unit. cooling the dry coil with the fan only. In more moderate
Seasonal Shutdown temperatures the IDC may be used with the recirculation
pump back in operation to achieve evaporative cooling.
The following services should be performed when the unit
is to be shutdown for a prolonged period: Note: dry-bulb temperature must be above 36°F (2.2°C)
before operating water pump.
•Clean and flush the cold water sump with sump
strainer in place. Leave the drain open so rain IDC fan motors are suitable for variable frequency drive. A
and melting snow will drain from the unit. high quality pulse with modulating drive with proper pre-
cautions against voltage spikes, allows the motor to be run
•Clean the sump strainers and reinstall. as low as 20HZ. This will provide part load capacity by re-
•Drain the cold water sump and all piping that will ducing unit airflow.
be exposed to freezing temperatures. In winter operation, Imeco recommends that the pump
•Lubricate the fan shaft and motor bearings, motor should be the first item shut off to achieve capacity control.
base and motor base adjusting screws. By running the unit with a “dry coil” in during low wet bulb
•Close shut-off valve in water make-up line and conditions, the unit is protected from ice formation.
drain all exposed make-up piping. Supplementary heat must be supplied to the pan water
•Inspect the protective finish on the unit. Clean and during freezing conditions. The evaporative condenser’s
refinish as required. basin heater provides sufficient heat to keep the spray wa-
ter in the pan from freezing when the unit is not running. A
•On units equipped with electric water level con-
thermostat that senses the pan water temperature controls
trol packages, inspect stilling chamber to ensure
the heater, and is factory set at 42°F (5.6°C).
it is free of obstructions.
The heater is protected by a low water cutout switch that
Seasonal Startup
prevents the heater from operating when the pan water
•Remove freeze protection and fill water sump, level is too low. In addition to protecting the basin pan water,
exposed piping, etc. all exposed water piping, including the pump suction line,
•Ensure that basin heater or heat taping is turned pump, pump discharge piping (up to the overflow connec-
off by thermostat settings or manually tion), and the make-up water lines, should be traced with
•Open makeup valve and test flow to IDC makeup electrical heat tape and insulated. Some evaporative con-
valve. denser installations will permit all spray water to be drained
from the pan during cold weather operation. This permits
•Test makeup valve shutoff. dry operation of the Evaporative Cooler or Condenser when
•Check fan for obstructions and rotate by hand to the load and ambient temperatures are extremely low.
check for binding Units that require year-round operation in a freezing cli-
•Relubricate fan and pump bearings mate (without a remote sump) should be equipped with an
•Remove debris from all exposed surfaces, lou- electric pan water level control package. This package en-
vers, and fan guard. sures a constant water level without adjustment and also
maintains very close control of the pan water level. The
•Clean coil tubes, fins, etc., for good heat transfer system consists of a weather-protected electric float switch
•Prime recirculation pump and observe flow with stilling chamber mounted on the pan section and a
through pipe tree. weather-protected solenoid valve mounted on the water
makeup connection. When this system is used, it replaces
the mechanical water makeup valve.
 IDC EVAPORATIVE CONDENSERS S140-500 IOM
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Section 4.0 Maintenance

4.1 Maintenance Intervals

Maintenance of the IDC is relatively easy if sufficient consideration is given to the minimum maintenance requirements for
keeping evaporative-cooled condensers performing to specification. These can be easily scheduled using the following “easy
reference” preventative maintenance guide provided below as Figure 4-1. Recommended Maintenance Intervals.

RECOMMENDED MAINTENANCE INTERVALS

TYPE OF SERVICE START-UP MONTHLY EVERY 3 EVERY 6 EVERY 12
MONTHS MONTHS MONTHS

Inspect General Condition of Unit X X

Clean debris from unit X X X
Clean and flush sump X X X
Clean sump strainer X X X
Check and adjust sump water level X X
Inspect heat transfer section X X
Inspect spray nozzles X X
Check and adjust fan belt tension X X
Check and adjust bleed rate X X
Check operation of make-up valve X X
Check unit for unusual noise or vibration X X
Check fan bearing locking collars X X
Check motor voltage current X X
Lubricate fan shaft bearings X X X
Lubricate motor base adjusting screws X X
Lubricate the fan and pump motors X
Check fan for rotation without obstruction X X
Check fan & pump for proper rotation X
Drain sump and piping X
Inspect protective finish X
Lubricate capacity control and/or discharge X X X
closure damper bearings and working joints
Inspect/adjust damper linkage X X X
Inspect electric pan water level control X X X

Figure 4-1. Recommended Maintenance Intervals

Note: Before performing any maintenance or inspection, make certain that all power has been disconnected, locked out,
and tagged properly.
S140-500 IOM IDC EVAPORATIVE CONDENSERS
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4.2 Spare Parts Recommendations

Frick recommends that customers maintain the following spare parts “in stock” for the IDC evaporative-cooled condenser unit.
By maintaining this inventory of spare parts, change-out requirements can be immediately satisfied during preventative main-
tenance inspections.
It is also advisable to re-order parts prior to taking existing spares from inventory. This policy helps prevents downtime due to
“forgotten” spare parts order placement.
The type and recommended stock level for each part is listed below in Figure 4-2. Recommended Spare Parts List.

