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LIFE Operation and Maintenance Instructions For EVAPCO Closed Circuit Coolers and Evaporative condensers Member of International Institute of Ammonia Refrigeration www.iiar.org Mark owned by the Cooling Technology Institute...
Operation and Maintenance Instructions for LIFE Table of Contents Introduction 24 Cold Weather Operation Unit Layout Safety Precautions Freeze Protection of Recirculating Water Terminology Freeze Protection of Closed Circuit Cooler Coils Unit Accessories Initial Storage and/or Idle Period Recommendations Cold Water Basin Heaters International Building Code Provision Remote Sumps Electric Water Level Control...
Biological Contaminants in these Operation and Maintenance Instructions.) 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 as sociated terminology. Induced Draft equipment includes the following Evapco Product Models: ESW Product Lines •...
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.
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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. EVAPCO recommends...
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Recommended Minimum Maintenance Schedule FREQUENCY PROCEDURE Clean pan strainer Monthly or as needed Clean and flush pan** Quarterly or as needed Check bleed-off valve to make sure it is operative Monthly Check operating level in pan and adjust float valve Monthly if necessary Check water distribution system and spray pattern...
Recommended Maintenance Schedule (continued) OPTIONAL ACCESSORIES: Heater – Inspect elements for scale build-up Quarterly 10. Electronic Water Level Controller – Inspect junction box Semi-annually for loose wiring and moisture Electronic Water Level Controller – Clean probe ends Quarterly or as needed of scale build-up 12.
Seasonal Shut-Down Checklist When the system is to be shut down for an extended period of time, the following services should be performed. 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.
Basic Closed Circuit Cooler/Condenser Sequence of Operation for Wet or Evaporative Mode 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.
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. Unit Description...
Fan Belt Adjustment (Direct drive units do not require any 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.
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Induced Draft – On induced draft belt driven units provided with externally mounted motors, see Figure 3. Figure 3 – Externally Mounted Motor, Induced Draft On induced draft belt driven units with internally mounted motors (10, 12, 14, 20, 24 and 28 foot wide units). PHC-S, L and D Units, a motor adjustment tool is provided on the adjustment nut.
Forced Draft – LS and PM 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. ADJUSTMENT NUTS Figure 7 – PM Style Motor Adjustment ADJUSTMENT NUTS Figure 8a –...
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).
Repeat from full speed to minimum speed. Should vibration-inducing frequencies exist, the run-up and run- down test will isolate the resonant frequencies which then must then be locked-out in the VFD programming. For more details on the use of variable frequency drives, please download a copy of EVAPCO’s Engineering Bulletin 39 from evapco.com.
Recirculated Water System - Routine Maintenance Suction Strainer in Cold Water Basin The pan strainer as shown in Figures 10 through 14 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.
ADJUSTMENT WINGNUTS FLOAT ARM Water Make Up Valve MAKE-UP FLOAT BALL 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).
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 36A at evapco.com.
Evapco does not recommend the routine use of acid due to the destructive consequences of improper feeding; however, if acid is used as part of the site specific treatment protocol, it should be pre-diluted prior to introduction into the cooling water and fed by automated equipment to an area of the system which ensures adequate mixing.
During operation, off-line cleaning of evaporative cooling equipment should be undertaken on a regular basis. Inspections should be undertaken on a regular basis and should include both monitoring of microbial populations via culturing techniques and visual inspections for evidence of biofouling. Additionally, drift eliminators should be inspected and maintained in good operation condition. Service personnel must wear proper protective equipment (including approved respiratory protection equipment) while undertaking such cleaning efforts or any other maintenance efforts on evaporative cooling equipment.
Cold Weather Operation EVAPCO counterflow evaporative cooling equipment is well suited to operate in cold weather conditions. The counterflow design encases the heat transfer media (fill and/or coils) completely, and protects it from the outside elements such as wind which can cause freezing in the unit.
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Evaporative Condenser Closed Circuit Cooler Required Inlet Model Number Footprint Pressure (psi) ATC-E Products eco-ATC-A Products ATWB, eco-ATW & eco-ATWE Products 50E to 165E 122A to 263A 3’ and 4’ wide units** 170E to 247E 160A to 326A 8.5’x7.5’ 218E to 305E 205A to 504A 8.5’x9’...
Freeze Protection of Closed Circuit Cooler Coils The simplest and most effective way of protecting the heat exchanger coil from freezing is to use an inhibited ethylene or propylene glycol anti-freeze. If this is not possible, an auxiliary heat load and minimum flow rate must be maintained on the coil at all times so that the water temperature does not drop below 50°F when the cooler is shut down.
