EVAPCO AT Series Operation & Maintenance Instructions Manual
Induced draft & forced draft cooling towers
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- Operation & maintenance instructions manual (52 pages) ,
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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, SUN, LPT, LSTE...
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Page 2: Table Of Contents
Table of Contents Introduction 23 Cold Weather Operation Unit Layout Safety Precautions Freeze Protection of Recirculating Water Initial Storage and/or Idle Period Recommendations Unit Piping Unit Accessories International Building Code Provision Cold Water Basin Heaters Initial and Seasonal Start-Up Checklist Remote Sumps General Electric Water Level Control... -
Page 3: Introduction
Become familiar with your evaporative cooling equipment. Refer to the isometric drawings located on pages 30-49 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 During maintenance operations, the worker must use adequate personal protection equipment (PPE - A minimum, but not limited list of PPE are safety shoes, glasses, gloves, respiration protection, helmet) as prescribed by local authorities. For any exceptional, non routine work to be carried out, protection and adequate safety measures should be considered and a Last Minute Risks Assessment (LMRA) must be made by an authorized person in accordance with safety requirements of the country.
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Page 5: Initial Storage And/Or Idle Period Recommendations
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... -
Page 6: Initial And Seasonal Startup Checklist
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. Contact your local EVAPCO representative for additional information on unit storage. -
Page 7: Initial And Seasonal Startup
Initial and Seasonal Startup Checklist (Continued) 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. -
Page 8: Recommended Maintenance Schedule
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 9: Recommended Action
Initial and Seasonal Startup Checklist (Continued) Recommended Maintenance Schedule OPTIONAL ACCESSORIES: 10. Heater – Inspect elements for scale build-up Quarterly Electronic Water Level Controller – Inspect junction box for loose wiring Semiannually and moisture 12. Electronic Water Level Controller – Clean probe ends of scale Quarterly or as needed build-up 13. -
Page 10: Basic Cooling Tower Sequence Of Operation
(usually about 80°F [27°C]), 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 11: Fan System
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 12: Fan Belt Adjustment
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” (13 mm) when moderate pressure is applied midway between the sheaves. - Page 13 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.
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Page 14: Gear Drives
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 15: Variable Frequency Drives
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 16: Recirculated Water System - Routine Maintenance
Recirculated Water System – Routine Maintenance Suction Strainer in Cold Water Basin The pan strainer should be removed and cleaned monthly or as often as necessary. The suction strainer is the first line of defense in AT O&M 14X PAN SIDE CONN STRAINER DETAIL DWG keeping debris out of the system. -
Page 17: Product Line
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 18: Pressurized Water Distribution Systems
Pressurized Water Distribution Systems All EVAPCO cooling towers are supplied with wide orifice spray nozzles. The water distribution system should be checked monthly to make sure it is operating properly. Always check the spray system with the pump on and the fans off (locked and tagged out). -
Page 19: Gravity Fed Water Distribution Systems
Evaporative cooling equipment requires a bleed or blowdown line, located on the discharge side of the system 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. -
Page 20: Galvanized Steel - Passivation
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 prediluted prior to introduction into the cooling water and fed by automated equipment to an area of the system which ensures adequate mixing. -
Page 21: Gray Water And Reclaimed Water
(See EVAPCO’s Equipment Layout Manual for more information.) In addition, it is recommended that the building employ a site-specific water management program that is designed to minimize the risk of Legionellosis associated with building water systems. -
Page 22: Stainless Steel
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 23: Cold Weather Operation
“bypass” the tower’s water distribution system as a means of capacity control. EVAPCO recommends that the cooling tower bypass be installed in the condenser water piping system. -
Page 24: Unit Accessories
It is very important to maintain close control of the cooling tower during winter operation. EVAPCO recommends that an absolute MINIMUM leaving water temperature of 42°F (6°C) must be maintained; obviously, the higher the water temperature from the tower, the lower the potential for ice formation. -
Page 25: Forced Draft Unit Capacity Control
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 26: Troubleshooting
Verify that the system is connected to the grid. These are Generated (SUN) grid-interactive inverters and will not produce power without a stable grid connection. Utility voltage out of Contact EVAPCO. The acceptable range may be expanded if the range utility voltage differs from nominal. Individual Panel-Inverter Poor connection... - Page 27 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.
- Page 28 Troubleshooting (Continued) PROBLEM POSSIBLE CAUSE REMEDY Electric Water Level The valve won’t open 1. Verify that water pressure is above 5psi (0,35 bar) and below 125psi Control Not Working or close (7,0 bar). 2. Verify wiring with wiring diagram. Check supply voltage. 3.
