EVAPCO AT Series Operation & Maintenance Instructions Manual

Induced draft & forced draft cooling towers:

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Operation & Maintenance

Instructions

For EVAPCO Induced Draft &

Forced Draft Cooling Towers:

AT, AT ATLAS, AXS, LPT, LSTE

for LIFE

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Summary of Contents for EVAPCO AT Series

Page 1 Operation & Maintenance Instructions For EVAPCO Induced Draft & Forced Draft Cooling Towers: AT, AT ATLAS, AXS, LPT, LSTE for LIFE...
Page 2 Table of Contents Introduction Cleaning of Stainless Steel 21 Cold Weather Operation Safety Precautions Unit Layout Initial Storage and/or Idle Period Recommendations Freeze Protection of Recirculating Water International Building Code Provision Unit Piping Unit Accessories Initial and Seasonal Startup Checklist Cold Water Basin Heaters General Remote Sumps...
Page 3 Become familiar with your evaporative cooling equipment. Refer to the isometric drawings located on pages 28-48 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 for more information.
Page 4 All items attached to EVAPCO Cooling Towers 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.
Page 5 Initial and Seasonal Startup Checklist (Continued) Initial and Seasonal Startup 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.
Page 6 Initial and Seasonal Startup Checklist (Continued) Recommended Maintenance Schedule PROCEDURE FREQUENCY 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 if necessary Monthly Check water distribution system and spray pattern Monthly...
Page 7 Initial and Seasonal Startup Checklist (Continued) Recommended Maintenance Schedule OPTIONAL ACCESSORIES: Heater – Inspect elements for scale build-up Quarterly 10. Electronic Water Level Controller – Inspect junction box for loose wiring Semiannually and moisture Electronic Water Level Controller – Clean probe ends of scale Quarterly or as needed build-up 12.
Page 8 (usually about 80°F), at which time the bypass may be closed to cause total flow over the fill. EVAPCO does NOT recommend a partial water bypass due to the potential for freezing the heat transfer media during low ambient operation. Optional Defrost Cycle In more severe climates, the incorporation of a defrost cycle may be used to manage the ice formation in and on the unit.
Page 9 Feed grease slowly into the bearings or the seals may be damaged. A hand grease gun is recommended for this process. When introducing a new grease, all grease should be purged from the bearings. All EVAPCO units are supplied with extended grease lines to allow easy lubrication of the fan shaft bearings as shown in Table 1. UNIT DESCRIPTION...
Page 10 Fan System (Continued) 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 1/2” when moderate pressure is applied midway between the sheaves.
Page 11 Fan System (Continued) On induced draft belt driven units with internally mounted motors, as shown in Figures 6 and 7 and LPT units, as shown in Figure 8, a motor adjustment tool is provided. The tool will be found on the adjustment nut. To use, place the hex end over the adjustment nut. Tension the belt by turning the nut in the appropriate direction.
Page 12 Fan System (Continued) Gear Drives Induced draft units with gear drive systems require special maintenance. Please refer to the gear manufacturer’s 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.
Page 13 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).
Page 14 Recirculated Water System – Routine Maintenance Suction Strainer in Cold Water Basin AT O&M 14X PAN SIDE CONN STRAINER DETAIL DWG The pan strainer 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.
