I.O.M. #6 7/0 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE Covers Models from 25 to 00 tons. 525 East Stop 8 Road Greenwood, IN 4642 37-887-0729 fa: 37-88-277 Service Department fa: 37-885-8683 e-mail: sales@advantageengineering.com
TABLE OF CONTENTS.0 GENERAL. Introduction 3.2 Efficiency 3.3 Safety 3.4 Miscellaneous 3.5 General Information 4.6 Water Treatment 5.7 Specifications 5.8 Cut Away Drawing 6.9 How It works 7.0 Typical System Drawing 8 2.0 INSTALLATION 2. Inspection 9 2.2 Location 9 2.3 Process Connections 2 2.4 Freeze Protection 2 2.5 Stand Mounting Options 4 3.0 OPERATIONS 3. Low Ambient Air Temperature Sequence of Operation 5 3.2 Medium Ambient Air Temperature Sequence of Operation 5 3.3 High Ambient Air Temperature Sequence of Operation 5 3.4 Components 7 4.0 MAINTENANCE 4. Recommended Operation & Maintenance Schedule 8 4.2 Fan Motor Relubrication Intervals 8 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 2
. INTRODUCTION A. This manual covers fluid coolers from 25-00 tons. B. When calling for assistance from the Manufacturer s Service Department, it is important to know the model and serial number of the particular unit. The model number contains critical unit information which is helpful for troubleshooting and operating difficulties. The serial number allows the service team to locate manufacturing and testing records which can have additional information relating to a particular unit..2 EFFICIENCY A. Long term efficiency is determined by proper maintenance of the mechanical parts of the unit and the water quality. B. The Manufacturer recommends filtering where required to prevent solids from plugging critical parts (pumps, heaters, seals for eample). C. The Manufacturer highly recommends that the owner obtain the services of a competent water treatment specialist and his recommendations followed. The Manufacturer accepts no responsibility for inefficient operation, or damage caused by foreign materials or failure to use adequate water treatment..3 SAFETY A. It is important to become thoroughly familiar with this manual and the operating characteristics of the unit. B. It is the owner s responsibility to assure proper operator training, installation, operation, and maintenance of the unit. C. Observe all warning and safety placards applied to the chiller. Failure to observe all warnings can result in serious injury or death to the operator and severe mechanical damage to the unit..4 MISCELLANEOUS A. The ability of the unit to maintain process temperature control is significantly affected by the method of installation as outlined in section 2 of this manual. B. If the operator has questions concerning the installation, operation or maintenance of the unit, contact the Manufacturer s Service Department. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 3
.5 GENERAL INFORMATION A. The fluid cooler is a heat echanger that uses outdoor ambient air in conjunction with an evaporative water assist system to cool process water. B. The fluid cooler is self contained, meaning it has all the necessary controls and components to operate. C. The user must supply:. Pump tank station with piping to and from the unit. 2. City or well make-up water piping to the evaporation systems. 3. Compressed air piping to the process circuit. 4. Drain piping for the purge valve. 5. Main power electrical drop. D. The dry air cooling system will run anytime there is process water flow to the air coils.. Water flow is sensed by the onboard flow switch located on the inlet manifold to the air coils water circuit. 2. The fan will start and pull air across the coils. The fan speed is controlled by a motor drive that will adjust the RPM based on the process water eit temperature. The higher the temperature, the faster the fan will run. The RPM range is approimately 700 min. - 50 ma. The motor drive will also soft start the fan motor. E. The evaporation system is a cooling assist to the main dry air cooling system that runs during periods of high ambient air temperatures. After the flow switch is made (indicating the fluid cooler pump is running and cooling is required), and the fan is running, and the outdoor air temperature is 75 or higher, the evaporation system will automatically start and run. F. The evaporation system operates by pumping the sump water up to dual water distribution troughs and dripping the water over the top of special treated cellulose evaporative media. The water saturates and runs by gravity down the media and drains back to the sump to be recirculated. Some of this water will evaporate while on the elements and will cool the air stream going into the air coils. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 4
G. Other information:.6 WATER TREATMENT. The factory Leaving Water Temperature (LWT) set point is 80 F. LWT can be a adjusted lower if required by resetting the motor drive RPM. This will derate the fluid cooler s performance. A. The use of untreated or improperly treated water in a fluid cooler may result in scaling, erosion, corrosion, algae or slime. B. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment is required. C. Advantage assumes no responsibility for equipment failures which result from untreated or improperly treated water..7 SPECIFICATIONS MODEL HFC-25 HFC-50 HFC-75 HFC-00 GENERAL Capacity Tons 25 50 75 00 Flow Rate GPM 75 50 225 300 Design Water Temperature (F) 2 85 85 85 85 FANS Quantity 2 3 4 Horsepower: per motor 5 5 5 5 Amps: per motor @ 460/3/60 2 7.5 7.5 7.5 7.5 Amps: total unit @ 460/3/60 2 7.5 5 22.5 30 CONNECTIONS 3 (inches) Process Water Inlet 2 3 4 4 Process Water Outlet 2 4 4 6 Compressed Air /2 /2 /2 /2 Adiabatic Water Supply /2 /2 /2 /2 Adiabatic Water Drain DIMENSIONS 3 (inches) Height 96 /2 04 /2 04 /2 04 /2 Length 62 48 234 320 Depth 54 /2 54 /2 54 /2 54 /2 WEIGHTS 3 (pounds) Dry,300 3,600 5,400 7,200 Wet 2,200 5,400 8,00 0,800 Shipping,450 3,900 5,850 7,800 Notes. Cooling water from 95 F to 85 F with 73 F entering air prior to the cooling cool. Your Advantage representative can provide specific weather data for your area predicting typical operating conditions and water evaporation rates. Glycol/water is recommended for set point temperatures below 50 F and ambients below 40 F. 2. For 230/3/60 amps multiply by 2. For 575/3/60 amps multiply by.75. 3. Not for construction. Confirm dimensions and weights with Advantage prior to construction. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 5
.8 CUT AWAY DRAWING Air Outlet Shown in adiabatic pre-cooling mode with side panel, wetted media and fan cover removed. Fan Pre-Cooling system water distribution trough (shown with top covers removed) Compressed air connection and solenoid valve to assist coil drain Process Fluid Outlet Evaporative Media Air Inlet Process Fluid Cooling Coils are kept dry to minimize contamination Sump Pump circulates water to wet evaporative media Process Fluid Inlet Sump Drain Valve For Pre-Cooling System Make-Up Valve for adiabatic pre-cooling system 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 6
.9 HOW IT WORKS A. Warm process fluid is circulated through the closed loop cooling coil of the Hydra Hybrid Cooler. Cool ambient air is drawn across the coil by the unit s high efficiency direct drive fan/motor assembly drawing heat out of the process fluid and rejecting it to the surrounding air. B. The cooled process fluid is returned to the system reservoir to be circulated for process cooling. C. When the ambient temperature is slightly below the desired process fluid temperature, the Hydra Hybrid Cooler operates in the dry mode using no fluid. D. When the ambient temperature rises above the desired process fluid temperature, the Hydra Hybrid Cooler automatically switches to its adiabatic pre-cooling mode. E. The adiabatic pre-cooling mode uses water to wet an evaporative media installed in the air inlet prior to the cooling coil. When the warm ambient air is drawn across the media it evaporates some of the water cooling the air before it reaches the coil containing the process water. F. In the adiabatic mode the Hydra Hybrid Cooler can maintain fluid temperatures low enough to provide hydraulic and condenser cooling even at ambient temperatures above 95 F. G. When the ambient temperature drops the cooler automatically switches back to dry mode cooling to minimize water usage. H. When adiabatic pre-cooling is not required the sump is drained to minimize potential contamination. I. The unit is designed to be installed outside, elevated above an indoor reservoir so that the cooling coils and adiabatic sump drain by gravity when not in use. J. Each modular Hydra Hybrid Cooler includes a complete control system to optimize cooling and minimize water and electrical consumption. K. A custom computer program is available to predict normal maimum water temperatures and estimated annual water and electrical costs for your location. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 7
.0 TYPICAL SYSTEM DRAWING 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 8
2.0 INSTALLATION 2. INSPECTION A. A thorough inspection of the equipment, including all component parts and accessories, should be made immediately upon delivery. Any damage caused in transit, or missing parts, should be reported to the carrier at once. The consignee is responsible for making any claim for losses or damage. Electrical characteristics should also be checked at this time to ensure that they are correct. B. WARRANTIES. Please refer to the Limitation of Warrantys applicable to and in effect at the time of the sale/purchase of this product. C. SAFETY. Adequate precautions should be taken to safeguard the equipment and the premises from damage and the public from possible injury as appropriate for the installation and location of this product. 