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Page 29: Replacement Parts
(www.evapco.eu) for additional resources and/or contact your local EVAPCO sales representative. The local EVAPCO representative or Mr. GoodTower® Service Center can provide unit inspection(s) to help ensure you have the replacement parts you need to keep your equipment operating at peak performance regardless of the original manufacturer! To order replacement parts, please contact your local EVAPCO sales representative or Mr. -
Page 30: At 4' Wide Towers
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 31: At 6', 7.5', 8' & 8.5' Wide (Per Cell) Towers
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 32: At 6', 7.5', 8' & 8.5' Wide (Per Cell) Towers
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 33: At 7' Wide (Per Cell) Towers - End Connection
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 34: At 10' & 12' Wide' (Per Cell) Towers
AT 10’ & 12’ Wide (Per Cell) Towers – Side Connection FAN & FILL CASING SECTION 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... - Page 35 AT 10’ & 12’ Wide (Per Cell) Towers – End Connection FAN & FILL CASING SECTION FAN SCREEN 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...
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Page 36: At 14' X 24' (Per Cell) Towers - Side Connection
AT 14’ x 24’ (Per Cell) Towers – Side Connection FAN & FILL CASING SECTION FAN SCREEN ACCESS DOOR 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 37: At 14' X 24' (Per Cell) Towers - End Connection
AT 14’ x 24’ (Per Cell) Towers – End Connection FAN & FILL CASING SECTION FAN SCREEN 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 PAN &... -
Page 38: At 14' X 26' (Per Cell) Towers - End Connection
AT 14’ x 26’ (Per Cell) Towers – End Connection FAN & FILL CASING SECTION FAN SCREEN FAN CYLINDER ACCESS DOOR TEAO FAN MOTOR SLIDING MOTOR BASE FAN SCREEN SUPPORT DRIFT ELIMINATORS WATER INLET MECHANICAL CONNECTION EQUIPMENT SUPPORT FILL ALUMINUM FAN SHEAVE SPRAY BRANCH FAN BELT PAN END CONN DWG... -
Page 39: At 14' X 26' (Per Cell) Towers - Side Connection
AT 14’ x 26’ (Per Cell) Towers – Side Connection FAN & FILL CASING SECTION FAN SCREEN FAN CYLINDER 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 PAN &... -
Page 40: At 42' X 26' (Three Cell) Towers - Bottom Inlet
AT 42’ x 26’ (Three Cell) Towers — Bottom Inlet Connection, Bottom Outlet FAN & FILL CASING SECTION FAN SCREEN 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 PAN &... -
Page 41: All Box Sizes With Super Low Sound Fan
All Box Sizes with Super Low Sound Fan — Side or End Connections FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT 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 42: At Atlas
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 43 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 MAKEUP VALVE WITH ADJUSTABLE FLOAT WATER OUTLET CONNECTION SUCTION HOOD AND STRAINER FILL DOUBLE STACK...
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Page 44: Axs Towers All Box Sizes - Units With Super Low
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 MAKEUP VALVE WITH ADJUSTABLE FLOAT... - Page 45 SUN 8.5’ Wide Towers FAN & FILL CASING SECTION FAN SCREEN FAN CYLINDER DRIFT ELIMINATORS ACCESS DOOR FILL WATER INLET CONNECTION PAN & PLENUM SECTION AIR INLET LOUVER MEDIA PLENUM SECTION MOTOR SIDE FRAMED AIR MAKEUP VALVE WITH INLET LOUVER ADJUSTABLE FLOAT WATER OUTLET CONNECTION...
- Page 46 SUN 12’ Wide Towers FAN & FILL CASING SECTION FAN CYLINDER FAN SCREEN ACCESS DOOR WATER SPRAY SYSTEM FILL DRIFT ELIMINATORS PAN & PLENUM SECTION AIR INLET LOUVER MEDIA MOTOR SIDE PLENUM SECTION MAKEUP VALVE WITH ADJUSTABLE FLOAT FRAMED AIR INLET LOUVER COLD WATER BASIN SUCTION HOOD...
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Page 47: Lpt Towers
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 48: Lste 4' & 5' Wide Towers
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 49: Lste 8' & 10' Wide Towers
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 50 Notes...
- Page 51 Notes...
- Page 52 FOR EVAPCO AUTHORIZED PARTS AND SERVICE, CONTACT YOUR LOCAL EVAPCO SALES REPRESENTATIVE OR LOCAL SERVICE CENTER EVAPCO, Inc. — World Headquarters & Research/Development Center P.O. Box 1300 • Westminster, MD 21158 USA 410.756.2600 • marketing@evapco.com • evapco.com North America Europe Asia Pacific EVAPCO, Inc.
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