Page 1
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. ____________
© Copyright 2008
All rights reserved.
Page 2
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, please 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.
Fiberglass Cooling Towers ii
Page 3
Table of Contents
CHAPTER 1: SAFETY................................................................6
1-1 How to Use This Manual.................................................................................6
Safety Symbols Used in this Manual.....................................................................6
1-2 Warnings and Precautions..............................................................................7
1-3 Responsibility.................................................................................................. 7
CHAPTER 2: FUNCTIONAL DESCRIPTION.............................8
2-1 Models Covered in This Manual......................................................................8
2-2 General Description ........................................................................................ 8
2-3 Standard Features .......................................................................................... 8
Materials of Construction.......................................................................................8
2-4 Optional Features............................................................................................ 9
CHAPTER 3: INSTALLATION..................................................10
3-1 Tower Installation Location............................................................................10
Roof Installation...................................................................................................10
Ground Installation..............................................................................................10
Alternative Installations .......................................................................................10
3-2 Assembling the Cooling Tower in the Field...................................................12
3-3 Rigging.......................................................................................................... 13
3-4 Installing the Fan Package............................................................................ 13
3-5 Installing Piping............................................................................................. 13
3-6 Setting Up the Water Balancing Valve .......................................................... 16
3-7 Initial Start-up................................................................................................ 16
CHAPTER 4: OPERATION.......................................................17
4-1 Bleed-Off and Evaporation Rates.................................................................. 17
4-2 Winter Operation Considerations.................................................................. 17
CHAPTER 5: MAINTENANCE .................................................18
5-1 Preventative Maintenance.............................................................................18
Water Treatment .................................................................................................18
Routine Maintenance ..........................................................................................18
5-2 Corrective Maintenance ................................................................................ 19
Replacing Nozzles and Fill..................................................................................19
CHAPTER 6: APPENDIX..........................................................20
6-1 Technical Assistance .................................................................................... 20
Parts Department ................................................................................................20
Service Department.............................................................................................20
Sales Department................................................................................................20
Contract Department...........................................................................................20
6-2 Drawings and Specifications.........................................................................21
Fiberglass Cooling Towers iii
Page 4
6-3 Parts List.......................................................................................................24
6-4 Electrical Schematics....................................................................................25
Fiberglass Cooling Towers iv
Page 5
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............................................. 14
Figure 5: Flexible PVC Outlet Coupler........................................................................................15
Figure 6: Throttling Valve Pressures............................................................................................ 16
Figure 7: Dimensions and Weights............................................................................................... 21
Figure 8: Tower Performancec.................................................................................................... 22
Figure 9: Cooling Tower Nozzle Capacity................................................................................... 23
Figure 10: Supplied Parts for Field Assembly.............................................................................. 24
Figure 11: Spare Parts List............................................................................................................ 24
Figure 12: Typical Wiring Diagram ............................................................................................. 25
Fiberglass Cooling Towers v
Page 6
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.
Fiberglass Cooling Towers Chapter 1: Safety Page 6 of 25
Page 7
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.
Fiberglass Cooling Towers Chapter 1: Safety Page 7 of 25
Page 8
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.
2-2 General Description
The fiberglass cooling tower system is constructed of lightweight polyester-reinforced
fiberglass for corrosion resistance and durability. PVC fill material resists decay, corrosion,
and microorganisms, and handles temperatures up to 130ºF (54ºC). Access panels allow easy
inspection of fill material. Fan blades are factory-tuned for optimum performance. ABS water
distribution nozzles are pre-piped and feature a non-clogging design.
2-3 Standard Features
Materials of Construction
Component Material
Shell Fiberglass-reinforced polyester
Fan blade Aluminum fabrication
Fan motor support Galvanized, mild steel
Fill, eliminator PVC Plastic
Louver pack PVC Plastic
Nozzle ABS plastic
Piping assembly Schedule 80 PVC plastic
Fasteners Stainless Steel
Support Feet Fiberglass brackets standard
Bottom Outlet Fiberglass
Water Balancing Valve Aluminum
Fiberglass Cooling Towers Chapter 2: Functional Description Page 8 of 25
Page 9
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. It is
used on towers with basin reservoirs to guard against freeze-up when your tower system is
shut down.
Structural Base. The structural base is a factory-provided structural steel mounting base. It
speeds tower installation and gives your tower proper support.
Access Ladder. The access ladder meets OSHA specifications and allows for easier
maintenance and inspection.
Fiberglass Cooling Towers Chapter 2: Functional Description Page 9 of 25
Page 10
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. You are
responsible for contacting a structural engineer to verify support requirements.
Choose a site with easy access to simplify routine maintenance. This consideration is
especially important when a tower is located near a roof edge.