It is very important to maintain close control of the cooler or condenser during winter operation. EVAPCO recommends that an absolute MINIMUM leaving water temperature of 42° F must be maintained for cooler applications. The higher the leaving temperature from the cooler or condenser, the lower the potential for ice formation.
However, low speed fan operation or variable frequency drives maintain a positive pressure in the unit which helps prevent ice formation on the fan drive components. For more information on cold weather operation, please download a copy of EVAPCO’s Engineering Bulletin 23 at evapco.com...
Troubleshooting Problem Possible Cause Remedy Overamping Fan Motors Reduction in air static 1. On a forced draft unit verify that the pump is on, and water is flowing pressure over the coil. If the pump is off, and the unit was not sized for dry operation, the motor may over-amp.
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Problem Possible Cause Remedy Scaled Inlet Louvers on Improper water treatment, Scale should not be removed using a power washer or wire brush AT Units insufficient bleed rates or because it could damage the louvers. Remove the louver assemblies and excessive cycling of the let them soak in the cold water basin of the unit.
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These areas may include the coil connections, the cold water basin near the support steel, and around field erected platforms and catwalks. The rust spots can be removed with a good cleaning. EVAPCO recommends using either Naval Jelly or a good stainless steel cleaner, such as Mother’s Wax in conjunction with a Scotch-Brite pad.
The following pages contain exploded view drawings of all current Evapco closed circuit coolers and condensers. Please use these drawings to help identify the major parts of your unit. To order replacement parts, please contact your local EVAPCO representative or Mr.
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ATWB & eco-ATWB 3’ Wide Units FAN & COIL CASING SECTION FAN SCREEN FAN CYLINDER BELT GUARD TEFC FAN MOTOR WATER INLET CONNECTION DRIFT ELIMINATOR PUMP RISER PIPING COIL COIL CONNECTIONS PAN SECTION MAKE-UP VALVE WITH ADJUSTABLE FLOAT PUMP RISER PIPING AIR INLET LOUVER RECIRCULATING PUMP/ MOTOR ASSEMBLY...
ATC-E/ATWB/eco-ATWB 4’x4’ & 4’x6’ Wide Units FAN & COIL CASING SECTION FAN SCREEN FAN CYLINDER DRIFT ELIMINATOR BELT GUARD WATER INLET CONNECTION TEFC FAN MOTOR PUMP RISER PIPING COIL COIL CONNECTIONS PAN SECTION MAKE-UP VALVE WITH ADJUSTABLE FLOAT PUMP RISER PIPING AIR INLET LOUVER RECIRCULATING PUMP/ MOTOR ASSEMBLY...
ATC-E/ATWB/ eco-ATWB 4’x9’ & 4’x12’ Wide Units FAN & COIL CASING SECTION FAN SCREEN FAN CYLINDER BELT GUARD WATER INLET CONNECTION DRIFT ELIMINATOR TEFC FAN MOTOR PUMP RISER PIPING COIL PAN SECTION MAKE-UP VALVE WITH ADJUSTABLE FLOAT PUMP RISER PIPING AIR INLET LOUVER RECIRCULATING PUMP/ MOTOR ASSEMBLY...
FAN SCREEN ATC-E/ATWB/eco-ATC-A/eco-ATWB 7’ Wide Units FAN SCREEN SUPPORT BEARING SUPPORT FAN & COIL CASING SECTION FAN CYLINDER ACCESS DOOR DRIFT ELIMINATORS SWING OUT MOTOR COVER FAN BELT FAN MOTOR SHEAVE PUMP RISER PIPING TEFC FAN MOTOR COIL COIL CONNECTIONS PAN SECTION MAKE-UP VALVE WITH ADJUSTABLE FLOAT...
ATC-E/ATWB/ eco-ATC-A/eco-ATWB 8’ & 8.5’ Wide Units FAN & COIL CASING SECTION BEARING SUPPORT FAN SCREEN FAN SCREEN SUPPORT DRIFT ELIMINATORS FAN CYLINDER ACCESS DOOR SWING OUT MOTOR COVER TEFC FAN MOTOR PUMP RISER PIPING COIL COIL CONNECTIONS PAN SECTION MAKE-UP VALVE WITH ADJUSTABLE FLOAT COLD WATER BASIN...
