Cooling Tower Water and Chilled Water Pump Tanks Part Number: A0552321 Bulletin Number: SC5-605.8 Effective: 6/2014 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.
Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ................................................................................... 5 Safety Symbols Used in this Manual ..................................................................... 5 1-2 Warnings and Precautions ................................................................................ 6 1-3 Responsibility ..........................
Lubricating Pump Motors and Seals ................................................................... 49 Maintaining Makeup Valve Assemblies ............................................................... 49 CHAPTER 6: APPENDIX.......................................................... 50 6-1 Technical Assistance ..................................................................................... 50 Parts Department ..................................................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and optional features.
1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: þ Follow all SAFETY CODES. þ Wear SAFETY GLASSES and WORK GLOVES. þ Disconnect and/or lock out power before servicing or maintaining the equipment.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual covers many models of cooling tower pump tanks and chilled water pump tanks with operating capacities of 100 to 6,125 gallons (378 to 23,183 liters). Pump tanks are designed, specified, and engineered to meet the needs of the process specified at the time of purchase. Model numbers are listed on the serial tag. Model numbers start with a CT or CW to describe cooling tower or chilled water tank configurations.
2-3 Standard Features All tower and chilled water pump tanks come standard with the following: • ODP motors and cast iron impellers on standard pumps • Centrifugal pump(s) with cast iron housings, cast iron impellers and mechanical seals • Solid diamond-plate pump ledge • Standard hardware includes thermometer(s), compound liquid-filled pump pressure gauge(s) with trim, and drain valve • Heavy gauge 304 stainless steel construction.
2-4 Optional Features All cooling tower and chilled water pump tanks are available with the following: • Standby pump • Frame reinforcement for supporting other equipment • Special paint • Mild steel well and fittings (divider if applicable) • Second pump ledge • Support legs • OSHA handrail and ladder • Thermostat and thermowell • Extra thermostats and plugged 1/2” NPT thermostat openings • High- and/or low-temperature alarm • High- and/or low-pressure alarm • High- and/or low-level alarm • No flow alarm
Chapter 3: Installation 3-1 Uncrating Your Pump Tank Caution! Due to the size and weight of larger model pump tanks, the manufacturer recommends using bonded professional millwrights to unload and move larger pump tanks. Rig the pump tank from the frame only and use spreader bars to prevent load transfer to any pump tank components. Rig the frame from at least four points and balance the load before lifting to clear the skid.
3-4 Installing Separate Tank Ledge Models Pump tanks from the 2000, 2700, 3700, and 5100 Series are a two-component design with separate tank and pump ledge assemblies. These models include a hardware package and assembly drawing located in the information packet. The tank and pump ledge were temporarily joined together at the factory, so all components should line up properly in the field. General guidelines for installation are the following: • Two-piece models are not designed to be lifted as a unit.
3-7 Making Piping Connections Piping systems vary with process application and pump tank configuration. Typical system configurations are available in the Appendix, but the details may or may not apply to your application. Refer to Figure 1 on page 13 for pipe sizing guidelines. Piping systems must be designed by a person knowledgeable in piping system design and configuration. Our contracting department can design and install a piping system tailored to your process.
Figure 1: Pipe Sizing Guide Pipe Sizing Guide Pipe Size Flow-Steel Pipe Flow-PVC Pipe 1/2 2 2 3/4 5 5 1 10 10 1 1/4 20 20 1 1/2 30 30 2 50 55 2 1/2 100 100 3 160 160 4 320 320 6 900 1000 8 2000 2100 10 3500 3700 12 5000 5800 Based on 10’ head loss/100’ of pipe (new pipe) — open piping systems. A safety factor of 15 to 20% should be added based on local conditions.
Tower Tank Piping Connections Return From Process (Single Well). Connect process return piping to the cooling tower inlet with appropriate balancing valves and gauges. Size this line to the tower flow rate. Return From Process (Dual Well). Connect process return piping to the hot well. Size piping to the process flow rate. Re-circulation Pump Discharge (Dual Well). Connect to the cooling tower inlet with appropriate balancing valves and gauges. Size according to the pump discharge rate. Return From Tower.
