Frick XLP3 Owner's manual

Form 140.925-IOM (APR 2019)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 140
Replaces: Nothing
Dist: 3, 3a, 3b, 3c
XLP3 Evaporative Condenser
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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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
Table of Contents
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.
WARNING
CAUTION
DANGER
NOTICE
INSTALLATION
INTRODUCTION ............................................................... 4
Safety .................................................................................4
Shipping..............................................................................4
Pre-Rigging Checks ............................................................4
Cold Weather Operation.....................................................4
Location..............................................................................4
Warranties..........................................................................4
Unit Operation....................................................................5
RIGGING & ASSEMBLY......................................................5
Rigging ...............................................................................5
Section Assembly ...............................................................5
Table 1 - Recommended Vertical Dimension and Spreader
Bar Length .....................................................................5
Wiring the Factory Terminal Box (EC Fan System Only)...... 7
OPTIONAL ACCESSORY INSTALLATION............................8
Bottom Water Outlet (Optional) .........................................8
Offset Access Platform, Perimeter Guardrail and Ladder....8
Ladder Safety Cage (Optional)..........................................10
Table 2 - Ladder Safety Cage Bolting Location and
Quantities ....................................................................10
Automatic Bearing Greasers (Optional for Belt Drive Fan
System Units Only) ...................................................... 11
Heater Control Panel (Optional)........................................ 11
FIELD CONNECTIONS......................................................13
Table 3 - Supplies for Installing Field Connections............ 13
OPERATION
SAFETY PRECAUTIONS...................................................14
START-UP PROCEDURE ..................................................15
Considerations for Initial Start-Up .................................... 15
General............................................................................. 15
Cleaning............................................................................ 15
Inspection......................................................................... 15
Start-up............................................................................ 15
EXTENDED SHUTDOWN..................................................16
PROLONGED OUTDOOR STORAGE..................................16
Storage Preparation ......................................................... 16
Motor Recommendations ................................................. 17
Electronically Commutated (EC) Motors............................ 17
Belt Drive Fan System ...................................................... 17
Maintenance Requirements During Storage...................... 18
Start-Up Preparation After Prolonged Storage................. 18
COLD WEATHER OPERATION..........................................18
Inspection and Maintenance............................................. 18
Fan Section Icing Protection............................................. 18
BASIN WATER AND INTERNAL PIPING
FREEZE PROTECTION ......................................................18
Cold Water Basin Protection............................................. 18
COIL FREEZE PROTECTION..............................................19
Minimum Operation.......................................................... 19
OPERATION CONSIDERATIONS
FOR ACCESSORIES .........................................................19
Basin Heater (Optional) .................................................... 19
Stand Alone Frick Heater Control Panel (Optional)........... 19
Operation ......................................................................... 19
VIBRATION CUTOUT SWITCH (VCOS) ............................20
Mechanical Vibration Cutout Switch (Standard)................20
Electronic Vibration Cutout Switch (Optional) ..................20
FAN CONTROL................................................................ 22
EC Fan System Fan Control............................................... 22
Independent Fan Control (Optional).................................. 22
MAINTENANCE
DETAILED COMPONENT
MAINTENANCE PROCEDURES .........................................24
Cold Water Basin..............................................................24
Table 4 - Cold Water Basin Water Levels .........................24
EC Fan System..................................................................24
Belt Drive Fan System ......................................................24
Water Distribution System and Heat Transfer Section...... 26
Water Level Control.......................................................... 27
CORROSION PROTECTION ..............................................28
Water Treatment .............................................................. 28
Corrosion and Scale Control ............................................. 28
Gray Water and Reclaimed Water..................................... 29
Chemical Treatment Requirements ................................... 29
Table 5 – Quality Guidelines for Treated Circulated Water 29
Passivation ....................................................................... 29
Biological Control ............................................................. 29
Long Term Care of Stainless Steel ....................................30
Jobsite Considerations......................................................30
System Cleaning...............................................................30
BLEED RATE....................................................................30
RECOMMENDED MAINTENANCE INTERVALS ..................32

