EVAPCO AT 110-112 Operation And Maintenance Instructions Download Page 4 | Manualshive

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Installation Precautions

WARNING: The water inlet and outlet connections are not designed to support piping. The piping always need to be

supported (by others).

Storage Precautions

WARNING: Never use plastic sheets or tarps to protect a unit during storage. This practice can trap heat inside the

unit and could potentially cause damage to plastic components.

Label on the casing section(s)

.

2A

(2)

2

(2)

35

17A

33

2

EVAPCO LOGO (both sides)

2A

RIGGING INSTRUCTIONS (both ends)

33

WATER IN

17A WARNING ELIMINATORS
35

DO NOT COVER ELIMINATORS

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Summary of Contents for AT 110-112

Page 1: ...O Europe S r l Via Ciro Menotti 10 I 20017 Passirana di Rho Milan Italy Phone 39 02 9399041 Fax 39 02 93500840 Email evapcoeurope evapco it EVAPCO Europe GmbH Insterburger Straße 18 D 40670 Meerbusch Germany Phone 49 2159 6956 0 Fax 49 2159 6956 11 Email info evapco de EUROPEAN OPERATION AND MAINTENANCE INSTRUCTIONS For EVAPCO Induced Draft and Forced Draft Cooling Towers For EVAPCO Authorized Par...

Page 2: ...Assembly 14 Cold Water Basin 14 Operating Water Levels 14 Water Make Up Valve 15 Drift Eliminators 15 Pressurized Water Distribution System 15 Bleed Off Valve 16 Water Treatment and Water Chemistry 17 Bleed or Blowdown 17 Galvanized Steel Passivation 17 Water Chemistry Parameters 18 Control of Biological Contamination 18 Gray Water and Reclaimed Water 19 Air Contamination 19 Stainless Steel 19 Mai...

Page 3: ...perly secured locked and in place WARNING For assembling or disassembling the unit or unit sections please follow the rigging instructions or the instructions on the yellow labels on the individual unit sections WARNING 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 prote...

Page 4: ...age Precautions WARNING Never use plastic sheets or tarps to protect a unit during storage This practice can trap heat inside the unit and could potentially cause damage to plastic components Label on the casing section s 2A 2 2 2 35 17A 33 2 EVAPCO LOGO both sides 2A RIGGING INSTRUCTIONS both ends 33 WATER IN 17A WARNING ELIMINATORS 35 DO NOT COVER ELIMINATORS ...

Page 5: ...ve 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 Th...

Page 6: ...eration 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 Sliding motor base Inspect and grease annually or as needed 13 Check fan screens inlet louvers and fans Remove any dirt or debris monthly 14 Inspect and clean protective finish annually Galvanized scrape and coat with ZRC...

Page 7: ...wo or More Days Energize motor space heaters or run motors for 10 minutes twice daily 2 One Month or longer Rotate motor shaft fan 10 turns bi weekly 3 One Month or longer Megger test motor windings semi annually 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 s...

Page 8: ...tly Excessive cycling can lead to scale build up and reduce wet and dry performance Bypass Mode During winter months when cooling load is minimal bypass mode may be used as a form of capacity control Bypass mode allows the water to bypass the tower s water distribution system and deposits the inlet water directly into the cold water basin Alternatively the incoming water bypass can be piped direct...

Page 9: ...greases which are suitable for operation between 40 C and 120 C For colder operating temperatures contact the factory Chevron Multifak Premium 3 Total Ceran WR2 or similar Shell Alvanias 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 Most EVAPCO units are ...

Page 10: ...earing sleeve and cause bearing failure Ambient Temp Texaco Mobil Exxon Total 32 C to 0 C DTE Heavy 17 C to 43 C 0 to 38 C Regal R O 220 DTE Oil BB Teresstic 220 Table 2 Sleeve Bearing Lubricants Oil drippage may result from over oiling or from using too light an oil Should this condition persist with correct oiling it is recommended that the next heavier weight oil be used All bearings used on EV...

Page 11: ...ure 6 LPT Motor Adjustment On induced draft belt driven units with internally mounted motors 3 m 3 6 m 4 2 m 6 m 7 2 m and 8 4 m wide units as shown in Figure 5 LPT units as shown in Figure 6 and PM units as shown in Figure 7 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 counterc...

Page 12: ...e a minimum of a 30 second delay when switching from high speed to low speed Sequence of Operation for Two Fan Units with Two Speed Motors During Peak Load 1 Both fan motors on full speed full water flow over both cells 2 One fan motor on high speed one fan motor on low speed full water flow over both cells 3 Both fan motors on low speed full flow over both cells 4 One fan motor on low speed one f...

Page 13: ...requencies in the field a run up and run down test must be performed Additionally VFD carrier frequencies should be adjusted to best align the VFD with the electrical system Refer to your drive s start up procedures for additional information and instruction The procedure of checking for resonant frequencies requires stepping through the VFD s operating range at 2 Hz intervals from the lowest oper...