Avoid locations where wind currents can re-circulate tower discharge air.
Stay clear of roof discharge points. Avoid stacks, exhaust fans, dust collector discharges, or
any process that can contaminate air circulating through the tower.
Caution! Multiple tower installations require at least five feet (60”/ 152cm) clearance
between towers to reduce freeze-ups. The manufacturer is not responsible for
damages resulting from improper site selection.
Ground Installation
Elevate the tower so that positive pressure is on pump suction and to allow maintenance
access to the underside of the tower cell.
Alternative Installations
Outside Installation with the Pump Tank Reservoir Inside. Water exits the tower and
drains to a pump tank reservoir inside the building below. The tower outlet must be at least
three feet (approximately 1 meter) above the top of the pump tank. The outside tower basin
must drain completely when shut down to avoid winter freeze up.
Outside Installation Using the Tower Basin as a Reservoir. Process pump suction piping
is directly connected to the bottom outlet on the tower. Install the optional outlet basket filter
and automatic float assembly. Contact the Sales department for this accessory kit.
Note: A dimension of 60”is required between the tower air inlet and the wall of a
building. See above caution for required distance between towers.
Fiberglass Cooling Towers Chapter 3: Installation Page 10 of 25
Page 11
Figure 1: Structural Steel Support Requirements
Structural steel
2 X 2 angle
to support
tower basin,
flush with top
of structural
steel rails
B
D
C
C
TSE50
C
B
A
C
Model A B C D
number in. cm in. cm in. cm in. cm
SF2003 52 132.1 50 127.0 16 40.6 78 175.3
SF2004 52 132.1 50 127.0 16 40.6 78 175.3
SF2005 68 172.7 67 170.2 22 55.9 78 175.3
SF2007 68 172.7 67 170.2 22 55.9 78 175.3
SF2009 87 221.0 85 215.9 28 71.1 78 175.3
SF2011 87 221.0 85 215.9 28 71.1 78 175.3
SF2015 87 221.0 85 215.9 28 71.1 78 175.3
Note: The illustration in Figure 1 shows structural steel with spacing for two (2) cooling towers. Your
installation may vary.
Dimension A – Centerline for fiberglass mounting feet provided with cooling tower. This is so bolt holes
can be made to secure the tower to the structural support.
Dimension B & C – Location of basin support steel.
Dimension D – Provides proper distance of 60” between cooling towers and distance between cooling
tower and the wall of a building.
Fiberglass Cooling Towers Chapter 3: Installation Page 11 of 25
Page 12
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. Inspect both sections for any damage, and locate the red orientation mark on one of
the vertical sides of each section.
3. The manufacturer supplies self-adhesive gasketing material to insure a water-tight
seal between the top and bottom sections. Install this material on the top of the
attachment flange on the lower section prior to mating the top and bottom sections.
Make sure that the flange is clean, dry, and free of rough spots before applying the
gasketing material.
4. Align the holes in the gasket with the bolt holes in the flange, then remove the paper
on the back side. Cut the gasketing material to fit properly, and apply the gasket to
the flange as you realign gasket holes with flange holes. Repeat on all four sides of
the tower.
5. Apply silicone caulk in cut lines and voids to complete sealing between sections.
6. Unbolt the top section from the skid and make sure that the flange on the top section
is clean, dry, and free of rough spots.
7. Place the upper section on the gasketed lower section, aligning the red orientation
marks. Take care not to disturb the gasketing and silicone caulk while aligning bolt
holes.
8. After aligning, bolt the two sections together with the fasteners provided. Use a flat
washer under the bolt head on top and a flat washer, a lock washer, and nut on the
bottom side of the flange.
Fiberglass Cooling Towers Chapter 3: Installation Page 12 of 25
Page 13
p
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
Spreader bar wide
enough to protect
cooling tower shell
Caution! Use appropriately rated
hoist to support equipment.
Do not let the rigging transfer any load to the cooling tower shell. Provide support to
the bottom of the cooling tower when rigging. Do not rig from the corners of the
o
tional base. Do not rig less than 8 inches from the corners.
3-4 Installing the Fan Package
Install the fan package after the tower is in position.
I-beam
Rope stay
The rope stay goes
all the way around the
tower to keep the
vertical rope in position.
1. Remove the dunnage securing the fan package to the pallet.
2. Carefully rig the package using the lifting eyebolts provided.
3. Mounting holes have been pre-drilled at the factory; move the package into position
and fasten it securely with the stainless steel hardware provided.
3-5 Installing Piping
Make sure that all piping attached to the cooling tower is externally supported. Do not
support anything from the cooling tower shell.
The cooling tower and related fittings and connections are constructed of plastic materials
and are not designed to bear external weight.
Do not apply high torque to the fittings that are made up into the tower fittings. Use a backup
wrench when applying torque to the fittings.
