Operating & Service Manual - Cooling Tower Systems, Inc.
Contents
1. Replace the pump with one matching planned volume of water Adjust the fan mounting Correct the blade angle settings Tighten loose bolts Supply oil up to the level specified Check supply voltage Notify power company if necessary Adjust fan blade angles Adjust fan blade angles Adjust the angle of the sprinkler pipes in the sprinkler head Eliminate blockage at the upper edge of the filling Renew the eliminator Adjust the water flow by means of the valve 40 Years of Manufacturing Experience Cooling C Tower Systems The best just got better Construction amp Installation Data Fan motor CD Air GD Water Fan guard Motor frame ass y V Belt Speed reducer Fan Blade ass y Sprinkler pipe Tension device Eliminator Sprinkler head Stand pipe FRP casing PVC Filling Filling supportor ma 9 A e LTE RNN Casing supportor rame assy ns AN 7 rR a SSCS Automatic filler lt A Water Sump Water basin Quick filler Inlet Outlet www coolingtowersystems com 10 40 Years of Manufacturing Experience Cooling Tower d Systems The best just got better Guarantee COOLING TOWER SYSTEMS INC GUARANTEE IS AS FOLLOWS DOMESTIC WITHIN THE CONTINENTAL UNITED STATES A Ten Years on FRP fiberglass casing and cold water basins B Two 2 years on all PVD fillings C One 1 year on all fan motors major drive components and all2. Model No LBC Model as ce ole e LBM 055C 225 amp 250 6306zz 6308zz 6309z 300 amp 350_ 6306zz 6308zz LBM 300 www coolingtowersystems com ois 40 Years of Manufacturing Experience 5 MAINTENANCE AND CONTROL 5 1 Sprinkler Pipe The sprinkler pipe must be clean without blockage If there is some foreign material retarded in the pipe take the following steps A Loosen the set screw or lock nut on sprinkler device then remove sprinkler pipe and clean B Align the dot mark on sprinkler head and reinstall For T 25 T 215 models they are fitted with type A and B pipe the hole pitch is different to assure even water distribution 5 2 Sprinkler Head The sprinkler head rotation will slow or even stop if scale is stuck to it In this case check it as follows A T 25 T 260 refer to Fig 1 a remove set screw cap on top of sprinkler head b loosen nut and washer then take head off c clean it with fresh water and check if any component is worn out B T 270 T 3000 refer to Fig 2 a remove the cap and take circlip off b pull the rotary part off the fixing part and check replace if necessary Part 8 Set Screw Sprinkler Pipe Part A FIG 2 www coolingtowersystems com Cooling Tower The best just got better 5 3 Tower Casing No coating is needed for the tower casing as it is made of F R P If it becomes soiled wipe it with soap or a water soaked piece of cl
3. is essential and the following instructions are very important 6 1 Belt Adjustment Before operation open the adjustment access cover and check whether the washer on the adjusting bolt is aligned with the adjusting gauge Ref Fig A Tighten the adjusting nut if necessary During operation the belt may stretch allowing belt slip and abrasion Hence the belt tension should be checked according to the following A 50 hours after commissioning B Thereafter carry out 3 checks each at 100 hour intervals C After the 4 check at 350 hours then check each month Off Season Shut Down For a long time shut down slacken the adjusting nut 4 5mm to prevent bolt stretch Re adjust belts prior to putting the cooling tower back into service Adjustment Precaution If a gap exists between the adjusting gauge and the washer the belts are too slack If the washer and the adjusting nut overlap the adjusting gauge the belts are too tight Adjusting Gauge FIG A www coolingtowersystems com Align washer with adjusting gauge The life of the belts depends on the maintenance of proper tension The adjusting gauge is factory set and should not be altered 6 2 Testing of Drive Operation After checking the belt adjustment spin the fan by hand to see whether it is free If it soins freely and smoothly start the fan motor After 2 to 4 hours operation check amperage and voltage and compare the readings with moto
