FRITERM FDH, FDW, FDV Installation, Operation And Maintenance Manual
Dry Coolers
INSTALLATION, OPERATION AND
INSTALLATION, OPERATION AND
INSTALLATION, OPERATION AND INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
MAINTENANCE INSTRUCTIONS
MAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONS
FDH, FDV, FDW
www.friterm.com
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CONTENTS
1. ABOUT THIS MANUAL/GENERAL ............................................................................................ 1
1.1 Examining the operating manual ................................................................................................... 1
1.2 Warranty ........................................................................................................................................ 1
2. SAFETY REGULATIONS .............................................................................................................. 5
2.1 Symbols and warning signs ........................................................................................................... 5
2.2 Personal protection ........................................................................................................................ 6
2.2.1 Personal protection signs ........................................................................................................ 6
2.3 Warnings ....................................................................................................................................... 8
2.4 Improper use .................................................................................................................................. 9
2.4.1 Hazardous rotating machinery ................................................................................................ 9
2.4.2 Hazardous voltage .................................................................................................................. 9
2.4.3 Hazardous thermal .................................................................................................................. 9
2.4.4 Hazardous refrigerant ........................................................................................................... 10
2.5 Environmental protection ............................................................................................................ 11
3. LABELLING ................................................................................................................................... 11
3.1 Product code ................................................................................................................................ 11
3.2 Type plate .................................................................................................................................... 11
3.3 Friterm Logo................................................................................................................................ 12
4. TECHNICAL DATA ...................................................................................................................... 12
4.1 Standards ..................................................................................................................................... 12
4.2 Product ........................................................................................................................................ 12
4.3 Fans ............................................................................................................................................. 13
4.3.1 Fan connection diagrams ...................................................................................................... 14
4.4 Control Systems .......................................................................................................................... 16
4.4.1 Thermostat (Dixell XC650C) Keyboard .............................................................................. 16
4.4.2 Icons ..................................................................................................................................... 17
4.4.3 Parameters ............................................................................................................................ 18
4.4.4 Tables of Alarms .................................................................................................................. 21
4.4.5 Wiring Connection: .............................................................................................................. 22
4.4.6 The Adjustment of Thermostat Control Part According to the Application of Different
Fan Number ................................................................................................................................... 23
4.4.7 Power Wiring ....................................................................................................................... 24
4.4.8 Control Wiring ..................................................................................................................... 25
4.5 Sound pressure level .................................................................................................................... 26
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4.6 Sound power level ....................................................................................................................... 26
5. TRANSPORT AND STORAGE ................................................................................................... 27
5.1 Check for completeness and transport damage ........................................................................... 27
5.2 Transport ..................................................................................................................................... 27
5.3 Storage ......................................................................................................................................... 30
6. INSTALLATION ............................................................................................................................ 30
6.1 Location ....................................................................................................................................... 31
6.2 Requirements at the set up point ................................................................................................. 31
6.2.1 Outdoor set up of FCH unit .................................................................................................. 31
6.2.2 Set up next to wall ................................................................................................................ 31
6.2.3 Set up in pit-hallow .............................................................................................................. 32
6.2.4 Several FDH units ................................................................................................................ 33
6.2.5 Requirements at the set up point (FDW units) ..................................................................... 33
6.2.6 Several FDW units ............................................................................................................... 34
6.2.7 Requirements at the set up point (FDV units) ...................................................................... 34
6.2.8 Side-by-side setup (FDV units) ............................................................................................ 35
6.3 Mounting ..................................................................................................................................... 35
6.3.1 Ideal mounting scheme ......................................................................................................... 38
6.3.2 Leg mounting ....................................................................................................................... 38
6.4 Electrical Connection .................................................................................................................. 51
7. OPERATION .................................................................................................................................. 52
7.1 Initial commissioning .................................................................................................................. 52
7.2 Regular commissioning ............................................................................................................... 52
7.3 Shutting down.............................................................................................................................. 53
7.4 Step control application (If Applicable) ...................................................................................... 53
8. MAINTENANCE ........................................................................................................................... 54
8.1 Maintenance intervals .................................................................................................................. 54
8.2 Fan motor maintenance ............................................................................................................... 55
8.3 Periodical controls (Once a year) ................................................................................................ 56
9. TROUBLESHOOTING .................................................................................................................. 57
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1. ABOUT THIS MANUAL/GENERAL
This document specifies the instructions for installation, operating and maintenance of the
Dry Coolers (FDH, FDV, FDW models) manufactured by FRITERM A.Ş., Turkey.