Fiberglass Cooling Towers Chapter 3: Installation Page 13 of 25
Page 14
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
balancing
valve
P
Typical bottom outlet
TWR
TWR
Support piping to eliminate
load from tower casing
Type 2
pressure
gauge
Caution!
Do not apply
excessive torque
to fittings
Type 2
inlet
Cooling tower
Overflow
3/4" constant
bleed
Drain
To drain
Figure 4: Cooling Tower with Basin as Reservoir Piping Diagram
Pressure
gauge
Caution!
Do not apply
excessive torque
to fittings
Overflow
Drain
To drain
Support piping to eliminate
load from tower casing
Tower water
T
P
Cooling
tower
TR
TR
Strainer basket
reservoir
Inlet
Balancing valve
Side outlet
3/4" constant bleed
3/8" drain line
Drain line is intended to prevent
NOTE:
tower freeze-up. Do not valve.
TWR
Makeup
City water line
Building
exterior
TR
Makeup
P
P-1
Thermostat-mount
in piping (1/2" fitting)
TWS
1/4" swing check valve
12" above highest point
in return line
3/4" constant bleed
To drain
P
P-1
TWR
TWS
TWS
Bypass
Tower water return
Tower water supply
City water
TWR
TWS
Bypass
Tower water return
Tower water supply
City water
Fiberglass Cooling Towers Chapter 3: Installation Page 14 of 25
Page 15
Figure 5: Flexible PVC Outlet Coupler
g
Clamps
(from AEC)
(from Sterling)
Tower outlet
Flexible PVC
Flexible PVC
coupling
Coupling
(from AEC)
(from Sterlin
Outlet pipe must be
supported from building
structure or tower steel
)
Fiberglass Cooling Towers Chapter 3: Installation Page 15 of 25
Page 16
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.
Figure 6: Throttling Valve Pressures
Pressure Model
psig KPa
SF2003 10 psig 68.95
SF2004 7 psig 48.26
SF2005 3 psig 10.68
SF2007 5 psig 34.47
SF2009 6 psig 41.37
SF2011 8 psig 55.16
SF2015 10 psig 68.95
Warning! Exceeding these pressure limits will damage the tower fill and nozzle and void
the tower warranty.
3-7 Initial Start-up
Check for proper rotation on all fan and pump motors. Refer to the arrows atop the tower and
on pump housings.
Fill the system with water and adjust the float valve if you are using a float. Maintain a water
level in the tower basin approximately one inch (25 mm) below the overflow opening.
The tower basin acts as a sump to maintain water level. Towers using inside tanks do not
carry water in the basin.
Fiberglass Cooling Towers Chapter 3: Installation Page 16 of 25
Page 17
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. For automatic bleed rate control, a
conductivity controller is available through the Sales department.
4-2 Winter Operation Considerations
All cooling towers are subject to ice formation in sub-freezing weather. Your cooling tower
requires a certain amount of attention and maintenance to prevent damage during these
operating conditions.
Follow these guidelines to reduce the chance of ice buildup:
• Maintain full design flow. Any reduction in water flow greatly increases the
probability of ice forming on and around the air inlet louvers.
• Do not use free cooling applications during freezing weather. Reduced water
temperatures or loading dramatically increases the chance of ice formation. Make sure
that the leaving water temperature is set above 80ºF (27ºC) during sub-freezing
weather so heat from the water warms the air inlet louvers and reduces ice formation
when the fan is off. Using a thermostat to control fan cycling by leaving water
temperature is mandatory.
• Do not run fans backward to thaw ice. Ice can form on the fan ring, fan guard, and
support structures, and can severely damage fan blades. Reversed airflow can also
blow water vapor out onto the roof and create ice fields around the cooling tower.
• Maintain a heat load of at least 60% of tower capacity at all times during operation in
freezing weather. A lack of substantial load can create uneven temperatures in the
tower and cause freezing.
• If you shut down your cooling tower during freezing weather, you must drain it
completely. We recommend that you use an indoor reservoir tank to permit water to
drain into the tank on system shutdown, whether for emergencies or actual planned
shutdowns.
• An alternative is to use basin heaters if a tower basin is used as a sump. Basin heaters
are available as an option. However, basin heaters can permit freeze-up during power
failures if water remains in the sump. The customer is responsible for determining risk
factors for each specific application.
Fiberglass Cooling Towers Chapter 4: Operation Page 17 of 25
Page 18
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.
Caution! Uncontrolled microorganism growth causes system problems such as fouling
and corrosion, and can spread bacterially-transmitted diseases.
You must reduce slime growth and bacterial contamination to eliminate disease-causing
bacteria.
Properly used, environmentally approved microbiocide controls system bacteria. