Fiberglass Cooling Towers Part Number: 882.00440.00 Bulletin Number: SC6-610.6 Effective: 9/10/07 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. DCN No.
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................................................................ 6 1-1 How to Use This Manual ................................................................................. 6 1-2 1-3 Warnings and Precautions .............................................................................. 7 Responsibility .................................................................................................. 7 Safety Symbols Used in this Manual ..............................
6-3 6-4 Parts List ....................................................................................................... 24 Electrical Schematics ....................................................................................
List of Figures Figure 1: Structural Steel Support Requirements ......................................................................... 11 Figure 2: Rigging Arrangement .................................................................................................... 13 Figure 3: Cooling Tower with Tower Reservoir Piping Diagram ................................................ 14 Figure 4: Cooling Tower with Basin as Reservoir Piping Diagram .............................................
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: ; Follow all SAFETY CODES. ; Wear SAFETY GLASSES and WORK GLOVES. ; 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 fiberglass cooling tower models. Model numbers are listed on the serial tag. A model number followed by –Q is specially-constructed, and the information in this manual may not apply. Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service.
2-4 Optional Features Side Outlet. The side outlet is used when the tower basin is used as a reservoir. Starter Package. The starter package includes a starter, a remote On/Off switch, a thermostat, and a well. Basin Reservoir. The basin reservoir includes an automatic float valve, overflow and drain connections, and an outlet basket strainer for towers with no inside reservoir. Basin Heater. The basin heater includes a heater and a low water level heater shutoff.
Chapter 3: Installation 3-1 Tower Installation Location Roof Installation Select a location over or nearest to the heaviest building structural members. These members should be outside load-bearing walls, building columns, or roof joists. You may need to spread the load over several structural members to provide support without over-stressing any one member. See Figure 1 on page 11 for structural steel support requirements.
Figure 1: Structural Steel Support Requirements Structural steel B B 2 X 2 angle to support tower basin, flush with top of structural steel rails D A C C C C TSE50 Model number SF2003 SF2004 SF2005 SF2007 SF2009 SF2011 SF2015 Note: A in. 52 52 68 68 87 87 87 B cm 132.1 132.1 172.7 172.7 221.0 221.0 221.0 in. 50 50 67 67 85 85 85 C cm 127.0 127.0 170.2 170.2 215.9 215.9 215.9 in. 16 16 22 22 28 28 28 D cm 40.6 40.6 55.9 55.9 71.1 71.1 71.1 in. 78 78 78 78 78 78 78 cm 175.3 175.3 175.3 175.
3-2 Assembling the Cooling Tower in the Field Your cooling tower may have been shipped on two skids to reduce shipping charges. One skid contains the lower section, identified by the black fill wrapped in plastic on the inside of the lower section. The second skid contains the top tower section bolted over the fan/motor assembly. Perform the following procedure to properly assemble the two sections if the sections shipped separately. 1. Remove the clear plastic protective wrapping from the fill. 2.
3-3 Rigging Handle the fiberglass cooling tower shell section very carefully. Until installed and properly supported, it is subject to handling damage. See Figure 2 for rigging information. Caution! Use an appropriately rated hoist to support the equipment. Figure 2: Rigging Arrangement Channel I-beam Spreader bar wide enough to protect cooling tower shell Rope stay Caution! Use appropriately rated hoist to support equipment.
Install the piping according to the piping diagrams in Figure 3 on page 14, Figure 4 on page 14, and Figure 5 on page 15. Figure 3: Cooling Tower with Tower Reservoir Piping Diagram Type 2 pressure gauge Type 2 balancing valve Type 2 inlet TWR P TWR Caution! Support piping to eliminate load from tower casing Cooling tower Do not apply excessive torque to fittings Typical bottom outlet 3/4" constant bleed Bypass 3/8" drain line NOTE: Drain line is intended to prevent tower freeze-up.