ATC-E/ATWB/eco-ATC-A/eco-ATWB 10’ & 12’ Wide Units FAN & COIL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT TEAO FAN MOTOR FAN CYLINDER SLIDING MOTOR BASE ACCESS DOOR MECHANICAL EQUIPMENT SUPPORT DRIFT ELIMINATORS COIL CONNECTIONS WATER DISTRIBUTION SPRAY BRANCH PUMP RISER PIPING COIL PAN SECTION MAKE-UP VALVE...
eco-ATWB-E 8.5’ Wide Units FAN & COIL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT FAN CYLINDER ACCESS DOOR SWING OUT MOTOR COVER COIL CONNECTIONS COIL PAN SECTION COLD WATER BASIN FRAMED AIR INLET LOUVER AIR INLET LOUVER MEDIA LOUVER RETAINER...
eco-ATWB-E 10’ & 12’ Wide Units FAN & COIL CASING SECTION FAN SCREEN SUPPORT FAN SCREEN FAN CYLINDER ACCESS DOOR COIL COIL CONNECTIONS PAN SECTION COLD WATER BASIN FRAMED AIR INLET LOUVER AIR INLET LOUVER MEDIA LOUVER RETAINER...
ESW4 8.5’ Wide Units FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT BEARING SUPPORT FAN SHAFT FAN CYLINDER BEARING DRIFT ELIMINATORS SWING OUT MOTOR COVER TEFC FAN MOTOR FILL FAN MOTOR SHEAVE FAN BELT SPRAY BRANCH ACCESS DOOR PAN SECTION AIR INLET LOUVER MEDIA...
ESW4 12’ Wide Units FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT MECHANICAL EQUIPMENT SUPPORT FAN CYLINDER DRIFT ELIMINATORS FILL ALUMINUM FAN SHEAVE SLIDING MOTOR BASE FAN BELT TEAO FAN MOTOR WATER DISTRIBUTION ACCESS DOOR SPRAY BRANCH PAN SECTION AIR INLET LOUVER MEDIA REDISTRIBUTION...
eco-ATC-H and eco-ATWB-H 8.5’ Wide Units FAN SCREEN SUPPORT FAN SECTION FAN SCREEN FAN CYLINDER ACCESS DOOR SWING OUT MOTOR COVER TEFC FAN MOTOR DRY COIL COIL CASING SECTION DRY COIL CONNECTIONS DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH WET COIL WET COIL CONNECTIONS PAN SECTION...
eco-ATC-H / eco-ATWB-H 10’ and 12’ Wide Units FAN SCREEN SUPPORT FAN SECTION FAN SCREEN TEAO FAN MOTOR FAN CYLINDER ACCESS DOOR MECHANICAL EQUIPMENT SLIDING MOTOR BASE SUPPORT COIL CASING SECTION DRY COIL DRY COIL CONNECTIONS DRIFT ELIMINATORS WET COIL WATER DISTRIBUTION CONNECTIONS SPRAY BRANCH...
ESWA 8.5’ Wide Units FAN SCREEN FAN SCREEN SUPPORT BEARING SUPPORT FAN CYLINDER FAN SHAFT FAN & FILL CASING SECTION BEARING DRIFT ELIMINATORS SWING OUT MOTOR COVER TEFC FAN MOTOR FILL FAN MOTOR SHEAVE FAN BELT SPRAY BRANCH ACCESS DOOR COIL PAN SECTION SUCTION HOOD...
ESWA 12’ Wide Units FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT MECHANICAL EQUIPMENT SUPPORT FAN CYLINDER DRIFT ELIMINATORS FILL ALUMINUM FAN SHEAVE SLIDING MOTOR BASE FAN BELT TEAO FAN MOTOR WATER DISTRIBUTION ACCESS DOOR SPRAY BRANCH PAN SECTION COIL SUCTION HOOD &...
LSC-E/LSWE/eco-LSWE 4’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH WATER DISTRIBUTION SPRAY BRANCH SUPPORT DRIFT ELIMINATOR SUPPORT COIL CONNECTIONS COIL PUMP RISER PIPING PAN SECTION ACCESS DOOR MIGRATION BAFFLE WRAPPER MAKE-UP VALVE WITH ADJUSTABLE FLOAT SUCTION STRAINER BEARING SUPPORT FAN HOUSING...
LSC-E/ LSWE/ eco-LSWE 5’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH WATER DISTRIBUTION SPRAY BRANCH SUPPORT DRIFT ELIMINATOR SUPPORT COIL COIL CONNECTIONS PUMP RISER PIPING PAN SECTION MIGRATION BAFFLE MAKE-UP VALVE WRAPPER WITH ADJUSTABLE FLOAT SUCTION STRAINER ACCESS DOOR BEARING SUPPORT...