RECOMMENDED SPARE PARTS LIST

MODEL SERIAL NUMBER

PART NUMBER RECOMMENDED STOCK LEVEL
FAN BELTS* ......................................................................................................................................... One Set
FAN BEARINGS* ................................................................................................................................. One Set
FAN BUSHING ..................................................................................................................................... One Set
MOTOR BUSHING .............................................................................................................................. One Set
FAN SHEAVE ....................................................................................................................................... One Set
MOTOR SHEAVE ................................................................................................................................. One Set
FLOAT VALVE ....................................................................................................................................... One
SPRAY NOZZLES ................................................................................................................................ One Set
FAN MOTOR* ....................................................................................................................................... One Set
SPRAY PUMP* ..................................................................................................................................... One
FAN SHAFT .......................................................................................................................................... One

Figure 4-2. Recommended Spare Parts List

* Parts noted to be considered as “critical components” to be stocked by customers to ensure continuous unit operation.
 IDC EVAPORATIVE CONDENSERS S140-500 IOM
INSTALLATION - OPERATION - MAINTENANCE Page 21

4.3 Lubrication To check both parallel and angular alignment, refer to Fig-
ure 4-3. Sheave Alignment and follow these instructions:
Standard Motors
1. While placing a straight edge across the top of both mo-
Standard IDC fan motors are specifically designed for this
tor and fan sheaves, check for four points of contact.
application to be maintenance free and no greasing is re-
quired. Replacement motors are available from Imeco. Part 2. If a four-point contact is achieved, skip to the belt
numbers can be found on the motor nameplate. tensioning section.
Special Motors 3. To adjust for parallel misalignment, adjust the motor or
fan shaft sheave.
On occasion, special motors (i.e. two-speed, Chem Duty,
etc.) may be specified. These motors must be maintained Fan Blade Inspection
per the motor supplier’s recommendations and may require Inspect fan blades for damage or debris. Ensure aluminum
external lubrication lines and special grease. blades are intact. Ensure that debris which can disturb fan
Note: The grease for special motor bearings and the fan balance is removed from fan.
bearings may not be compatible. Please check the lubri- 4.5 Sump Drainage
cation label on the unit.
The sump and piping should be drained every three months
Fan Bearings and the pump inlet screen should be cleaned. For units with
Check monthly and relubricate bearings (while bearings integral pumps, the water pump inlet is equipped with a
are being rotated). The grease will increase in temperature drain plug. Removing the plug allows the sump and pump
approximately 30°F (16.7°C) during relubrication. Use hand screen to be cleaned and flushed. An FPT coupling is pro-
grease gun only. vided to allow piping to be attached as shown in Figure 4-
Bearings used on the belt drive IDC units are prelubricated 4. Sump Drain Location.
with grease chosen for its chemical and mechanical stabil-
ity in an evaporitive-cooling environment. The type of grease
used is lithium-complex based with synthetic oil. For
relubrication, use any good quality lithium-based grease
conforming to NLGI Grade No. 2 consistency.
The following types of grease meet the above criteria:
•MOBILITH 22
•MOBILUX #2
•SHELL ALVANIA #2
•UNIREX N2
•TEXACO MULTIFAX #2
•TEXACO PREMIUM RB
Grease and grease fittings should be free of dust, rust, metal
particles, abrasives and chemical impurities such as free
acid or free alkali.
4.4 Drivetrain
Belt tension should be checked every month as described
in section 4.6. The sheaves should be tight on the shafts
and should be aligned properly to minimize belt wear. The
belts should be checked for wear along the edges, as any
irregularity will cause vibration.
Sheave Inspection
Check the sheaves for proper alignment, excessive corro-
sion, and wear or damage. Also, check the belt for exces-
sive heat. If the belt is too hot to touch, then the sheaves
may be damaged or need aligning.
