04302024 - EVAPCO Cooling Tower OM Manual.pdf

OPERATION & MAINTENANCE

MANUALS

Letterkenny Army Depot Bldg 350 Dynamometer Closed Loop Cooling System

OPERATION & MAINTENANCE MANUALS

Letterkenny Army Depot LEAD Bldg 350 Dynamometer Closed Loop Cooling System

Table of Contents

1 Warranty Letter

2 Cooling Tower – Evapco 400HP

3 Variable Frequency Drive – Franklin Control System P Series

4 Pumps – Taco Vertical In-Line KV 1509

5 Expansion Tank – Taco CX-42-125

6 Air Control – Taco AC25F-125

7 Circuit Setter Flow Balancing Valve – Taco ACCU-FLO-250-AF-3

8 Multi-Purpose Valve – Taco MPV-015-4 for LIFE

Operation and Maintenance Instructions

FOR EVAPCO INDUCED DRAFT AND FORCED DRAFT CLOSED

CIRCUIT COOLERS AND EVAPORATIVE CONDENSERS

Bulletin 116D

For EVAPCO Authorized Parts and Service, Contact Your Local EVAPCO Representative or the Local Mr. GoodTower® Service Provider

ATC-E/eco-ATC/ ATWB/eco-ATW eco-ATWB-E ESWA/ESWB eco-LSWE

LSWE/LSC-E

eco-LRWB

LRWB/LRC

eco-ATWB-H PMC-E/eco-PMC

PMCQ/PMWQ

MTW/MTC

EVAPCO...SPECIALISTS IN HEAT TRANSFER PRODUCTS AND SERVICES.

Visit EVAPCO’s Website at: http://www.evapco.com

EVAPCO, Inc. — World Headquarters & Research/Development Center

EVAPCO, Inc. • P.O. Box 1300 • Westminster, MD 21158 USA PHONE: 410-756-2600 • FAX: 410-756-6450 • E-MAIL: marketing@evapco.com

EVAPCO, Inc.

World Headquarters P.O. Box 1300 Westminster, MD 21158 USA Phone: 410-756-2600 Fax: 410-756-6450 E-mail: marketing@evapco.com

EVAPCO Asia/Pacific

EVAPCO Asia/Pacific Headquarters 1159 Luoning Rd. Baoshan Industrial Zone Shanghai, P. R. China, Postal Code: 200949 Phone: (86) 21-6687-7786 Fax: (86) 21-6687-7008 E-mail: marketing@evapcochina.com

EVAPCO Europe

EVAPCO Europe BVBA European Headquarters Industrieterrein Oost 4010 3700 Tongeren, Belgium Phone: (32) 12-395029 Fax: (32) 12-238527 E-mail: evapco.europe@evapco.be

EVAPCO East 5151 Allendale Lane Taneytown, MD 21787 USA Phone: 410-756-2600 Fax: 410-756-6450 E-mail: marketing@evapco.com

EVAPCO Midwest 1723 York Road Greenup, IL 62428 USA Phone: 217-923-3431 Fax: 217-923-3300 E-mail: evapcomw@evapcomw.com

EVAPCO West 1900 West Almond Avenue Madera, CA 93637 USA Phone: 559-673-2207 Fax: 559-673-2378 E-mail: contact@evapcowest.com

EVAPCO Iowa 925 Quality Drive Lake View, IA 51450 USA Phone: 712-657-3223 Fax: 712-657-3226

EVAPCO Iowa Sales & Engineering 215 1st Street, NE P.O. Box 88 Medford, MN 55049 USA Phone: 507-446-8005 Fax: 507-446-8239 E-mail: evapcomn@evapcomn.com

EVAPCO Newton 701 East Jourdan Street Newton, IL 62448 USA Phone: 618-783-3433 Fax: 618-783-3499 E-mail: evapcomw@evapcomw.com

EVAPCOLD Manufacturing 521 Evapco Drive Greenup, Ill 62428 USA Phone: 217-923-3431 E-mail: evapcomw@evapcomw.com EVAPCO-BLCT Dry Cooling, Inc.

1011 US Highway 22 West Bridgewater, New Jersey 08807 USA Phone: 1-908-379-2665 E-mail: info@evapco-blct.com Refrigeration Valves & Systems Corporation A wholly owned subsidiary of EVAPCO, Inc.

1520 Crosswind Dr.

Bryan, TX 77808 USA Phone: 979-778-0095 Fax: 979-778-0030 E-mail: rvs@rvscorp.com EVAPCO Northwest 5775 S.W. Jean Road, Suite 210 Lake Oswego, Oregon 97035 USA Phone: 503-639-2137 Fax: 503-639-1800 EvapTech, Inc.

A wholly owned subsidiary of EVAPCO, Inc.

8331 Nieman Road Lenexa, KS 66214 USA Phone: 913-322-5165 Fax: 913-322-5166 E-mail: marketing@evaptech.com Tower Components, Inc.

A wholly owned subsidiary of EVAPCO, Inc.

5960 US HWY 64E

Ramseur, NC 27316 Phone: 336-824-2102 Fax: 336-824-2190 E-mail: mail@towercomponentsinc.com

EVAPCO Europe, S.r.l.

Via Ciro Menotti 10 I-20017 Passirana di Rho Milan, Italy Phone: (39) 02-939-9041 Fax: (39) 02-935-00840 E-mail: evapcoeurope@evapco.it

EVAPCO Europe, S.r.l.

Via Dosso 2 23020 Piateda Sondrio, Italy

EVAPCO Europe GmbH Meerbuscher Straße 64-78 Haus 5 40670 Meerbusch, Germany Phone: (49) 2159-69560 Fax: (49) 2159-695611 E-mail: info@evapco.de

Flex coil a/s A wholly owned subsidiary of EVAPCO, Inc.

Knøsgårdvej 115 DK-9440 Aabybro Denmark Phone: (45) 9824 4999 Fax: (45) 9824 4990 E-mail: info@flexcoil.dk

EVAPCO S.A. (Pty.) Ltd.

A licensed manufacturer of EVAPCO, Inc.

18 Quality Road Isando 1600 Republic of South Africa Phone: (27) 11-392-6630 Fax: (27) 11-392-6615 E-mail: evapco@evapco.co.za

Evap Egypt Engineering Industries Co.

