FRITERM FDH Manual

www.friterm.com
Adiabatic Cooling Systems
INSTALLATION, OPERATION AND
INSTALLATION, OPERATION AND INSTALLATION, OPERATION AND
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
MAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONS
MAINTENANCE INSTRUCTIONS

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İÇİNDEKİLER
1. ABOUT THIS MANUAL/ GENERAL .............................................................................................. 3
1.1 Examining the o erating manual .......................................................................................................... 3
1.2 Res onsibilities ...................................................................................................................................... 3
1.2.1 Manufacturer’s Res onsibilities ..................................................................................................... 3
1.2.2 Contractor’s Res onsibilities (Installation, Commissioning) .......................................................... 4
1.2.3 O erator’s or Owner’s Res onsibilities (O eration and Maintenance) ......................................... 4
1.3 Warranty ................................................................................................................................................ 5
2. SAFETY REGULATIONS .............................................................................................................. 6
2.1 Symbols and warning signs.................................................................................................................... 6
2.2 Personal rotection ............................................................................................................................... 7
2.2.1 Personal rotection signs ............................................................................................................... 7
2.2.2 Warning signs ................................................................................................................................. 8
2.3 Warnings................................................................................................................................................ 8
2.4 Im ro er Use ......................................................................................................................................... 9
2.4.1 Hazardous rotating machinery ....................................................................................................... 9
2.4.2 Hazardous voltage .......................................................................................................................... 9
2.4.3 Hazardous thermal ....................................................................................................................... 10
2.5 Environmental rotection ................................................................................................................... 10
3. SPRAY SYSTEM DEFINITION ..................................................................................................... 10
3.1 Ecomesh water s ray system .............................................................................................................. 10
3.2 Direct Adiabatic Water S ray System.................................................................................................. 13
3.3 Adiabatic Cooling Pad System ............................................................................................................. 14
3.3.1. Recirculated Adiabatic Cooling Pad System .......................................................................... 15
3.3.2. Uncirculated Adiabatic Cooling Pad System .......................................................................... 15
4. TRANSPORT AND STORAGE ................................................................................................... 16
4.1 Check for com leteness and trans ort damage ................................................................................. 16
4.2 Trans ort ............................................................................................................................................. 16
5. INSTALLATION ....................................................................................................................... 17
5.1 Location ............................................................................................................................................... 17
5.2 Requirements at the set u oint ....................................................................................................... 18
5.2.1 Horizontal ty es set u side by side ............................................................................................. 18
5.2.2 Vertical ty es set u next to wall ................................................................................................. 18
5.2.3 Vertical ty es set u in it-hallow ................................................................................................ 19
5.2.4Horizontal ty es set u in it-hallow ............................................................................................ 20

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5.2.5Horizontal ty es set u next to wall .............................................................................................. 21
6. COMPONENTS OF ADIABATIC COOLING SYSTEM ..................................................................... 22
6.1 Water S raying System ....................................................................................................................... 22
6.1.1 Fitting grou ................................................................................................................................. 23
6.1.2 Nozzles .......................................................................................................................................... 23
6.1.3 Water s raying i es .................................................................................................................... 25
6.2 Meshes ................................................................................................................................................ 25
6.3 Cooling Pad .......................................................................................................................................... 26
6.4 Fittings, Tighten elements and system installation ............................................................................. 26
6.4.1 Installation for vertical and horizontal ty e units ........................................................................ 27
6.4.2 Installation for V ty e units .......................................................................................................... 29
6.4 Controller and Electric connection ...................................................................................................... 41
6.4.1 Direct adiabatic water s ray system controller ........................................................................... 41
6.4.2 Ecomesh s ray system controller ................................................................................................. 41
6.4.3 Controller Working Princi le and Definition ................................................................................ 42
6.4.4 Electric connection system ........................................................................................................... 43
6.5.5 Adiabatic cooling ad system controller ...................................................................................... 45
7. OPERATION ........................................................................................................................ 45
7.1 Initial commissioning ........................................................................................................................... 47
7.2 Regular commissioning........................................................................................................................ 47
7.2.1 S raying system water characteristics ......................................................................................... 47
7.3 Shutting down ..................................................................................................................................... 48
8. MAINTENANCE ....................................................................................................................... 48
8.1 Maintenance intervals ......................................................................................................................... 48
8.3 Periodical Controls (Once a year) ........................................................................................................ 49
8.4 Cleaning ............................................................................................................................................... 49
. TROUBLESHOOTING .............................................................................................................. 50