2.2 LOCATION A. Before handling and placing the unit into position a review of the most suitable location must be made. B. The product is designed for outdoor installation. A number of factors must be taken into consideration when selecting a location. Most important is the provision for a supply of ambient air to the product, and removal of heated air from the area. C. Higher fluid temperatures, decreased performance, and the possibility of equipment failure may result from inadequate air supply. D. Other considerations include:. Loading capacity of the roof or floor. 2. Distance to suitable electrical supply. 3. Accessibility for maintenance. 4. Local building codes. 5. Adjacent buildings relative to noise levels. 6. Location of drain for pre-cooling system. 7. Location of air and city water supply. 8. Location of indoor pump tank to allow gravity drain of coil. E. Fluid coolers must be located to insure an adequate supply of fresh air to the fans. When units are located adjacent to walls or in enclosures, care must be taken to ensure that the warm discharge air is not deflected and short-circuited back to the air intakes. F. Additionally, each fluid cooler should be located and positioned to prevent the introduction of discharge air into the ventilation systems of the building on which the fluid cooler is located and adjacent 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 9
building. For detailed recommendations on fluid cooler layout, please consult with your service representative or the factory. G. Walls Or Obstructions. The air intake of the unit must be a minimum of 4 feet (.25 m) away from any wall or obstruction. Overhead obstructions are not permitted. If enclosed by three walls, the condenser must be installed as indicated for units in a pit. Non air intake side must have a minimum clearance of 2 feet (.65 M). Air In 4 ft (.25 m) minimum 2 ft (.65 m) minimum Air intake sides facing wall or obstruction Non Air intake sides facing wall or obstruction H. Multiple Units. A minimum of 8 feet (2.5 m) is required between multiple units placed side by side. If placed end to end, the minimum distance between units is 4 feet (.25 m). Air In Air In 8 ft (2.5 m) minimum Air intake sides facing another module require a minimum of 8 feet separation. 3 ft (.9 m) minimum When non air intake side face each other, a minimum of 3 feet is required between the units. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 0
I. Units In Pits. The top of the unit must be level with or above the top of the pit. In addition, a minimum of 8 feet (2.5 m) is required between the unit and the pit walls. Air In 8 ft (2.5 m) minimum 8 ft (2.5 m) minimumm J. Louvers/Fence. Louvers and fences must have a minimum of 80% free area and 4 feet (.25 m) minimum clearance between the unit and lovers and or fence. Height of louvers or fences must not eceed top of the unit. Air In 4 ft (.25 m) minimum 4 ft (.25 m) minimum K. Hydra Fluid Coolers are large, heavy mechanical equipment and must be handled as such. A fully qualified and properly equipped crew with necessary rigging should be engaged to set the unit in position. Spreader bars must be used when lifting so that the lifting force must be applied vertically. Ensure the unit is placed in a level position. The unit should be securely anchored to the building structure, or concrete pad. The weight of the unit is not enough to hold in place during a strong wind, the legs must be anchored. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page:
2.3 PROCESS CONNECTIONS Compress Air Supply Process Water Out Process Water In Adiabatic Pre-Cooling Water Supply Adiabatic Pre-Cooling System Drain Compressed Air Supply A. Process water connections:. Process water inlet. Slope the process water inlet supply towards the indoor pumping station to aid in process water draining. A 5% slope is recommended. 2. Process water outlet. Slope the process water outlet towards the indoor pumping station to aid in process water draining. A 5% slope is recommended. Terminate the return line above tank water level. Do not terminate the return water line below the holding level of the tank. B. Compressed Air:. A compressed air supply of about 5 CFM @ 30 psi (when engaged) is required to assist coil draining. 2. Compressed air must be dry to prevent freezing in cold climates. C. Adiabatic System Water Supply:. A supply of water is required for the adiabatic system for high ambient operation. 2. This water supply must be manually drained or other method of protection must be implemented when freezing may occur. D. Sump Purge Line:. The sump purge line must be connected to an open drain. Slope the purge line towards the open drain. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 2