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION - OPERATION - MAINTENANCE
XLP3 Evaporative Condenser
with EC Fan System
XLP3 Evaporative Condenser
Factory Pre-Assembled
Lader with Safety Cage
(Optional)
Coil Connection:
Refrigerant Vapor In
Coil Connection: Refrig-
erant Liquid Out
Terminal Box
Pump
Factory Pre-Assembled
Platforms with Perimeter
Handrails (Optional)
BranchLokTM
Removal
System
Access Door
with Safety
Handle
and Step
Coil
Basin
Strainer
Internal
Walkway
EC
Fan
System
XLP3 Evaporative Condenser with EC Fan System
XLP3 Evaporative Condenser
with Belt Drive Fan System

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
INTRODUCTION
Safety
Adequate precautions appropriate for the installation and
location of these products should be taken to safeguard the
equipment and the premises from damage, and the public from
possible injury. The procedures listed in this manual must be
thoroughly reviewed prior to rigging and assembly. Read all
warnings, cautions and notes.
When the fan speed of the unit is to be changed from the factory
set speed, including the use of a variable speed device, steps
must be taken to avoid operating at or near the fan’s “critical
speed” which could result in fan failure and possible injury or
damage. Refer to “Fan Control” in the Operation section of this
manual.
WARNING
In the event of extended lifts or where hazards exist, the
lifting devices should be used in conjunction with safety
slings placed under the unit.
Shipping
Frick XLP3 Evaporative Condensers are factory assembled to
ensure uniform quality with minimum field assembly. As standard,
models ship in two sections per cell (lower and upper). Contact
your local Frick Representative for more information. For the
dimensions and weights of a specific unit or section, refer to
the submittal drawings.
WARNING
Only personnel qualied to do so should undertake the
installation, operation, maintenance, and repair of this
equipment. Proper care, procedures, and tools must be
used in handling, lifting, installing, operating, maintaining,
and repairing this equipment to prevent personal injury
and/or property damage.
Pre-Rigging Checks
When the unit is delivered to the job site, it should be checked
thoroughly to ensure all required items have been received and
are free of any shipping damage prior to signing the bill of lading.
The following parts should be inspected (if applicable for
the unit's conguration):
Sheaves,Belts, and
Bearings
Bearing Supports
Fan Motor(s)
Fan Guard(s)
Fan(s) and Fan Shaft(s)
Float Valve Assembly(s)
Water Distribution System
Coil Surface
Cold Water Basin
Accessories
Interior Surfaces
Exterior Surfaces
Spray Water Pumps
Mating Surfaces Between
Sections/ Modules
Miscellaneous Items: All bolts, nuts, washers, and sealer tape required
to assemble sections or component parts are furnished by Frick and
shipped with the unit. A checklist inside the envelope marked “Custom-
er Information Packet” indicates what miscellaneous parts are included
with the shipment and where they are packed. This envelope will be
attached to the side of the unit or located in a box inside the unit.
INSTALLATION
Unit Weights
Before rigging any unit, the weight of each section should be
verified from the unit submittal drawing. Unit print weights in-
clude the final assembled unit with all accessories. Accessory
weights (found on the respective drawing) can be deducted from
the total weight.
Anchoring
Seven-eighths inch (7/8”) diameter holes are provided in the bot-
tom flange of the basin section for bolting the unit to the support
beams. Refer to the suggested support drawing included in the
submittal for location and quantity of the mounting holes. The
unit must be level for proper operation. Anchor bolts must be
provided by others. The IBC rating is only certified with standard
anchorage locations. Using alternate anchorage locations or al-
ternate steel supports will void any IBC wind or seismic ratings.
Contact your local Frick Representative for details.
CAUTION
Unit must be properly anchored in place before operation
begins.
Cold Weather Operation
These products must be protected by mechanical and operational
methods against damage and/or reduced effectiveness due to
possible freeze-up. Refer to “Cold Weather Operation” in the
Operation section of this manual or contact your local Frick
Representative for recommended protection alternatives.
WARNING
Before an actual lift is undertaken, ensure no water, snow,
ice, or debris has collected in the basin or elsewhere in
the unit. Such accumulations will add substantially to the
equipment’s lifting weight.
Location
All evaporative cooling equipment must be located to ensure
an adequate supply of fresh air to the fans. When units are lo-
cated adjacent to walls or in enclosures, care must be taken to
ensure the warm, saturated, discharge air is not deflected and
redirected back to the air intakes. Each unit must be located and
positioned to prevent the introduction of discharge air into the
ventilation systems of the building on which the unit is located
and of adjacent buildings. For detailed recommendations on Frick
equipment layout, contact your local Representative.
NOTICE
Each unit must be located and positioned to prevent the
introduction of discharge air into the ventilation systems
of the building on which the unit is located and of adjacent
buildings.
Warranties
Please refer to the Limitation of Warranties (located in the
submittal package) applicable to and in effect at the time of the
sale/purchase of these products.