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1. ABOUT THIS MANUAL/ GENERAL
This document specifies the instructions for installation, operating and maintenance of the
products which have water spry system (FDH, FDV, FDW, FCH, FCV, FCW, NCH and NCV
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. In case of absence of this manual another
copy could be obtained from the manufacturers’ web page. It should be printed out and kept
in an accessible place to everyone whoever should carry out any work regarding the product.
(htt ://www.friterm.com/tr-TR/catalogue/4 )
•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
1.2.1 Manufacturer’s Responsibilities
•The manufacturer is strictly responsible for supplying a manual accompanying the product
which comprises the necessary and enough detailed information regarding the
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

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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 is 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 ready 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.
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.

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•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.
•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 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.

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•The product should be installed and commissioned in accordance with the
national/international regulations and rules.
•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.
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
•
Please do not try to resolve any problem by trial and error.
2.2
Personal protection
While working on and standing by the product, protective clothing must be worn.
•Safety shoes
•Safety helmet
•
Protective gloves for fitting and rep
•Chemical-
resistant clothing and protective gloves for cleaning work, especially when
handling solvents
•
Safety goggles for cleaning work, especially while handling solvents or using compressed
air for cleaning
•Hearing protection
2.2.1
Personal protection signs
Head Protection
Foot Protection
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IN CASE OF DANGER
!
Please ask assistance from an authorized
technician or expert.
Please do not try to resolve any problem by trial and error.
Personal protection
While working on and standing by the product, protective clothing must be worn.
Protective gloves for fitting and rep
air work
resistant clothing and protective gloves for cleaning work, especially when
Safety goggles for cleaning work, especially while handling solvents or using compressed
Personal protection signs
Head Protection
Eye Protection
Foot Protection
High Visibility
Clothing
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While working on and standing by the product, protective clothing must be worn.
resistant clothing and protective gloves for cleaning work, especially when
Safety goggles for cleaning work, especially while handling solvents or using compressed
Eye Protection
Clothing

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Protective Clothing
Respiratory Protection
2.2.2 Warning signs
No SmokingFlammable
High Voltage
Hand Injuries
Fire Risk
2.3 Warnings
•In an
unexpected situation use the emergency stop button which is set up on an easily
accessible place.
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Protective Clothing
Hand Protection
Respiratory Protection
No SmokingFlammable
High Voltage
Hot Surfaces
Hand Injuries
Poisoning Danger
Fire Risk
Frostbite Hazard
unexpected situation use the emergency stop button which is set up on an easily
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Hot Surfaces
Poisoning Danger
Frostbite Hazard
unexpected situation use the emergency stop button which is set up on an easily

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•
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
•
Set up the unit with extreme cleanliness.
•
The unit must not be operated if it is damaged. FR
damages.
•
The unit must be installed, operated and maintained by authorized/qualified personnel
only.
•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.
2.4 Improper Use
Danger of injuries in improper using;
2.4.1
Hazardous rotating machinery
Danger of cutting hands and fingers. Lids should be unscrewed by an authorized
technician.
Use hand protection.
2.4.2 Hazardous voltage
Electrical voltage can cause serious injuries or death. Do not contact with
voltage direct or indirect. Do not forget to power off the unit before you begin
maintenance work.
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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
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
The unit must be installed, operated and maintained by authorized/qualified personnel
is allowed on the product without written permission from the
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
Danger of injuries in improper using;
Hazardous rotating machinery
Danger of cutting hands and fingers. Lids should be unscrewed by an authorized
Use hand protection.
Electrical voltage can cause serious injuries or death. Do not contact with
voltage direct or indirect. Do not forget to power off the unit before you begin
maintenance work.
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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.
. must be informed about all
The unit must be installed, operated and maintained by authorized/qualified personnel
is allowed on the product without written permission from the
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
Danger of cutting hands and fingers. Lids should be unscrewed by an authorized
Electrical voltage can cause serious injuries or death. Do not contact with
voltage direct or indirect. Do not forget to power off the unit before you begin