4. on the moving parts are tight As the cooling tower is installed on top of the roof it is desirable to cover up the tower casing and the air exhaust outlet 8 WATER TREATMENT A Bacterial Contamination Bacterial contamination of recirculated water in the cooling tower is possible It is therefore recommended that after the cooling Remove old belts and replace with new sets Pulley No 2 Slacken adjusting nut and move intermediate pulley assembly in direction of arrow Pulley No 3 FIG C tower is commissioned a reguar maintenance program be investigated This should included treatment of the recirculated water As we are not experts in this field we strongly recommend that a reputable water treatment company be consulted for the treatment of the system s recirculated water B Water Quality Control Poor quality of recirculated water due to air pollution corrosion scale and algae growth will impede the performance of water cooling equipment We recommend a periodic water analysis and that blow down be initiated to maintain the water quality within the water cooling system to the following criteria Permissible Value of Water Analysis JCI Code PARAMETER PH 25 C Electric conductivity uv cm Total hardness CaCO3 ppm M alkalinity CaCOQ3 ppm Chlorine ion Cl ppm Sulphuric acid ion S04 pom Silicic acid SiO2 ppm Ferric Fe ppm www coolingtowersystems com Make up w
5. ade The cooling tower blades move large volumes of air quietly and efficiently a T 25 T 230 Made of reinforced plastic material the blades are coupled to the fan hub by bolts and paste b T 240 Made of aluminum alloy the blades are freely adjustable by the pitch angle scale of the fan hub 2 PREPARATIONS FOR STARTING 2 1 Open the drain at the bottom of the water basin and wash dust and dirt away while scrubbing the water basin with a brush 2 2 Trial Circulation Wafer Fill water in the water basin to the level where the discharge from the ball tap stops Slowly rotate the sprinkler by hand to check whether it is free Start the circulating pump and after washing the interior of the tower and the water pipes thoroughly refill the circulating water 2 3 Checking After the circulation test check if there is any dirt or foreign matter sticking to the interior of the tower or the outlets of the sprinkling pipes Check to see if the speed reducer belt has been adjusted correctly After confirming that that the fan revolves smoothly by turning it by hand check the state of the gap between the tip of the blades and the tower casing Measure the supplied voltage and make sure that the power supply is in the regulated type Revolve the fan for a short time and make sure that air is blown upward Revolve the fan two or three hours to see if any vibrations or abnormal sounds are generated Slowly move the float of the b
6. all tap up and down and make sure the discharge and control system of water is accurate In case the tower has been left idle for a long time check the following points and make sure that nothing is wrong Confirm the insulation of the motor with a megger see that it is 1MQ or above using a 500V megger See that no loose nuts are found at various important junctions such as the tightened places of fan driving motor and the junctions between the supporting base and the tower casing Turn the sprinkler with hand and see if it operates smoothly 40 Years of Manufacturing Experience Cooling Tower C TS Systems The best just got better 3 STARTING 3 1 Pump Driving In order to make the circulating water fill every part of the circulation system revolve the circulation pump for a short while to drain the air out of the piping of the circulating water Before entering steady operation confirm again that the water basin is filled to the specified level and then start the pump Gradually open the adjusting valve and adjust it so that the water will reach the volume specified on the name plate of the cooling tower When circulation of water becomes steady check to see if the sprinkler is revolving smoothly and properly 3 2 Fan Driving Clean up the surroundings of the tower and make sure that no foreign matter is near the air inlet and outlet When the equipment goes into steady operation measure phase volta
7. ater 200 below 50 below 50 below 50 below 50 below 30 below 0 3 below Circulating water 500 below 200 below 100 below 200 below 200 below 50 below 1 0 below 40 Years of Manufacturing Experience Cooling f Tower Jd Systems The best per got better Trouble Analysis Table Rise in cooling water temperature Drop in the volume of cooling water Noise and vibration Excessive current draw Water carry over www coolingtowersystems com 295 Excess or inadequate cooling water flow Irregular flow of air Recirculation of air exhausted from tower Irregular operation of sprinkler pipes Improper flow of air Blocking of the filling Blocking of the sprinkler pipe holes Blocking of strainer mesh Drop in the water level of water basin Improper selection of water circulating pump Fan blade tips touching fan stack Improper mounting of fan blades Loose belts Shortage of speed reducer oil Drop in voltage Irregularities in the angles of the fan blades Overload through excess airflow Irregular operation of sprinkler pipes Blocking of the filling Defective eliminator Too much circulating water Adjust to the specified flow Improve ventilation Same as above or install baffles Remove dust and scale Adjust the angle of fan blades Clean the blocked areas See section for maintenance and adjustment Remove strainer and clean Adjust float valve