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
Unit Operation
Prior to start-up and unit operation, refer to the Frick Operation
& Maintenance sections in this manual.
RIGGING & ASSEMBLY
Rigging
Refer to Table 1 for the recommended vertical dimension “H”
from the lifting device to the spreader bar. In the event of ex-
tended lifts or where hazards exist, the lifting devices should
be used in conjunction with safety slings placed under the unit.
NOTICE
For weight information, refer to the submittal drawing
package.
NOTICE
Any motors or accessories shipped in the cold water basin
must be removed prior to installing the upper (mechanical
and coil casing) section.
Most single cell XLP3 Evaporative Condenser products are de-
signed to be lifted in one assembled piece as shown in Figure
1. Verify the total unit shipping weight is below 35,000 lbs
before performing a single-piece lift. A two-piece lift is shown
in Figure 2.
WARNING
Single piece lift is ONLY possible when total unit shipping
weight is under 35,000 lbs. Please refer to the shipping
weight shown on the Unit Print from submittal package.
Single piece lifting must be done using lifting ears on the
base of the upper casing section (See Figure 1).
Section Assembly
1. Remove any motors or accessories shipped in the cold water
basin. Rig the basin section. The rigging hook must be placed
above the section’s center of gravity as detailed in Figures 1 and 2.
2. Wipe down the flanges with acetone to remove dirt or mois-
ture which may have accumulated during shipment and storage.
3. Install sealer tape on the mating flange of the bottom section
to ensure an airtight seal between the top and bottom section.
Install flat butyl sealer tape (Frick part #554000) supplied with the
unit, on the mating flanges of the lower section in a continuous
line. At each corner, allow 1” overlap. See Figure 3.
CAUTION
Before proceeding, bolt the basin sections securely to the
supporting steel.
4. Lower the flexible connection on the pump discharge piping
below the elevation of the lower section before rigging the coil
casing section.
5. Lower the upper section (coil casing and mechanical) until it
is hovering 2-6” above the lower section.
6. Insert drift pins per Figure 5. Start at the corner hole and skip
every 3 or 4 holes along the length of the unit, inserting drift
pins to align the coil casing section and the lower section holes.
Repeat this process on the other side.
7. Fasten the hardware between the coil casing and lower sec-
tion per Figure 4. Lower the coil casing section the rest of the
way onto the lower section, keeping mounting holes aligned.
Figure 1 — Single-Piece Lift
L
H
Table 1 – Recommended Vertical Dimension and Spreader Bar Length
Model Number Number of
Basin Sections
Number of
Casing
Sections
Basin Section Casing Section or Single
Piece Lift
Spreader Bar
Length (L)
Minimum
Height (H)
Center of
Gravity from
Air Inlet Face
Spreader Bar
Length (L)
Minimum
Height (H)
XLP3-1012xxxx-xxxx 1 1 10' 13'-8" 4'-2" 10' 9’-2”
XLP3-1018xxxx-xxxx 1 1 10' 13'-8" 4'-2" 10' 13’-8”
XLP3-1024xxxx-xxxx 2 2 10' 13'-8" 4'-2" 10' 9’-2”
XLP3-2012xxxx-xxxx 2 2 10' 13'-8" 4'-2" 10' 9’-2”
XLP3-1036xxxx-xxxx 2 2 10' 13'-8" 4'-2" 10' 13’-8”
XLP3-2018xxxx-xxxx 2 2 10' 13'-8" 4'-2" 10' 13’-8”
XLP3-1212xxxx-xxxx 1 1 12' 13'-8" 5' 10' 9’-2”
XLP3-1218xxxx-xxxx 1 1 12' 13'-8" 5' 10' 13’-8”
XLP3-1224xxxx-xxxx 2 2 12' 13'-8" 5' 10' 9’-2”
XLP3-2412xxxx-xxxx 2 2 12' 13'-8" 5' 10' 9’-2”
XLP3-1236xxxx-xxxx 2 2 12' 13'-8" 5' 10' 13’-8”
XLP3-2418xxxx-xxxx 2 2 12' 13'-8" 5' 10' 13’-8”