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2.4.3 Hazardous thermal
Danger of burns and frostbites.
Adiabatic cooling systems are design to work at summer season when the
temperature is high.
the system is full drained.
The danger of frostbite can occur if there is insufficient frost
the unit cannot be drained completely, frostbite hazard occurs after draining.
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
safe and proper working must be complied.
3. SPR
AY SYSTEM DEFINITION
3 types of adiabatic cooling systems
direct,ecomesh and cool pad
adiabatic cooling systems
3.1 Ecomesh
water spray system
Ecomesh Spray System concept is based on intermittently and efficiently evaporating water
on a large mesh area in front of the heat rejection surface of
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Danger of burns and frostbites.
Adiabatic cooling systems are design to work at summer season when the
temperature is high.
When the temperature is low at winter season; be sure that
the system is full drained.
The danger of frostbite can occur if there is insufficient frost
the unit cannot be drained completely, frostbite hazard occurs after draining.
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.
AY SYSTEM DEFINITION
3 types of adiabatic cooling systems
can be applied to
dry coolers and condenser of
adiabatic cooling systems
.
water spray system
Ecomesh Spray System concept is based on intermittently and efficiently evaporating water
on a large mesh area in front of the heat rejection surface of
Condensers
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Adiabatic cooling systems are design to work at summer season when the
When the temperature is low at winter season; be sure that
The danger of frostbite can occur if there is insufficient frost
protection. Also if
the unit cannot be drained completely, frostbite hazard occurs after draining.
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
concerning environmental protection and the technical issues for
dry coolers and condenser of
Friterm A.Ş;
Ecomesh Spray System concept is based on intermittently and efficiently evaporating water
Condensers
and Dry Coolers.

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Water spray provides an adiabatic cooling effect of till 25 °C for the incoming air stream and
it can be initiated via an ambient sensor or alternatively by external control override. As soon
as settings exceed, a pre-set level controller initiates water spray in order to make air
temperature lower during high ambient periods.
Advantages of Ecomesh Water Spray System:
•Running Cost: Lower condensing temperature provides reliable operation and lower
annual electricity running costs.
•Reduced Water Consumption:Water is used whenever it is required at significantly
reduced quantities.
•Flexible System:Sectional panel and coil clip design suits with any brand and model of
mini-splits, air cooled chillers, rooftop units, air cooled condensers and dry coolers on the
market.
•Lower Maintenance Cost:Reduced condenser pressure leads to reduced discharge
temperature which extends the compressor reliability and life.
•Quick Response:Large mesh surface area provides efficient adiabatic cooling surface
with minimum air flow reduction, hence, water evaporates very rapidly to cool the
incoming air.
•Eliminates Health Risks:It uses water directly without any water reservoir, hence, the
health risks associated with a still water reservoir are completely eliminated.
•Green Solution: Reduced energy consumption, hence, less indirect CO 2 emission.
•Continuity of heat transfer efficiency:Since the water is not sprayed directly to the heat
exchanger fin surface, it is sprayed on the ecomeshsurface; no lime layer is formed on
the fins. Thus, the reduction of the thermal transfer efficiency is prevented.
Moisture Content
Tem erature

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Picture
1
-
Ecomesh water spray system at vertical type
condensers
Picture 2
-
Ecomesh water spray system at V type
condensers
Picture
3-Ecomesh water spray system at horizontal type
condensers
Picture 4
-
Ecomesh water spray system at V type
dry coolers
Picture
5-Ecomesh water spray system at horizontal type
dry coolers