8. essure and vibration b T 2200 T 3000 Provided with hot dip galvanized steel to resist corrosion and rust 1 5 Motor Support Framework Made of hot dip galvanized steel to resist corrosion and rust 1 6 Air Inlet Louver The P V C plastic mesh is fitted on the air inlet to prevent foreign material from falling into the basin of water splashing out of the basin 1 7 Filling Made of rigid polyvinyl chloride sheet which is embossed and corrugated in a honeycomb configuration It provides maximum air to water contact for highest thermal efficiency 1 8 Sprinkler Device Consists of a set of sprinkler pipes and one sprinkler head that is mounted on top of the stand pipe on the cooling tower The sprinkler is rotated by the pressure of circulating water There are numerous holes in the sprinkler pipe to allow the water to jet out as the pump impacts rotation The speed can be controlled by adjusting the sprinkling angle in accordance with the water flow rate There are two types of sprinkler heads a T 25 T 260 refer to figure 1 The outer casing is made of nylon material the sliding part is lubricated by the water www coolingtowersystems com Cooling Tower CTS The best just got better b T 270 T 3000 refer to figure 2 The whole body is made of aluminum alloy and is fitted with sealed type bearings to take thrust and radial loads and to ensure that the sprinkler head revolves smoothly 1 9 Fan Bl
9. ges and phase currents to see if the motor is operating at the rated current range indicated on the name plate 4 CAUTIONS DURING OPERATION 4 1 Performance Since the cooling performance will be affected by the volume of the circulating water be sure to maintain the regulation water flow at all times Keep the interior of the tower always clean and take care that no scale or moss grows 4 2 Water Level When the level of the water in the water basn drops air is sucked in and cavitation may develop therefore it is necessary to keep the water at the proper level at all times 4 3 Functioning Pay close attention to the vibration noise temperature of the cooling water and electric current during operation and make sure that nothing goes wrong Vibrations or noises come mainly from the moving parts in the speed reducer and the fan be careful not to overlook even a slight defect Revolution of the Sprinkler T 2 40 60 80 250 300 350 400 700 800 3000 12 17 Sprinkler Head T 2 Model No 3 15 20 50 70 125 200 300 500 800 10 20 40 60 100 175 250 400 700 1000 LSU Model No Specifications LSH 300 LSH 100 LSH 125 LSH 150 LSH 200 LSH 250 ee Circlip po Bearing Bearing Housing ee 7 SS ll Nut A 10 Head po 11 Body S S S S Cap 6405 6006Z www coolingtowersystems com 40 Years of Manufacturing Experience Cooling Tower The best just got better D V Belts the end of
10. i Cooling ib C Tower y Systems Operating Instructions and Service Manual T 2 Model Cooling Towers MEMBER 196 Lower Cherry Street Macon GA 31201 800 752 1905 478 755 1905 800 203 4925 FAX 478 755 8304 FAX www coolingtowersystems com info coolingtowersystems com Preface Adequate knowledge of cooling tower maintenance and control is necessary for optimum safe performance over time In this manual equipment construction function operation and checking procedures will be described as follows 1 TOWER CONSTRUCTION 1 1 Type CTS incorporates an induced draft counter flow design with an axial flow fan mounted on top of the tower to draft air out The low internal pressure loss and circular shaped design ensure optimum efficiency and space economy 1 2 Casing The F R P fiberglass reinforced polyester is composed of fiberglass mat laminated from unsaturated polyester resin The high structural strength of the material protects the unit against impact and cracking Gel coat is then applied to form a smooth surface 1 3 Water Basin Also made of F R P material The circular shaped basin with a cylindrical suction sump ST200 1000 keeps cavitation of the pump to a minimum A drain connection is provided for removal of accumulated dirt from the basin 1 4 Tower Support Framework a T 25 T 2175 The F R P base legs are incorporated with the water basin in a single unit to withstand wind pr