Page 14: ... through 312 960 230 mm AT 114 0124 through 314 1272 280 mm AT 26 517 through 28 917 230 mm AT 212 59 through 212 99 230 mm AT 215 29 through 215 99 230 mm AT 216 49 through 216 914 230 mm AT 220 112 through 220 918 230 mm AT 224 018 through 224 920 230 mm AT 228 0124 through 428 1248 280 mm AT 420 124 through 424 936 280 mm LSTE LSTE LSTE LSTE 416 5112 8P 112 10 112 through through through throug...

Page 15: ...e safety measures against the risk of a fall in accordance with local regulations Remove one or two eliminator sections from the top of the unit protect the fill by use of a hard board before entering the unit and walking on the fill Never walk on the eliminators Once standing on the fill the remaining drift eliminators can be removed On induced draft models lifting handles are provided along the ...

Page 16: ...has been cleaned the suction strainer should be checked to make sure it is in good operating condition and positioned properly so that cavitation or air entrapment does not occur When inspecting and cleaning the water distribution system always check that the orientation of the water diffusers is correct as shown below for LPT and LSTE models in Figure 13 and as shown in Figure 14 for AT UAT and P...

Page 17: ...lt 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 durin...

Page 18: ...t 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 The location of the pH probe and acid feed line should be design...

Page 19: ...fresh air intakes to prevent any drift biological activity or other unit discharge from entering the building s air system 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 304L and Type 316L with a No 2B unpolished finish Type 304L stainless s...

Page 20: ... Aggressive Cleaning Removal of Fingerprints or Grease Repeat processes 1 and 2 then use a hydro carbon solvent like Acetone or alcohol As with any hydro carbon solvent caution must be taken when using the product Do not use in confined spaces or while smoking Keep solvents out of contact with hands and skin Household glass cleaner Spic n Span are other options for cleaners After cleaning towel dr...

Page 21: ...on may result in component failure and cause a shutdown of the cooling unit The use of a bypass should also be considered Typically winter loads are less than peak summer loads When this is the case a cooling tower bypass needs to be incorporated into the system design to allow water to bypass the tower s water distribution system as a means of capacity control EVAPCO recommends that the cooling t...

Page 22: ...g tower during winter operation EVAPCO recommends that an absolute MINIMUM leaving water temperature of 6 C must be maintained obviously the higher the water temperature from the tower the lower the potential for ice formation This assumes that proper water flow over the tower is maintained Induced Draft Unit Capacity Control The simplest method of capacity control is cycling the fan motor on and ...

Page 23: ...ced draft units The VFD control system allows the fans to run at nearly an infinite range of speeds to match the unit capacity to the system load During periods of reduced load and low ambient temperatures the fans can be maintained at a minimum speed which will ensure a positive air flow through the unit This positive air flow in the unit will prevent moist air from migrating towards the cold fan...

Page 24: ... length of time required to completely defrost the ice from the unit The frequency and length of the defrost cycle is dependent on the control methods and ambient cold weather conditions Some applications will build ice quicker than others which may require longer and more frequent defrost periods Frequent inspection of the unit will help fine tune the length and frequency of the defrost cycle For...

Page 25: ...ty directly affects AMP reading 1 Check voltage across all three legs of the motor 2 Verify that the motor is wired per the wiring diagram and connections are tight Verify that the fan is rotating in the correct direction If not switch the leads so it runs correctly Verify that the fan and motor turn freely by hand If not there may be damage to the internal motor components or bearings Check for p...

Page 26: ... in the unit will neutralize and dissolve the buildup of scale Please note that the time required for soaking the inlet louvers depends on the severity of the scale buildup Mechanical make up valve water pressure must be between 140 and 340 kPa If pressure is too high the valve will not close A pressure reducing valve can be added to lower the pressure For the 3 Probe Electronic Water Level Contro...

Page 27: ...ance of the unit s surface should be done on a regular basis 1 Verify that water pressure is above 0 35 bar and below 7 0 bar 2 Verify wiring with wiring diagram Check supply voltage 3 Verify that there is not a blockage in the Y Strainer 4 Confirm the probes are not dirty 5 Check Red LED on circuit board If it is on the valve should be closed For a 3 Probe Assembly Simulate Low Water Condition LE...

Page 28: ...acement Parts EVAPCO has replacement parts available for immediate shipment Most orders ship within 24 hours from time of order To order replacement parts please visit www evapco eu to find your local contact ...

Page 29: ... FILL CASING SECTION ICT UNITS AIR INLET LOUVER SUCTION HOOD STRAINERS MAKE UP VALVE WITH ADJUSTABLE FLOAT OUTLET CONNECTION FAN CYLINDER FAN SCREEN FAN FAN MOTOR WATER INLET CONNECTION DRIFT ELIMINATORS FILL ACCESS DOOR PAN SECTION ...

