Sterling A0552321 User Manual
Cooling Tower Water and
Chilled Water Pump Tanks
Part Number: A0552321
Bulletin Number: SC5-605.7
Effective: 4/11/08
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. ____________
© Copyright 2008
All rights reserved.
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.
Notify the transportation company’s local agent if you discover damage
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals (if applicable)
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the parts and service department
immediately at (262) 641-8610. Have the order number and item number available. Hold
the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Pump Tanks ii
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.................................................................................................. 6
CHAPTER 2: FUNCTIONAL DESCRIPTION...............................7
2-1 Models Covered in This Manual......................................................................7
2-2 General Description ........................................................................................7
2-3 Standard Features ..........................................................................................8
2-4 Optional Features............................................................................................ 9
CHAPTER 3: INSTALLATION ...................................................10
3-1 Uncrating Your Pump Tank........................................................................... 10
3-2 Installation Location Considerations.............................................................. 10
3-3 Rigging.......................................................................................................... 10
3-4 Installing Separate Tank Ledge Models........................................................11
3-5 Installing Optional Equipment........................................................................ 11
3-6 Making Electrical Connections......................................................................11
3-7 Making Piping Connections...........................................................................12
Tower Tank Piping Connections .........................................................................14
Chilled Water Piping Connections.......................................................................15
3-8 Initial Start-up................................................................................................ 15
CHAPTER 4: OPERATION ........................................................16
4-1 Start-up ......................................................................................................... 16
4-2 Determining Flow Rate.................................................................................. 16
4-3 Stand-by Pump Usage..................................................................................17
Single Stand-by pump:........................................................................................17
Dual Stand-By Pump...........................................................................................17
4-4 Shut-down..................................................................................................... 17
CHAPTER 5: MAINTENANCE...................................................18
5-1 Preventative Maintenance.............................................................................18
Water Treatment .................................................................................................18
Lubricating Pump Motors and Seals....................................................................18
Maintaining Makeup Valve Assemblies...............................................................18
CHAPTER 6: APPENDIX ...........................................................19
6-1 Technical Assistance .................................................................................... 19
Parts Department ................................................................................................19
Service Department.............................................................................................19
6-2 Remote Starters and NEMA Panels..............................................................20
Pump Tanks iii
NEMA Panel Standard Features.........................................................................20
NEMA Panel Options ..........................................................................................20
6-3 Drawings and Specifications.........................................................................21
Cooling Tower Water Pump Tanks......................................................................21
Chilled Water Pump Tanks..................................................................................23
Process Pump Curves and Specifications...........................................................25
Re-circulation Pump Curves and Specifications..................................................26
6-4 Parts List.......................................................................................................27
Recommended Spare Parts................................................................................27
Spare Process Pump Seals and Casing Gaskets...............................................27
Spare Re-circulating Pump Seals and Casing Gaskets......................................27
6-5 Optional Assembly Detail Drawings.............................................................. 28
Tank Support Leg Assembly Detail: 4 Legs ........................................................28
Tank Support Leg Assembly Detail: 6 Legs ........................................................29
Tank Support Leg Assembly Detail: 7 Legs ........................................................30
Tank Ladder Assembly Detail..............................................................................31
Sightglass Assembly Detail.................................................................................32
6-6 Typical Piping Diagrams................................................................................ 33
Typical Single Well Cooling Tower Water Pump Tank Piping System................33
Typical Dual Well Cooling Tower Pump Tank Piping System.............................34
Typical Single Well Chilled Water Pump Tank Piping System............................35
Typical Dual Well Chilled Water Pump Tank Piping System...............................36
Pump Tanks iv
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. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the equipment.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the equipment safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your equipment provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, and parts lists. A
spare parts list with part numbers specific to your machine is provided with your shipping
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your
serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
Danger! DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
Warning! WARNING indicates a potentially hazardous situation or practice which, if not
avoided, could result in death or serious injury.
Caution! CAUTION indicates a potentially hazardous situation or practice which, if not
avoided, may result in minor or moderate injury or in property damage.
Pump Tanks Chapter 1: Safety 5 of 36
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.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.
; Refrigeration systems can develop refrigerant pressures in excess of 500 psi (3,447.5
kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION SYSTEM. This
must be performed by a qualified service technician only.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
Pump Tanks Chapter 1: Safety 6 of 36
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. The number following is the approximate capacity up to the overflow of the
tank well(s) and a D at the end indicates a dual well configuration. Additional numbers are
added to signify pump horsepower. For example, a CT1600D-20-20-10 pump tank is a
cooling tower tank, 1,615 gallon (6,113 liter) capacity to its overflow, has dual wells, a 20 hp
process pump, a 20 hp dual standby pump and a 10 hp recirculation pump.
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.
2-2 General Description
Single well pump tanks are reservoirs for chilled water and tower cooling water processes.
Process pump(s) deliver water through the chiller or cooling tower as well as through the
process. Dual well tanks have re-circulation pump(s) to deliver water from the hot side to the
chiller or tower. The water then returns to the cold side, where process pump(s) deliver
cooled water directly to process.