11. internal moving parts NOTE An Extended Manufacturer s Warranty is available for an additional nominal fee and is set into place as part of the original purchase INTERNATIONAL ORDERS WARRANTY A Eighteen 18 months after shipping date B One 1 year after initial start up of Cooling Tower C Note only A or B is applicable which ever comes first Cooling Tower Systems Inc wishes to Thank You for your patronage and we look forward to adding you as a satisfied customer www coolingtowersystems com 11 40 Years of Manufacturing Experience
12. oth and then wash it thoroughly with water 5 4 Water Basin As dust and dirt are liable to get into the water basin open the drain at the bottom of the drop in tank from time to time and wash it clean This applies also to the water basin in particular as sediments are liable to accumulate near the outlet so keep the tank clean so that the strainer mesh will not be clogged 5 5 Filling No special care is needed if the control of the quality of water is adequate during operation 5 6 Fan Watch the surface of the blades carefully to see that no damage develops and make sure that proper space is maintained between the internal wall of tower casing and the tip of blades 5 7 Coating It is desirable to periodically recoat the metal parts as they are subject to rusting 40 Years of Manufacturing Experience Cooling Tower C TS Systems The best just got better 6 V BELT SPEED REDUCER With increasing public awareness of noise our engineers have developed a V belt drive to reduce operating noise levels This new drive produces much lower noise levels than those obtained from conventional gear drives of the equivalent size The V belt is a wide angle 60 C and is made of a special polyurethane compound with polyester tension cords tensile member Very compact V belt drives are possible with this belt T 2 Model No With proper maintenance the V belt drive will operate reliably however proper maintenance
13. r nameplate data Check the motor temperature and check noise and vibration 10 15 20 30 40 50 60 80 100 125 150 200 225 350 400 500 600 700 800 1000 360 6 3 Maintenance The following work should be performed A Drive Section Clean out the inside of the driving section annually B Motor Insulation Before putting the tower into service in each cooling season check the motor insulation with a 500 Volt Megger A resistance greater than 1MQ is acceptable C Bearings Although it is unneccessary to lubricate the sealed bearings an annual change of grease will extend their life To repack the bearings remove the seal plates with a sharp tool inserted as indicated by the arrow in Fig B Replace the seal plates after replacing the bearings Adjusting Nut amp Locknut Adjusting Bolt Washer 40 Years of Manufacturing Experience Cooling Tower The best just got better To replace belts remove the belt cover from the belt case slacken the adjusting nut and push the intermediate pulley assembly toward the motor refer Fig C e otor Pulley No l Pulley No 4 7 PRECAUTIONS IN PROLONGED IDLENESS Unless the circulation water is drained it may freeze in winter and cause the pipes to crack If the drain of the drop in tan is kept open rain water and snow water will not accumulate in it Make sure that tightening bolts on the various parts of the tower especially
14. their life and should be replaced with belts Maintain belt adjustment as decribed above This drive as recommended in the V belt table Since V belts are uses high quality special V belts The V belts are not widely available please contact our nearest designed to operate 5 000 to 10 000 hours If slipping distributor for replacement Belts must always be or belt abrasion becomes evident after operating over replaced in matched sets i e both upper and 5 000 hours then replace the belt sets If after 5 000 lower sets must be replaced simultaneously hours excessive adjustments of belt tension are Hence one faulty belt requires the replacement of up to required due to belt stretch the belts have reached 10 belts V Belt Table I V Belt Speed Belts No Belts No Belts No Reducer T 2 Model non hale V ea Mia of Upper of Lower Model No Pulley Pulley i Ss amuso o jeu V Belt Table Il V Belt Speed Belts No Belts No Belts No Reducer T 2 Model Fan speed aaa H of Upper of Lower ONS R R P M Total Model No Pulley EEN www coolingtowersystems com 4 40 Years of Manufacturing Experience Cooling C Tower Systems The best just got better MOTOR AND V BELT SPEED REDUCER Item No Description Support Pin Adjusting Lever Adjusting Gauge Adjusting Spring Adjusting Bolt KeyA Housing Cover No 2 60008 00 909 799 Pulley No 3 OS V BELT SPEED REDUCER BEARING TABLE V Belt Speed Reducer
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