The instructions below must be followed strictly for the labor health and safety reasons during
installation and maintenance of products.
Upon receipt, the product should be visually inspected, and in case of any damage or fault, the
supplier must be notified within 7 days.
The manufacturer will not accept any responsibility in these situations;
• Damages caused by persons,
• Damages product due to the disregarding of the recommendations indicated in this
handbook.
1.1 Examining the operating manual
To follow the instructions defined in this document is a prerequisite for safety of the staff and
for the products to be operated in a fault-free and safe manner.
• The operating manual must always be available.
• All persons who are responsible for the transport, assembly, initial commissioning,
operating, maintenance or repair of the component must be acquainted with the operating
manual. The operator should accept in written form that they are acquainted with the
operating manual.
• Whenever you have difficulty in understanding and/or comprehend and description or
definition given/expressed in this manual, please immediately ask for help from an
expert or from then manufacturer. It is of great importance to understand this manual
completely and correctly for the sake of labor health and safety.
1.2 Responsibilities
The manufacturer is strictly responsible for supplying a manual accompanying the product
which comprises the necessary and enough detailed information regarding the
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1.2.1 Manufacturer’s Responsibilities
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installation/mounting and operation of the product. Besides, the product is expected to fulfill
the requirements and satisfy with the anticipated functioning.
The construction of the product should comply with the presumed operational conditions. The
product is expected to be robust enough and resistive against all the mechanical, thermal
and
chemical challenges. The material used to produce should be compatible with the fluid and
the mixture of fluids used as heat transfer media.
All the materials and components used in constructing the product should be resistive against
all the stress and pressure that the product will be subjected to.
1.2.2 Contractor’s Responsibilities (Installation, Commissioning)
• Should follow all the instructions and provide all the conditions stated in this manual.
• All the documentation accompanying the product are complementary to this manual. The
safety instructions and all other information stated in this manual should be considered.
• The national regulations regarding the protection of environment and labor safety should
be strictly followed besides the instructions for safe and correct operation.
• In case of any problem encountered during the installation, FRITERM A.Ş. should be
informed and asked for technical assistance if necessary.
• Emergency instructions and the required infrastructure should be prepared and redy for
use in any case.
• The regular maintenance/servicing periods and instructions should be determined and
defined.
• The additive in order to prevent the freezing of the operating fluid should be feed as
requires and as much as required.
• If storage of the product for a long period is needed, a clean, non-hazardous and low
humidity environment is recommended.
• The fans of the products that are stored horizontally are recommended to be run for 4-5
hours a week. In case of difficulty of running the fans, then they should be covered and
protected from rain and excess humidity.
• In case of storing vertically, it is not recommended to store more than 1 month.
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1.2.3 Operator’s or Owner’s Responsibilities (Operation and
Maintenance)
• The director is the responsible person who employs the adequate staff for servicing
• operating and monitoring the system.
• All requirements and instructions in this operating manual must be complied with.
• The documentation of purchased products is a constituent part of this operating manual.
All safety information in this operating manual and all other information must be
observed.
• All relevant regulations concerning accident prevention and environmental protection
must be complied as well as the confirmed technical regulations for safe and proper
working.
• Personal ineligibility. All the work should be conducted by authorized and trained
personnel.
• Any defect/damage/malfunction caused by disregarding the instructions given in this
manual is the responsibility of the operator.
• Any defect/damage/malfunction caused by the misuse of the product is the responsibility
of the operator.
• The product should not be put in operation without the completion of the installation and
commissioning.
• The personnel who is responsible for the operation/servicing/maintenance of the product
should be provided with all the necessary documentation including this manual.
1.3 Warranty
• The manufacturer warrants that the equipment delivered to the client shows no defects
caused by failure of design, material, manufacturing and/or workmanship within the
warranty period.
• The client must notify in written form within 10 days from the receipt of the goods, any
perceptible defects including transport damages. For hidden defects, he must notify and
explain in details the defect in written form within 10 days from observation time.
• Unless otherwise agreed, the warranty period shall be 24 months starting from the date of
delivery.
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• The warranty does not cover defects in the product’s operation stemming from a fault in
materials or parts provided by the client, nor shall it cover an installation that has not been
assembled according to the manufacturer’s instructions and according to professional
practice. The products or parts that the costs are not paid to the producer are out of
manufacturer’s warranty.
