Frick IDSC / ECOSS Series Owner's manual

IDSC / ECOSS™
Stainless Steel Evaporative Condenser
Form 140.010-IOM (APR 2018)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 140
Replaces: 140.010-IOM (OCT 2017)
Dist: 3, 3a, 3b, 3c
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,
DAMAGE TO THE UNIT, OR IMPROPER OPERATION.
Please check www.johnsoncontrols.com/frick for the latest version of this publication.

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
SAFETY PRECAUTION DEFINITIONS
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment and/or minor injury.
Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
DANGER
WARNING
CAUTION
NOTICE
IMPORTANT! READ BEFORE PROCEEDING!
This manual provides the information needed for safe installation, operation, and maintenance for IDSC/ECOSS™Evaporative
Condensers. Close attention to the instructions provided in this manual will ensure proper installation and operation, and a long
satisfactory unit life.
It is strongly recommended that one becomes fully familiar with this manual prior to operating or working on an IDSC/ECOSS™
Evaporative Condenser.
After installation the unit must be properly connected to an appropriately designed and installed refrigeration system. The engi-
neering plans, piping layouts, etc., must be detailed in accordance with local codes and applicable industry standards and practices.
Units should be rigged and installed as outlined in this manual. These procedures should be reviewed in detail prior to the actual
rigging operation to acquaint all personnel with the procedures to be followed.
If any questions or comments arise regarding this manual, we encourage you to call your sales representative.
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continuous product improvement, the information contained in this document is
subject to change without notice. While Johnson Controls-Frick makes no commitment to update or provide current information
automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest Frick Factor or the
nearest Frick Sales ofce.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in question. If
there is any question in the mind of operating / service personnel as to the applicability of these documents, then prior to working
on the equipment, they should verify with the owner whether the equipment has been modied and if current literature is available.
WARNING
External wiring is NOT to be connected inside an IDSC/ECOSS™ factory mounted electrical panel unless specically
indicated as required eld wiring on the JCI - Frick electrical drawings provided. Devices such as relays, switches,
transducers and controls may NOT be installed inside the Frick IDSC/ECOSS™electrical panel. NO external wiring is
allowed to be run through the Frick IDSC/ECOSS™electrical panel. All wiring must be in accordance with Johnson
Controls-Frick published specications and must be performed ONLY by qualied Johnson Controls-Frick personnel.
Johnson Controls-Frick will not be responsible for damages/problems resulting from improper connections to the con-
trols or application of improper control signals. Failure to follow this will void the manufacturer’s warranty and may
cause serious damage to property or injury to persons.
NOTICE
This manual, in combination with the applicable cooling coil data, unit G&A drawing, unit electrical drawing, and struc-
tural support drawing, provides the information necessary to safely install and start up a Frick IDSC/ECOSS™unit. Due
to the possibility of customization associated with the IDSC/ECOSS™product line, there may be areas beyond the scope
of this manual. If there are any questions about a special application lacking the required information, please contact
the installing contractor or your local Frick Sales Ofce.