2.4 FREEZE PROTECTION A. This fluid cooler must be protected by mechanical and operational methods against damage and/or reduced effectiveness due to possible freeze-up. B. Please refer to the product catalog or contact your service representative or the factory for protection alternatives. C. Winter Operation. When operating the Hydra system in freezing weather, it is highly recommended that a glycol/water fluid be used to prevent coil damage from freezing. Coil freeze-up is not covered by the manufacturer s warranty. 2. Recommended concentrations for typical commercial glycol solutions: Ambient Temperature F 30 20 0 0-0 -20-30 -40-50 -60 Percentate of Glycol By Volume for Freeze Protection 8% 8 29 36 42 46 50 54 57 60 Percentate of Glycol By Volume for Burst Protection 2% 2 20 24 28 30 33 35 35 35 3. Freeze protection is required in systems where fluid must be pumped at the lowest anticipated temperature where no ice crystals are permitted. 4. Burst protection is adequate when the system will remain dormant during cold weather and where adequate space is available for some epansion caused by an ice/slush miture. 5. Confirm concentrations with your glycol supplier. Follow glycol manufacturers requirements for solution preparation. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 3
2.5 STAND MOUNTING OPTIONS A. Most Hydra Fluid Coolers are elevated in some manner to provide the gravity induced return flow to the central system pump tank. B. The elevation is typically provided by a support structure, know as a stand. Shown here are several options to consider for stand earth mounting. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 4
3.0 OPERATIONS 3. LOW AMBIENT AIR TEMPERATURE SEQUENCE OF OPERATION A. For ambient air temperatures of 45 F and below.. Power in On. 2. Process water pumped to the unit from a remote pump station. 3. Process water flow switch closes and signals the motor drive to start and run the fan to draw air over the coils. 4. Fan motor drive senses the eiting process water temperature from the coils and adjusts the fan RPM (700-50) in relation to the process water eiting temperature. 5. Process water flow stops (remote pump station set point temperature is satisfied), the unit flow switch will sense the loss of process water flow and signal the fan motor drive to stop the fan. 6. The PLC will energize the compressed air solenoid valve for one minute to allow air to enter the coil s upper manifold and push the water out of the process circuit and back to the pump station to prevent it from freezing inside the air coils. 7. Nothing further will happen until flow starts again. 3.2 MEDIUM AMBIENT AIR TEMPERATURE SEQUENCE OF OPERATION A. For ambient air temperatures of 46 F - 75 F.. Power in On. 2. Process water pumped to the unit from a remote pump station. 3. Process water flow switch closes and signals the motor drive to start and run the fan to draw air over the coils. 4. Fan motor drive senses the eiting process water temperature from the coils and adjusts the fan RPM (700-50) in relation to the process water eiting temperature. 5. Process water flow stops (remote pump station set point temperature is satisfied), the unit flow switch will sense the loss of process water flow and signal the fan motor to stop the fan. 6. Nothing further will happen until flow starts again. 3.3 HIGH AMBIENT AIR TEMPERATURE SEQUENCE OF OPERATION (ADIABATIC COOLING MODE) A. For ambient air temperatures of 75 F and above.. Power in On. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 5
2. Process water pumped to the unit from a remote pump station. 3. Process water flow switch closes and signals the motor drive to start and run the fan to draw air over the coils. 4. Fan motor drive senses the eiting process water temperature from the coils and adjusts the fan RPM (700-50) in relation to the process water eiting temperature. 5. Sump water level switch signals the PLC that the sump is full or empty. 6. If sump is full, disregard the sequence 7-0. 7. If sump is empty, the sump water make-up valve opens and begins flushing (via the PVC flush pipe) any debris that may have collected in the dry sump out the open purge valve and into the user s drain. 8. Sump water purge valve closes after 30 seconds of debris flushing. 9. Sump water make-up solenoid continues sending water to the sump. 0. Sump level switch senses a full sump and closes the sump water make-up solenoid valve.. Sump pump starts and send sump water to the dual water distribution troughs. 2. Sump water drips out the bottom of the distribution troughs and onto the evaporative media. 3. Evaporative media becomes saturated with sump water and runs by gravity down the media and drains into the sump pan to be recirculated. 4. Ambient outdoor air is drawn through the media and evaporates some of the sump water and cools the air before it reaches the air coils. 5. Sump water make-up valve opens and closes to replace evaporated water to maintain proper sump level. 6. Process water flow stops (remote pump station set point temperature is satisfied) the unit flow switch will sense the loss of process water flow and signal the fan motor drive to stop the fan. 7. The sump pump will stop. 8. The sump water in the evaporative media will continue to drain back to the sump until the media is dry. 9. Nothing further will happen until flow from the remote pump station starts again, ecept that if the unit does not run for many hours the sump will automatically do a daily purge to maintain sump cleanliness. This daily purge will happen once every 24 hours. The 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 6