If the sheaves have excessive corrosion or are worn or
damaged, they should be replaced. Check for sharp edges
from wear or pitting of the grooves from corrosion. Either Figure 4-3. Sheave Alignment
condition will promote belt wear and increase turnover.
Groove gauges are also available to make it easy to see if
the grooves are worn. If more than 1/32" of wear can be
seen, the sheave should be replaced.
Sheaves for the motor and fans are designed for this spe-
cialized application and are available from Imeco (do not
substitute).
Alignment of sheaves is extremely important for proper belt
installation. The sheaves are aligned at the factory, but should
be rechecked when new belts are installed. Use a straight
edge to check alignment. Misalignment will show up as a
gap between the outside face and the straight edge. Two Figure 4-4. Sump Drain Location
conditions for misalignment exist, angular and parallel.
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4.6 Belt Replacement and Tensioning 4. If the above procedure still results in the belt squealing,
but the belt is still taut on the slack side, a more precise
Replacement
method of testing the belt tension must be used. In this
When the decision is made to replace the belt, follow these case, use a belt-tensioning gage available from V-belt
steps: drive manufacturers or from IMECO.
1. Lock out and tag the starter. All belt tension measuring devices should include operat-
2. After the power has been turned off and the motor guard ing instructions. These are spring-loaded devices that use
removed, loosen the motor mount adjustment nuts. a hook to place tension on a stationary belt. Tension read-
3. Move the motor until there is enough slack in the belt so ings are observed at a point where the belt deflects a pre-
it can be removed without prying. determined distance. Tension is usually applied at the belt
span’s mid-point as measured between the tangent of belt
4. Remove the old belts and inspect for unusual wear. Ex- contact for both sheaves. Reference Figure 4-5.
cessive wear may indicate problems with alignment or Belt Tensioning Schematic.
sheave damage.
4.7 New Belt Run-in
5. Use replacement belts from the factory to ensure a proper
belt equivalent. During initial startup of new belts, a belt run-in procedure is
recommended. During start-up, follow these instructions:
6. Inspect other drive components such as bearings and
sheaves for alignment, wear, lubrication, etc. During start-up, look and listen for unusual noise or vibra-
tion.
7. Clean the sheaves of debris before installing the new
belt. 1. After shutting down and locking out the starter, check the
bearings and motor. If they feel hot, the belt tension may
8. Install the new belt, align the drive, and tension the belt
be too tight.
according to the procedures outlined here.
2. Run the drive under full load for 24 hours of continuous
Tensioning
operation. Running the belts under full load allows them
Proper belt tension is very important to ensure maximum to seat themselves into the grooves.
belt life. If too little tension is applied, the belt will slip. Too
3. After running the drive, check the tension of the belts.
much tension can reduce belt and bearing life. It is not rec-
Re-tension to the recommended values. This run-in pro-
ommended that belt dressing be used when belt slippage
cedure will reduce the future need for re-tensioning and
occurs as this will damage the belt and cause premature
failure. will help extend the life of the belts.
1. Decrease the center distance between the sheaves (by 4.8 Coil Assembly
turning the tensioning nut counter clockwise) so the An evaporative-cooled condenser’s operational readiness
sheaves are somewhat loose. is dependent on the condition of the coil. Coils that are dirty,
2. Apply tension to the belt by turning the tensioning nut blocked from air-flow, or physically damaged may affect
clockwise. overall heat transfer capability of the IDC to a significant
3. Operate the drive a few minutes to seat the belt in the degree.
sheave grooves. Observe the operation of the drive dur- Periodically conduct a visual inspection of the coil section
ing start-up. A slight bowing of the slack side of the drive and refrigerant line connections. Remove any airborne de-
indicates proper tension. If the slack side remains taut bris that may have collected on the face of intake louvers or
during the peak load, the drive is to tight. Excessive bow- on the coils themselves. If separate air filtration exists prior
ing or slippage indicates insufficient tension. If the belt to the intake louvers, ensure that adequate “free area” ex-
squeals as the motor comes on, it is not tight enough. ists to meet intake-air CFM requirements.
The drive should be stopped and the belt tightened. Further need for cleaning or repair of an IDC coil should be
Note: Do not over-tighten the drive.