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
Contents
GENERAL INFORMATION
SAFETY ....................................................................... 4
INFORMATION ON COMPONENT PARTS ...................... 4
CASING/COIL/BASIN/WATER SYSTEM.......................... 4
EC FANS WITH AXITOP ............................................... 5
PUMPS........................................................................ 6
OPTIONS AND ACCESSORIES...................................... 6
Electric Basin Heaters .................................................6
INSTALLATION
TRANSPORTATION, STORAGE,
UNPACKING AND MOUNTING................................7
TRANSPORTATION ......................................................7
STORAGE .....................................................................7
UNPACKING..................................................................7
MOUNTING ..................................................................7
Adjustment Of Mechanical Float Assembly ..............10
CONNECTING THE UNIT ..............................................10
SAFETY INSTRUCTIONS .............................................10
Safety Instructions For Setup And Start-Up..............10
System-side safety requirements..............................11
Customer-side safety precautions............................. 11
LOCATION REQUIREMENTS ........................................11
NOTES ON CONNECTING THE UNIT............................11
CONNECTING THE WATER PIPES................................11
RECIRCULATED WATER SYSTEM ............................... 11
CONNECTING THE UNIT TO THE SYSTEM ..................11
Important considerations regarding installation ........ 12
UNIT ELECTRICAL CONNECTION & PROTECTION........12
PERFORM ACCEPTANCE TEST....................................12
Acceptance Test:.......................................................12
TEST READINESS FOR OPERATION ............................12
OPERATION
PUTTING THE UNIT INTO OPERATION FOR THE FIRST
TIME ..........................................................................13
TAKING A UNIT OUT OF OPERATION..........................13
SHUTTING THE UNIT DOWN ......................................13
PUTTING THE UNIT INTO OPERATION AFTER
A SHUTDOWN............................................................13
MAINTENANCE
BEFORE STARTING ANY MAINTENANCE ....................14
WITH ALL MAINTENANCE WORK ...............................14
AFTER ALL MAINTENANCE WORK..............................14
INSPECTION AND MAINTENANCE PLAN.....................14
CLEAN UNIT ...............................................................15
General .....................................................................15
Cleaning Of Coil, Casing And Basin ...........................15
WATER TREATMENT ...................................................16
WATER TREATMENT AND MINIMUM WATER QUALITY
REQUIREMENTS .........................................................16
Biological Control......................................................16
Chemical treatment...................................................16
Water Treatment Guidelines:.....................................16
TROUBLESHOOTING.................................................... 17
SERVICE.....................................................................17
TROUBLESHOOTING TABLE ........................................17
APPENDIX I
1 GENERAL INFORMATION ..........................................18
1.1 RESPONSIBILITIES ................................................18
1.2 LEGAL NOTES .......................................................18
1.3 OPERATING INSTRUCTIONS..................................19
1.3.1 Scope................................................................19
1.4 CONVENTIONS FOR SAFETY SIGNS
AND NOTICES.......................................................19
2 SAFETY....................................................................20
2.1 LABELING ON THE UNIT....................................... 20
2.2 BASIC SAFETY NOTICES ...................................... 20
2.3 PROPER INTENDED USE........................................21
2.4 MECHANICAL RESIDUAL HAZARDS ......................22
2.5 ELECTRICAL RESIDUAL HAZARDS.........................22
2.6 THERMAL RESIDUAL HAZARDS ............................22
2.7 RESIDUAL HAZARDS WITH REFRIGERANT ............23
Halocarbons:.............................................................23
Ammonia: .................................................................23
2.8 RESIDUAL HAZARDS CAUSED BY VIBRATIONS .....24
2.9 COMBINED RESIDUAL HAZARDS ..........................25
3 INFORMATION ON COMPONENT PARTS................... 27
4 TRANSPORTATION, STORAGE,
UNPACKING & MOUNTING .................................. 27
4.1 TRANSPORTATION ...............................................27
4.2 LONG TERM STORAGE..........................................27
4.3 UNPACKING..........................................................27
4.4 MOUNTING...........................................................27
5 CONNECTING THE UNIT ........................................... 27
5.1 SAFETY INSTRUCTIONS........................................27
5.2 LOCATION REQUIREMENTS...................................29
5.3 NOTES ON CONNECTING THE UNIT ......................29
5.4 CONNECTING THE WATER PIPES ..........................29
5.5 CONNECTING THE UNIT TO THE SYSTEM .............29
5.6 UNIT ELECTRICAL CONNECTION & PROTECTION . 30
5.7 PERFORM ACCEPTANCE TEST.............................. 30
5.8 TEST READINESS FOR OPERATION...................... 30
5.9 PUTTING THE UNIT INTO OPERATION FOR THE
FIRST TIME ............................................................... 30
5.10 TAKING THE UNIT OUT OF OPERATION.............. 30
5.11 SHUTTING THE UNIT DOWN............................... 30
5.12 PUTTING THE UNIT INTO OPERATION AFTER A
SHUTDOWN.............................................................. 30
6 MAINTENANCE ........................................................30
6.1 BEFORE STARTING ALL MAINTENANCE.................31
6.2 WITH ALL MAINTENANCE WORK..........................31
6.3 AFTER ALL MAINTENANCE WORK........................33
6.4 INSPECTION AND MAINTENANCE PLAN ...............33
6.5 MAINTENANCE WORK..........................................33
6.6 CLEAN UNIT..........................................................33
7 WATER TREATMENT.................................................33
7.1 WATER TREATMENT AND MINIMUM WATER QUAL-
ITY REQUIREMENTS...................................................33
7.2 BLEED OR BLOW DOWN RATE:..............................33
8 TROUBLESHOOTING.................................................34
8.1 SERVICE................................................................34
8.2 TROUBLESHOOTING TABLE...................................34