Chilled Water Piping Connections Process Pump Discharge (Single Well). Connect process pump discharge to the chiller evaporator water inlet. Size to the chilled water flow rate. Chiller evaporator inlet and outlet should have valves and temperature and pressure gauges. Outlet of the evaporator is connected to the chilled process water supply. Process Pump Discharge (Dual Well). Connect directly to the chilled water process supply. Size according to process flow requirements. Return (Single Well).
Chapter 4: Operation 4-1 Start-up 1. Close the drain line at the bottom of the pump tank. 2. Open the 1” makeup water valve and allow the tank to fill until the automatic float valve shuts off. Adjust the float level so the standing water level is 16” from the top of the tank, 12” on 150 Series pump tanks. Some tower systems may require a lower level to allow for drawback from the cooling towers. 3. Check all wiring integrity, field installed controls and voltage. 4.
4-3 Stand-by Pump Usage All stand-by pumps should be checked intermittently to make sure they are operational for when they may be required for usage. Single Stand-by pump: 1. Open the suction valve fully and lock down. 2. Open the discharge valve slowly until it is equal to the pump it will be replacing. 3. Shut down the pump being replaced and make sure the suction and discharge valves are fully closed. Dual Stand-By Pump 1.
Pump Tanks Chapter 4: Operation 18 of 67
The first status screen’s appearance will vary depending on the configuration.
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↑ ↓ Menu Use the ↑ and ↓ keys to switch the selected menu item. Press the ↵ key to go to the selected screen. Press the Esc to return to the Status screens. Active Alarms Use the ↑ and ↓ keys to change the display to view other active alarms. The Alarm Reset Screen follows the last active alarm screen. Press the ↵ key to silence the alarm horn. Press the Esc to return to the Menu.
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↑ ↓ 4-1 Alarm History When the Alarm History screen is activated, it will display the most recent alarm. Use the ↑ key to view the previous alarm and ↓ key to the next alarm. Press the Esc to return to the Menu. 4-2 Setup When the cursor is in the upper left of the screen, use the ↑ and ↓ keys to change the SETUP screen displayed. To change a setting on a screen, press the ↵ key to select the first item on the page.
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↑ ↓ 4-3 Manual Mode When the system is offline, each of the digital and analog outputs can be activated from the manual screen. While any of the outputs are in manual mode, the system cannot be brought online. To change the the status of one of the items on the screen, press the ↵ key to select the first item on the page. Use the ↑ and ↓ keys to change the selected item or use the ↵ key to move to the next item. The items on the Manual Mode screen will vary depending on the control’s configuration.
4-4 Hour Meters Each pump and fan has a run-time hour meter. The hour meters are displayed on the last Status screen. 4-5 Options – Analog Inputs Ambient Temperature Sensor Adds an ambient temperature sensor. It must be installed before a digital output can be configured for a wintercooler pump. Evaporator In Temperature Adds an evaporator in temperature sensor. Evaporator Out Temperature Adds an evaporator out temperature sensor.
4-6 Options – Analog Outputs Cold Side Retransmission The selected analog output will retransmit the Cold Side Temperature. The range of temperature transmitted is dictated by the Cold Side Retransmission Min and Max settings. Hot Side Retransmission The selected analog output will retransmit the Hot Side Temperature. The range of the temperature transmitted is dictated by the Hot Side Retransmission Min and Max. Process 3 Way Valve This valve is used with the Wintercooler output option.
Recirc Low Flow Switch Adds a Recirc Low Flow Switch Alarm input. See Alarm section of this document for more information. Recirc Low Pressure Switch Adds a Recirc Low Pressure Switch Alarm input. See Alarm section of the document for more information. Wintercooler Flow Switch Used to verify that the Wintercooler Pump is generating flow. A digital output must be configured for a Wintercooler Pump.
Wintercooler Pump When all of the following conditions are met, the wintercooler pump will activate • The wintercooler pump is enabled. • At least one recirc pump is active. • The ambient temperature is less than or equal to the the wintercooler on SP. • The tank cold side temperature is more than 2 degrees above the chiller SP. The winter cooler pump will remain active until any of the following occur: • The wintercooler pump is disabled. • All recirc pumps are off.
