Delta TM-105312 User Manual

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Delta Cooling Towers, Inc.

TM Series Cooling Tower

Installation, Operation & Maintenance

Manual

Revised 1-8-2007

Table of Contents

Delta Cooling Towers

Principle of Cooling Towers………………..…………….

2

 

 

Cooling Tower Terms and Definitions……………………

2

 

 

Water Treatment……..………………………….………..

3

 

 

 

 

 

General Information

Safety………………..………………………………….…

3

 

 

Approximate Weights………………..……………………

4

 

 

Dimensions & Other Physical Data……..………...………

4

 

 

 

 

 

Handling & Installation

On-SiteInspection………………..………..…….….…….

5

 

 

Off Loading……..……………..…………………………..

5

 

 

Anchoring……..……….…………………………..………

8

 

 

Electrical Wiring of Fan Motor & Accessories……..……..

8

 

 

Location, Piping & Connections……..…….……….……..

8

 

 

PVC Solvent Cementing Instructions………………...……

10

 

 

 

 

 

Operation and Maintenance

Safety in Operation of the Fan..…..………..…….….…….

11

 

 

Water Distribution System……..………………………….

11

 

 

Fan & Mechanical Drive System….………………..…...…

12

 

 

Start-upInstructions………………………………..……..

12

 

 

Water Level in Tower Sump…..……..…….……….……..

13

 

 

Cold Weather Operation…………...………………...……

14

 

 

Trouble-ShootingGuide.…………...……………….….…

16

 

 

Motor Trouble-ShootingGuide…………...………....……

18

 

 

 

 

 

Other Information

Cooling Tower Optional Accessories..…..…...….….…….

19

 

 

Recommended Replacement Parts……..………………….

19

 

 

Preventative Maintenance Checklist….……………….…..

20

 

Important: Delta’s cooling towers have been designed to providetrouble-freeservice over an extended period of time. To obtain the design performance, it is necessary that the cooling tower be installed, operated and maintained as prescribed in these instructions.

Only persons possessing the skill and experience described herein should attempt to install this equipment. Prior to installation, these instructions should be read carefully by the person who is to install the cooling tower to be certain that its installation, operation and maintenance are thoroughly understood.

Questions regarding the installation, operation or maintenance of this equipment should be directed to Delta Cooling Towers, Inc., Rockaway, New Jersey, (Telephone: 973/586-2201).

Step-by-stepinstructions contained in this brochure are based on normal installation conditions only. Abnormal or unusual combinations of field conditions should be brought to the attention of Delta Cooling Towers or its representative prior to installation of the equipment. The information contained herein is subject to change without notice in the interest of product improvement.

Revised 1-8-2007

1

Delta Cooling Towers

Principle of Cooling Towers

All Cooling Towers operate on the principle of removing heat from water by evaporating a small portion of the water that is recirculated through the unit.

The heat that is removed is called the latent heat of vaporization.

Each one pound of water that is evaporated removes approximately 1,000 BTU's in the form of latent heat.

Cooling Tower Terms and Definitions

BTU - A BTU is the heat energy required to raise the temperature of one pound of water one degree Fahrenheit in the range from 32° F. to 212° F.

Cooling Range - The difference in temperature between the hot water entering the tower and the cold water leaving the tower is the cooling range.

Approach - The difference between the temperature of the cold water leaving the tower and thewet-bulbtemperature of the air is known as the approach. Establishment of the approach fixes the operating temperature of the tower and is a most important parameter in determining both tower size and cost.

Drift - The water entrained in the air flow and discharged to the atmosphere. Drift loss does not include water lost by evaporation. Proper tower design and operation can minimize drift loss.

Heat Load - The amount of heat to be removed from the circulating water within the tower. Heat load is equal to water circulation rate (gpm) times the cooling range times 500 and is expressed in BTU/hr. Heat load is also an important parameter in determining tower size and cost.

Ton - An evaporative cooling ton is 15,000 BTU's per hour.

Wet-Bulb Temperature - The lowest temperature that water theoretically can reach by evaporation.Wet-BulbTemperature is an extremely important parameter in tower selection and design and should be measured by a psychrometer.

Pumping Head - The pressure required to pump the water from the tower basin, through the entire system and return to the top of the tower.

Make-Up - The amount of water required to replace normal losses caused bybleed-off,drift, and evaporation.

Bleed Off (Blowdown) - The circulating water in the tower which is discharged to waste to help keep the dissolved solids concentration of the water below a maximum allowable limit. As a result of evaporation, dissolved solids concentration will continually increase unless reduced by bleed off.

Revised 1-8-2007

2

Water Treatment

The Delta Cooling Towers are manufactured from corrosion-resistantplastics which are resistant to water treatment chemicals including common fungicides and bactericides.