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
GENERAL INFORMATION
Figure 2 - Hinged Fan Panels and Interior Walkway
The fully welded, leak-free basin affords generous access to
the strainer and pump inlet. The fully welded step / funnel
design, coupled with sloped panels in the basin, minimizes
sediment accumulation and standing water.
Figure 3 - Stainless Steel Basin
Figure 4 - Inlet Air Louvers
This manual has been written for professionals in the re-
frigeration eld. Basic knowledge of handling evaporative
condensers is presupposed.
• Always keep the operating instructions including
Appendix I: Safety Installation Operation & Maintenance
in the unit's immediate vicinity at all times.
• Ensure that the operating instructions including Appendix I:
Safety Installation Operation & Maintenance are accessible
to all people that have anything at all to do with the unit
at all times.
• Ensure that the operating instructions including Appendix I:
Safety Installation Operation & Maintenance are read and
understood by all people that have anything at all to do
with the unit.
SAFETY
For safety information please refer to Appendix I, 2 Safety.
INFORMATION ON COMPONENT PARTS
For safety information see Appendix I, 3 Information on
component parts.
CASING/COIL/BASIN/WATER SYSTEM
All Frick IDSC/ECOSS™evaporative cooling products are
fully constructed with 304/304L materials which are self-
passivating. The ASME certied and constructed condenser
coils are fabricated with ANSI rated materials. All coils are
supplied standard as ASME “U” Stamp Compliant. When
ASME is required, only the “U” stamp tag needs to be applied.
Figure 1 - Stainless Steel Coil
All coils are CRN-certied and possess a less than 1” tube
diameter leading to a reduced refrigerant charge. The coils
have an extended operating pressure range (maximum op-
erating pressure is 380 psig). They are generously pitched
to ensure complete drainage of the condensed refrigerant.
There is NO bowing of the tubes which often creates liquid
traps in the coil, that leads to incomplete drainage.
The 2 box sections allow for precision alignment during
assembly. The frame prole and panels t tightly together
with a structural interlocking design to ensure the correct
alignment to prevent any water leakage at the seams. Hinged
fan panels open up to a service walkway located within the
fan deck compartment giving open access to drift elimina-
tors and spray nozzles.

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
The inlet louvers are watertight, UV and corrosion resistant,
with a robust, aerodynamically optimized construction. They
have low pressure loss and zero line of sight to water in the
basin – preventing any sunlight from entering the basin. This
retards biological growth and contributes to maintenance-
free operation.
The water spray distribution system consists of a stainless
steel water distribution box; a low pressure, clog-resistant
spray nozzle design with an increased nozzle diameter to
prevent orice blockage and to maintain continuous, uniform
ow despite debris from airborne particulate; optimized
water distribution over the entire coil surface area; a riser
pipe from the pump positioned within the casing to prevent
breakage; and a stainless steel strainer.
Figure 5 - Water Spray Nozzle
EC FANS WITH AXITOP
Figure 6 - Direct Drive Fan Motor
All EC direct drive fan motors are wired (power and control)
to a common junction box, eliminating associated eld wir-
ing and labor. They allow for variable motor speed with no
efciency losses and additional equipment requirements
(VFD’s, lters or inverter duty motors). Motor speed control
is achieved without efciency penalty.
Soft start keeps the start-up current below FLA, reducing the
load on power supply components. Integrated phase failure
protection, power factor correction, harmonics lters, locked
rotor and over-temperature protection; real-time diagnostics
(measured process value, motor speed, operating hours,
power consumption, and motor temperatures); lower EC
motor temperature rise at reduced speed resulting in longer
motor bearing life; no resonant frequency harmonics or vi-
bration to encounter; no location or lead length constraints;
and no shielded cables.
The mounting arms are bolted to the ange on the fan
orice and allow for a quick and simple removal if required.
The motors can be lifted and removed by one person – NO
motor davits required.
MMC – Motor Management Controller – factory wired to all
direct drive EC motors for controlling fan speed and control
setpoint.
NOTICE
During longer storage or downtime periods, the fans must
be operated for 2 to 4 hours each month.
NOTICE
In the case of fans with protection type IP55 or higher, any
sealed condensate drain holes must be opened at least
every six months.
NOTICE
The fan motors use a separate electronic power circuit
that is controlled via Motor Management Control MMC.
The motors can be powered at three-phase (3~, 380 -
480 V AC, 50/60 Hz) voltages. Please refer to the wiring
diagrams or motor terminal box information for the elec-
trical connection.
The AxiTop diffuser is designed to recover wasted energy by
purposely and efciently decelerating the ow and reducing
swirl, boosting the pressure rise of the impeller. Aerodynamic
efciency is increased and acoustic noise is reduced.
AxiTop is currently available for ebm-papst axial fan sizes
800 mm and 910 mm. There are no moving parts and it can
be retrotted with ease onto existing systems that already
use ebm-papst fans (allowing for space).