A licensed manufacturer of EVAPCO, Inc.

5 El Nasr Road Nasr City, Cairo, Egypt Phone: 2 02 24022866 /2 02 24044997 Fax: 2 02 24044667/2 02 24044668 E-mail: Primacool@link.net / Shady@primacool.net

EVAPCO (Shanghai) Refrigeration Equipment Co., Ltd.

1159 Luoning Rd., Baoshan Industrial Zone Shanghai, P.R. China, Postal Code: 200949 Phone: (86) 21-6687-7786 Fax: (86) 21-6687-7008 E-mail: marketing@evapcochina.com

Beijing EVAPCO Refrigeration Equipment Co., Ltd.

No. 66 the 4th Block Yanxi Economic Development Zone Huairou District Beijing, P.R. China, Postal Code: 101407 Phone: (86) 10 6166-7238 Fax: (86) 10 6166-7395 E-mail: evapcobj@evapcochina.com

EVAPCO Australia (Pty.) Ltd.

34-42 Melbourne Road P.O. Box 436 Riverstone, N.S.W. Australia 2765 Phone: (61) 2 9627-3322 Fax: (61) 2 9627-1715 E-mail: sales@evapco.com.au

EVAPCO Composites Sdn. Bhd No. 70 (Lot 1289) Jalan Industri 2/3 Rawang Integrated Industrial Park Rawang, Selangor, 48000 Malaysia Phone: 60 3 6092-2209 Fax: 60 3 6092-2210

EvapTech Asia Pacific Sdn. Bhd A wholly owned subsidiary of EvapTech, Inc.

B-6-1, IOI Boulevard Jalan Kenari 5, Bandar Puchong Jaya 47170 Puchong, Selangor Darul Ehsan Malaysia Phone: (60-3) 8070-7255 Fax: (60-3) 8070-5731 E-mail: marketing-ap@evaptech.com

EVAPCO North America

EVAPCO South America EVAPCO Brasil Equipamentos Industriais Ltda.

Rua Alexandre Dumas, 1601 Conj. 13, 14, 14 – Edifício Stelvio Mazza 04717-004 São Paulo - Brazil Phone: (55) 19-5681-2000 for LIFE Operation and Maintenance Instructions

Table of Contents

Introduction Safety Precautions Terminology Initial Storage and/or Idle Period Recommendations International Building Code Provision Initial and Seasonal Start-Up Checklist

General Initial and Seasonal Start-Up Maintenance Checklist Seasonal Shut-Down Checklist

Basic Closed Circuit Cooler/Condenser Sequence of Operation Fan System

Fan Motor Bearings Fan Shaft Ball Bearings Fan Shaft Sleeve Bearings – (4’ wide LS units only) Fan Belt Adjustment Gear Drives eco-W/WE Air Inlet

Fan System – Capacity Control Fan Motor Cycling Sequence of Operation for Fan Motor Cycling Two-Speed Motors

Sequence of Operation for Two Fan Units with Two Speed Motors during Peak Load Variable Frequency Drives

Sequence of Operations / Guidelines for Multi-fan Units with a VFD during Peak Load eco-WE

Recirculated Water System – Routine Maintenance Suction Strainer in Cold Water Basin Cold Water Basin Operating Level of Water in Cold Water Basin Water Make Up Valve Pressurized Water Distribution Systems Bleed-Off Valve Pump (When Supplied)

Water Treatment and Water Chemistry Bleed or Blowdown Galvanized Steel – Passivation Water Chemistry Parameters Control of Biological Contamination Gray Water and Reclaimed Water Air Contamination

Cold Weather Operation Unit Layout Freeze Protection of Recirculating Water Freeze Protection of Closed Circuit Cooler Coils Unit Accessories

Cold Water Basin Heaters Remote Sumps for LIFEOperation and Maintenance Instructions

Electric Water Level Control Vibration Cut Out Switches

Capacity Control Methods for Cold Weather Operation Induced Draft Unit Capacity Control Forced Draft Unit Capacity Control

Ice Management Induced Draft Units Forced Draft Units

Troubleshooting Replacement Parts

Part Identification Drawings ATWB/eco-ATW 3’ Wide Units ATWB/eco-ATW 4’x4’ & 4’x6’ Wide Units ATC/ATWB/eco-ATW 4’x9’ & 4’x12’ Wide Units ATC-E/ATWB/eco-ATC/eco-ATW 8’ & 8.5’ Wide Units ATC-E/ATWB/eco-ATC/eco-ATW 10’ & 12’ Wide Units eco-ATWE 8.5’ Wide Units eco-ATWE 10’ Wide Units eco-ATWE 12’ Wide Units MTW & MTC 4’ Wide Units (4’ x 6’ & 4’ x 9’) MTW & MTC 8’ Wide Units MTW & MTC 10’ Wide Units MTW & MTC 12’ Wide Units ESWA 8.5’ Wide Units ESWA 12’ Wide Units ESWA 14’ Wide Units LSC-E/LSWE/eco-LSWE 4’ Wide Units LSC-E/LSWE/eco-LSWE 5’ Wide Units LSC-E/LSWE/eco-LSWE 8’ Wide Units (Single Side Fans) LSC-E/LSWE/eco-LSWE 10’ Wide Units LRC/LRWB 3’ Wide Units LRC/LRWB 5’ Wide Units LRC/LRWB 8’ Wide Units PMC-E 5’ Wide Units PMC-E/PMWQ 10’ and 12’ Wide Units Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57-59

Introduction

Congratulations on the purchase of your EVAPCO evaporative cooling unit. EVAPCO equipment is constructed of the highest quality materials and designed to provide years of reliable service when properly maintained.

Evaporative cooling equipment is often remotely located and periodic maintenance checks are often overlooked. It is important to establish a regular maintenance program and be sure that the program is followed. This bulletin should be used as a guide to establish a program. A clean and properly serviced unit will provide a long service life and operate at peak efficiency.

This bulletin includes recommended maintenance services for unit start up, unit operation and unit shutdown and the frequency of each. Please note: the recommendations of frequency of service are minimums. Services should be performed more often when operating conditions necessitate.