4-11 Standby Pump Control The stand pump’s required IO (one digital output and one digital input per pump) will start with the first available input and output after the recirc pumps have been assigned their required IO. The process pump standby will be assigned the first available IO and the recirc pump standby will take the next. Standby pumps, if enabled, will activate if the primary pump fails.
4-13 Alarms When an alarm occurs, the alarm horn/light (optional) is activated and the active alarm is shown on the display. Pressing the ↵ key on the display will silence the alarm horn/light. If an alarm is still active 10 minutes (adjustable by Alm Silence Time) after the it was silenced, the alarm horn/light will activate again. Each alarm that occurs will be logged on the Alarm History screen. In addition to the alarm name, the tank temperatures and tank level are logged at the time the alarm occurs.
Evap. Inlet Temperature Sensor Failure This alarm occurs when all of the following conditions are met: • The system is online. • The control detects an evap inlet temperature sensor failure. This alarm will remain active until any of the following conditions are met: • The system is no longer online. • The control no longer detects an evap inlet temperature sensor failure when the alarm is reset. Evap.
High Process Pressure Fault This alarm occurs when all of the following conditions are met: • A process pump has been active for 15 seconds. • The process pump pressure is greater than or equal to the High Pressure Fault setpoint. • The Process Pressure Sensor Failure alarm is not active. This alarm will remain active until any of the following conditions are met: • The system is no longer online. • The process pump pressure is less than the High Process Pressure Fault setpoint when the alarm is reset.
High Recirc Pressure Warning This alarm occurs when all of the following conditions are met: • A recirc pump has been active for 15 seconds. • The recirc pump pressure is greater than or equal to the High Recirc Pressure Warning setpoint. • The High Recirc Process Pressure Fault is not active. • The Recirc Pressure Sensor Failure alarm is not active. This alarm will remain active until any of the following conditions are met: • The system is no longer online.
Hot Side Temperature Sensor Failure This alarm occurs when all of the following conditions are met: • The system is online. • The control detects a hot side temperature sensor failure. This alarm will remain active until any of the following conditions are met: • The system is no longer online. • The control no longer detects a hot side temperature sensor failure when the alarm is reset. Level Sensor Failure This alarm occurs when all of the following conditions are met: • The system is online.
Low Process Pressure Fault This alarm occurs when all of the following conditions are met: • A process pump has been active for 15 seconds. • The process pump pressure is less than or equal to the Low Process Pressure Fault setpoint. • The Process Pressure Sensor Failure alarm is not active. This alarm will remain active until any of the following conditions are met: • The system is no longer online. • The process pump pressure is greater than the Low Process Pressure Fault setpoint when the alarm is reset.
Low Recirc Pressure Warning This alarm occurs when all of the following conditions are met: • A recirc pump has been active for 15 seconds. • The recirc pump pressure is less than or equal to the Low Recirc Pressure Warning setpoint. • The Recirc Low Pressure Fault is not active. • The Recirc Pressure Sensor Failure alarm is not active. This alarm will remain active until any of the following conditions are met: • The system is no longer online.
Misc Alarm This alarm occurs when all of the following conditions are met for 5 seconds: • The system is online. • The Misc Alarm Input is in alarm condition (determined by the Misc Alarm NO/NC variable). This alarm will remain active until the system is taken offline or the Misc Alarm Input is not in alarm condition when the alarm is reset. Process Amp Sensor Failure This alarm occurs when all of the following conditions are met: • The system is online. • The control detects a process amp sensor failure.
Process Pump Motor Fault Alarm While this alarm is active, the process pump is not allowed to run. If another process pump is enabled or the stand-by pump is enabled and configured as a process, it will start after a 2 second delay. This alarm occurs when all of the following conditions are met for 3 seconds: • The system is online. • The process pump is enabled. • The process pump run input is not active.
Recirc. Low Pressure Switch Alarm This alarm occurs when all of the following conditions are met for the Recirc Low Pressure Delay: • The system is online. • At least one process pump is active. • The Recirc Low Pressure Switch Input is not active. The alarm will remain active until the system is taken offline or the Recirc Low Pressure Switch Input is active when the alarm is reset. Recirc. Pressure Sensor Failure This alarm occurs when all of the following conditions are met: • The system is online.