Figure 4-5. Belt Tensioning Schematic

 IDC EVAPORATIVE CONDENSERS S140-500 IOM
INSTALLATION - OPERATION - MAINTENANCE Page 23

left to the judgement of a certified or factory-trained service operation. The water level is easily adjusted by loosening
person. Contact the local Frick representative if a coil or its the wing nut on the valve and raising or lowering the ball to
connections appears to have been significantly damaged. maintain the proper level. The recommended operating pres-
sure for the water makeup valve is 15 to 20 PSI.
4.9 Water Makeup Requirements
Moisture Eliminators
At its rated capacity (given in tons), an IDC unit will evapo-
rate 3 gallons/min per 100 tons. The moisture eliminators are located on top of the unit and
prevent losses of the spray water due to water being en-
When the water evaporates, any impurities remain. Recir- trained in the air stream as it passes through the unit. The
culating water flow then requires refreshing to prevent even- eliminators should be checked monthly to remove any ob-
tual scale build up. A bleed-off valve is located on the spray structions that might be trapped between the blades and to
pump discharge line to bleed off an equal amount of water ensure proper positioning.
to that evaporated. (3 GPM per 100 tons)
Water Distribution System
For conditions where the original water hardness is very
high or a large number of airborne contaminants may be The spray nozzles are accessible through the access door.
washed into the recirculating spray water, a higher bleed- After tagging and locking out the fan motor, remove a sec-
off rate or chemical treatment may be required. Consult a tion of eliminators to find the spray header underneath (DO
local water treatment company for recommendations. NOT OPERATE UNIT WITHOUT ELIMINATORS). The large
orifice, cleanable type nozzles should be checked monthly
4.10 Water Treatment to see that the spray pattern is complete and even. Figure
If the condition of the water is such that constant bleed-off 4-6. PowerFlow™ Orientation, shows the nozzle in the
will not control scale or corrosion, chemical treatment may spray headers with the proper in-line orientation.
be necessary. If a water treatment program is used it must If the nozzles are not operating properly, check that the
meet the following requirements: strainer in the pan or that the water distribution pipes do not
•The chemicals must be compatible with zinc gal- have accumulated dirt or debris. Also, check the nozzles by
vanic protection. removing them and clean any that may need cleaning.
•The circulating water must be maintained between NOTE: When cleaning the nozzles and distribution sys-
6.5 and 7.5 pH, 1000 PPM (maximum) tem, always ensure that the initial orientation of the
dissolved solids, 125-PPM (maximum) Chlorides, nozzles is maintained.
and 125-PPM (maximum) Sulfites. Heat Transfer Section
•Chemicals should be fed into the recirculated wa- The coil should be examined monthly for signs of scale
ter, but not into the cold water sump, on a continu- buildup, and any obstructions between the tubes should be
ous metered basis to avoid localized high con- removed. If there is evidence of scale buildup on the coil,
centrations which may cause corrosion. These check the bleed valve for adequate bleed-off. If the bleed-
chemicals are normally fed into the pump dis- off valve is functioning properly, contact your local water
charge line. Batch feeding of chemicals does not treatment company for recommendations.
provide adequate control of water quality and is Pan-Water Electric Level Control Packages
not recommended.
Inspect Stilling Chamber for obstructions every three
•Acid water treatment is not recommended. months.
•The use of simple bleed-off or chemical treatment
for control of scale or corrosion does not preclude
4.11 Protective Finish
the need to control biological contamination. Treat- Standard IDC units are protected by a thick layer of hot dip
ment with biocide is a necessary portion of re- galvanizing. it should be part of the maintenance program
quired water treatment! to annually inspect and “touch-up” any significant scratches
For specific recommendations on water treatment, contact that may penetrate the heavy layer of Zinc protection. Deep
a competent water treatment supplier. The following para- scratches should be cleaned of any surface soil, grease,
graphs provide detailed information regarding critical main- etc., and then coated with a “zinc-rich” cold galvanizing
tenance considerations. compound or Zinc solder.
Bleed-Off Valve If surrounding components will not be damaged by
flame-level heat, a blowtorch can be used to slowly heat
Check monthly to ensure that it is not blocked and that the scratch to the melt point of a Zinc solder rod. Apply the
water is flowing as required. The bleed valve should always Zinc until it smoothly flows over the scratch. Discontinue
be open, unless the flow is controlled by a water treatment torch application and quickly use a manual wire brush to
system. spread the molten Zinc evenly over the damaged area.
Strainer Care must be taken not to use this technique near any heat
The pan water strainer is located at the bottom of the pan sensitive bearings, belts, mastic seals, etc. A “hot work”
section at the suction connection of the spray pump. The approval should be obtained from the work area’s desig-
strainer should be cleaned monthly, or as conditions re- nated Safety Officer before conducting the procedure.
quire, to keep it clean. The strainer is easily accessible by Special units constructed from Stainless Steel components
removing the inlet louver at the pump end. Do not operate generally do not require “special care” to maintain normal
the unit without the strainer. corrosion protection. However, Stainless Steel units should
Makeup Valve be protected from direct exposure to caustic or acidic chemi-
A float-actuated valve controls the pan-water level. This valve cals.
should be checked monthly for proper operation and water All units should be cleaned as local conditions require. Also,
level. The pan water level should be even with the centerline periodic inspections for structural or component damage
of the overflow when the unit is not running. This will pre- from wind, lightening, or freezing weather will help maxi-
vent the pump from cavitating when the spray system is in mize the unit’s life.
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Figure 4-6. PowerFlow™ Orientation