• The products called “Dry Coolers” mainly used in order to cool the fluid (usually water
but in case of atmospheric conditions below zero degree, antifreezer added solution) to a
desired temperature. The fluid to be cooled down should be transferred to the Dry cooler
via the piping properly installed according to the rules and related instructions. The usage
of the Dry Cooler out of its anticipated functioning is out of the scope of warranty.
• In sub-zero temperatures sufficient antifreeze solution must be added and fluid should be
checked by measuring the freezing temperature on a regular basis. In case of occurring
any damage on the product due to freezing of the fluid, all the fitting actions and materials
used in order to repair the product will be out of manufacturer’s warranty.
• The warranty shall not cover equipment and/or its accessories if they have been modified
by the client without manufacturer’s written consent.
• The warranty clause can only be invoked by the client if the equipment is used normally
and in conformity with its purpose and manufacturer’s instructions.
• The manufacturer’s liability hereunder shall be limited to repair, modify or replace the
parts or equipment that shows defect within the limitation of the items under this article.
• The warranty period of the repaired or modified or replaced parts or equipment shall in no
way extend the warranty period of the original ones.
• The works resulting from the warranty conditions shall be carried out in the
manufacturer’s workshop after the client has sent the defective equipment or parts for
repair or replacement.
• The manufacturer’s responsibility is strictly limited to the obligations as stipulated herein
and it is expressly agreed that he shall not be found to make any other indemnity. In
particular, he shall in no case be liable to compensate loss caused directly or indirectly by
a defect in the equipment delivered.
• The product should be installed and commissioned in accordance with the
national/international regulations and rules.
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In case of operational conditions with temperatures below zero the sufficient amount of antifreezer (
• For the fans having thermal protection, the related wiring should be definitely done and it
is considered as contractor’s and/or owners responsibility. Any defect caused by
misconnection of the thermal protection wiring in accordance to the circuit diagrams
given in this manual would be out of manufacturer’s warranty.
• The power supply which the product is supplies should not deviate 10% from the values
given on the label.
DANGER OF FREEZING
e.g.Ethelene Glycol) should be added unless the water will stay in the system at still times. In order
to be able to avoid the danger of freezing a sufficient amount of antifreezer solution should be
added to reach a freezing temperature of 7-10 C below the operation temperature.
2. SAFETY REGULATIONS
2.1 Symbols and warning signs
The following terms and/or symbols are used in the operating manual for particularly
important information.
Safety messages and symbols are quoted at the relevant positions in the operating manual if
there is danger such as death, personal injury and environmental damage. These safety
warnings must be strictly adhered to.
Indicates a hazardous situation which, if not avoided, may
result in death or serious injury
Indicates a hazardous situation which, if not avoided, may result
in serious injury.
Indicates a hazardous situation which, if not avoided, may result
in moderate or minor injury.
Additional notes, information and tips.
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IN CASE OF DANGER
Switch off the power
Switch off the main
Please ask assistance from an authorized technician
Please do not try to resolv
While working on and standing by the
Protective gloves for fitting and repair work
resistant clothing and protective gloves for cleaning work, especially when
Safety goggles for cleaning work, especially
compressed air for cleaning
2.2.1 Personal protection signs
Head Protection
Foot Protection
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or expert
e any problem by trial and error
, protective clothing must be worn.
handling solvents
Eye Protection
High Visibility Clothing
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!
•
•
•
•
2.2 Personal protection
• Safety shoes
• Safety helmet
•
• Chemical-
handling solvents
•
.
.
product
while
or using
• Hearing protection
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Protective Clothing
Respiratory Protection
No Smoking
High Voltage
Hand Injuries
Fire Risk
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Hand Protection
Flammable
Hot Surfaces
Poisoning Danger
Frostbite Hazard
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2.2.2 Warning signs
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2.3 Warnings
• In an unexpected situation use the emergency stop button which is set up on an easily
accessible place.
• Do not exceed maximum operating pressure given on the unit’s type plate.
• Unless the advised safety devices available or fully active the unit must not be
operated.
• Set up the unit with extreme cleanliness.
• The unit must not be operated if it is damaged. FRİTERM A.Ş. must be informed
about all damages.
• The unit must be installed, operated and maintained by authorized/qualified personnel
only.
•
• In case of using any other fluid and additives specified on the label (water, Ethylene
Glycol, propylene Glycol, Brandname thermal fluids) may cause damage, leakage,
danger and environmental pollution.
• No modification is allowed on the product without written permission from the
manufacturer.
• Operational conditions are limited within the specified range by the manufacturer. In
case of need to operate the product out of the range, a confirmation should be asked
from FRITERM A.Ş.
The product is delivered with 2 bar pressure. Upon receipt, it must be checked with
schrader valve.