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
Figure 2 — Two-Piece Lift
L
H
L
H
Rigging of Upper Coil Section
Rigging of Lower Fan Section
center of gravity
8. Secure the hose connecting the sections of the pump dis-
charge pipe with the hose clamps provided.
9. On units with more than one casing, install the remaining
casings using the same procedure as the first. When installing
two or more casings, on the basin section, sealer tape must be
applied to both cross flanges (see Figure 3).
10. On units operating with a remote sump tank, install a bleed
line with valve between the system circulating pump discharge
riser and a convenient drain. Locate the bleed line in a portion
of the riser piping that drains when the pump is off. Units that
are furnished with a factory-installed circulating pump include
a bleed line with valve.
CAUTION
Before proceeding, bolt the basin sections securely to the
supporting steel.
Figure 3 — Sealer Tape Application
Figure 4 — Fastening of Upper and Lower Sections
Figure 5 — Section Alignment Using Drift Pins

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
Wiring the Factory Terminal Box (EC Fan System Only)
Electrical Power Quality
This unit requires clean electrical power to operate properly.
Voltage and frequency should be within 10% of the designed
voltage for the unit. Failure to provide this power may damage
the unit. The EC fan motors contain built-in protection circuits
that will shut down the fan if there is a power quality issue. If
the fans go into protection mode, the unit must be shut down
and restarted to return to normal operation.
WARNING
When connecting power to the unit, do not penetrate the
top of the control panel. Doing so may allow moisture to
enter the panel. All cable and conduit should be supported
separately from the unit. Do not penetrate the unit for
supports or other connections.
Power Connections
The XLP3 Condenser requires a 3 phase 60Hz power source (50Hz
also available). The voltages available are 200 to 240V and 380V
to 480V. Please ensure that the correct voltage is supplied to
the unit. If unsure, check your unit’s submittal to verify that the
provided power matches your unit. On the factory terminal box,
remove the NEMA plug located on the side of the panel near the
disconnect switch. This will maintain the panel’s NEMA 4 rating
and prevent water ingression to the unit.
NOTICE
Any motors or accessories shipped in the cold water basin
must be removed prior to installing the upper (mechanical
and coil casing) section.
Controls Connections
The controls wiring should be provided in a separate conduit
from any power wiring. Frick recommends penetrating the control
panel from the bottom or side panel observing standards. It is
also recommended to use shielded wire to avoid interference.
To control the XLP3 Evaporative Condenser fan speed, a control
signal of 4-20mA is used. The signal commands the fans off at
4mA and full speed at 20mA. The 4-20mA should be wired as
outlined in the wiring diagram in the submittal package. Control
wiring can be routed into the terminal box through the NEMA
plug located on the bottom of the panel.
Figure 6a — Terminal Box Location
Terminal Box
Figure 6b — Terminal Box
H