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Section 5.0 Troubleshooting

Accurate troubleshooting is greatly facilitated by knowing proper unit capacities, dimensions, and other specifications. Detailed
information for specific units is provided in the form of a drawing package shipped/submitted with the equipment delivery.
Reference Figure 5-1. IDC Series Standard Unit Specifications and Figure 5-2. IDC Series Standard Unit Dimensions for
basic design, capacities, and troubleshooting data for Imeco IDC units.
Once it is found that a unit is not performing to specifications, experienced maintenance personnel know that a methodical
troubleshooting approach significantly reduces the time necessary to pinpoint appropriate responses. Use of the following
troubleshooting guide is strongly recommended to minimize unnecessary repair costs and downtime.
The key to efficient use of the troubleshooting guide is to eliminate the simplest cause(s) until it is possible to isolate the specific
problem/s that need to be rectified. For example, a five-minute determination of local ambient wet bulb temperature may prove
that a unit is operating under extreme weather conditions. A maintenance troubleshooting “log” can prove invaluable in keeping
up-to-date on such conditions and issues.
The following discussion details possible conditions and related causes for troubleshooting IDC condenser units:
5.1 Condition: High Condensing Pressure
Possible Cause # 1: IDC Unit / Cooling System Power Failure Or Brownout
· Check all fans, pumps, and control panels, for internal power distribution failures (such as blown fuses or overloads) or
eliminate them from consideration. Also, determine if the utility or stand-by power supply back up has failed to supply
adequate, consistent power. Should main or standby power supply equipment need updating, contact a local electrical
expert or design/build contractor to provide for consistent power.
Possible Cause # 2: Excessive Wet Bulb Temperature
· Wet bulb temperature can be determined by using a “sling sychrometer” to take a reading near the inlet of the cooling
tower/s. Background or ambient wet bulb is determined with the sling sychrometer at an upwind location or by cross-
referencing local ambient “dry bulb” and humidity levels.
· If background wet bulb is in specification and the wet bulb at the inlet is out of specification – exhaust air recirculation may
be excessive. Refer to the siting discussion provided in Section 1.0 and consult with the cooling system engineer to
determine if re-siting or other cooling system changes are needed.
Possible Cause # 3: Insufficient Water Flow/Pressure To Spray Tree
· Check water flow and pressure at the IDC inlet pipe connection. Even if this was checked and confirmed at the time of
start-up, changes to plant water supply or internal piping may have created additional pressure drops (line losses) between
the pump/s and the spray tree connection.
· The IDC spray-piping tree requires 2-10 PSI at the connection at the flow rates (in GPM) specified for the unit. This informa-
tion is available from the local representative.
· For remote pump applications, water must be supplied at the pressure and flow rate specified on the customer drawings.
Possible Cause # 4: Inadequate Water Distribution
· In the event that a few nozzles prove to be clogged or restricted, it may be necessary to remove the spray piping “tree” and
clean all of the nozzles thoroughly (as discussed in Section 4.0 Maintenance). This will ensure that all nozzles are clean and
properly realigned before re-installing the spray tree.
Possible Cause # 5: Low Fan Output
· Check fan voltage and amp draw readings and compare to specifications. If amp draw is excessive, check airflow pathways
to ascertain that no restrictions exist. Restrictions may be blocking flow through intake louvers, eliminators, or the fan guard.
Clear all air restrictions and rotate fan to check for binding blade tips in the orifice.
· If the fan has an adjustable-pitch propeller, check angle-of-attack adjustment location on each blade. All blades should have
the same angle as specified for the unit. If amp draw is still low, increase the setting for all fins by a fraction of a degree and
take new amp draw readings.
Possible Cause # 6: Inadequate Water Treatment
· Check scale buildup on coil. A1/32” thickness of scale buildup can cause a 30% capacity reduction (as rated in cooling tons
per hour).
Possible Cause # 7: Improperly Sized Or Applied Ancillary Component Or System Piping
· Check system piping against system designer’s plans and specifications. Look for unusual mixed piping sizes/materials,
excessive vertical/horizontal distances, “add-on” flow restricting devices, and poor quality pipe-fitting and support anchors.
Possible Cause # 8: IDC Unit Experiencing “Recirculation” Due To Improper Siting
· Recirculation of warm, moist exhaust air can rob up to 30% of the IDC unit’s cooling capacity. Since this is a highly variable
condition depending on weather conditions and the operational timing of nearby cooling units, plant maintenance is encour-
aged to consult with the cooling system design engineer.
· Generally speaking, an IDC unit should be located above roof level, as far away as possible from other exhaust stacks, and
upwind of higher wind-diverting structures. Any diversion from these rules-of-thumb should be re-examined by the system
design engineer.
Possible Cause # 9: Non-condensables In Receiver or Condenser
· Check condenser and receiver to determine if non-condensables have contaminated the system. If non-condensables are
found, proceed with repairs as prescribed by the refrigeration equipment/system supplier (e.g., evacuating the refrigerant
lines/system and recharging after eliminating leak or source of contamination).
 IDC EVAPORATIVE CONDENSERS S140-500 IOM
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5.2 Condition: Excessive Deposits, Scale, Or Turbidity