Standby pumps may be used as backups for both process and re-circulation during service or
maintenance procedures. Manifolding options provide ease of connection to process and can
ease the transition to standby pumps.
Pump Tanks Chapter 2: Functional Description 7 of 36
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.
Note: Despite its name, stainless steel is still susceptible to discoloration. A
stainless steel tank will not “rust through” even though the surface of the
metal may appear to be rust colored. This appearance may be caused by
water quality (high chloride content or increased acidity in the water) or
cross contamination from carbon steel dust in the vicinity of the stainless
steel. The integrity of the stainless steel remains in tact even though its
appearance is not perfectly clean.
• Factory-installed insulation and covers (chilled water pump tanks)
• Water strainer basket on cooling tower water pump tank models
• Threaded (up to 3” and flanged 4” and above) overflow opening, return openings
(chilled water pump tanks), and process water return (dual-well cooling tower pump
tanks)
• 1” automatic water makeup valve for “hands-off” level control
• 1/2” opening for field-installed thermometer
• 2” valved drain connection
• Twin 1/2” plugged openings for sight glasses
• Six 1/2” plugged openings with brackets for optional/future thermostats
• Baffles and sidewall reinforcements on larger models
• Full-size pump trim for maximum efficiency including butterfly valve (less handle)
and reducer (if necessary) on the suction side; increaser, check valve and butterfly
valve (less handle) on the discharge side
• One year warranty on parts and labor (labor in North America only)
Pump Tanks Chapter 2: Functional Description 8 of 36
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
• Re-circulating (P2) pump (standard on dual well tanks)
• Dual duty (P3) standby pump with isolation valving
• Additional plugged or valved openings
• Clayton float valve
• Discharge manifold with process and re-circulation pump standby butterfly valving
• NEMA 1 pump starter(s), mounted or un-mounted
• NEMA 12-rated central control panel
• Protection for outdoor installation
Chilled water pump tanks are also available with:
• Automatic pressure regulating bypass valve for single well tanks; assures full flow
through the chiller evaporator
Cooling tower water pump tanks are also available with:
• Insulation
• Cover
Pump Tanks Chapter 2: Functional Description 9 of 36
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.
3-2 Installation Location Considerations
Consider the following points when locating your pump tank:
• Locate close to the chillers and/or cooling towers and the process itself to minimize
field piping expense
• Locate adjacent to drain and city water sources
• Consult a structural engineer to assure that the floor, mounting pad, or structural steel
support is of adequate strength
3-3 Rigging
Due to the large size and weight of the pump tanks, we recommend professional rigging and
installation. We have a nationwide installation organization that can install your system.
Do not remove the base skid until the unit is at the final location. Lower the unit (do not drop
it) from any truck, platform, or shipping dock.
All 150 through 400 Series pump tanks are provided with lifting lugs on the pump tank
frame. All 500 Series and larger tanks are provided with lifting lug brackets on the pump tank
body. When lifting, use adequately rated hoist, lifting straps and/or chains. Avoid transferring
the load to the pumps and any other components.
Metal pump tanks are provided with slots in the frame for use with fork trucks of sufficient
capacity and properly sized forks.
Pump Tanks Chapter 3: Installation 10 of 36
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. Fully and separately support
both tank and ledge assemblies when they are moved.
• Providing a level area for the tank installation will simplify reconnecting the pump
ledge to the tank.
• Floor mounted tanks and ledges are joined together with support plates and the pump
trim. Gravity and mass provide most of the structural integrity.
• Leg-mounted tanks and ledges are joined together with support plates, the pump trim,
and bolts between the facing surfaces of the tank and ledge. Typically, the tank
assembly is lifted and mounted on the four legs first, then the pump ledge is lifted with
a fork truck, and the two remaining legs are attached. Use the center leg bolt holes and
the facing surface bolts to bring together and align the ledge and the tank. See
assembly drawings on pages 28-30for detailed instructions.
• Butterfly valves bridge the gap between the ledge and tank flanges. These butterfly
valves may be shipped loose or mounted to the pump suction connection to the tank.
• The flanges may not always line up as expected due to the tendency of the metal to
move as it cools. Extra effort may be required to help align the flanges to bring the
tank sections together properly.
Caution! Improper handling may also cause movement of the flanges. Be sure the lifting
lugs or forklift holes are used for moving the tank and base. Do not use any of
the piping as a means of moving the equipment into position.
3-5 Installing Optional Equipment
See pages 28 to 32 in the Appendix for assembly details for the tank legs, ladder, and sight
glass.
3-6 Making Electrical Connections
Supply electricity of the voltage, phase, and cycle listed on the serial tag. Pump motor voltage
must be within plus or minus ten percent of the nameplate voltages.
Pump Starters. Pump motor starters may be pre-mounted, shipped loose, or not provided,
depending on the options specified on the order.
On/Off Selector Switch. All pump starters are supplied with an on/off selector switch on the
starter enclosure cover.
Pump Tanks Chapter 3: Installation 11 of 36
Loading...