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
PUMPS
Figure 7 - Water Pump
The water pump is a close-coupled centrifugal unit with
ductile iron housing, closed impeller, mechanical seal TEFC
motor; vertical alignment reduces installation footprint; bleed
line from riser pipe supplied complete with regulating valve;
lower recirculating ow rate results in less energy consump-
tion. Two types of pumps are available: 5 HP and 7.5 HP
OPTIONS AND ACCESSORIES
Electric Basin Heaters
For low temperature climates, immersion heater packages
are provided – factory tted – to maintain the water tem-
perature in the basin at 40°F. The design temperature of 40°F,
has been determined with the fans being off, and options are
available for ambient temperatures of -20°F.
Factory installed electrical contactors and wiring are also an
available option. Additional, available options include electri-
cal immersion heater(s) furnished with built in thermostat,
thermostat/low water protection probe and controller, and
electronic water level/heater control device.
Remote Sump: an oversized, 12” nominal ange mount con-
nection and includes the necessary gaskets and hardware to
connect to the basin (12” ange not included).
Ladder and Platform: for easy access to the catwalk. See
Figure 8.
Figure 8 - Ladder and Platform
Electronic water level controller: includes alarm oat switches
indicating if water level is too low or too high (see Figure 9).
Figure 9 - Electronic Water Level Controller

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION
INSTALLATION
TRANSPORTATION, STORAGE,
UNPACKING AND MOUNTING
WARNING
Crushing danger with falling down! (see Appendix I, 4
Transportation, Storage, Unpacking & Mounting)
TRANSPORTATION
NOTICE
Read and observe all transport signs on the units' pack-
aging! (see Appendix I, 4.1 Transportation)
STORAGE
NOTICE
Danger of corrosion and dirt build-up! (see Appendix
I, 4.2 Storage)
See additional information in General Information section.
UNPACKING
The two parts of the unit are packed and shipped separately
on their own substructure. See Figure 10.
After removing both sections of the unit from the truck:
üremove plastic wrapping
üloosen bolts connecting the unit to the substructure
üremove clamps, etc.
üremove any accessories shipped loose in the basin (boxed)
üensure that delivery is complete and without damage. In
case of damage or missing parts, contact the manufacturer
immediately
Figure 10 - Upper Section of Unit On Substructure
MOUNTING
Condensers will need to be structurally supported with two
parallel I-beams traversing the entire length of the unit.
(See Figure 11) I-beams must be level to within 1/8” over a
6’ span. Shims cannot be used to level the unit as this will
compromise the load bearing surface.
Mounting holes (13/16” diameter) are provided at the base of
the basin section, in the side panel anges, to enable secur-
ing each unit to the support structure utilizing ¾” diameter
bolts. Refer to the Frick unit certied drawing for the bolt
hole locations.
All support beams and anchoring bolts will be provided
by others and must be selected in accordance with sound
structural engineering standards. When selecting the sup-
port beams, each beam should be calculated with a uniform
load equivalent to 2/3 (66%) of the unit’s operating weight.
A1 &A2A3 &A4
B3
B4
B2
B1
Figure 11 - IDSC/ECOSS™Steel Support Dimensions (See
Table for Dimensions)
IDSC/ECOSS™Steel Support Dimensions
10' Wide Models A1 B1
IDSC 1012-06-10 to -12-30 9' 9¾" 11' 11¾"
IDSC 1018-06-15 to -12-30 9' 9¾" 18' 4"
A2 B2
IDSC 1024-06-20 to -12-60 9' 9¾" 24' 1½"
IDSC 1036-06-20 to -12-80 9' 9¾" 36' 10"
12' Wide Models A1 B1
IDSC 1212-08-15 to -12-40 11' 10" 11' 11¾"
IDSC 1218-08-20 to -12-50 11' 10" 18' 4"
A2 B2
IDSC 1224-08-30 to -12-80 11' 10" 24' 1½"
IDSC 1236-06-60 to -12-100 11' 10" 36' 10"
24' Wide Models A3 B3
IDSC 2412-08-30 to -12-80 23' 10" 11' 11¾"
IDSC 2418-06-60 to -12-100 23' 10" 18' 4"
A4 B4
IDSC 2424-10-60 to -12-120 23' 10" 24' 1½"
IDSC 2436-08-80 to -12-200 23' 10" 36' 10"