Possible Cause # 1: Inadequate Filtration Or Treatment Of Spray Water
· Filtration is an inherent requirement for evaporative cooling systems due to the concentration of dissolved solids and
“washing” of air particulate. Recommended filters types include bag, mesh, centrifugal, and sand & gravel.
· Filtration equipment must be maintained regularly. All filters (partial/side flow designs in particular) must be cleaned or
back-flushed regularly.
· In the event that plant-cooling system seems to have inadequate filtration, Imeco recommends that the system design
engineer consult with a local water treatment expert. Until the situation is resolved, blow-down rates should be increased to
eliminate as much excess particulate as possible.
Possible Cause # 2: Water pH is Out Of Range
· pH must be less than 9.0 and greater than 6.5. Water treatment equipment is designed to slug feed biocides of various pH
levels to minimize bacterial counts. Skimping on chemical will allow algae blooms and high bacterial counts. Excessive or
chlorine based biocides may lower pH and shorten the life of Zinc-protected steel components.
· Calibrate biocide chemical injection rate. Drain system and make-up with clean water to re-balance pH. Run system for 24
hours and observe any change in pH range.
· Repeat above steps and determine if process is adding bases/acids or is in some way affecting overall pH levels in the
cooling water flow. Eliminate any leaks (process-to-cooling-water) that may be changing pH levels in the water flow.
5.3 Condition: Excessive Slime Plugging Water/Air Passages
Possible Cause # 1: Low Blow-down Rate
· Calibrate IDC cooling water blow-down controls. Readjust if necessary to meet requirements specified by cooling system
design engineer.
Possible Cause # 2: High Bacterial Count
· Take sample for lab analysis. If analysis indicates high bacterial count, start by physically removing excess slime. Calibrate
chemical biocide feed. Drain water from system and make-up with fresh supply before returning system to service.
Possible Cause # 3: High Nutrient Levels
· Take sample for analysis. If analysis indicates excessive nutrients, repeat above steps.
· Take samples during operation to determine if source of nutrients is airborne or leaked from process by heat exchanger, etc.
Eliminate source or increase blow-down rates accordingly if discharge permit allows.
5.4 Condition: Low or High Water Level
Possible Cause # 1: Drain/Overflow Piping Clogged
· Remove debris and refill basin to test flow.
Possible Cause # 2: Make-up Valve Malfunctioning
· Replace make-up valve assembly and refill basin to operating level.
Possible Cause # 3: Pump Output Incorrect
· Take flows and pressure readings from pump/piping in question. Determine if pump may be throttled with means of butterfly
valve. Make necessary throttle adjustments and check basin after (1) hour of operation.
Possible Cause # 4: Equipment/Piping Leak
· Make-up water pressure too high (maximum should be no more than 60 PSI). If necessary, install regulator in city water
make-up piping.
· Inspect all equipment and piping for water leak. If found, shut off system. Fix leak or bypass if possible before returning system
to operation.
5.5 Condition: Excessive Noise or Vibration
Possible Cause # 1: Debris-laden Fan Blades
· Clean/remove debris from fan and retest unit operation.
Possible Cause # 2: Improperly Aligned Drive Components
· Inspect fan and drive assembly for improperly aligned drive components. Replace failed components and realign drive
assembly per maintenance instructions.
Possible Cause # 3: Damaged Noise Control Device
· Check device for damage to insulation, door, wall panels, or damaged inlet louvers.
Possible Cause # 4: Loose Tower Components
· Inspect for loose components/fasteners and repair or replace as necessary.
Possible Cause # 5: Out Of Specification Fan Speed
· Determine actual drive ratio by turning fan slowly by hand and comparing the number of motor sheave revolutions for one
revolution of the fan. Multiply actual ratio by the speed (RPM) noted on the IDC unit’s motor nameplate.
· Contact factory for order information regarding original fan speed. If different than actual, replace existing, improper replace-
ment sheaves or belt.
Continued....
S140-500 IOM IDC EVAPORATIVE CONDENSERS
Page 28 INSTALLATION - OPERATION - MAINTENANCE
Possible Cause # 6: Out Of Specification IDC Unit Structural Steel or Supports
· Failed structural steel/support beams, isolators, or attaching hardware. Replace any component having excess corrosion or
fatigued connections.
Possible Cause # 7: Excessive Background Noise/Refraction
· Turn off IDC and have accurate sound readings taken during “noisy” hours of operation. Turn on IDC and take simultaneous
readings with unit in operation. If background noise exceeds IDC sound levels, consider sound isolation of background
noise sources.
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FAN SPRAY PUMP REMOTE SUMP DIMENSIONS REFRIG. WEIGHTS

