Summary of Contents for Reymsa HFC Series
- Page 1 All-Fiberglass Cooling Towers Installation, Operation & Maintenance Manual Closed Circuit Fluid Cooler Standard & Low Sound Fans Series...
- Page 3 The following manual has been prepared to support our customers with the installation and maintenance process of the “state of the art” Closed Circuit Fluid Cooler HFC Series. Our Installation, Operation & Maintenance manual (IOM) has been written and reviewed by our engineering department based on theoretical knowledge and practical experience.
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Page 4: Table Of Contents
D.7. SPRAY PUMP D.8. COPPER COIL UNIT E. TROUBLE-SHOOTING APPENDIX A: EXAMPLE OF STRUCTURAL BASE FOR A REYMSA CLOSED CIRCUIT FLUID COOLER APPENDIX B: EXAMPLES OF ACCESSORIES ASSEMBLY INSTRUCTIONS APPENDIX C: MINIMUM DISTANCE BETWEEN TOWERS AND OBSTRUCTIONS APPENDIX D: WATER MAKE-UP FLOAT VALVE... - Page 5 Figure A-39: Fan duct installation on a fan adaptor Figure A-40: Fan duct alignment Figure A-41: Fan duct installation in a fan adaptor for a quadruple fan tower Figure A-42: Optional accessories by REYMSA Figure A-43: Optional safety accessories Figure A-44: Vibration switch recommended location...
- Page 6 Figure D-2: Copper coil unit pulled out for maintenance purpose when tower is on the ground Figure D-3: Copper coil unit pulled out for maintenance purpose when tower is on the roof Figure AP-1: Float valve parts REYMSA COOLING TOWERS, INC. www.reymsa.com...
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Page 7: Installation
1622 1622-LS 1627 1627-LS DISTANCE “D” Figure A-1: Minimum recommended distance between towers For a complete table of minimum distances between towers and obstructions please refer to “APPENDIX C: MINIMUM DISTANCE BETWEEN TOWERS AND OBSTRUCTIONS”. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 8: Environmental And Safety
Closed Circuit Fluid Cooler. ▪ REYMSA Closed Circuit Fluid Coolers are industrial equipment with rotating parts. Care must be taken to install them in a safe area whose access is restricted only to authorized personnel. -
Page 9: Assembly Instructions
Figure A-5: Fan duct lifting Figure A-3: Single fan tower fork lifting F. Before tower’s assembly, REYMSA recommends to install a steel base structure that supports the tower’s operational weight; also place an isolation pad (supplied by others) between the tower and the base structure for support purposes. -
Page 10: Figure A-6: Typical Anchorage For A Single Fan Tower
3. 5/8 HOLE 4. 1/2 FLAT WASHER 5. 1/2” LOCK WASHER 6. 1/2 NUT (SUPPLIED BY OTHERS) LOWER SECTION STEEL BASE STRUCTURE (SUPPLIED BY OTHERS) RECIRCULATION WATER OUTLET Figure A-7: Upper and lower parts installation REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 11: Table A-2: Receiving Flange Type (Single Fan Towers)
(see Figure A-9). Secure it with the stainless steel nut and bolt sets supplied by REYMSA. There are two different types of receiving flanges, each one has its own assembly pieces (see Table A-2 to verify the type of receiving flange of your tower). -
Page 12: Double Fan Towers
Figure A-11: Double fan tower crane lifting lifting F. Before tower’s assembly, REYMSA recommends to install a steel base structure that supports the tower’s operational weight; also place an isolation pad (supplied by others) between the tower and the base structure for support purposes. -
Page 13: Figure A-13: Basin Lifting (Optional)
2. 1/2” FLAT WASHER 3. 5/8” HOLE 4. 1/2” FLAT WASHER LOWER 5. 1/2” LOCK WASHER 6. 1/2” NUT SECTION STEEL BASE SUPPORT WATER OUTLET (SUPPLIED BY OTHERS) Figure A-15: Fan duct, upper and lower parts installation REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 14: Table A-3: Receiving Flange Type (Double Fan Towers)
(Figure A-17). Secure it with the stainless steel nut and bolt sets supplied by REYMSA. There are two different types of receiving flanges, each one has its own assembly pieces (see Table A-3 to verify the type of receiving flanges of your tower). -
Page 15: Quadruple Fan Towers
(supplied by REYMSA); then replace the galvanized bolts with the stainless steel nut and bolt set supplied by REYMSA. Then bolt down and secure both sections to the structural base with stainless steel nut and bolts set (supplied by others, see figure A-22). -
Page 16: Figure A-21: Basin Lifting (Optional)
Lower section 2, then proceeds to bolt together the vertical flanges of sections 1 & 2; use first the galvanized bolts and nuts to join sections (supplied by REYMSA), once both sections are well together then replace galvanized bolts with the stainless steel nut and bolts sets supplied by REYMSA. -
Page 17: Figure A-25: Upper Section 1 & 2 For A Quadruple Fan Tower On Plane
(Figure A-27). Secure it with the stainless steel nut and bolt sets supplied by REYMSA. There are two different types of receiving flanges, either one has its own assembly pieces (see Table A-4 to verify the Type of receiving flange of your tower). -
Page 18: Table A-4: Receiving Flange Type (Quadruple Fan Towers)
Figure A-27: Fan duct alignment for a quadruple fan tower M. Continue to place fan duct 2 on top of tower section 1, following the same instructions mentioned on previous step. Follow the same instructions for the remaining fan ducts. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 19: Single Fan Tower (Gear Driven Models)
Figure A- 28: Crane lifting for HFC-F models F. Before tower’s assembly, REYMSA recommends to install a steel base structure that supports the tower’s operational weight; also place an isolation pad (supplied by others) between the tower and the base structure for support purposes. -
Page 20: Figure A-30: Upper Body Section Installation For Hfc-F Models
” Safety nut Figure A-31: Fan duct assembly for HFC-F models M. Place the corrosion resistant safety screen mesh on top of the Fan Deck Section (see figure A-32). Figure A-32: Screen mersh assembly for HFC-F models REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 21: Spray Pump
1. Remove the spray pump from the packaging. Assemble spray line assembly to the spray pump using the bolts and gasket (supplied by REYMSA). 2. Check to make sure that the piping is aligned to the spray pump in a straight line position (see Figure A-33 ). -
Page 22: Copper Coil Unit
COPPER COIL UNIT PROCESS FLUID OUTLET PORT PROCESS FLUID INLET PORT CHEMICAL STEEL BASE SUPPORT ACCESS DOOR TREATMENT SUPPLY (SUPPLIED BY OTHERS) Figure A-34: Copper coil unit REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 23: Low Sound Fan Closed Circuit Fluid Cooler: Fan Adaptors
(see Figure A-36); make sure the bolt holes and the marks inside the Fan adaptor are aligned (Figure A-37). Then secure it using the stainless steel nut and bolt sets supplied by REYMSA. Figure A-37: Fan adaptor alignment Figure A-36: Fan adaptor installation B. -
Page 24: Figure A-38: Fan Adaptor 2 Installation
C. Then place the Fan Duct on top of the Fan Adaptor (see Figure A-39); make sure the bolt holes and the marks inside the Fan Duct are aligned (see Figure A-40). Then secure it using the stainless steel nut and bolt sets supplied by REYMSA. Figure A-40: Fan duct alignment Figure A-39: Fan duct installation in a fan adaptor D. -
Page 25: Optional Accessories
A.2.8. OPTIONAL ACCESSORIES A.2.8.1. ACCESSORIES - SAFETY REYMSA offers a variety of optional accessories to help ensure the safety of the personnel operating the Closed Circuit Fluid Cooler, like ladder, catwalk, handrail, and davit support, hoist, and trolley (See Figure A-42). -
Page 26: Figure A-43: Optional Safety Accessories
HANDRAIL DAVIT STRUCTURE / DAVIT SUPPORT / HOIST / Stainless/galvanized steel railing OSHA construction, TROLLEY including toe guard. Stainless steel tubular support and galvanized steel davit structure. Figure A-43: Optional safety accessories REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 27: Vibration Switch
Cooling Towers A.2.8.2. VIBRATION SWITCH Vibration switches provided by REYMSA are shock sensitive mechanisms for shutdown of the Closed Circuit Fluid Cooler fan motors. These switches use a magnetic latch to ensure reliable operation whenever shutdown protection from damaging shock/vibration is desired. As the level of vibration or shock increases an inertia mass exerts force against the latch arm and forces it away from the magnetic latch causing the latch arm to operate the contacts. -
Page 28: Figure A-47: Vibration Switch Detail
1/4 turn clockwise (less sensitive). Restart the motor to verify that the instrument will not trip on start-up. ▪ At this setting, you should expected the vibration switch will trip when abnormal shock/vibration exists. ▪ Verify the vibration switch sensibility annually to prevent any malfunction. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 29: Basin Heater