Follow appropriate water treatment practices as required and take frequent sample tests to avoid possible water contamination. We also recommend water treatment maintenance as a measure of protection of the environment in the vicinity of any cooling tower or other equipment open to atmosphere.

To determine the appropriate water treatment practices for your particular application, it is suggested that you contact a water treatment firm for their recommendation. A list of water treatment firms is available for your reference. It is not necessarily complete nor do we recommend a specific firm. The list will be mailed to you on request or consult your local yellow pages.

Bleed-offis also important to water quality. Evaporation of the recirculated water does not remove the dissolved solids that are present in the water. Withoutbleed-off,the continual buildup of these solids will impair the proper functioning of the piping and other equipment in the system.

A bleed line can be connected in any part of the system for routing to the sewer. Normally, it is most desirable to make this connection in the hot water line at the cooling tower. A petcock type valve, installed in the bleed line is recommended. Normally, bleed-offof 1% to 2% of the recirculation water flow is satisfactory. The required amount ofbleed-offwater must be substituted with properly controlled amounts ofmake-upwater.

General Information

Safety

When handling, lifting, installing or operating the cooling tower, always employ safe work procedures, according to best practices of the trade and according to applicable construction, electrical and safety standards, regulations and codes.

Follow all safety practices described in these instructions.

Revised 1-8-2007

3

Approximate Weights

The TM Series cooling towers are manufactured in three basic sections; a polyethylene tower body, a polyethylene sump, and a fan assembly section. The tower body ships with the fan assemblies installed. The tower sump ships as a separate piece.

 

Approximate Weights (lbs.)

Overall

 

Dimensions

 

 

 

 

 

 

 

(inches)

Model Group

 

Shipping

Operating

L x W x H

 

 

Body

Sump

 

 

TM-105312TM-115412

 

4,850

1,660

11,800

198” x 102” x 186”

 

 

 

 

 

 

 

TM-205312TM-215412

(2)

4,850

(2)

1,660

23,600

198” x 204” x 186”

 

 

 

 

 

 

 

 

TM-305312

TM-315412

(3)

4,850

(3)

1,760

35,400

198” x 306” x 198”

 

 

 

 

 

 

 

 

TM-405312

TM-415412

(4)

4,850

(4)

1,760

47,200

198” x 408” x 198”

 

 

 

 

 

 

 

 

TM-505312

TM-510412

(5)

4,850

(5)

1,760

59,000

198” x 510” x 198”

 

 

 

 

 

 

 

 

TM-605312

TM-610412

(6)

4,850

(6)

1,760

70,800

198” x 612” x 198”

 

 

 

 

 

 

 

 

Dimensions and Other Physical Data

For cooling tower dimensions, design for foundations, assembly and layout, refer to the following drawings which are a part of these instructions:

 

Model Group

Title

Drawing No.

 

TM-105312TM-115412

1

Cell

DT-D-87-901

 

TM-205312TM-215412

2 Cell (5 - 7.5 HP)

DT-D-87-902

 

 

 

2 Cell (10 – 15 HP)

DT-D-87-903

 

 

 

 

 

 

TM-305312TM-315412

3

Cell

DT-D-87-904-1

 

 

 

 

 

DT-D-87-904-2

 

TM-405312

TM-415412

4

Cell

DT-D-87-905-1

 

 

 

 

 

DT-D-87-905-2

 

TM-505312

TM-510412

5

Cell

DT-D-87-906-1

 

 

 

 

 

DT-D-87-906-2

 

 

 

 

 

 

 

TM-605312

TM-610412

6

Cell

DT-D-87-907-1

 

 

 

 

 

DT-D-87-907-1

 

 

 

 

 

 

Revised 1-8-2007

 

 

4

 

Handling and Installation of Your TM Series Cooling Tower

On -SiteInspection

Upon arrival at the job site, carefully inspect the shipment for any damage. If shipping damage has occurred, notify the driver or the carrier immediately and make a notation of the damage on the shipping bill of lading. Check that all items listed B/L have been received.

Offloading

The TM Series cooling towers are normally delivered to the site on a 30 inch high drop deck trailer. Both the tower body assembly and sump assembly are strapped down to the truck bed. The sump assembly should be unloaded first.

Lifting with crane:

Use fabric slings of sufficient strength for better load distribution and protection of the plastic tower body.

Wrap slings underneath tower sump assembly to lift and set into place.

Lift tower body by attaching slings, kept separate by spreader bars, to the four lifting bars as shown below.

Spreader bars must be used to lift vertically on the lifting bar. Above the spreader bars use adequate length straps specifically designed for vertical lifting in order to maintain an angle of 60° or less between slings.

Lifting Bar

Revised 1-8-2007

5

Store tower assembly as shipped until the time of installation, in a secure, level and debris free location at the job site.