IDC NH3 MOTOR WATER MOTOR WATER SUMP GALLONS HEIGHT CTRS CHARGE UNIT UNIT HEAVIEST
MODEL TONS CFM HP GPM HP IN DRAIN REQUIRED H B NH3 LBS SHIPPING OPERATING SECTION
420 297.9 81,297 15 715 5 6" PE 10" PE 600 211.75 30.25 425 16,099 22,511 11,957
435 308.5 84,866 20 715 5 6" PE 10" PE 600 211.75 30.25 425 16,199 22,611 12,057
450 319.1 88,567 25 715 5 6" PE 10" PE 600 211.75 30.25 425 16,299 22,711 12,157
490 347.5 84,602 20 715 5 6" PE 10" PE 600 218.50 37.50 530 18,196 24,829 14,054
505 358.1 87,245 25 715 5 6" PE 10" PE 600 218.50 37.50 530 18,296 24,929 14,154
520 368.8 82,090 25 715 5 6" PE 10" PE 600 225.25 44.25 640 20,262 27,117 16,192
540 383.0 87,245 30 715 5 6" PE 10" PE 600 225.25 44.25 640 20,362 27,217 16,292
575 407.8 105,237 15 1,050 7.5 6" PE 10" PE 900 211.75 30.25 640 24,173 33,800 17,953
615 436.2 115,820 20 1,050 7.5 6" PE 10" PE 900 211.75 30.25 640 24,273 33,900 18,053
645 457.4 124,806 25 1,050 7.5 6" PE 10" PE 900 211.75 30.25 640 24,373 34,000 18,153
670 475.2 132,594 30 1,050 7.5 6" PE 10" PE 900 211.75 30.25 640 24,473 34,100 18,253
700 496.4 117,018 20 1,050 7.5 6" PE 10" PE 900 218.50 37.50 800 27,322 37,281 21,102
735 521.3 125,805 25 1,050 7.5 6" PE 10" PE 900 218.50 37.50 800 27,422 37,381 10,202
765 542.5 133,792 30 1,050 7.5 6" PE 10" PE 900 218.50 37.50 800 27,522 37,481 21,302
800 567.4 127,402 30 1,050 7.5 6" PE 10" PE 900 225.25 44.25 960 30,423 40,716 24,313
835 592.2 133,792 40 1,050 7.5 6" PE 10" PE 900 225.25 44.25 960 30,523 40,816 24,413
870 617.0 153,000 40 1,050 7.5 6" PE 10" PE 900 229.25 48.25 890 32,222 44,065 24,183
895 634.8 141,700 30 1,050 7.5 6" PE 10" PE 900 237.00 56.00 1,070 35,123 47,300 27,833
940 666.7 153,000 40 1,050 7.5 6" PE 10" PE 900 237.00 56.00 1,070 35,243 47,420 27,953
840-2E 595.8 162,594 (2)15 1,430 (2)5 (2)6" PE (2)10" PE 1,200 223.75 30.25 850 32,198 45,022 11,957
870-2E 617.0 169,732 (2)20 1,430 (2)5 (2)6" PE (2)10" PE 1,200 223.75 30.25 850 32,398 45,222 12,057
900-2E 638.2 177,134 (2)25 1,430 (2)5 (2)6" PE (2)10" PE 1,200 223.75 30.25 850 32,598 45,422 12,157
980-2E 695.0 169,204 (2)20 1,430 (2)5 (2)6" PE (2)10" PE 1,200 230.50 37.50 1,060 36,393 49,658 14,054
1010-2E 716.2 174,490 (2)25 1,430 (2)5 (2)6" PE (2)10" PE 1,200 230.50 37.50 1,060 36,592 49,858 14,154
1040-2E 737.6 164,180 (2)25 1,430 (2)5 (2)6" PE (2)10" PE 1,200 237.25 44.25 1,280 40,523 54,234 16,192
1080-2E 766.0 174,490 (2)30 1,430 (2)5 (2)6" PE (2)10" PE 1,200 237.25 44.25 1,280 40,724 54,434 16,292
1150-2E 815.6 210,474 (2)15 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,346 67,600 17,953
1230-2E 872.4 231,640 (2)20 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,546 67,800 18,053
1290-2E 914.8 249,612 (2)25 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,746 68,000 18,153
1340-2E 950.4 265,188 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,946 68,200 18,253
1400-2E 992.8 234,036 (2)20 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 230.50 37.50 1,600 54,644 74,562 21,102
1470-2E 1,042.6 251,610 (2)25 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 230.50 37.50 1,600 54,844 74,762 21,202
1530-2E 1,085.0 267,584 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 230.50 37.50 1,600 55,044 74,962 21,302
1600-2E 1,134.8 254,804 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 237.25 44.25 1,920 60,846 81,432 24,313
1670-2E 1,184.4 267,584 (2)40 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 237.25 44.25 1,920 61,046 81,632 24,413
1740-2E 1,234.0 306,000 (2)40 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 241.25 48.25 1,780 64,444 88,130 24,183
1790-2E 1,269.5 283,400 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 249.00 56.00 2,140 70,246 94,600 27,833
1880-2E 1,333.3 306,000 (2)40 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 249.00 56.00 2,140 70,486 94,840 27,953
840-2S 595.8 162,594 (2)15 1,430 (2)5 (2)6" PE (2)10" PE 1,200 223.75 30.25 850 32,198 45,022 11,957
870-2S 617.0 169,732 (2)20 1,430 (2)5 (2)6" PE (2)10" PE 1,200 223.75 30.25 850 32,398 45,222 12,057
900-2S 638.2 177,134 (2)25 1,430 (2)5 (2)6" PE (2)10" PE 1,200 223.75 30.25 850 32,598 45,422 12,157
980-2S 695.0 169,204 (2)20 1,430 (2)5 (2)6" PE (2)10" PE 1,200 230.50 37.50 1,060 36,393 49,658 14,054