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
OPTIONAL ACCESSORY INSTALLATION
Bottom Water Outlet (Optional)
1. The bottom connection seal, Figure 7, is typical for all bottom
remote sump outlets. Flange mounting hardware and gasket to
be supplied by others.
2. Bottom connection seal kit(s) ship in plastic tubs.
Offset Access Platform, Perimeter Guardrail and Ladder
1. Lift the platform by fastening the lifting device to the top
guard rail so it does not slide while lifting. Lift the platform so
that the support gussets align with the mounting brackets on
the unit. See Figure 8.
2. Fasten the platform gussets to the mounting brackets using
the supplied hardware as shown in Figure 8, Detail A.
3. Loosely fasten the lower and intermediate appropriate lad-
der brackets and diagonal braces to the factory installed ladder
brackets as shown in Figure 8, Detail B and Figure 9, Detail A.
Check your submittal for the ladder orientation ordered. Attach
the ladder to the platform and fasten the lower and intermediate
brackets to the ladder side rails as shown in Figure 8, Detail B
and Figure 9, Detail A.
4. Tighten all ladder bracket fasteners.
5. Cut the ladder to length required and fasten the ladder foot
to the landing surface (anchorage hardware provided by others).
6. Using the supplied hardware, install the perimeter guardrails
at the bracket points as shown in Figure 10, Detail A and Detail B.
7. At the point where two vertical support meet, install the
factory supplied fastener through each support as shown in
Figure 10, Detail C.
NOTICE
For platform and ladder options ordered but not listed,
refer to the customer information packet supplied on the
unit.
Figure 7 — Bottom Water Outlet
Figure 8 — Platform Installation and Air-Intake Face
(Face D) Ladder Installation
Detail A. Platform Mounting
Detail B. Intermediate and Lower Ladder Bracket
Platform Lifting
Locations
Platform
Gusset Support
Mounting
Brackets
Platform Mounting
Fasteners (Qty. 4)

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
Figure 9 — End Ladder Installation
Detail A. End Ladder Bracket
Detail A. Perimeter
Guardrail
Installation
Detail B. Corner
Guardrail Installation
Detail C. Perimeter Guardrail Installation
Figure 10 — Perimeter Guardrail Installation

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XLP3 EVAPORATIVE CONDENSERS
INSTALLATION
Ladder Safety Cage (Optional)
1. If the safety cage is shipped in multiple pieces, reassemble
the safety cage.
2. Bolt the safety cage to the ladder using flatwashers and lock-
nuts. Orient all fasteners with bolt heads inside safety cage.
See Figure 11, Detail A through D and refer to Table 2 for the
quantity of bolting locations for different safety cage heights.
NOTICE
Safety gates are provided for all handrail openings, and all
components are designed to meet OSHA requirements.
Share two lower
fasteners on
upper ladder
bracket
Upper ladder
bracket
Hoop
Detail D
Figure 11 — Safety Cage
Detail A
Detail B
Detail C
Table 2 — Ladder Safety Cage Bolting Location and Quantities
Cage Height (ft) Bolting Location Cage Height (ft) Bolting Location Cage Height (ft) Bolting Location
A B C D A B C D A B C D
4 1 – – 1 12 1 1 2 1 20 1 1 4 1
51 1 – 1 13 1 1 2 1 21 1 1 4 1
61 1 – 1 14 1 1 2 1 22 1 1 4 1
71 1 – 1 15 1 1 2 1 23 1 1 4 1
81 1 – 1 16 1 1 2 1 24 1 1 4 1
91111 17 1 1 3 1 25 1 1 5 1
10 1111 18 1 1 3 1 27 1 1 5 1
11 1111 19 1 1 3 1