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3.2 Direct Adiabatic Water Spray System
Directadiabatic water spray system comprises a series of specialized water nozzles fitted
intermittently. The nozzles are designed to pulverize the water and provide a very fine mist of
atomized water droplets which are readily absorbed by the high temperature ambient air
approaching the coil.
It is necessary that the water used in this system must undergo for a strict water treatment regime
to reduce the risk of corrosion and prevent dirty water in the water circuit. Moreover the hardness
of the water should be taken and pass from high efficiency filtration system.Otherwise, the lime
and residue that accumulates on the heat exchanger fins will eventually reduce product capacity
and shorten its lifetime.
Epoxy coated fins can be used for dry coolers with spraying systems as an additional protection
due to the abrasive effects. The epoxy coating has a very high resistance to salt and acid in the
environment.It is preferred that the unit is made of epoxy-powder coated galvanized steel and
stainless steel in advanced corrosive environments.It is important to take these precautions to
ensure the dry coolers are long-lived, although they are much less exposed to the harmful effects
of water than the water towers.
The amount of water to be consumed in order to saturate the intake air, varies depending on the
sprayer used and the spraying pressure.The choice depends on the relative humidity of the
ambient air; It should be ensured that water is sprayed in sufficient quantity to bring the relative
humidity as close to 100% as possible.For this reason, some more water is sprayed from the
completely evaporating amount and the increased water remains as the liquid in the environment.
This measure also provides safety against the loss that can occur over time in the performance of
the spray system.
Picture 6-Horizontal type condenser with direct spraying system

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Picture 7-V type dry cooler with direct spraying system
3.3Adiabatic Cooling Pad System
In adiabatic cooling pad systems, coolpads are placed in special sheet metal assemblies which
are mounted in front of fin block. With the aid of the pump, water wets the pads from the upper
part of the pad system. The outside air, which is dry and hot, is pre-cooled by passing it through
wet cooling pads.The temperature of the air that contact with the wet cooling pads is
approximated to the wet thermometer temperature.
The water does not contact directly with the fins. Thusfins lifetime is longer than the direct
spraying systems.Also pads prevent contamination of fins.
Since the microorganisms, minerals and similar parts do not mix into the air during the
evaporation phase of water, the working principle is completely healthy.
The system ensures that product efficiency can be increased with minimum water consumption.

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System can be built in two ways as recirculated and uncirculated.
3.3.1. Recirculated Adiabatic Cooling Pad System
In recirculated adiabatic systems, water that flow over the pads, collected at the drain pan. When
it reaches a certain level, it is pumped back to the upper part water spraying line by the circulation
pump.
3.3.2. Uncirculated Adiabatic Cooling Pad System
In uncirculated systems, the amount of water supplied through the cooling pads is provided by
the appropriate automation system, depending on the external air relative humidity.
A small amount of water collected in the pan under the pads is drained by a drainage line.

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Picture 8- V Type dry cooler with adiabatic cool pad system
4. TRANSPORT AND STORAGE
4.1 Check for completeness and transport damage
•Attention! May cause severe injuries or unrecoverable damages in case of uncontrolled
fall down.
•Instructions on lift and transportation should be strictly followed.
•Check if there is any damage on product or package. Immediately after receipt, the
delivery must be inspected for possible transport damage. Any damage must be reported
immediately to the shipping company. If it is to be expected that the transport damage
may affect proper operation, then the product must not be commissioned.
•Upon receipt, the product should be visually inspected, and in case of any damage or
shortage, the supplier should be notified within 7 days.
4.2 Transport
The product may only be lifted and moved by persons who:
1. Are authorised to operate crane systems,
2. Are authorised to drive motorised handling product
3. Also know the transport and lifting instructions according to the operating manual and the
assembly drawing.

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Suitable transport equipment must be used.
5. INSTALLATION
The system installer is responsible for the proper installation according to standards and
guidelines (DIN EN 292 / 294) which contains installation and security guidelines.
Before installing, it must be ensured that the technical specifications of the product are in
accordance with the desired working conditions.
5.1 Location
•The spraying system is designed only for permanent installation. It should be fixed to a
stable base.
•In recirculated or uncirculatedadiabatic cooling pad systems, excess water accumulating
in the drain pan and must be properly well trained. Product must be installed in such a
way that will not obstruct the drainage.
The working area should be well ventilated and should not be contained any hazardous
substances or explosives.
•Air motion should not be adversely affected by obstructions and inlet air should not be
undesirably heated or cooled by some other product.
•All the blind bolts and/or flanges should be removed right before the installation.
•The site where the installation process is being carried out should be provided as clean as
possible and low humidity.

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5.2 Requirements at the set up point
5.2.1 Horizontal types set up side by side
5.2.2 Vertical types set up next to wall
Smin ≥H

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5.2.3 Vertical types set up in pit-hallow