This alarm will remain active until any of the following conditions are met: • The system is no longer online. • The control no longer detects a tower fan amp sensor failure when the alarm is reset. Tower Fan Motor Fault Alarm While this alarm is active, the fan is not allowed to run. This alarm occurs when all of the following conditions are met for 3 seconds: • The system is online. • The fan is enabled. • The fan run input is not active.
Chapter 5: Maintenance 5-1 Preventative Maintenance Water Treatment Control of slime, algae, and bacteria growth is extremely important. Cooling towers and reservoir pump tanks are superb environments for microorganism growth. Warm water, organic debris, and air encourage bacterial growth. Treat your system with chemicals (microbiocides) to control microorganism growth.
Chapter 6: Appendix 6-1 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us.
6-2 Remote Starters and NEMA Panels Pump tanks can be provided with electrical controls such as basic motor starters or elaborate NEMA panels. Motor starters or NEMA panels can be shipped loose for field installation or pre-mounted for space saving convenience. Motor starters are equipped with on/off selector switches for turning the pump on with overload relays to protect the motor when operating.
6-3 Drawings and Specifications Cooling Tower Water Pump Tanks Top View Side View (P2 Pump Shown Only For Clarity) Front View American Standards Maximum tower tons Return water & Dimensions overflow Model Single Dual gallons pumps/ connections inches number well well Overflow Operating ledge Inches L W H CT140 (D) 25 13 125 100 3 3” NPT 72 36 40 5” CLMP 78 39 390 350 3 95 56 64 PT390 (D) CT480 (D) 90 45 450 360 3 4” FLG 102 49.5 52 CT720 (D) 135 68 675 540 4 4” FLG 114 73.
Figure 2: Standard Pumps and Trim Based on Cooling Tower Capacities (Flow Based on 3 gpm per Ton) American Standards Capacity Nominal Nominal flow cooling tower tons gallons 20 60 30 90 40 120 50 150 60 180 75 225 80 240 100 300 125 375 150 450 175 525 200 600 250 750 300 900 Pump horsepower Amp draw 460/3/60 Shipping weight (lbs.) • P1 • P2 Trim size (inches) Maximum flow (gpm) Shipping weight (lbs.) 1½ 2.6 — 60 Trim size inches 2½” 2½” 3” 3” 4” 4” 4” 4” 6” 6” 6” 6” 6” 6” 3 4.8 95 90 2 50 25 5 7.
Chilled Water Pump Tanks Side View Top View (P2 Pump Shown Only For Clarity) Front View American Standards Maximum tons chilled H2O Capacity Maximum Return water & overflow Connections inches 3” NPT 5” CLMP 4” FLG 4” FLG 6” FLG 6” FLG 6” FLG 6” FLG 6” FLG 8” FLG 10” FLG Tank weight (less pumps) Dimensions Model Single Dual gallons Pumps/ inches number well well Overflow Operating Ledge L W CW140 (D) 47 23 125 110 3 72 36 146 73 390 350 3 95 56 PC390 (D) CW480 (D) 175 87 450 420 3 102 4
Figure 3: Standard Pumps and Trim Based on Chiller Capacities (Flow based on 2.4 gpm per ton) American Standards Capacity Nominal Nominal flow refrigeration tons gallons 25 60 35 84 50 120 60 144 75 180 90 216 100 240 125 300 155 372 185 444 220 528 250 600 310 744 375 900 Pump horsepower Amp draw 460/3/60 Shipping weight (lbs.) 1½ 2.6 — 60 • P1 • P2 Trim size (inches) Maximum flow (gpm) Shipping weight (lbs.) Trim size inches 2½” 2½” 3” 3” 4” 4” 4” 4” 6” 6” 6” 6” 6” 6” 3 4.8 95 90 5 7.