Page 15 Recirculated Water System — Routine Maintenance (Continued) 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 2 for unit specific levels. PRODUCT LINE OPERATING DEPTH* 4’...
Page 16 When inspecting and cleaning the water distribution system, always check that the orientation of the spray nozzles is correct as shown below for LSTE/LPT models in Figure 15 and as shown in Figure 16 for AT models. Check or ensure that the top of the EVAPCO logo on the nozzle is parallel with the top of the water distribution pipe, as shown in Figure 16.
Page 17 Recirculated Water System — Routine Maintenance (Continued) Gravity Fed Water Distribution Systems All induced draft crossflow units (AXS) utilize a water distribution system that relies on gravity to disperse water through the spray nozzles. Lifting handles are provided on the hot water basin covers to allow access to the water distribution system as shown in Figure 17.
Page 18 Evaporative cooling equipment requires a bleed or blowdown line to remove concentrated (up) water from the system. For any chemically treated system, the bleed or blowdown line should be piped to a sanitary sewer or on-site water treatment plant. EVAPCO recommends an automated conductivity controller to maximize the water efficiency of your system.
Page 19 Reclaimed water can increase the potential of corrosion, microbiological amplification, and scale formation compared to municipal or potable makeup water. EVAPCO recommends that an extra safety factor be applied to the values noted in Table 4 when Gray or Reclaimed water is used due to variability in alkalinity, ammonia, hardness, oxidizing biocides, and phosphates.
Page 20 Stainless steel is the most cost effective material of construction available to extend the life of an evaporative cooling unit. The stainless steel sheet material utilized by EVAPCO is Type 304 and Type 316 with a No. 2B unpolished finish. Type 304 stainless steel is a basic chromium-nickel austenitic stainless steel and is suitable for a wide range of applications.
Page 21 Prevailing winds can create icing conditions on the inlet louvers and fan screens adversely affecting airflow to the unit. For additional information on unit layout, please refer to EVAPCO’s “Equipment Layout Manual,” available in the document library on www.evapco.com.
Page 22 A remote sump located in an indoor heated space is an excellent way to prevent freezing in the cold water basin during idle or no load conditions because the basin and associated piping will drain by gravity whenever the circulating pump is idle. EVAPCO can provide connections in the cold water basin to accommodate for remote sump installations.
Page 23 The defrost cycle requires the use of two speed motors with reverse cycle starters or reversible variable frequency drives. All motors supplied by EVAPCO are capable of reverse operation.
Page 24 Troubleshooting PROBLEM POSSIBLE CAUSE REMEDY Overamping Fan Reduction in air static 1. On a forced draft unit verify that the system pump is on, and water Motors pressure is flowing over the fill. If the system pump is off, and the unit was not sized for dry operation, the motor may over-amp.
Page 25 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™...
Page 26 Troubleshooting (Continued) PROBLEM POSSIBLE CAUSE REMEDY Electric Water Level The valve won’t open 1. Verify that water pressure is above 5psi and below 125psi. Control Not Working or close 2. Verify wiring with wiring diagram. Check supply voltage. 3. Verify that there is not a blockage in the Y-Strainer 4.