LSC-E/LSWE/eco-LSWE 8’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH WATER DISTRIBUTION SPRAY BRANCH SUPPORT COIL CONNECTIONS DRIFT ELIMINATOR SUPPORT COIL PUMP RISER PIPING PAN SECTION MIGRATION BAFFLE MAKE-UP VALVE WITH ADJUSTABLE FLOAT WRAPPER ACCESS DOOR MOTOR BASE RECIRCULATOR PUMP/ BEARING SUPPORT MOTOR ASSEMBLY...
LSC-E/ LSWE/ eco-LSWE 10’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH WATER DISTRIBUTION SPRAY BRANCH SUPPORT COIL CONNECTIONS DRIFT ELIMINATOR SUPPORT PUMP RISER PIPING COIL PAN SECTION MIGRATION BAFFLE SUCTION HOOD & STRAINER WRAPPER ACCESS DOOR MOTOR BASE FAN HOUSING RECIRCULATOR PUMP/...
LRC/LRWB/ eco-LRWB 3’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH DRIFT ELIMINATOR SUPPORT COIL WATER DISTRIBUTION PUMP RISER PIPING SPRAY BRANCH SUPPORT COIL CONNECTIONS PAN SECTION FAN HOUSING FAN SHEAVE FAN WHEEL FAN WRAPPER FAN BELT SUCTION HOOD TEFC FAN MOTOR SUCTION STRAINER...
LRC/LRWB/eco-LRWB 5’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH DRIFT ELIMINATOR SUPPORT WATER DISTRIBUTION SPRAY BRANCH SUPPORT PUMP RISER PIPING COIL COIL CONNECTIONS PAN SECTION FAN HOUSING FAN SHEAVE FAN WRAPPER FAN BELT SUCTION HOOD SUCTION STRAINER BLEED LINE AND VALVE MOTOR ACCESS DOOR TEFC FAN MOTOR...
LRC/LRWB/ eco-LRWB 8’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS DRIFT ELIMINATOR SUPPORT COIL WATER DISTRIBUTION SPRAY BRANCH PUMP RISER PIPING WATER DISTRIBUTION SPRAY BRANCH SUPPORT COIL CONNECTIONS PAN SECTION FAN HOUSING FAN WHEEL FAN WRAPPER FAN BELT SUCTION HOOD SUCTION STRAINER FAN SHEAVE PUMP RISER PIPING...
PMC-E/eco-PMC 5’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH DRIFT ELIMINATOR SUPPORT COIL COIL CONNECTIONS WATER DISTRIBUTION SPRAY BRANCH SUPPORT PUMP RISER PIPING PAN SECTION FAN CYLINDER SUCTION STRAINER COLD WATER BASIN FAN BELT ACCESS DOOR TEFC FAN MOTOR RECIRCULATOR PUMP/ ADJUSTABLE MOTOR BASE...
PMC-E/eco-PMC 10’ and 12’ Wide Units COIL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH COIL CONNECTIONS DRIFT ELIMINATOR SUPPORT PUMP RISER PIPING COIL WATER DISTRIBUTION SPRAY BRANCH SUPPORT PAN SECTION COLD WATER BASIN FAN CYLINDER PUMP RISER PIPE ACCESS DOOR FAN BELT TEFC FAN MOTOR ADJUSTABLE MOTOR BASE...
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PHC-S & L 12’ Wide-Single Side Air Inlet Units FAN SCREEN TEFC FAN MOTOR ADJUSTABLE MOTOR BASE FAN CYLINDER MECHANICAL EQUIPMENT TOP COIL/FAN SECTION SUPPORT SLIDING MOTOR BASE TEFC FAN MOTOR COIL WATER DISTRIBUTION BRANCH SUPPORT PUMP RISER PIPING WATER DISTRIBUTION BRANCH COIL CONNECTIONS BOTTOM-PAN SECTION...
FAN SCREEN PHC-D 12’ and 14’ Wide-Two Sided Air Inlet Units FAN CYLINDER MECHANICAL EQUIPMENT SUPPORT TOP COIL/FAN SECTION WATER DISTRIBUTION BRANCH PUMP RISER PIPING SLIDING MOTOR BASE WATER DISTRIBUTION TEFC FAN MOTOR BRANCH SUPPORT COIL DRIFT ELIMINATORS COIL CONNECTIONS ACCESS DOOR PUMP RISER PIPING BOTTOM-PAN SECTION...
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For EVAPCO Authorized Parts and Service, Contact Your Local EVAPCO Representative or the Local Mr. GoodTower Service Provider ® EVAPCO, Inc. — World Headquarters & Research/Development Center P.O. Box 1300 • Westminster, MD 21158 USA 410-756-2600 p • marketing@evapco.com • evapco.com...
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