Cooling Towers A.2.8.3. BASIN HEATER REYMSA offers as an optional accessory the basin heater systems designed to provide freeze protection during shutdown or standby conditions. The basin heater system consists of an electric immersion heater(s), a heater control panel and combination level sensor/thermostat well. Electric immersion heaters are sized (kW rating, voltage, phase, and sensor cord immersion length) for the specific tower, basin size, and climate. -
Page 30: Figure A-51: Basin Heater Control Panel Diagram
WARNING Improper operation, maintenance or repair of basin heater can be dangerous and could result in injury or equipment damage. Safety precautions and warnings are provided in section “D.6 BASIN HEATER “ of this manual. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 31: Electric Water Level Control System
Cooling Towers A.2.8.4. ELECTRIC WATER LEVEL CONTROL SYSTEM Electric water level control system is an optional accessory offered by REYMSA includes water level controller, stilling chamber, and solenoid valve for water make up (see Figure A-52 & Figure A-53). Figure A-52: Electrical Water level control system... -
Page 32: Motor Shaft Grounding Ring
▪ Do not use thread lock to secure the mounting screws as it may compromise the conductive path to ground. CAUTION ▪ Motor must be grounded to common earth ground with drive according to applicable standards. ▪ Rings should not operate over a keyway because the edges are very sharp. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 33: Tower Set-Up
A.3. TOWER SET-UP A.3.1. LEVELING AND TOWER SUPPORTS REYMSA Closed Circuit Fluid Coolers should always be installed on a level surface and adequately supported. REYMSA recommends supporting Closed Circuit Fluid Coolers on an isolation pad and a structural base; care must be taken to ensure that the basin sump (the lowest portion of the tower basin) is completely supported (see Figure A-56). -
Page 34: Figure A-57: Pipe Connections For A Single Fan Tower
15. WATER MAKE-UP (BACK SIDE) 16. OVERFLOW (BACK SIDE) 17. DRAIN (BACK SIDE) 18. PURGE (BACK SIDE) 19. TEMPERATURE SENSOR (BACK SIDE) 20. BASIN HEATER (BACK SIDE) Figure A-58: Pipe connections for a double fan tower REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 35: Figure A-59: Pipe Connections For A Quadruple Fan Tower
▪ Make-up (basin section) - Make-up water needs to compensate the water losses due to evaporation, drift and purge. To control make-up water flow, a mechanical float valve is included by REYMSA as a standard feature. A NPT connection is provided and marked as Make-up Water. Electric automatic fill valve with control is available as an optional (refer to section “A.2.8.4. -
Page 36: Wiring
Improper grounding can result in severe personal injury. Always disconnect, tag and lock the incoming main power source before opening the electrical enclosure. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 37: Procedure To Wire The Fan Motor
Cooling Towers A.3.3.2. PROCEDURE TO WIRE THE FAN MOTOR REYMSA suggest that after extended shut down, the model should be checked with insulations tester prior to restarting motor. 1. To gain access to the motor, remove the fan guard on top of the fan duct. -
Page 38: Start-Up
B.1. FILLING SYSTEM WITH WATER A. Open make-up valve(s) and allow basin(s) and piping to fill to the tower overflow level. REYMSA’s Closed Circuit Fluid Coolers are previously marked with the operation level on the basin, as a reference you could use Table B-1. -
Page 39: Spray Pump
▪ The original oil should be replaced after 500 hours of operation or four weeks, whichever comes first. ▪ After the initial oils change, oils should be changed every 2500 hours or every six months, whichever comes first. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 40: Fan
10% of the value described on the data plate. To adjust the pitch of the fan blades, call your local REYMSA representative for assistance. -
Page 41: Operation
REYMSA recommends using the following basic operation parameters on their Closed Circuit Fluid Cooler to ensure a long life expectancy. -
Page 42: Configuration And Start-Up For Abb Ach550-Uh
VFD ON @ MIN FREQ 32°F Figure C-4: Measuring range RTD. C.1.2 CONFIGURATION AND START-UP FOR ABB ACH550-UH REYMSA recommends the next connection diagram for ABB ACH550-UH: AGND AGND SIGNAL 4-20 mA 0-10 V BRIDGE... - Page 43 4009 100% VALUE: 100.0°C 4011 INTERNAL SETPNT: DESIRED COLD WATER TEMPERATURE Select transmitter’s range: 4-20mA(2-10V) As feedback increases drive speed should: INCREASE Do you want to change PID tunings? 4001 GAIN: 4002 INTEGRATION TIME: 30.0 s REYMSA COOLING TOWERS, INC. www.reymsa.com...
- Page 44 Do you want to continue with timed funcs set-up? SKIP Do you want to cont. With relay and analog output set-up? SKIP Do you want to copy parameters to panel? Parameters upload successful Note: Refer to VFD user manual for more information. REYMSA COOLING TOWERS, INC. www.reymsa.com...
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Page 45: Water Distribution System
A different parameter, whether lower or higher, will affect the Closed Circuit Fluid Cooler performance. ▪ The normal operation range of spray nozzles is 2-10 psi. REYMSA recommends maintaining water inlet pressure between 4-8 psi to achieve a proper water distribution. Operation below this range will cause the nozzle to produce smaller than expected spray cone, lowering fill´s performance. -
Page 46: Water Treatment And Water Chemestry
(below the copper coil) to dilute the chemicals in the water. Direct exposure of the copper coil to the chemicals may accelerate corrosion. Chemical treatment Water Distribution Pan supply Chemical treatment supply INCORRECT CORRECT Figure C-7: Chemical treatment connection installation. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 47: Suspended Solids
Closed Circuit Fluid Cooler. It is recommended that every Closed Circuit Fluid Cooler is fitted with a solid separator. REYMSA offers a centrifugal separator as a design option for suspended solid control (see Figure C-8). -
Page 48: Corrosion
Corrosion of system components shortens its life, reducing operational reliability. However, since REYMSA Closed Circuit Fluid Coolers are constructed of FRP, corrosion is not an issue for the tower, but it is for the system and the copper coils. -
Page 49: Cold Weather Operation
VFD must be programed to “skip” resonant frequencies that cause unusual rumbling or grinding noise. WARRANTY VOID If fan motors are cycling (ON-OFF) at full voltage controlled by temperature signal or heat load demand. Rapid ON-OFF cycles can damage the fan. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 50: Basin Heater Operation
REYMSA. C.5.1. BASIN HEATER OPERATION REYMSA recommends the use of an Immersion Heater System in the Tower basin, designed to provide freeze protection. Such system consists on heating element (3-12 kW), control panel, temperature and level sensors (refer to section “A.2.8.3. -
Page 51: Seasonal Shut-Down
Cooling Towers C.6. SEASONAL SHUT-DOWN When the system needs to be shut-down for a certain period of time longer than 3 days, REYMSA Cooling Towers recommends the following procedure. ▪ Ensure that all electronic components (fan, motors, and control panels) are unplugged and locked out, failure to do so could result in personal injury or property damage. -
Page 52: Maintenance
D. MAINTENANCE Proper maintenance is necessary to increase the equipment’s service life. Adequate knowledge of the operation and maintenance of REYMSA cooling towers is essential for efficient and safe operation. WARNING Operation, Maintenance and Repair of REYMSA Closed Circuit Fluid Cooler should be done by Qualified Personnel. -
Page 53: Tower Maintenance Schedule
All-Fiberglass Cooling Towers D.1 TOWER MAINTENANCE SCHEDULE Table D-1: Recommended Tower and optional equipment maintenance schedule REYMSA COOLING TOWERS - MAINTENANCE SCHEDULE PROCEDURE FREQUENCY OCT NOV OCT NOV Inspection for: -Unusual noises -Vibration Monthly -Water lea kage -Excessive drift According to... -
Page 54: Basin
9. Remove, clean and replace the strainer. 10. Refill the basin with fresh water. 11. Remove the protective covering from the cold water outlet (mentioned above on #5). 12. Put the Louvers back into place in the Closed Circuit Fluid Cooler. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 55: Tower Body
8. Flush the interior with low-pressure water and remove any buildup. 9. Inspect the sidewalls, the fill and drift eliminator supports and the water distribution manifold for any cracks or damaged part. If the drift eliminators have cracks or are damaged, call your local REYMSA Representative for assistance. -
Page 56: Fan Motor
Rapid ON-OFF cycles can damage the fan. WARNING In Double Fan Closed Circuit Fluid Cooler (per cell), ensure to Start-Stop the fan motors at the same time. If you need more information, please contact REYMSA. REYMSA COOLING TOWERS, INC. www.reymsa.com... - Page 57 14. Clean the outside surface of the motor to ensure proper motor cooling. Check the motor insulation at a manufacturer’s authorized service station. 15. Reverse procedure to install fan and motor. 16. Replace the fan guard. REYMSA COOLING TOWERS, INC. www.reymsa.com...
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Page 58: Gear Reducer
5. Gear oils containing Extreme Pressure (EP) additives are not recommended. OIL CAPACITY GEAR REDUCER MODEL GALLONS LITERS Table D-2: Oil capacity for gear reducer models. Note: Please contact REYMSA to confirm the proper gear reducer model of your Closed Circuit Fluid Cooler. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 59: Basin Heater
12. After tank is full or flow is established turn heater on. WARNING The inmension heater should be covered with at least 2” of fluid, while heater is energized to prevent any failure by overheating. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 60: Spray Pump
Fill system with clean water, add cleaning chemicals (1 lb. for every 40 to 50 gallons of water or manufacturer’s instruction). Start pump and heat up system. Let system run for a few hours and then drain and refill with fresh water. Your pumps are now ready for continuous duty. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 61: Copper Coil Unit
Figure D-3: Copper coil unit pulled out Figure D-2: Copper coil unit pulled out for maintenance purpose when tower is on the roof. for maintenance purpose when tower is on the ground. REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 62: Trouble-Shooting
Higher heat load through Compare actual heat load versus design heat load. copper coil unit. Contact your REYMSA representative for advice on possible upgrade or addition of another Closed Circuit Fluid Cooler. Verify the GPM and Delta T. Higher heat load through Compare actual heat load versus design heat load. - Page 63 Tower. Use the throttling valve to adjust the pressure. Closed Circuit Fluid Coolers are designed to operate between 2 psi and 10 psi at the Tower inlet, REYMSA recommends to work between 4-8 psi. Damaged or reversed louvers Replace the louvers if damaged.
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Page 64: Appendix A: Example Of Structural Base For A Reymsa Closed Circuit Fluid Cooler
APPENDIX A: EXAMPLE OF STRUCTURAL BASE FOR A REYMSA CLOSED CIRCUIT FLUID COOLER. FOR REFERENCE ONLY Consult your REYMSA representative for the recommended support of a specific model REYMSA COOLING TOWERS, INC. www.reymsa.com... - Page 65 All-Fiberglass Cooling Towers APPENDIX A: EXAMPLE OF STRUCTURAL BASE FOR A REYMSA CLOSED CIRCUIT FLUID COOLER. FOR REFERENCE ONLY Consult your REYMSA representative for the recommended support of a specific model REYMSA COOLING TOWERS, INC. www.reymsa.com...
- Page 66 APPENDIX A: EXAMPLE OF STRUCTURAL BASE FOR A REYMSA CLOSED CIRCUIT FLUID COOLER. FOR REFERENCE ONLY Consult your REYMSA representative for the recommended support of a specific model REYMSA COOLING TOWERS, INC. www.reymsa.com...
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Page 67: Appendix B: Examples Of Accessories Assembly Instructions
All-Fiberglass Cooling Towers APPENDIX B: EXAMPLE OF ACCESSORIES ASSEMBLY INSTRUCTIONS. FOR REFERENCE ONLY Consult your REYMSA representative for the recommended support of a specific model REYMSA COOLING TOWERS, INC. www.reymsa.com... - Page 68 APPENDIX B: EXAMPLE OF ACCESSORIES ASSEMBLY INSTRUCTIONS. FOR REFERENCE ONLY Consult your REYMSA representative for the recommended support of a specific model REYMSA COOLING TOWERS, INC. www.reymsa.com...
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Page 69: Appendix C: Minimum Distance Between Towers And Obstructions
1619 1622 1627 707-SL 808-SL 810-SL 812-SL 714-SL 816-SL 819-SL 822-SL 827-SL 1414-SL 1616-SL 1619-SL 1622-SL 1627-SL 1012-F 1016-F 1216-F 1218-F * Suggested clearances and conditions can vary * All clearances are expressed in feet REYMSA COOLING TOWERS, INC. www.reymsa.com... -
Page 70: Appendix D: Water Make-Up Float Valve
If inlet pressure to the mechanical float valve exceeds 50 psi. Example of stems Float valve installed in a cooling Tower 1 ½” 1” ½” Plastic float Copper float Example of valves Figure AP-1: Float valve parts REYMSA COOLING TOWERS, INC. www.reymsa.com... - Page 72 REYMSA COOLING TOWERS, INC. www.reymsa.com (IOM/HFC/HFC-F/HFC-SL/ENG/OCT18)
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