Page 27 EVAPCO has replacement parts available for immediate shipment. Most orders ship within 24 hours from time of order! The following pages contain exploded view drawings of all current EVAPCO cooling towers, organized by product line and size . Please use these drawings to help identify the major parts of your unit. If you are unable to identify the part you need using these figures, please visit www.evapco.com for additional resources and/or contact your local EVAPCO sales representative.
Page 28 AT 4’ Wide Towers FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT FAN CYLINDER ALUMINUM FAN SHEAVE BEARING SUPPORT DRIFT ELIMINATORS SPRAY BRANCH ACCESS DOOR WATER INLET CONNECTION MOTOR COVER FAN BELT FAN MOTOR SHEAVE TEFC FAN MOTOR FILL PAN SECTION MAKEUP VALVE WITH...
Page 29 AT 6’, 7.5’, 8’ & 8.5’ Wide (Per Cell) Towers — Side Connection FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN CONNECTION SIDE SUPPORT FAN CYLINDER BEARING SUPPORT ALUMINUM FAN SHEAVE DRIFT ELIMINATORS SWING-OUT MOTOR COVER TEFC FAN MOTOR FILL FAN MOTOR SHEAVE FAN BELT...
Page 30 AT 6’, 7.5’, 8’ & 8.5’ Wide (Per Cell) Towers — End Connection FAN & FILL CASING SECTION BEARING SUPPORT FAN SCREEN FAN SCREEN SUPPORT FAN CYLINDER ALUMINUM FAN SHEAVE ACCESS DOOR FAN BELT SPRAY BRANCH SWING-OUT MOTOR COVER WATER DISTRIBUTION FAN MOTOR HEADER BOX SHEAVE...
Page 31 AT 7’ Wide (Per Cell) Towers – End Connection FAN & FILL CASING SECTION FAN CYLINDER FAN SCREEN FAN SCREEN SUPPORT BEARING SUPPORT ALUMINUM FAN SHEAVE DRIFT ELIMINATORS SPRAY BRANCH ACCESS DOOR FAN BELT FAN MOTOR SHEAVE SWING-OUT MOTOR COVER WATER DISTRIBUTION HEADER BOX TEFC FAN MOTOR...
Page 32 AT 10’ & 12’ Wide (Per Cell) Towers – Side Connection FAN SCREEN FAN SCREEN SUPPORT CONNECTION SIDE FAN & FILL CASING SECTION MECHANICAL EQUIPMENT SUPPORT FAN CYLINDER DRIFT ELIMINATORS FILL SLIDING MOTOR BASE ALUMINUM FAN SHEAVE TEAO FAN MOTOR FAN BELT ACCESS DOOR SPRAY BRANCH...
Page 33 AT 10’ & 12’ Wide (Per Cell) Towers – End Connection FAN SCREEN FAN & FILL CASING SECTION ACCESS DOOR TEAO FAN MOTOR SLIDING MOTOR BASE FAN CYLINDER FAN SCREEN SUPPORT DRIFT ELIMINATORS MECHANICAL FILL EQUIPMENT SUPPORT WATER DISTRIBUTION HEADER BOX ALUMINUM FAN SHEAVE WATER INLET FAN BELT...
Page 34 AT 14’ x 18’ (Per Cell) Towers – Side Connection 14X18 AT SI UNIT RIGGING DWG 022-02691 FAN & FILL 14X18 AT SI UNIT RIGGING DWG FAN SCREEN 022-02691 CASING SECTION ACCESS DOOR TEAO? FAN MOTOR FAN & FILL FAN SCREEN SLIDING MOTOR BASE MECHANICAL CASING SECTION...
Page 35 AT 14’ x 18’ (Per Cell) Towers – End Connection 14X18 AT EI UNIT RIGGING DWG 022-02692 14X18 AT EI UNIT RIGGING DWG 022-02692 FAN SCREEN FAN SCREEN TEAO MOTOR FAN & FILL ACCESS DOOR TEAO MOTOR FAN & FILL ACCESS DOOR SLIDING MOTOR BASE SLIDING MOTOR BASE...
Page 36 14X18 AT BI UNIT RIGGING DWG AT 14’ x 18’ (Per Cell) Towers – Bottom Inlet Connection, Bottom Outlet 022-02693 14X18 AT BI UNIT RIGGING DWG 022-02693 FAN SCREEN FAN & FILL CASING SECTION ACCESS DOOR TEAO? FAN MOTOR FAN & FILL FAN SCREEN CASING SECTION SLIDING MOTOR BASE...
Page 37 AT 14’ x 24’ (Per Cell) Towers – Side Connection FAN SCREEN FAN & FILL ACCESS DOOR CASING SECTION TEAO FAN MOTOR SLIDING MOTOR BASE FAN CYLINDER FAN SCREEN SUPPORT DRIFT ELIMINATORS WATER INLET CONNECTION FILL MECHANICAL EQUIPMENT SUPPORT ALUMINUM FAN SHEAVE FAN BELT SPRAY BRANCH PAN &...
Page 38 AT 14’ x 24’ (Per Cell) Towers – End Connection FAN & FILL FAN SCREEN CASING SECTION ACCESS DOOR TEAO FAN MOTOR SLIDING MOTOR BASE FAN CYLINDER FAN SCREEN SUPPORT DRIFT ELIMINATORS MECHANICAL FILL EQUIPMENT SUPPORT ALUMINUM FAN SHEAVE FAN BELT SPRAY BRANCH PLENUM SECTION PAN &...