Process Pump Curves and Specifications TOTAL HEAD P1 PROCESS PUMP CURVES - 60 CYCLE KG/ PSI FEET 2 CM 7 100 6.5 220 90 200 6 5.5 80 180 5 70 160 60 HP 4.5 10 HP 60 140 15 HP 20 HP 25 HP 3.5 50 3 120 5 HP 7 1/2 HP 100 40 HP 40 3 HP 100 200 2.5 U.S. GALLONS PER MINUTE LITERS PER MINUTE A0548756 500 300 1000 400 1500 500 2000 Pump Information Model 16 50 52 52 54F 55F 56F 57 57 63 63 50 HP 30 HP 4 IMP. 5.2” 6.0” 5.75” 6.5” 6.5” 6.5” 6.3” 6.4” 6.87” 7.5” 8.
Re-circulation Pump Curves and Specifications TOTAL HEAD P2 RECIRCULATING PUMP CURVES - 60 CYCLE KG/ PSI FEET CM2 110 45 100 3 40 90 2.5 35 80 3 HP 30 70 2 25 1.5 30 HP 60 20 HP 5 HP 50 7 1/2 HP 20 40 25 HP 15 HP 10 HP 1 1/2 HP 100 U.S. GALLONS PER MINUTE LITERS PER MINUTE 200 500 300 1000 400 1500 500 2000 600 700 2500 800 3000 900 3500 1000 1100 1200 1300 4000 4500 5000 A0548756 Pump Information Model 60 16 17 103 104 95 96 96 96 IMP. 4.6” 5.2” 5.3125” 8.0” 8.0” 8.6” 8.9” 9.
6-4 Parts List Recommended Spare Parts Part number Quantity A0550190 1 A0501073 1 A0069286 1 (if required) A0069285 1 (if required) A0102396 1 A0069538 1 A0102394 1 Description Pressure gauge Temperature gauge Strainer basket, 12” (approx. 30.5 cm) Strainer basket, 18” (approx. 45.7 cm) Float valve, 1” (approx. 25.4 mm) Plastic ball float, 6” (approx. 15.2 mm) Float rod, 10” (approx. 25.
6-5 Optional Assembly Detail Drawings Tank Support Leg Assembly Detail: 4 Legs Pump Tanks Chapter 6: Appendix 59 of 67
Tank Support Leg Assembly Detail: 6 Legs Pump Tanks Chapter 6: Appendix 60 of 67
Tank Support Leg Assembly Detail: 7 Legs Pump Tanks Chapter 6: Appendix 61 of 67
Tank Ladder Assembly Detail Pump Tanks Chapter 6: Appendix 62 of 67
Sightglass Assembly Detail Pump Tanks Chapter 6: Appendix 63 of 67
6-6 Typical Piping Diagrams Typical Single Well Cooling Tower Water Pump Tank Piping System P P Cooling tower 3/8" drain intended to prevent tower freeze-up. Do NOT valve.
Typical Dual Well Cooling Tower Pump Tank Piping System P P Cooling tower 3/8" drain intended to prevent tower freeze-up. Do NOT valve. 1/4" swing check valve mounted 12" above highest point in return piping Bypass 3/4" constant bleed Tower water return Backflow preventer (by others) Overflow Strainer basket Makeup Dual well tower water reservoir Cooling tower fan control (optional) Tower water supply Recirc.
Typical Single Well Chilled Water Pump Tank Piping System 1/4" swing check valve located 12" above highest point in return line Tower water return and supply Bypass Chilled water return Chilled water supply Backflow preventer (by others) Overflow T P T P Evaporator Single chilled water reservoir Makeup Condenser Return T Drain Chiller P P-1 To container (by others) Auto pressure regulating valve assembly (optional) Caution! Do not connect city water makeup if glycol is used in the system Cauti
Typical Dual Well Chilled Water Pump Tank Piping System 1/4" swing check valve located 12" above highest point in return line Tower water return and supply Bypass Chilled water return Chilled water supply Backflow preventer (by others) Overflow T Makeup Dual chilled water reservoir P T P Evaporator Condenser T Return Cold side Hot side T Return Drain P P-1 P P-2 Chiller P P-3 To container (by others) Standby Caution! Do not connect city water makeup if glycol is used in the system