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION
WARNING
Danger of injury and damages to the property! (see
Appendix I, 4.4 Mounting)
üLift bottom section of unit from the substructure to in-
tended place of use.
üSecure bottom section of unit to the support structure
with ¾” diameter bolts (not provided).
o Use all of the bolt holes to x the unit to the support
structure (for bolt hole locations, see unit certied
drawing).
o Make sure that all mounting bolts are tightened equally
to achieve a load distribution on the connections that
is as balanced as possible.
üLift top section of unit from the substructure and position
on top of the bottom structure (see Figure 12). Figure 12 - Lifting Top Section of the Unit
18' LONG UNITS
12' LONG UNITS
10' WIDE UNITS
12' WIDE UNITS
100.6
(8' - 4.6")
134.8
(11' - 2.8")
116.5
(9' - 8.5") 110.3
(9' - 2.3")
51° 120.0
(10' )
49°
45° 120.0
(10' )
59°
120.0
(10' )
120.0
(10' )
Figure 13 - Lower Section of the Unit - Lifting Guidelines

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION
üAlign the top section with the bottom section (see Figure
14).
Figure 14 - Aligning Top and Bottom Sections
10' WIDE UNITS
12' WIDE UNITS
18' LONG UNITS
12' LONG UNITS
60° 120.0
( 10' )
48°
106.3
(8' - 10.3")
138.2
(11' - 6.2")
120.0
( 10' )
113.9
( 9' - 5.9")
51°
109.0
(9' - 1")
120.0
( 10' )
120.0
( 10' )
49°
üAppropriately guiding the top section safely above the
section joint and free from pinch points (see Figure 15).
Figure 15 - Positioning the Top Section of the Unit
Figure 16 - Upper Section of the Unit - Lifting Guidelines

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IDSC/ECOSS™EVAPORATIVE CONDENSERS
INSTALLATION
üBolt the top section and the bottom section together from
the inside.
üClose the gap between the lower and the upper riser pipe
section with the pipe connector.
o Tip: liquid soap will help slide the pipe connector over
the PVC pipe.
üClamp pipes together.
Ladder And Platform
ü See specic conguration installation instructions for the
posts, railing, ladders, cages and gates included in the
packaged materials. (Walkway, toe boards and post bases
are pre-assembled.)
Adjustment Of Mechanical Float Assembly
The brass makeup water valve with armature and circular
oat for basin water level adjustment is delivered pre-
assembled. Set circular oat height to a maximum water
level of 14¼ inches.
CONNECTING THE UNIT
SAFETY INSTRUCTIONS
Safety Instructions For Setup And Start-Up
WARNING
Danger of injuries and damage to property with escap-
ing refrigerant! (see Appendix I, 5.1 Safety instructions
Danger of injuries and damage to property with escap-
ing refrigerant!)
NOTICE
Danger of damage to the system's cooling equipment!
(see Appendix I, 5.1 Safety instructions Damage to the
system's cooling equipment!)
NOTICE
Danger of corrosion and dirt build-up for units using
ammonia as refrigerant! (see Appendix I, 5.1 Safety
instructions, Danger of corrosion and dirt build-up for
units using ammonia as refrigerant!)
WARNING
The electrical installation must only be performed by
electricians in compliance with relevant rules (or ap-
plicable national and international regulations)!
Figure 17 - IDSC/ECOSS Induced Draft Condenser Congurations - For Corresponding Air Inlet & Basin Heights, See Table.
NOTE: Consult Factory for additional information. For reference only, use certied drawings for design purposes.
IDSC/ECOSS CONFIGURATIONS AND AIR INLET & BASIN HEIGHTS (in.)
Unit
Size
Single Unit Dual End to End Dual Side by Side Quad Unit
Inlet Louver
Height (L)
Basin
Height (H)
Inlet Louver
Height (L)
Basin Height
(H)
Inlet Louver
Height (L)
Basin
Height (H)
Inlet Louver
Height (L)
Basin
Height (H)
10’ x 12’
36 63.5 48 75.5 N/A N/A N/A N/A
12’ x 12’ 36 63.5 48 75.5 78 105.5 78 105.5
10’ x 18’ 48 75.5 48 75.5 N/A N/A N/A N/A
12’ x 18’ 48 75.5 78 105.5 78 105.5 78 105.5
DUAL UNITS
END TO END
SINGLE UNIT
DUAL UNITS
SIDE TO SIDE QUAD UNITS
H
LL
H
L
H
L
H