Page 30: ...FAN FILL SPRAY BRANCH ACCESS DOOR TEFC FAN MOTOR FAN MOTOR SHEAVE FAN BELT SWING OUT MOTOR COVER FAN SCREEN FAN CYLINDER BEARING SUPPORT FAN SHAFT BEARING FAN SCREEN SUPPORT MAKE UP VALVE WITH ADJUSTABLE FLOAT WATER OUTLET CONNECTION COLD WATER BASIN FRAMED AIR INLET LOUVER AIR INLET LOUVER MEDIA SUCTION HOOD STRAINER ...

Page 31: ...OOD STRAINER MAKE UP VALVE WITH ADJUSTABLE FLOAT COLD WATER BASIN AIR INLET LOUVER MEDIA FAN SCREEN FAN SCREEN SUPPORT FAN ACCESS DOOR TEAO FAN MOTOR DRIFT ELIMINATORS FILL WATER DISTRIBUTION SPRAY BRANCH MECHANICAL EQUIPMENT SUPPORT SLIDING MOTOR BASE ALUMINUM FAN SHEAVE FAN BELT FAN CYLINDER AT UAT 3 m and 3 6 m WIDE CELLS ...

Page 32: ...CHANICAL EQUIPMENT SUPPORT FAN SCREEN FAN CYLINDER DRIFT ELIMINATORS FILL WATER INLET CONNECTION WATER DISTRIBUTION SPRAY BRANCH ALUMINUM FAN SHEAVE FAN BELT FAN SCREEN SUPPORT FAN PLENUM SECTION MAKE UP VALVE WITH ADJUSTABLE FLOAT WATER OUTLET CONNECTION SUCTION HOOD STRAINER AIR INLET LOUVER MEDIA COLD WATER BASIN FRAMED AIR INLET LOUVER ...

Page 33: ...OR SUCTION HOOD SUCTION STRAINER FAN SHEAVE FAN BELT FAN WHEEL MAKE UP VALVE WITH ADJUSTABLE FLOAT TEFC FAN MOTOR FAN HOUSING FAN WRAPPER WATER INLET CONNECTION FILL WATER DISTRIBUTION SPRAY BRANCH DRIFT ELIMINATORS DRIFT ELIMINATOR SUPPORT FILL SUPPORT CHANNEL WATER DISTRIBUTION SPRAY BRANCH SUPPORT CASING ...

Page 34: ...RIFT ELIMINATORS FILL WATER DISTRIBUTION SPRAY BRANCH WATER INLET CONNECTION CASING FILL SUPPORT CHANNEL WATER DISTRIBUTION SPRAY BRANCH SUPPORT MOTOR COVER FAN HOUSING BEARING SUPPORT MIGRATION BAFFLE ACCESS DOOR MOTOR BASE SUCTION STRAINER MAKE UP VALVE WITH ADJUSTABLE FLOAT WATER OUTLET CONNECTION ...

Page 35: ...TION BAFFLE ACCESS DOOR BEARING SUPPORT FAN HOUSING MOTOR BASE WATER OUTLET CONNECTION OUTLET HOOD STRAINER FAN SCREENS NOT SHOWN FOR CLARITY DRIFT ELIMINATORS FILL WATER DISTRIBUTION SPRAY BRANCH WATER INLET CONNECTION CASING FILL SUPPORT CHANNEL WATER DISTRIBUTION SPRAY BRANCH SUPPORT ...

Page 36: ...E FLOAT COLD WATER BASIN SUCTION STRAINER ADJUSTABLE MOTOR BASE ACCESS DOOR FAN BELT TEFC FAN MOTOR FAN CYLINDER SUPER LOW SOUND FAN WATER INLET CONNECTION LIFTING EARS DRIFT ELIMINATORS CASING WATER DISTRIBUTION SPRAY BRANCH WATER DISTRIBUTION SPRAY BRANCH SUPPORT FILL SUPPORT CHANNEL FILL ...

Page 37: ...FLOAT WATER OUTLET CONNECTION COLD WATER BASIN FRAMED AIR INLET LOUVER AIR INLET LOUVER MEDIA SUCTION HOOD STRAINER ACCESS DOOR FAN BELT FAN MOTOR SHEAVE TEFC FAN MOTOR SWING OUT MOTOR COVER FAN CYLINDER BEARING SUPPORT FAN SCREEN FAN SCREEN SUPPORT SUPER LOW SOUND FAN FAN SHAFT FAN BEARING DRIFT ELIMINATORS FILL WATER DISTRIBUTION SPRAY BRANCH ...

Page 38: ...E UP VALVE WITH ADJUSTABLE FLOAT COLD WATER BASIN AIR INLET LOUVER MEDIA ACCESS DOOR TEAO FAN MOTOR SLIDING MOTOR BASE MECHANICAL EQUIPMENT SUPPORT FAN SCREEN SUPER LOW SOUND FAN FAN SCREEN SUPPORT FAN CYLINDER DRIFT ELIMINATORS FILL ALUMINUM FAN SHEAVE FAN BELT SPRAY BRANCH AT UAT WITH SUPER LOW SOUND FAN 3 3 6 and 4 2 m WIDE CELLS ...

Page 39: ...39 ...

Page 40: ... 2012 EVAPCO Europe Bulletin 113 E 1216 ...

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