After checking, unless the product has 2 bar pressure Friterm must be notified
immediately.
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Danger of injuries in improper using;
2.4.1 Hazardous rotating machinery
Danger of
authorized technician.
Use hand protection.
oltage can cause serious injuries or death. Do not contact with
voltage direct or indirect. Do not
begin maintenance work.
Some of the components of the unit such as fin and tube have high
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Lids should be unscrewed by an
forget to power off the unit before you
2.4 Improper Use
9
2.4.2 Hazardous voltage
Electrical v
cutting hands and fingers.
2.4.3 Hazardous thermal
temperatures.
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Danger of burns and frostbites.
The danger of frostbite can occur if there
if the unit cannot be drained completely, frostbite hazard occurs after
Fluid: Glycol
Yanıcı özelliğinden dolayı etilen glikol her zaman ate
No smoking.
suitable fire
while working with fire or sparks.
Due to the hazardous effect on human skin and nerve system please avoid
direct contact of skin.
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ficient frost protection.
o prevent ignition
For protection use protective clothing.
10
is insuf
Also
draining.
2.4.4 Hazardous
Ensure
fighting equipment is used in order t
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2.5 Environmental protection
While handling the product, it has to be ensured that materials which can endanger the
environment are disposed of properly. Service materials must not be allowed to enter the
sewerage system and the ground water system.
All relevant national regulations concerning environmental protection and the technical issues
for safe and proper working must be complied.
3. LABELLING
3.1 Product code
3.2 Type plate
Type FDH 2E 8012 E121 3 SD- 6p Fan speed ( Δ/ Y) 890/ 690 rpm
Serial Nr. Total Power
TS min/ max. - 40/ +110 °C Power Supply 400 V AC 3 Ph 50 Hz
Dry Weight
Internal Vol.
Medium Water- Glycol/ Fluid G2 Prod. Year
409 kg
41.4 L.
Max. Opr. Pr. 16 Bar
Test Pr. / Medium 20 Bar/ Dry Air
( Δ/ Y) 3.6/ 2.3 kW
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3.3 Friterm Logo
4. TECHNICAL DATA
4.1 Standards
• 97/23/EC PED (Pressure Equipment Directive)
• EN 378 “Refrigeration systems and heat pumps, technical safety and environmental
requirements”
• Capacity standard for dry coolers is defined according to the EN 1048 standard with
the ratio of % 34 ethylene glycol. (
Test methods for establishing the performance)
• The system installer is responsible for that the inherent installation and security
information are harmonized with the valid standards and guidelines (DIN EN 292 /
294).
4.2 Product
The basic principle is to transfer the return water load in the system to air by the aid of a heat
exchanger including fans. Its working principle is that the air sucked by fans cools the fluid
within the tube while it passing through the fins. Thanks to closed fluid circuit, quantity of
water does not diminish hence it is not needed to add extra water to the system.
The unit is delivered for operation with a specific operating point:
• Air inlet temperature and volumetric flow
• Fluid inlet temperature and volumetric flow
Heat exchangers- Air-cooled liquid coolers dry coolers-
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4.3 Fans
• Highly efficient axial Ziehl Abegg, EBM or equivalent fans are used.
• Fans diameters: Ø800/ Ø910 mm
• 400V 3~50Hz,
• Triphase fans can work at two different speeds. Furthermore, providing speed control
is optional for EC fans.
• Variable fan speed regulation can be achieved using triphase fans with frequency
inverter and sine filter.
• Variable voltage speed control system could be used as an alternative fan speed
control system.
• All motors are suitable for speed control applications up to 100 %.
• All motors have feature internal thermal protection.
• Standard wiring of all motors are for one speed.
• Working temperature for exterior mounting is between -40 ºC and +50 ºC - +70 ºC.
• Fans are designed with assuming fans working Fans run in a housing designed to
maximize air flow.
• Recommended starting for motors is 6 starts per hour, maximum starting for motors is
10 starts per hour.
• In case of prolonged stoppage of system, run the fan motors at least 4 hours per week.
• Motor protection IP54; insulation class F.
• Friterm reserves the right to use fans of different manufacturers. Depending on the
type, the fan data may slightly vary.
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4.3.1 Fan connection diagrams
EBM 400V Fan Connection Diagram
Only specified section in bold lines are scope of supply.
Wiring of Safety Switch and Motor
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Z.ABEGG 400V Fan Connection Diagrams
Only specified section in bold lines are scope of supply.
Wiring of Safety Switch and Motor
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