Page 39 AT 14’ x 26’ (Per Cell) Towers – End Connection FAN SCREEN FAN & FILL CASING SECTION FAN CYLINDER ACCESS DOOR TEAO FAN MOTOR SLIDING MOTOR BASE FAN SCREEN SUPPORT DRIFT ELIMINATORS WATER INLET MECHANICAL CONNECTION EQUIPMENT SUPPORT FILL X26 PAN END CONN DWG ALUMINUM FAN SHEAVE SPRAY BRANCH FAN BELT...
Page 40 AT 14’ x 26’ (Per Cell) Towers – Side Connection FAN SCREEN FAN & FILL FAN CYLINDER CASING SECTION ACCESS DOOR TEAO FAN MOTOR SLIDING MOTOR BASE FAN SCREEN SUPPORT DRIFT ELIMINATORS WATER INLET CONNECTION MECHANICAL FILL EQUIPMENT SUPPORT ALUMINUM FAN SHEAVE SPRAY BRANCH FAN BELT X26 PAN SIDE CONN DWG...
Page 41 AT 42’ x 26’ (Three Cell) Towers — Bottom Inlet Connection, Bottom Outlet FAN SCREEN FAN & FILL CASING SECTION FAN CYLINDER FAN SCREEN SUPPORT SLIDING MOTOR BASE TEAO FAN MOTOR ACCESS DOOR DRIFT ELIMINATORS MECHANICAL FILL EQUIPMENT SUPPORT ALUMINUM FAN SHEAVE SPRAY BRANCH FAN BELT FRAMED AIR...
Page 42 All Box Sizes with Super Low Sound Fan — Side or End Connections FAN SCREEN FAN SCREEN SUPPORT FAN & FILL CASING SECTION CONNECTION SIDE MECHANICAL EQUIPMENT SUPPORT FAN CYLINDER DRIFT ELIMINATORS FILL SLIDING MOTOR BASE ALUMINUM FAN SHEAVE TEAO FAN MOTOR FAN BELT ACCESS DOOR SPRAY BRANCH...
Page 43 AT Atlas FAN & FILL CASING SECTION (ONE CELL SHOWN) GEAR BOX DRIVE SHAFT FAN STACK SHAFT COVER TEFC FAN MOTOR MECHANICAL EQUIPMENT SUPPORT ACCESS DOOR DRIFT ELIMINATORS BOTTOM INLET PIPING FILL WATER DISTRIBUTION SPRAY BRANCH PAN & PLENUM SECTION (ONE CELL SHOWN) FRAMED AIR INLET LOUVER PLENUM SECTION...
Page 44 AXS Towers SINGLE STACK FAN SCREEN SUPPORT FAN SCREEN WATER INLET CONNECTION TEAO FAN MOTOR FAN CYLINDER SLIDING MOTOR BASE MECHANICAL EQUIPMENT SUPPORT WATER DISTRIBUTION SYSTEM FAN BELT ALUMINUM FAN SHEAVE MAKE-UP VALVE WITH ADJUSTABLE FLOAT WATER OUTLET CONNECTION SUCTION HOOD AND STRAINER FILL DOUBLE STACK...
Page 45 AXS Towers All Box Sizes — Units with Super Low Sound Fans FAN SCREEN SUPPORT FAN SCREEN SUPER LOW SOUND FAN WATER INLET CONNECTION TEAO FAN MOTOR FAN CYLINDER SLIDING MOTOR BASE MECHANICAL EQUIPMENT SUPPORT WATER DISTRIBUTION SYSTEM FAN BELT ALUMINUM FAN SHEAVE MAKE-UP VALVE WITH ADJUSTABLE FLOAT...
Page 46 LPT Towers FILL CASING SECTION DRIFT ELIMINATORS SPRAY BRANCH DRIFT ELIMINATOR SUPPORT CASING FILL SUPPORT CHANNEL FILL WATER INLET SPRAY BRANCH SUPPORT CONNECTION PAN SECTION FAN SHEAVE FAN HOUSING FAN BELT FAN WRAPPER SUCTION HOOD SUCTION STRAINER MOTOR ACCESS DOOR TEFC FAN MOTOR FAN WHEEL ACCESS DOOR...
Page 47 LSTE 4’ & 5’ Wide Towers FILL CASING SECTION DRIFT ELIMINATORS WATER INLET CONNECTION FILL SUPPORT FILL CHANNEL SPRAY BRANCH SPRAY BRANCH SUPPORT CASING PAN SECTION ACCESS DOOR FAN SCREENS ( NOT SHOWN FOR CLARITY ) MIGRATION BAFFLE WRAPPER MAKEUP VALVE WITH ADJUSTABLE FLOAT SUCTION &...
Page 48 LSTE 8’ & 10’ Wide Towers FILL CASING SECTION DRIFT ELIMINATORS SPRAY BRANCH FILL WATER INLET CONNECTION FILL SUPPORT CHANNEL CASING SPRAY BRANCH SUPPORT PAN SECTION MIGRATION BAFFLE FAN SCREENS ( NOT SHOWN FOR CLARITY ) SUCTION & STRAINER HOOD WRAPPER ACCESS DOOR MOTOR BASE...
Page 49 Notes...
Page 50 Notes...
Page 51 Notes...
Page 52 Indaiatuba, São Paulo, Brazil (55) 11.4025.1670 (55) 11.5681.2000 fantr@fantr.com vendas@evapco.com.br RECYCLED Paper made from EVAPCO, Inc. • P.O. Box 1300 • Westminster, MD 21158 USA recycled material 410.756.2600 • marketing@evapco.com • evapco.com ©2024 EVAPCO, Inc. TWR24OM Printed on recycled paper using soy-based ink...

This manual is also suitable for:

At atlas series Axs series Lpt series Lste series