1010-2S 716.2 174,490 (2)25 1,430 (2)5 (2)6" PE (2)10" PE 1,200 230.50 37.50 1,060 36,592 49,858 14,154
1040-2S 737.6 164,180 (2)25 1,430 (2)5 (2)6" PE (2)10" PE 1,200 237.25 44.25 1,280 40,523 54,234 16,192
1080-2S 766.0 174,490 (2)30 1,430 (2)5 (2)6" PE (2)10" PE 1,200 237.25 44.25 1,280 40,724 54,434 16,292
1120-2S 794.3 200,070 (2)15 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,346 67,600 17,953
1200-2S 851.1 220,020 (2)20 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,546 67,800 18,053
1260-2S 893.6 237,120 (2)25 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,746 68,000 18,153
1300-2S 922.0 251,940 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 223.75 30.25 1,280 48,946 68,200 18,253
1360-2S 964.5 222,300 (2)20 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 230.50 37.50 1,600 54,644 74,562 21,102
1430-2S 1,014.2 239,020 (2)25 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 230.50 37.50 1,600 54,844 74,762 21,202
1490-2S 1,056.7 254,220 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 230.50 37.50 1,600 55,044 74,962 21,302
1560-2S 1,106.4 242,060 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 237.25 44.25 1,920 60,846 81,432 24,313
1620-2S 1,148.9 254,220 (2)40 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 237.25 44.25 1,920 61,046 81,632 24,413
1690-2S 1,198.6 281,520 (2)40 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 241.25 48.25 1,780 64,444 88,130 24,183
1745-2S 1,234.0 260,730 (2)30 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 249.00 56.00 2,140 70,246 94,600 27,833
1810-2S 1,283.7 281,520 (2)40 2,100 (2)7.5 (2)6" PE (2)10" PE 1,800 249.00 56.00 2,140 70,486 94,840 27,953
1620-4Q 1,148.9 305,690 (4)15 2,860 (4)5 (4)6" PE (4)10" PE 2,400 235.75 30.25 1,700 64,396 90,044 11,957
1670-4Q 1,184.4 319,230 (4)20 2,860 (4)5 (4)6" PE (4)10" PE 2,400 235.75 30.25 1,700 64,796 90,444 12,057
1730-4Q 1,227.0 333,140 (4)25 2,860 (4)5 (4)6" PE (4)10" PE 2,400 235.75 30.25 1,700 65,196 90,844 12,157
1880-4Q 1,333.3 318,100 (4)20 2,860 (4)5 (4)6" PE (4)10" PE 2,400 242.50 37.50 2,120 72,784 99,316 14,054
1940-4Q 1,375.9 328,250 (4)25 2,860 (4)5 (4)6" PE (4)10" PE 2,400 242.50 37.50 2,120 73,184 99,716 14,154
2000-4Q 1,418.4 308,700 (4)25 2,860 (4)5 (4)6" PE (4)10" PE 2,400 249.25 44.25 2,560 81,048 108,468 16,192
2080-4Q 1,475.2 328,250 (4)30 2,860 (4)5 (4)6" PE (4)10" PE 2,400 249.25 44.25 2,560 81,448 108,868 16,292
2190-4Q 1,553.2 395,930 (4)15 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 235.75 30.25 2,560 96,692 135,200 17,953
2340-4Q 1,659.6 435,410 (4)20 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 235.75 30.25 2,560 97,092 135,600 18,053
2450-4Q 1,737.6 469,250 (4)25 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 235.75 30.25 2,560 97,500 136,000 18,153
2550-4Q 1,808.5 498,580 (4)30 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 235.75 30.25 2,560 97,892 136,400 18,253
2660-4Q 1,886.5 439,920 (4)20 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 242.50 37.50 3,200 109,288 149,124 21,102
2790-4Q 1,978.7 473,010 (4)25 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 242.50 37.50 3,200 109,688 149,524 21,202
2910-4Q 2,063.8 503,090 (4)30 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 242.50 37.50 3,200 110,088 149,924 21,302
3040-4Q 2,156.0 479,030 (4)30 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 249.25 44.25 3,840 121,692 162,864 24,313
3170-4Q 2,248.2 503,090 (4)40 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 249.25 44.25 3,840 122,092 163,264 24,413
3270-4Q 2,319.1 575,280 (4)40 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 253.25 48.25 3,560 128,888 176,260 24,183
3370-4Q 2,390.1 532,800 (4)30 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 261.00 56.00 4,280 140,492 189,200 27,833
3540-4Q 2,510.6 575,280 (4)40 4,200 (4)7.5 (4)6" PE (4)10" PE 3,600 261.00 56.00 4,280 140,972 189,680 27,953

Figure 5-1. Standard IDC Series Unit Specifications

 IDC EVAPORATIVE CONDENSERS S140-500 IOM
INSTALLATION - OPERATION - MAINTENANCE Page 31

Figure 5-2. Standard IDC Series Unit Dimensions

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