Become familiar with your evaporative cooling equipment. Refer to the isometric drawings located on pages 31-52 for information on the arrangement of components in your equipment.

If you should require any additional information about the operation or maintenance of this equipment, contact your local EVAPCO representative. You may also visit www.evapco.com or www.mrgoodtower.com for more information.

Safety Precautions

Qualified personnel should use proper care, procedures and tools when operating, maintaining or repairing this equipment in order to prevent personal injury and/or property damage. The warnings listed below are to be used as guidelines only.

WARNING: This equipment should never be operated without fan screens and access doors properly secured and in place.

WARNING: A lockable disconnect switch should be located within sight of the unit for each fan motor associated with this equipment. Before performing any type of service or inspection of the unit make certain that all power has been disconnected and locked in the “OFF” position.

WARNING: The top horizontal surface of any unit is not intended to be used as a working platform. No routine service work is required from this area.

WARNING: The recirculating water system may contain chemicals or biological contaminants including Legionella Pneumophila, which could be harmful if inhaled or ingested. Direct exposure to the discharge airstream and the associated drift generated during operation of the water distribution system and/or fans, or mists generated while cleaning components of the water system require respiratory protection equipment approved for such use by governmental occupational safety and health authorities.

Terminology

Throughout this manual, the terms “Induced Draft” and “Forced Draft” are used. Below is a list of EVAPCO Closed Circuit Cooler and Condenser products offerings and associated terminology.

Induced Draft equipment includes the following Evapco Product Models:

� ES Product Lines

• ESWA - Closed Circuit Cooler

• ESWB - Closed Circuit Cooler

� AT Product Lines

• ATWB - Closed Circuit Cooler

• ATC-E - Evaporative Condenser

� MT Product Lines

• MTW - Closed Circuit Cooler

• MTC - Evaporative Condenser

� Containerized Product Lines

• CATWB - Closed Circuit Cooler

• CATC - Evaporative Condenser

� eco Product Line

• eco-ATW - Closed Circuit Cooler

• eco-ATWE - Wet/Dry Closed Circuit Cooler

• eco-ATWB-H - Wet/Dry Closed Circuit Cooler

• eco-ATC - Wet/Dry Evaporative Condenser

Forced Draft equipment includes the following Evapco Product Models:

� LR Product Lines

• LRWB - Closed Circuit Cooler

• LRC - Evaporative Condenser

� LS Product Lines

• LSWE - Closed Circuit Cooler

• LSC-E - Evaporative Condenser

� PM Product lines

• PMC-E - Evaporative Condenser

• PMC-EQ - Evaporative Condenser

• PMWQ - Closed Circuit Cooler

Initial Storage and/or Idle Period Recommendations

If the unit will sit for idle periods of time it is recommended that the following be performed in addition to all component manufacturers recommended maintenance instructions.

• The fan/motor/pump bearings and motor bearings need to be turned by hand at least once a month. This can be accomplished by tagging and locking out the unit’s disconnect, grasping the fan assembly (or removing the pump motor fan guard), and rotating it several turns.

• If unit sits longer than a few weeks, run gear reducer (if equipped) for 5 minutes weekly.

• If unit sits longer than 3 weeks, completely fill gear reducer with oil. Drain to normal level prior to running.

• If unit sits longer than one month, insulation test motor windings semi-annually.

• If fan motor sits idle for at least 24 hours while the spray pumps are energized distributing water over the coil, motor space heaters (if equipped) should be energized. Alternatively, fan motors may be energized for 10 minutes, twice daily, to drive any moisture condensation out of the motor windings.

International Building Code Provisions

The International Building Code (IBC) is a comprehensive set of regulations addressing the structural design and installation requirements for building systems – including HVAC and industrial refrigeration equipment. The code provisions require that evaporative cooling equipment and all other components permanently installed on a structure must meet the same seismic design criteria as the building.

All items attached to Evapco Closed Circuit Coolers or Evaporative Condensers must be independently reviewed and isolated to meet applicable wind and seismic loads. This includes piping, ductwork, conduit, and electrical connections. These items must be flexibly attached to the Evapco unit so as not to transmit additional loads to the equipment as a result of seismic or wind forces.

Initial and Seasonal Start-Up Checklist

General

1. Verify that the overall installation reflects the requirements of the installation guidelines found in EVAPCO Bulletin 311 –

Equipment Layout Manual available at www.evapco.com.

2. For multi-speed fan motors, verify that 30 second or greater time delays are provided for speed changes when switching from high to low speed. Also check to see if interlocks are provided to prevent simultaneously energizing high and low speed, and confirm both speeds operate in the same direction.

3. Verify all safety interlocks work properly.

4. For units operating with a variable frequency drive, make certain that minimum speed requirements have been set. Check with VFD manufacturer for recommended minimum speeds. Check with VFD manufacturer for recommendations on locking out resonance frequencies. See “Fan System Capacity Control” section for more information.

5. Verify that a water treatment plan has been implemented including passivation of galvanized steel units. See “Water Treatment” section for more details.

6. If the unit is going to sit idle for an extended period of time, follow all manufacturers’ fan motor and pump instructions for long term storage. Plastic sheets or tarps should never be used to protect a unit during storage. This practice can trap heat inside the unit, and could potentially cause damage to plastic components. See your local EVAPCO representative for additional information on unit storage.

7. For units subject to freezing climates, high humidity climates, or idle periods lasting 24 hours or more, motor space heaters are suggested and (if equipped) should be energized. Alternatively, fan motors may be energized for 10 minutes, twice daily, to drive any moisture condensation out of the motor windings.

BEFORE BEGINNING ANY MAINTENANCE, BE CERTAIN THAT THE POWER IS TURNED OFF

AND THE UNIT IS PROPERLY LOCKED AND TAGGED OUT!

Initial and Seasonal Start-Up

1. Clean and remove any debris, such as leaves and dirt from the air inlets.

2. Flush the cold water basin (with the strainer screens in place) to remove any sediment or dirt.

3. Remove the strainer screen, clean and reinstall.

4. Check mechanical float valve to see if it operates freely.

5. Inspect water distribution system nozzles and clean as required. Check for proper orientation.

(This is not required at initial start-up. The nozzles are clean and set at the factory).