sump will not refill after the daily purge if the ambient outdoor temperature has fallen below 75 F. 3.4 COMPONENTS A. Flow Switch. The flow switch senses process water flow into the air coils and provides consent to the control circuit to start and run the unit. B. Fan. The fan will move 20,000 CFM @50 RPM. RPM is controlled via the motor drive. The RPM range is 700-50. The fan starts anytime process water flow is present. C. Air Coils. Dual air to water coils, rifled copper tube with aluminum fins. D. Compressed Air Solenoid. The air solenoid is controlled via the PLC. At ambient outdoor air temperatures of 45 F or less, the valve is opened to force drain the process water out of the air coil tubes after the pump station stops process water flow delivery to the unit. E. Compressed Air Check Valve. The check valve prevents process water from entering the compressed air supply piping. F. Sump Pan. The sump pan catches/holds un-evaporated water and foreign debris that has washed off the evaporative media. It also serves as a reservoir for the sump pump. G. Sump Purge Valve. Automatically empties the sump once every 24 hours to remove accumulated foreign debris and empties the sump when the ambient air temperature falls below 45 F. H. Level Switch. Monitors sump water level and activates the water make-up circuit. Also triggers an alarm when the sump level fails to fall during purge cycles. I. Sump Water Make-Up Solenoid. Supplies water to the sump for water make-up and to flush debris out of the sump pan during purge cycles via the PVC flush pipe. J. Sump Pump. Supplies sump water to the dual distribution troughs. K. Distribution Troughs. Dual troughs receive water from the sump pump and supply/drip water over the evaporative media, approimately 0 GPM to each side. L. Evaporative Media. Receives water from the distribution troughs and provides an absorbent area for maimum evaporation potential. Un-evaporated water drains from them into the sump pan. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 7
M. Frame and Enclosure. Galvanized and stainless steel frame parts, sheet metal enclosure panels and ABS plastics fan shroud. N. Electrical System Enclosure. Concealed N-4 electrical cabinet with 4 4 main power junction bo. P. Control System. PLC and 24 vdc power supply. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 8
4.0 MAINTENANCE 4. RECOMMENDED OPERATION AND MAINTENANCE SCHEDULE SERVICE Inspect general condition of unit Clean debris from unit Clean and flush sump Check and adjust sump water level Inspect heat transfer section Inspect wetted media Inspect wetter distribution trough Check operation of make-up valve Check unit for unusual noise or vibration Check motor voltage and current Lubricate fan motor bearings Check fan for rotation without obstruction Check fan and pump motor for proper rotation Drain sump and piping Check air solennoid operation Inspect protective finish Start Up Monthly 6 Months Winter Operation S 4.2 FAN MOTOR RELUBRICATION INTERVALS A. New motors having been in storage for over a year should be relubricated by the procedure noted below. The following relubrication intervals are suggested as a guide for long operating life. The Hydra HFC-25 uses a 5HP 25T frame fan motor. Hours of Service Per Year 5000 hrs Continuous Normal Application Seasonal Service Motor is idle for 6 or more months Continuous high ambients, dirty or moist locations, high vibration, or where shaft end is hot (pumps - fans) 5 HP - 25T Frame 5 yrs 2 yrs yr beginning of season 6 months B. LUBRICANT: Baldor motors are pre-greased normally with Shell Oil company s Dollum R. Several equivalent greases which are compatible with the Baldor furnished grease are Chevron Oil s SRI No.2 and Teaco Inc. Premium RD. C. PROCEDURE: Over greasing bearings can cause premature bearing failure. If motor is equipped with Alemite fitting, clean tip of fitting and apply gun. Use to 2 full strokes on motors in NEMA 25T frame. D. CAUTION: Keep grease clean. Lubricate at standstill. Remove and replace drain plugs at standstill. Do not mi petroleum grease and silicone grease in motor bearings. 37-887-0729 Fa: 37-88-277 Service Department Fa: 37-885-8683 Page: 9
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