CAUTION: For extended lifts, use duplicate rigging, fabric slings around body as shown, as an additional safety precaution.

Installing

The cooling tower should be assembled in place on the previously prepared foundation.

After re-checkingthe rigging, lift the sump section of each cell and secure properly to the foundation.

Attach the fiberglass sump box to the center support post using the hardware provided as shown.

Revised 1-8-2007

6

The body section should then be lifted and carefully position to align the support post of the sump with the corresponding groove of the tower body. Note that the four corner posts are slightly higher than other post to ease installation alignment.

Set one end of the tower body onto the corner post at one end of the sump first. This can be accomplished by use of a rope tether attached to the lifting bar at one end of the housing. Continue setting and aligning support post along the sides of the tower moving from one end to the other. This step may require a couple installers to align multiple posts simultaneously. You may use a rubber mallet or blocking wood to aid aligning post.

IMPORTANT: Make sure that all posts are correctly seated into the pocket of the tower body.

For single cell units, the four corner sump posts should then be secured to the main housing with the provided stainless steel angle brackets and hardware. On Multi-celltowers, the outermost four corner posts should be secured to the main housing with the provided stainless steel angle brackets and hardware.

Before installing PVC louver panels, verify that all post are correctly seated into the pockets of the tower body.

Install PVC louver panels between each support post. Panels are numbered and marked on top of each panel, and should be installed with corresponding numbered window opening. Insert bottom of panel into window opening and work your way up to the top. Panels should be mounted flush with inside top of louver opening inside tower and should direct incoming air downward. Secure panels with self-tappingscrews provided.

Revised 1-8-2007

7

On multi cell towers, install PVC water redirector panels between each sump usingself-tappingscrews provided (See sketch below). Start with screwing the PVC post from the bottom up. Next apply a heavy bead of RTV sealant on the end of each redirector panel. Start screwing the redirector panels from the end nearest the post toward the center. Do not screw overlapping panels to allow for expansion and contraction.

(Side View of Redirector Panels)

Multi Cell Water Redirectors.

Secure tops of adjacent multi cell units together by bolting the two steel support angle brackets provided to the lifting lugs of each cooling tower shell. The angle brackets should then be bolted together with hardware provided.

Anchoring

The foundation must be flat, smooth and rigid enough to be capable of independent support of the cooling tower assembly and water load in the sump at its maximum level. The tower assembly can also be mounted on I-beamsusing the integrally moldedI-beampockets (See tower drawings).

Four hold-downanchor lugs are provided on the sump of each tower cell.

Support beams and anchor bolts are to be furnished by others.

Beams should be sized at least 7” wide and in accordance with acceptable structural practices. These beams should be located in the integrally molded I-beampockets, and should run the length of the unit.

Use anchor bolts sized for a minimum of 15,000 lbs. pull-outload per anchor lug for wind loading.

Revised 1-8-2007

8

Electrical Wiring of Fan Motor and Accessories

Installation of a vibration cut-outswitch is recommended. (Refer to tower accessories available).

All electrical work should be performed only by qualified personnel and in accordance to prevailing electrical codes, practices and safety standards.

The motor starter should be sized on voltage, nominal horsepower, and maximum full load current. This current value can be found on the motor nameplate. If the starter cannot accept the maximum full load motor current, the next size should be used.

Motor heaters should be selected on the basics of maximum full load current and service factors based on the motor nameplate.

Standard “Cooling Tower Service” motors are supplied with a minimum of a 1.15 Service Factor.

Optional two speed motors are single winding variable torque.

Run flexible conduit with some slack from the motor conduit box to terminal box outside the tower where rigid conduit can be used.

Conduit holding clip screws can be tapped directly into the tower wall. Use maximum 3/8” long screws.

For the typical wiring schematic of fan motor and tower accessories, see Delta dwg. DT –B-78-001,included with these instructions.

Location, Piping and Connections

Piping should be adequately sized in accordance with accepted standard practices.

Gravity drain to indoor storage sump requires proper head differential and piping design considerations. Allowance must be made for flow, pipe size, piping layout and distance of cooling tower from the indoor storage sump.

On multiple cell installations, valving and/or pipe sizing should balance pressure drops to provide equal inlet pressures. Equalizing fittings are provided in the sumps of each cell and can piped together to balance sump water level. Each cell should be valved separately to allow for flow balancing or isolation from service.

Prior to start-upcheck that the PVC locknuts on all bulkhead fittings are properly tightened to prevent nuisance leaks. A chain wrench can be used to check and tighten the locknuts.

Check that the SS hexagonal nuts on the inlet and outlet PVC flanges are properly tightened to prevent nuisance leaks. While tightening the nuts, do not allow the bolt to rotate. This could damage the rubber seal under the flat washer on the bolt head located inside the cooling tower.

All supply and return piping must be independently supported.

Revised 1-8-2007

9