6. Check to ensure drift eliminators are securely in place and in the proper orientation.

7. Adjust fan belt tension as required. See “Fan Belt Adjustment” section.

8. Lubricate fan shaft bearings prior to seasonal start-up.

9. Turn the fan(s) and pumps by hand to insure it turns freely without obstructions.

10. Visually inspect the fan blades. Blade clearance should be approximately 3/8” (1/4” minimum) from tip of blade to the fan cowl.

The fan blades should be securely tightened to the fan hub.

11. If any stagnant water remains in the system including “dead legs” in the piping, the unit must be disinfected prior to the fans being energized. Please refer to ASHRAE Guideline 12-2000 and CTI Guideline WTP-148 for more information.

12. Manually fill the cold water basin up to the overflow connection.

13. For closed circuit coolers, fill the heat exchanger coil with the specified fluid and “burp” air from the system before pressurizing, using vents on coil inlets. Do not do this for evaporative condensers.

For eco-WE & eco-W with optional controls, see controls O&M for proper start up procedure.

After the unit has been energized, check the following:

1. Adjust mechanical float valve as required to the proper water level.

2. Unit basin should be filled to the proper operating level. See “Recirculating Water System Operating Levels” section for more details.

3. Verify fan is rotating in proper direction.

4. Start the spray water pump and check for proper rotation as indicated by the arrow on the front cover.

5. Measure voltage and current on all three power leads of pump and fan motor. The current should not exceed the motor nameplate full load amp rating taking the service factor into account.

6. Adjust bleed valve to proper flow rate. Maximum bleed off is 3 US GPM per 100 tons. Consult your qualified water treatment person to fine tune the minimum bleed necessary.

7. See fan and pump motor manufacturer maintenance and long term storage instructions for more detailed information. The motors should be lubricated and serviced in accordance with manufacturer’s instructions.

8. All new evaporative cooling equipment and associated piping should be pre-cleaned and flushed to remove grease, oil, dirt, debris and other suspended solids prior to operation. Any pre-cleaning chemistry should be compatible with the cooling equipment’s materials of construction. Alkaline formulations should be avoided for systems which include galvanized materials of construction.

Closed hydronic systems connected to either a closed-circuit cooler or dry cooler should be pre-cleaned and flushed to remove debris, grease, flash rust, oil, and other suspended solids prior to operation. Evapco recommends the use of inhibitor chemistry or inhibited glycol to minimize corrosion and scale during normal operation.

PROCEDURE

1. Clean pan strainer – monthly or as needed

2. Clean and flush pan* – quarterly or as needed

3. Check bleed-off valve to make sure it is operative – monthly

4. Lubricate pump and pump motor according to manufacturer’s instructions

5. Check operating level in pan and adjust float valve if necessary – monthly

6. Check water distribution system and spray pattern – monthly

7. Check drift eliminators – quarterly

8. Check the fan blades for cracks, missing balancing weights, and vibrations – quarterly

9. Lubricate fan shaft bearings – every 1000 hours of operation or every three months

10. Lubricate fan motor bearings – see mfg’s instructions. Typically for non-sealed bearings, every 2-3 years

11. Check belt tension and adjust – monthly

12. Inspect and grease sliding motor base – annually or as needed

13. Check fan screens, inlet louvers, fans and dry cooler coil (eco-ATC, eco-ATW, eco-ATWE).

Remove any dirt or debris – monthly

14. Inspect and clean protective finish – annually

- Galvanized: scrape and coat with ZRC

- Stainless: clean and polish with a stainless steel cleaner.

15. Check water quality for biological contamination.

Clean unit as needed and contact a water treatment company for recommended water treatment program* – regularly

1. Gear Reducer – Check oil level with unit stopped – 24 hours after start-up & monthly

2. Gear Reducer/Piping – Do visual inspection for oil leaks, auditory inspection for unusual noises and vibrations – monthly

3. Gear Reducer – Replace oil – semi-annually

4. Oil Pump – Do visual inspection for leaks and proper wiring – monthly

5. Gear Reducer/Coupling – Check alignment of the system – 24 hours after start-up & monthly

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

OPTIONAL ACCESSORIES:

MAINTENANCE

CHECKLIST

* Evaporative cooling equipment must be cleaned on a regular basis to prevent the growth of bacteria including Legionella Pneumophila.

1. Two or more Days: Energize motor space heaters or run motors for 10 minutes twice daily

2. Few Weeks: Run gear reducer for 5 minutes

– weekly

3. Several Weeks: Completely fill gear reducer with oil. Drain to normal level prior to running.

4. One Month or longer: Rotate motor shaft/fan 10 turns – bi-weekly

5. One Month or longer: Megger test motor windings – semi-annually for LIFEOperation and Maintenance Instructions

OPTIONAL ACCESSORIES:

6. Coupling/Shaft – Inspect flex elements and hardware for tightness, proper torque & crack/deterioration – monthly

7. Heater Controller – Inspect controller and clean probe ends – quarterly

8. Heater – Inspect junction box for loose wiring and moisture – one month after start-up and semi-annually

9. Heater – Inspect elements for scale build-up – quarterly

10. Electronic Water Level Controller – Inspect junction box for loose wiring and moisture – semi-annually

11. Electronic Water Level Controller – Clean probe ends of scale build-up – quarterly

12. Electronic Water Level Controller –Clean inside the standpipe – annually

13. Solenoid Make-up Valve – Inspect and clean valve of debris – as needed

14. Vibration Switch (mechanical) – Inspect enclosure for loose wiring and moisture – one month after start-up and monthly

15. Vibration Switch – Adjust the sensitivity – during start-up and annually

16. Sump Sweeper Piping – Inspect and clean piping of debris – semi-annually

17. Water Level Indicator – Inspect and clean – annually

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

DURING IDLE PERIODS:

MAINTENANCE

CHECKLIST

Seasonal Shut-Down Checklist

When the system is to be shut down for an extended period of time, the following services should be performed.

1. The evaporative cooling unit cold water basin should be drained

2. The cold water basin should be flushed and cleaned with the suction strainer screens in place.

3. The suction strainer screens should be cleaned and re-installed.

4. The cold water basin drain should be left open.

5. The fan shaft bearings and motor base adjusting screws should be lubricated. This should also be performed if the unit is going to sit idle prior to initial start-up.

6. The make-up water supply, overflow and drain lines, as well as the recirculating pump and pump piping up to the overflow level must be heat traced and insulated to account for any residual water.

7. The finish of the unit should be inspected. Clean and refinish as required.

8. The fan, motor and pump bearings need to be turned at least once a month by hand. This can be accomplished by making sure the unit’s disconnect is tagged and locked out, and grasping the fan assembly, rotating it several turns.

9. Closed Circuit Coolers only - If the recommended minimum fluid flows thru the heat transfer coil cannot be maintained, and an anti-freeze solution is not in the coil, the coil must be drained immediately whenever the system pumps are shut down or flow stops during freezing conditions. This is accomplished by having automatic drain valves and air vents in the piping to and from the cooler. Care must be taken to ensure that the piping is adequately insulated and sized to allow the water to flow quickly from the coil. This method of protection should be used only in emergency situations and is neither a practical nor recommended method of freeze protection. Coils should not be drained for an extended period of time, as internal corrosion may occur. See Cold Weather Operation section of this document for more details.

See fan and pump manufacturer maintenance and long term storage instructions for more detailed instructions.

Basic Closed Circuit Cooler/Condenser Sequence of Operation

Note: The eco-ATW/eco-ATWE sequence of operation is unique and is explained in detail in the Sage2, Sage3 Panel Control Manual.

System Off / No Load

The system pumps and fans are off. If the basin is full of water a minimum basin water temperature of 40ºF must be maintained to prevent freezing. This can be accomplished with the use of optional basin heaters. See the “Cold Weather Operation” section of this bulletin for more details on cold weather operation and maintenance.

System/Condensing Temperature Rises

The recirculation pump turns on. The unit will provide approximately 10% cooling capacity with only the pump running. If the unit has positive closure dampers they should be fully opened before the pumps turn on.

If the system temperature continues to rise, the unit fan is cycled on. For a variable speed controller, the fans are turned on to minimum speed. See the “Fan System – Capacity Control” section of this bulletin for more details on fan speed control options. If the system temperature continues to rise, then the fan speed is increased as required, up to full speed.

Note: During sub-freezing weather the minimum recommended speed for variable speed controllers is 50%. ALL FANS IN OPERATING CELLS OF MULTIPLE CELL UNITS MUST BE CONTROLLED TOGETHER TO PREVENT ICING ON THE FANS.

System Temperature Stabilizes

Control the leaving fluid temperature (closed circuit coolers) or condensing temperature (evaporative condensers) by modulating the fan speeds with variable speed drives or by cycling fans on and off with single or two-speed drives.

System/Condensing Temperature Drops

Decrease the fan speed, as required.

System Off / No Load

The system pump turns off. The starter interlock will energize any optional basin heaters in cold weather.

The recirculation pump should not be used as a means of capacity control, and should not be cycled frequently. Excessive cycling can lead to scale build-up, and reduce wet and dry performance.

Dry Operation

During colder winter months it is possible to turn off the spray pump, drain the cold water basin, and just cycle the fans. Be sure to leave the basin drain open during this time to prevent collection of rain water, snow, etc. If the unit has positive closure dampers they should be fully opened before the fans turn on. If this method will be used on a centrifugal fan, forced draft unit, be sure to verify that the motor and drives have been properly sized to handle the reduction in static pressure experienced when the spray water is turned off.

NOTE: MINIMUM CONTROL POINT FOR PROCESS FLUID SHOULD NEVER BE LOWER THAN 42º F.

NOTE: WHEN A UNIT IS PROVIDED WITH A DISCHARGE DAMPER ASSEMBLY, THE CONTROL SEQUENCE SHOULD CYCLE THE DAMPERS OPEN AND CLOSED ONCE A DAY REGARDLESS OF CAPACITY REQUIRMENTS TO PREVENT THE ASSEMBLY FROM SEIZING. THE FAN MOTOR SHOULD BE SHUT OFF WHENEVER THE DAMPERS ARE CLOSED.

Fan System

The fan systems of both centrifugal and axial driven units are rugged; however, the fan system must be checked regularly and lubricated at the proper intervals. The following maintenance schedule is recommended.

Fan Motor Bearings

EVAPCO evaporative cooling units use either a T.E.A.O. (Totally Enclosed Air Over) or a T.E.F.C. (Totally Enclosed Fan Cooled) fan motor. These motors are built to “Cooling Tower Duty” specifications. They are supplied with permanently lubricated bearings and special moisture protection on the bearings, shaft and windings. After extended shut-downs, the motor should be checked with an insulation tester prior to restarting the motor.

Fan Shaft Ball Bearings

For induced draft units, lubricate the fan shaft bearings every 1,000 hours of operation or every three months. For forced draft units, lubricate the fan shaft bearings every 2,000 hours of operation or every six months. Use any of the following synthetic waterproof, polyurea inhibited greases which are suitable for operation between -20°F and 350°F. (For colder operating temperatures, contact the factory).

Mobil – Polyrex EM Chevron - SRI Timken Pillowblock Grease

Feed grease slowly into the bearings or the seals may be damaged. A hand grease gun is recommended for this process.

When introducing new grease, all grease should be purged from the bearings.

Most EVAPCO units are supplied with extended grease lines to allow easy lubrication of the fan shaft bearings as shown in Table 1.

Fan Shaft Sleeve Bearings – (4’ wide LS units only)

Lubricate the intermediate sleeve bearing(s) before unit start up. The reservoir should be checked several times during the first week to ensure that the oil reserve is brought to full capacity. After the first week of operation, lubricate the bearing(s) every 1,000 hours of operation or every three months (whichever occurs first). High temperatures or poor environmental conditions may necessitate more frequent lubrication. The oil reservoir consists of a large felt packed cavity within the bearing housing. It is not necessary to maintain the oil level within the filler cup.

Use one of the following industrial grade, non-detergent mineral oils. Do not use a detergent based oil or oils designated heavy duty or compounded. Different oils may be required when operating at temperatures below 30°F continuously. Table 2 provides a short list of approved lubricants for each temperature range. Most automotive oils are detergent based and may not be used.

Detergent oils will remove the graphite in the bearing sleeve and cause bearing failure.

All bearings used on EVAPCO equipment are factory adjusted and self aligning. Do not disturb bearing alignment by tightening the sleeve bearing caps.

Oil drippage may result from over-oiling or from using too light of an oil. Should this condition persist with correct oiling, it is recommended that a heavier weight oil be used.

Fan Belt Adjustment

The fan belt tension should be checked at start up and again after the first 24 hours of operation to correct for any initial stretch. To properly adjust the belt tension, position the fan motor so that the fan belt will deflect approximately 3/8” when moderate pressure is applied midway between the sheaves. Figure 1 and Figure 2 show two ways to measure this deflection. Belt tension should be checked on a monthly basis. A properly tensioned belt will not “chirp” or “squeal” when the fan motor is started.

Table 1 – Location of Grease Lube Line Fittings for Belt Driven Units

Unit Description Location of Lube Line Fittings

Induced Draft Units (Except MTW/MTC): Located just beside the fan casing 3’, 4’, 8’, 8.5’, 17’ wide access door

Induced Draft Units (Except MTW/MTC): Located inside the fan casing 10’, 12’, 14’, 24’, 28’ wide access door

Forced Draft Units Located on the bearing support or on the side of the unit

MTW/MTC Internally Mounted Motors Direct Drive. No bearing to lube

MTW/MTC Externally Mounted Motors Motor adjustment plate

Ambient Temp Texaco Mobil Exxon

30°F to 100°F Regal R&O 220 DTE Oil BB Teresstic 220

-25°F to 30°F Capella WF 32 DTE Heavy ------------------

Table 2 – Sleeve Bearing Lubricants

Figure 1 – Method 1 Figure 2 – Method 2

On induced draft belt driven units provided with externally mounted motors (3, 4, 8, 8.5 and 17 foot wide units) and LS, PM and MT Style forced draft units, both J-type adjustment bolts on the adjustable motor base should have an equal amount of exposed thread for proper sheave and belt alignment. See Figures 3, 4 & 7.

Figure 3 – Externally Mounted Motor, Induced Draft Figure 4 – Externally Mounted Motor, Large LS Units

Figure 5 – Internally Mounted Motor, Induced Draft

On induced draft belt driven units with internally mounted motors (10, 12, 14, 20, 24 and 28 foot wide units) and LR units, a motor adjustment tool is provided on the adjustment nut. See Figures 5 and 6. To use, place the hex end over the adjustment nut and tension the belt by turning the nut counterclockwise. When the belts are properly tensioned, tighten the lock nut.

Direct drive units do not require any adjustment.

Figure 6 – LR Motor Adjustment

Figure 7 – Externally Mounted Motor, MT Units

Gear Drives

Induced draft units with gear drive systems require special maintenance. Please refer to the gear manufacturers recommended maintenance instructions. These will be enclosed and shipped with the unit.

Air Inlet

Inspect the air inlet louvers (induced draft units) or fan screens (forced draft units) monthly to remove any paper, leaves or other debris that may be blocking airflow into the unit.

Fan System — Capacity Control

There are several methods for capacity control of the evaporative cooling unit. Methods include: Fan motor cycling, the use of two speed motors, and the use of variable frequency drives (VFD’s).

Note: for the eco-ATW with Sage2 and eco-ATWE with Sage3 consult the manual.

Fan Motor Cycling

Fan Motor Cycling requires the use of a single stage thermostat which senses the fluid temperature (closed circuit coolers) or condensing temperature (evaporative condensers). The contacts of the thermostat are wired in series with the fan motor’s starter holding coil.

Sequence of Operation for Fan Motor Cycling

Fan Motor Cycling is often found to be inadequate where the load has a wide fluctuation. In this method, there are only two stable levels of performance: 100% of capacity when the fan is on, and approximately 10% of capacity when the fan is off. Please note that rapid cycling of the fan motors can cause the fan motor to overheat. Controls should be set to only allow a maximum of six start/stop cycles per hour. The recirculation pump may not be used as a means of capacity control and should not be cycled frequently. Excessive cycling can lead to scale build-up, resulting in reduced wet and dry performance.

Two Speed Motors

The use of a two-speed motor provides an additional step of capacity control when used with the fan cycling method. The low speed of the motor will provide approximately 60% of full speed capacity.

Two-speed capacity control systems require not only a two-speed motor, but also a two-stage thermostat and the proper two-speed motor starter. The most common two-speed motor is a single winding type. This is also known as a consequent pole design. Two-speed two-winding motors are also available. All multi-speed motors used in evaporative cooling units should be variable torque design.

It is important to note that when two-speed motors are to be used, the motor starter controls must be equipped with a decelerating time delay relay. The time delay should be a minimum of 30 seconds when switching from high speed to low speed.

Sequence of Operation for Two Cell Units with Two Speed Motors during Peak Load

For eco-ATWE, see Sage2/Sage3 control Panel O&M

1. Both fan motors off – Pump running on one cell.

2. Both fan motors off – Pump running on both cells.

3. One fan motor on low speed, one fan motor off – Pump running on both cells.

4. Both fan motors on low speed – Pump running on both cells.

5. One fan motor on high speed, one fan motor on low speed – Pump running on both cells.

6. Both fan motors on full speed – Pump running on both cells.

Variable Frequency Drives

The use of a variable frequency drive (VFD) provides the most precise method of capacity control. A VFD is a device that converts a fixed AC voltage and frequency into an adjustable AC voltage and frequency used to control the speed of an AC motor. By adjusting the voltage and frequency, the AC induction motor can operate at many different speeds.

The use of VFD technology can benefit the life of the mechanical components with fewer and smoother motor starts and built-in motor diagnostics. VFD technology has particular benefit on evaporative cooling units operating in cold climates where airflow can be modulated to minimize icing and reversed at low speed for de-icing cycles. Applications using a VFD for capacity control must also use an inverter duty motor built in compliance with NEMA standard MG-1. This is an available option from EVAPCO.

NOTE: VFD's should not be used on pump motors. The pumps are designed to be operated at full speed and are not intended to be used as capacity control.

The type of motor, manufacturer of the VFD, motor lead lengths (between the motor and the VFD), conduit runs and grounding can dramatically affect the response and life of the motor. Select a high quality VFD that is compatible with the fan motor(s) in the EVAPCO unit(s). Many variables in the VFD configuration and installation can affect motor and VFD performance. Two particularly important parameters to consider when choosing and installing a VFD are switching frequency and the distance between the motor and VFD often referred to as lead length. Consult the VFD manufacturer’s recommendations for proper installation and configuration. The motor lead length restrictions can vary with the vendor. Regardless of motor supplier, minimizing lead length between the motor and drive is good practice.

Sequence of Operations / Guidelines for Multi-fan Units with a VFD during Peak Load

For eco-WE, see Sage2/Sage3 control Panel O&M

1. Both fan motors off – Pump running on one cell.

2. Both fan motors off – Pump running on both cells.

3. Both VFDs turn on at the manufacturer’s recommended minimum operating speed (20-25%) – Pump running on both cells.

4. Both VFDs speed up uniformly (they should be synchronized on start-up) – Pump running on both cells.

5. Both VFDs are on full speed – Pump running on both cells.

Note: the VFDs need to have a pre-set shutoff to prevent water temperatures from becoming too cold and to prevent the drive from trying to turn the fan at near zero speed. Operating below 25% of motor speed achieves very little return in fan energy savings and capacity control. Check with your VFD supplier if operating below 25% is possible.

For more details on the use of variable frequency drives, please download a copy of EVAPCO’s Engineering Bulletin 39 from www.evapco.com.

Recirculated Water System – Routine Maintenance

Suction Strainer in Cold Water Basin

The pan strainer as shown in Figures 8, 9, 10, 11, 12 and 13 should be removed and cleaned monthly or as often as necessary.

The suction strainer is the first line of defense in keeping debris out of the system. Make certain that the strainer is properly located over the pump suction, alongside the anti-vortexing hood.

Cold Water Basin

The cold water basin should be flushed out quarterly, and checked monthly or more often if necessary, to remove any accumulation of dirt or sediment which normally collects in the basin. Sediment can become corrosive and cause deterioration of basin materials.

When flushing the basin, it is important to keep the suction strainers in place to prevent any sediment from entering the system.

After the basin has been cleaned, the strainers should be removed and cleaned before refilling the basin with fresh water.

ANTI-VORTEXING

HOOD

ANTI-VORTEXING

HOOD

STRAINER

HANDLE

STRAINER

HANDLE

STRAINER

ASSEMBLY

STRAINER

ASSEMBLY

STRAINER

ASSEMBLY

ANTI-VORTEXING

HOOD

STRAINER

HANDLE

ANTI-VORTEXING

HOOD

STRAINER

HANDLE

STRAINER

ASSEMBLY

Figure 8 – Single Strainer Assembly Figure 9 – Dual Strainer Assembly

Figure 10 – LSWB/LSC-E/PMC-E/PMWQ Strainer Assembly

Figure 12 – MTW/C Strainer Assembly V-Sump Figure 13 – MTW/C Strainer Assembly Depressed Sump

Figure 11 – LRWB/LRC Strainer Assembly

At initial start up or after the unit has been drained, the unit must be filled to the overflow level. Overflow is above the normal operating level and accommodates the volume of water normally in suspension in the water distribution system and the riser piping.

The water level should always be above the strainer. Check by running the pump with the fan motors off and observing the water level through the access door or remove the air inlet louver.

Water Make Up Valve

A mechanical float valve assembly is provided as standard equipment on the evaporative cooling unit (unless the unit has been ordered with an optional electronic water level control package or the unit is arranged for remote sump operation). The make up valve is easily accessible from outside the unit through the access door or removable air inlet louver. The make up valve is a bronze valve connected to a float arm assembly and is activated by a large foam filled plastic float. The float is mounted on an all-thread rod held in place by wing nuts. The water level in the basin is adjusted by repositioning the float and all-thread using the wing nuts. Refer to Figure 14 for details.

ADJUSTMENT

WINGNUTS

FLOAT ARM

FLOAT BALL

MAKE-UP

VALVE

Figure 14 – Mechanical Water Make Up Valve for LIFEOperation and Maintenance Instructions

Table 3 - Recommended Operating Water Level

Evaporative Condenser Closed Circuit Cooler Operating Model Number Footprint Water Level*

ATC-E & eco-ATC Products ATWB, eco-ATW & eco-ATWE Products 50E to 165E 3’ and 4’ wide units** 9”

187E to 3714E 8.5’ wide thru 24’ wide 11” eco-ATC Products 176 to 4068 8.5’ wide thru 24’ wide 11”

CATC Products CATW Products 181 to 504 7.5’ wide units 11”

MTC Products MTW Products 47 to 206 4-3FG to 8-5J8 4” †

222 to 487 10-3G10 to 12-6N12 4” †

LRC Products LRWB Products 25 to 379 3’ wide thru 8’ wide units 8"

LSC-E Products LSW Products 36 to 170 4’x6’ thru 4’x12’ 11”

185 to 385 5.5’x12’, 5.5’x18’ 11” 400 to 515, 800 to 1030 8’x12’, 8’x24’, 10’x12’, 10’x24’ 12” 550 to 805, 1100 to 1610 8’x18’, 8’x36’, 10’x18’, 10’x36’ 15”

— Dual Fan Sided Units 12”

— 8’x12’, 8’x24’ 12”

— 8’x18’, 8’x36’ 15”

PMC-E Products PMWQ Products 175E to 375E – 10”

332E to 1985E 10’ and 12’ wide units 14”

— ESWB Products 8.5’ wide and 2.4M wide 9”

12’ wide 10”

– ESWA Products 8.5’ wide thru 14’ wide units 11”

Operating Level of Water in Cold Water Basin

The operating level should be checked monthly to make sure the water level is correct. Refer to Table 3 for unit specific levels.

* Measured from lowest point on basin floor.

** Not available on eco-ATWE.

† Measured from the overflow.

for LIFE General Information - Start-up & Maintenance

-The make up valve assembly should be inspected monthly and adjusted as required. The valve should be inspected annually for leakage and if necessary, the valve seat should be replaced. The make up water pressure for the mechanical valve should be maintained between 20 and 50 PSIG.

Pressurized Water Distribution Systems

Check the water distribution system monthly to make sure it is operating properly. Always check the spray system with the pump on and the fans off. On forced draft models, remove one or two eliminator sections from the top of the unit and observe the operation of the water distribution system. On induced draft models, lifting handles are provided along the top layer of eliminators.

Eliminators can be easily removed from the access door and the distribution system observed. The diffusers are essentially non-clogging and should seldom need cleaning or maintenance.

If the water diffusers are not functioning properly, it is a sign that the pan or system strainer has not been working properly and that foreign matter or dirt has accumulated in the water distribution pipes. The nozzles can be cleared by taking a small pointed probe and moving it rapidly back and forth in the diffuser opening.

If an extreme build-up of dirt or foreign matter occurs, remove the end cap in each branch to flush the debris from the header pipe.

The branches or header can be removed for cleaning, but do so only if necessary. Check the strainer in the pan to make sure it is in good condition and positioned properly so that cavitation or air entrainment does not occur.

All Evaporative Condensers and Closed Circuit Coolers, except the ESWA Closed Circuit Cooler, are supplied with ZMII® spray nozzles as standard. The ZMII® spray nozzles do not need to be oriented a specific way to achieve proper coil coverage. Figure 13 shows the standard orientation of the ZMII® spray nozzles.

Figure 15 – ZMII® Spray Nozzle Orientation All Coil Products except the ESWA

THREADED END CAP

Figure 16 – Proper Water Diffuser Orientation (2A Nozzles) ESWA Models (Except 14’ Wide Models)

For the ESWA, wide orifice water diffusers are supplied. When inspecting and cleaning the water distribution system, always check that the orientation of the water diffusers is correct as shown in Figures 16 and 17. For EvapJet nozzles, make sure that the top edge of the “EVAPCO” logo is parallel to the top of the water distribution pipe.

THREADED END CAP

Figure 17 – Proper Water Diffuser Orientation (EvapJet) ESWA 14’ Wide Models

Bleed-Off Valve

The bleed-off valve, whether factory or field installed, must be checked weekly to make sure it is functioning and set properly. Keep the bleed-off valve wide open unless it has been determined that it can be set partially open without causing scaling or corrosion.

Pump (When Supplied)

The pump and pump motor should be lubricated and serviced in accordance with the pump manufacturer’s instructions as supplied with the unit. The recirculation pump should not be used as a means of capacity control, used with a VFD or be cycled frequently.

Excessive cycling can lead to scale build-up, and reduce wet and dry performance. On 14' wide ESWA's, which are supplied with two pumps per cell, both pumps should be energized at the same time. One pump should not be on while the other pump is off.

Note: for the eco-ATWE, please consult the Sage2 and Sage3 manual.

The pump motor fan and impeller should be turned by hand if the pump assembly sits idle.

Water Treatment and Water Chemistry

Proper water treatment is an essential part of the maintenance required for evaporative cooling equipment. A well designed and consistently implemented water treatment program will help to ensure efficient system operation while maximizing the equipment’s service life. A qualified water treatment company should design a site specific water treatment protocol based on equipment (including all metallurgies in the cooling system), location, makeup water quality, and usage.

Bleed or Blowdown

Evaporative cooling equipment rejects heat by evaporating a portion of the recirculated water into the atmosphere as warm, saturated discharge air. As the pure water evaporates it leaves behind the impurities found in the system’s makeup water and any accumulated airborne contaminants. These impurities and contaminants, which continue to recirculate in the system, must be controlled to avoid excessive concentration which can lead to corrosion, scale, or biological fouling.

Evaporative cooling equipment requires a bleed or blowdown line, located on the discharge side of the recirculating pump, to remove concentrated (cycled up) water from the system. EVAPCO recommends an automated conductivity controller to maximize the water efficiency of your system. Based on recommendations from the water treatment company, the conductivity controller should open and close a motorized ball or solenoid valve to maintain the conductivity of the recirculating water. If a manual valve is used to control the rate of bleed it should be set to maintain the conductivity of the recirculating water during periods of peak load at the maximum level recommended by the water treatment company.

Galvanized Steel – Passivation

‘White Rust’ is a premature failure of the protective zinc layer on hot dip or mill galvanized steel which can occur as a result of improper water treatment control during the start-up of new galvanized equipment. The initial commissioning and passivation period is a critical time for maximizing the service life of galvanized equipment. EVAPCO recommends that the site specific water treatment protocol includes a passivation procedure which details water chemistry, any necessary chemical addition, and visual inspections during the first six (6) to twelve (12) weeks of operation. During this passivation period, recirculating water pH should be maintained above 7.0 and below 8.0 at all times. Since elevated temperatures have a harmful effect on the passivation process, the new galvanized equipment should be run without load for as much of the passivation period as is practical.

The following water chemistry promotes the formation of white rust and should be avoided during the passivation period:

1. pH values in the recirculating water greater than 8.3.

2. Calcium hardness (as CaCO3) less than 50 ppm in the recirculating water.

3. Anions of chlorides or sulfates greater than 250 ppm in the recirculating water.

4. Alkalinity greater than 300 ppm in the recirculating water regardless of pH value.

Changes in water chemistry control may be considered after the passivation process is complete as evidenced by the galvanized surfaces taking on a dull gray color. Any changes to the treatment program or control limits should be made slowly, in stages while documenting the impact of the changes on the passivated zinc surfaces.

• Operating galvanized evaporative cooling equipment with a water pH below 6.0 for any period may cause removal of the protective zinc coating.

• Operating galvanized evaporative cooling equipment with a water pH above 9.0 for any period may destabilize the passivated surface and create white rust.

• Re-passivation may be required at any time in the service life of the equipment if an upset condition occurs which destabilizes the passivated zinc surface.

For more information on passivation and white rust, please download a copy of EVAPCO’s Engineering Bulletin 36 at www.evapco.com.

Water Chemistry Parameters

The water treatment program designed for evaporative cooling equipment must be compatible with the unit’s…