Figure 5: Flexible PVC Outlet Coupler Tower outlet Flexible FlexiblePVC PVC coupling Coupling (from AEC) (from Sterling) Clamps (from AEC) (from Sterling) Outlet pipe must be supported from building structure or tower steel Fiberglass Cooling Towers Chapter 3: Installation Page 15 of 25
3-6 Setting Up the Water Balancing Valve Install the plug provided in the unused water inlet on the side of the tower. Tighten and check for leaks. To prevent damage to the tower fill material, use the water throttling valve and pressure gauge to regulate the water pressure to the tower spray nozzle(s). The recommended throttling valve is a butterfly-type valve that can be locked in the correct position with a locknut. See Figure 6 for recommended throttling valve pressures.
Chapter 4: Operation 4-1 Bleed-Off and Evaporation Rates A proper bleed-off rate is important to limit the concentration of minerals and foreign materials in re-circulated water. A bleed-off equal to the evaporation rate, normally about two gallons per hour per ton (7.57 liters per hour per 3,780 Kcal/hr), is sufficient for many makeup water conditions. Refer to the suggested bleed-off arrangements in Figure 3 and Figure 4 on pages 14 and 14 for more information.
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.
5-2 Corrective Maintenance Replacing Nozzles and Fill The PVC fill used in these cooling towers provides years of maintenance-free service under normal conditions. If you discover dirty water or defective nozzle(s) damage the fill, you can order a replacement kit from the parts department. You can easily remove and replace the fill by removing the tower access door on the side of the tower. Open the door to gain access to the nozzle system.
Chapter 6: Appendix 6-1 Technical Assistance Parts Department Call Toll-Free 7am–6pm CST [800] 423-3183 or call [262] 641-8610 Our Parts Department is ready to provide the parts to keep your systems up and running. OEM replacement parts ensure operation at design specifications. Please have the model and serial number of your equipment when you call. Consult the Customer Parts List included in your information packet for replacement part numbers.
6-2 Drawings and Specifications A A0536711 B Top View Fan guard Fan motor Motor support assembly Fan blade Supply piping Access door D Nozzle adaptor C Nozzle Rigid PVC tower fill Water diverter E Return piping Side View Cutaway View Figure 7: Dimensions and Weights Model A number in. cm SF2003 64 163 SF2004 64 163 SF2005 82 208 SF2007 82 208 SF2009 100 254 SF2011 100 254 SF2015 100 254 B in. 64 64 82 82 100 100 100 cm 163 163 208 208 254 254 254 Dimensions C D (supply) E (return) in.
Figure 8: Tower Performancec Model number SF2003 SF2004 SF2005 SF2007 SF2009 SF2011 SF2015 Cooling capacity tons Kcal/hr 50 151,200 75 226,800 100 302,400 125 378,000 150 453,600 175 529,200 200 604,800 Nozzles no. 1 4 4 4 4 4 4 Fan motor hp kW rpm 2 1.5 1,200 5 3.7 1,200 5 3.7 900 5 3.7 900 10 7.5 900 10 7.5 900 15 11.2 900 NEC amp draw 460/3/60 3.4 7.6 7.6 7.6 14.0 14.0 21.
Figure 9: Cooling Tower Nozzle Capacity Fiberglass Cooling Towers Chapter 6: Appendix Page 23 of 25
6-3 Parts List Figure 10: Supplied Parts for Field Assembly Part Number A0101485 A0533163 A0539417 A0533167 A0534122 A0539598 Quantity 1 110 55 55 55 40 ft. Description Silicone Stainless steel flat washers, 5/16” Stainless steel screws, 5/16”-18 x 1 3/4” Stainless steel hex nut, 5/16”-18 Stainless steel split lock washers, 3/8” FG Tower gasketing Figure 11: Spare Parts List Part SF2007 SF2003 c 5 SF2004 5 SF2005 d description qty Part no. qty Part no. qty Part no. qty Part no.
6-4 Electrical Schematics Figure 12: Typical Wiring Diagram 115/1/60 208-230-460/3/60 Fused disconnect switch ON/OFF switch Thermostat M Immerse bulb in tank Starter with overloads Non-fused disconnect at tower Fan Fiberglass Cooling Towers Chapter 6: Appendix Page 25 of 25
