MK2 ADIABATIC (SPRAY) COOLING SYSTEMS

1. HEALTH AND SAFETY
Refer to instructions for unit.
Installation and Maintenance Instructions
2. LEGIONELLA
An ultraviolet disinfection lamp is fitted as standard to
the unit and will kill any Legionella in the supply
water.
(IT IS MANDATORY THAT THE UV LAMP IS
CHANGED ONCE A YEAR. UNDER NO
CIRCUMSTANCE SHOULD THIS SYSTEM BE RUN
WITHOUT A FULLY FUCTIONING DISINFECTION
LAMP.)
The system is designed to drain daily, so as to not
harbour bacteria. Note, if the supply water
temperature is lower than 20°C then multiplication of
Legionella is inhibited. For this reason it is
recommended that the unit is supplied directly from a
cold mains whenever possible.
To reduce the possibility of supply water
exceeding 20°C and Legionella being in the supply
water it is necessary to loop the supply, rather than
create a “dead leg” in which water can stagnate.
3. GENERAL
The MKII adiabatic spray system has three models in
the range, two pumped and one non-pumped. The
pumped systems are available with two sizes of
single phase pump. All units are fitted with an
ultraviolet disinfection lamp.
The adiabatic system is housed in a steel IP55
enclosure and is available as a factory fitted option to
all of International Cooling Group’s condenser and
dry cooler models. It can also be supplied as a retrofit
kit for existing installations and can be remote
mounted.
Factory fitted units are supplied with the adiabatic
box fitted to the opposite end to the inlet/outlet
headers. DVG/DVH/MVH/MVG units are supplied
with the sparge pipes fully assembled; MDG/DKG
units are supplied with the sparge assemblies loose
for fitting on site. This is because they would interfere
with lifting the unit.
Installation Clearances
Installation clearances for particular condenser/dry
cooler model should be adhered to. In addition to
these clearances, provision for opening the adiabatic
door should be made (min 1025mm from door face).
A clearance below the coil face on flat bed units is
also required (min 250mm).
MK2 ADIABATIC
(SPRAY) COOLING
SYSTEMS
Flat Bed Units
Locate the sparge support beams under the coil at
the specified pitches (refer to unit drawing) and
secure to the side plates using clamps provided (note
locate the channels in descending hole positions to
enable a sufficient drop for draining). Fit the pipe
clamps into the channels and locate the sparge pipes
into the clamps, join using fittings supplied. The spray
nozzles should be pointing away from the coil face.
Make the connection with the adiabatic box. Ensure
that the drain solenoid is at the lowest point of the
system. The drain solenoid is normally fitted onto the
lowest point on the inlet of the sparge assembly (if
the unit is raised on steels and the adiabatic box
is remote then it may be necessary to reposition
the solenoid to avoid water trapping in the pipe work).
V Bank Units
Rivet the sparge support brackets to the support beams on
the coil face using the holes provided. Fit pipe clamp
arrangement to appropriate fixing positions on sparge
support brackets. Follow diagram for relevant positions to
provide a drop that allows good drainage. The spray
nozzles should be pointing across the coil face with all 3
rows pointing up at an angle of approximately 30° to the
vertical. Make the connection with the adiabatic box
ensuring that the lime scale inhibitor is fitted inline (if
supplied loose). Ensure that the drain solenoid is at the
lowest point of the system and non-return assembly at the
highest. The drain solenoid is normally fitted onto the
lowest point on the inlet of the sparge assembly. (If the
unit is raised on steels and the adiabatic box is remote
then it may be necessary to reposition the solenoid to
avoid water trapping in the pipe work).
All components must be handled with care during
assembly.
Water Supply and Drainage
Ensure that the method of supply complies with local
water regulations. The supply water must be clean
and free from particles. Although the unit is fitted with
an inline filter and some nozzle types have separate
filters it is the responsibility of the end user to ensure
a clean supply; no liability will be accepted for
blockage of nozzles. The minimum supply pressure
required is 2 bar.
Ensure that the supply pipe work does not transmit
any load or vibration to the unit pipe work. Supply
pressure at the control valve must be positive before
and during operation.
A significant proportion of the delivered water is
lost by evaporation, but there will be some over-spray
and provision should be made for drainage.
1

Under no circumstances should over spray
water be recycled back to the spray nozzles.
Units Fitted With Pumps
The maximum pump flows at 3 bar are 23l/m for
2HM4T and 46l/m for 2HM5T. For exact flow rates for
individual units refer to Searle quoting the operating
conditions required.
PUMPS ARE NOT SELF PRIMING AND REQUIRE
A MINIMUM OF 2 BAR AT THE INLET.
Pump ratings:
2HM4 (1 phase) Input Power 0.66Kw
Input Current 220-240V 2.92A
2HM5 (1 phase) Input Power 0.85Kw
Input Current 220-240V 3.72A
Frost Protection
The pump and spray system are self-draining so frost
protection is not necessary. However, frost protection is
required for the supply pipes up to the mains solenoid.
4. MILLENIUM CONTROLLER
Both pumped and non-pumped units are fitted with a
Millenium SA12 24V Controller, the controller is factory set
using a laptop and these settings cannot be altered by the
customer without a laptop and millenium software. Two
programs are available to download to the controller and
have the following strategies.
2
Standard Settings Pumped: -
On enable, the UV lamp is energised, after a 1 minute
delay the mains solenoid is energised allowing water to fill
the pump. A pressure switch is incorporated which has a 1
minute delay starting when the mains solenoid is opened;
this should be set between 1 and 1.5 bar. After a delay of
60 seconds the pump is energised. The pressure switch
will shut down the adiabatic system in the event of water
supply failure. To reset, interrupt the enable signal.
Standard Settings Non-Pumped: -
On enable, the UV lamp is energised, after a 1 minute
delay the mains solenoid is energised allowing water
directly to the nozzles. A pressure switch is incorporated
with a 1 minute delay after the mains solenoid is opened,
this should be set to between 1 and 1.5 bar. The pressure
switch will shut down the adiabatic system in the event of
water supply failure. To reset interrupt the enable signal.
Both adiabatic systems will shut down under fault
conditions due to the following:
• If the UV lamp fails
• If the pump delivery pressure falls below 1 bar
The controller will display its start and run functions as
below, "If the unit suffers a low pressure fault, then the
controller will store the event even when the power is
turned off. When the fault has been rectified press the ESC
button to reset the controller. To employ the Back Light
function press and hold any other button.
UNDER NO CIRCUMSTANCES SHOULD ANY OF THE
ABOVE SAFTEY FEATURES BE OVERRIDDEN.

UV Warm Up
Water On
Del Time 60
Yes
SEARLE ADIABATIC SYSTEM V1.2
Ultra Violet
Tube Warm
Up Delay
60 Seconds
Drain & Vent Solenoids
Close
Main Solenoid Opens
Yes
System Fills for 60
Seconds
SEARLE
Adiabatic
Control V1.2
(Off Line)
UV Dry Contact Closes within 18 Seconds
and Closed During Normal Operation
System Fill
Sol Energise
Pump Hold
Off Delay 60
Adiabatic
Pump Run
System
Pressurising
Pressure Switch Closes within 60 Seconds and
Closed during normal running
Adiabatic
System
Pressure
Healthy Fail
No
Pump Runs to Pressurise
the Pipe Work
Adiabatic Sprays
On
No
UV Fail
Alternating Flashing Display
Check
Pump
Press Switch
Water Supply
3

5 COMMISSIONING INSTRUCTIONS
The adiabatic control system can be linked a number
of different control systems; refer to the unit controller
instructions to check the settings and to initiate the
system.
Before running the unit for the first time, check that
all pipe joints are secure. Supply pressure at the
control valve must be positive before and during
operation and is recommended to be no less than 2
bar. The unit will not run unless an adequate supply
is present.
With condenser fans running, initiate the adiabatic
system. Set the system pressure / flow rate using the
flow regulator and pump bypass (pump models only).
The discharge pressure should be set between 3.7
and 5 bar depending on the unit water flow
requirements. Check the spray coverage is even and
if necessary adjust the spray direction by rotating the
sparge pipes.
A pressure switch is incorporated with up to 8
minute monitoring timer (dependant on unit type) and this
4
Adiabatic flow rates @ 5 Bar
is factory set to close at 1-1.5 bar, this will shut down
the adiabatic system in the event of water supply
failure.
The adiabatic system will shut down under fault
conditions due to the following:
1. If the UV lamp fails
2. If the water pressure falls below 1 bar.
3. There is a monitoring timer that overrides the
pressure switch for up to 8 minutes from the
time the unit is enabled (factory set at 1
minute). This allows the water flow to
stabilize. If the UV lamp or water supply has
failed, after the set delay the timer will lock
out all functions. To reset interrupt the enable
signal.
UNDER NO CIRCUMSTANCES SHOULD ANY OF
THE ABOVE SAFETY FEATURES BE
OVERRIDDEN.
1FAN 2FAN 3FAN 4FAN 5FAN
MODEL l/m l/m l/m l/m l/m
Vee bank
n/a 6.5 9.8 13.1 16.3
Flat bed
1.1 2.2 3.3 4.4 5.4
2x2 FAN 2x3 FAN 2x4 FAN 2x5 FAN 2x6 FAN
MODEL l/m l/m l/m l/m l/m
Vee bank
6.5 9.8 13.1 16.3 19.6
Flat bed
4.4 6.5 8.7 10.9 13.1
Note that maximum flow rate is based on 6 and 8 Pole requirements.
For 12 and 16 pole fans, the flow can be reduced to 85% of max flow- this is achieved at approx 3.7
bar.

6. MAINTENANCE
The following routine maintenance is required:
When the system is in standby over the winter
months it is important to initiate the system and allow
the pump to run for a period of 5 minutes every 2
months to the prevent bearings drying up.
Every 3 Months of use:
1. Remove and wipe clean the quartz sleeve of the
UV lamp.
2. Remove and clean the strainer.
3. Check the drain tubes are clear.
4. Check for blocked nozzles and replace filters if
necessary
Additionally, every 12 months, in the spring:
1. Dismantle and clean nozzles, replace nozzle
filters where applicable.
2. Check the coil for limescale deposition. If this is
significant it is necessary to further soften the
water supply.
3. It mandatory to remove and replace the UV
lamp element and clean the quartz sleeve
every 12 months. A lamp change record sheet is
fitted inside the adiabatic box, this must be
updated and the next due date recorded every
time the lamp is changed.
4. Check that the pump rotates freely.
5. Run the spray system, check it functions correctly
and also check the pipelines for damage / leaks
and that the spray nozzles are not blocked.
6. Ensure that the system drains completely when
UV lamp deactivates.
Additionally, every 3 years, in the spring:
1. Upon removing UV lamp sleeve/element, both
the UV lamp element and the quartz sleeve
should be replaced.
Lamp and sleeve can only be
removed from the reactor
chamber as 1 piece ensuring
the user is aware of any build
up of minerals on the quartz
sleeve.
The lamp is easily removed
and replaced for annual
maintenance
Lamp/Sleeve Combination
Instructions for UV Lamp replacement
Shut Down
1. Shut off mains solenoid and allow system to drain.
2. Unplug the power supply and let the lamp cool for
5 minutes.
3. Squeeze the sides of the safety cap in the area
opposite the tabs (do not squeeze tabs), and remove
the cap.
4. Pull the lamp plug off the lamp end. Do not pull on
the cord when removing the plug.
Lamp Removal
1. Unscrew the lamp/sleeve assembly and carefully
remove it from the reactor. Handle assembly by ends
only. If required, a wrench can be placed on the two
flat sides of the sleeve bolt.
Do not apply the wrench to the lamp end, which sits
within the sleeve bolt and protrudes 1/4”.
2. To remove the lamp from its sleeve, use a glove or
cloth to support and hold on to the sleeve. Holding
the sleeve bolt tight, unscrew the lamp end, the top of
which protrudes 1/4”above the sleeve bolt. Be
careful not to drop the sleeve. If required, place an
adjustable wrench on the two flat sides of the lamp
end.
Cleaning
1. Remove first O-ring, sleeve bolt and second O-ring
from lamp sleeve.
2. Clean lamp sleeve and sleeve bolt using a soft,
lint-free cotton cloth and a chemical scale-remover
such as Lime-a-WayTM or CLRTM (follow
manufacturer’s directions). Alternatively, use spirit
vinegar or hydrofluoric acid followed by mild
detergent. Remove all traces of cleaning solution by
thoroughly rinsing.
Lamp Installation
1. Each lamp and sleeve comes with two new Orings.
Place the new O-rings and the original sleeve
bolt on the lamp sleeve. Caution: Do not lubricate
any of the O-rings.
2. Put the lamp completely into the sleeve. Maintain it
in that position and screw the sleeve bolt into the
lamp end until solidly hand-tight. Caution: Over
tightening will break the quartz lamp sleeve.
3. Carefully place the lamp/sleeve assembly into the
reactor, making sure it is centered. Apply pressure to
the assembly and screw it into the reactor until solidly
hand-tight. Caution: Over tightening will break the
quartz lamp sleeve.
4. Push the plug onto the end of the lamp while
ensuring that the male
tab on the lamp end meets with the female tab on the
plug.
5. Push the safety cap on while ensuring that the
grounding wires are
under the cap and not in the way of the tabs.
Restarting
1. Press and hold the push-button on UV controller.
2. Connect the power supply to the outlet while
continuing to press the push-button. The indicator
light will flash green.
3. Continue to hold the push-button until the indicator
light flashes red, then release immediately.
4. If timer does not reset, unplug power supply, wait
15 seconds and then repeat steps 1-3 of “Restarting”.
5. Enable adiabatic system (force adiabatic system
on). After system has filled, check for leaks.
5

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7. INVALIDATION OF GUARANTEE
Searle accepts no liability according to Searle's terms
and conditions of sale, or for loss or damage arising
as a result of:
(i) Failure to install, set up or put to work any part of
equipment in the manner specified in the I&M
instructions, or
(ii) Failure to maintain the equipment in the manner
specified in the I&M instructions, or
(iii) Replacement parts, additional parts or
accessories manufactured by persons other than
Searle having been incorporated into, or attached to
the equipment, or
(iv) The equipment having been adapted for use,
operated or used in such a way as does not conform
to Searle's recommendations.
8. SPARES LISTS
2HM4 Pump 1 Phase 291-400-007
2HM5 Pump 1 Phase 291-400-008
Strainer c/w Ball Valve 265-117-004
Spray Tip 301AF1.6-100 296-100-185
Spray Tip Filter 301AF1.6-100 296-100-186
Solenoid Valve 1/4” N/O 264-632-101
Solenoid Valve 1/2” N/C 264-632-100
Solenoid Coil 291-600-142
Trojan UV Max D C/W Volt Free Contacts
249-600-004
Replacement UV Bulb Trojan UV Max D
249-600-005
Replacement Quartz Sleeve Trojan UV Max D
249-600-006
Pressure Gauge 0-6 bar 265-115-002
Inline scale inhibitor (blue)- pre spring 2005
265-127-026
Inline magnetic scale inhibitor- post spring 2005
265-127-027
0-6 bar Pressure Regulator 266-104-001
Rapid Pipe Clamp (7/8”) 200-200-622
Restrictor 264-624-701
½” Non Return Valve 264-624-700
Pressure Switch 216-152-103
Millenium Controller 200-800-453
Pushfit 22mm Cu Straight Conn 261-152-206
Pushfit 22mm Cu Equal Tee 261-152-207
Pushfit 22mm Cu Elbow 261-152-208
Pushfit Release Tool 261-152-209
Number 272-000-012 Issue Sep05/02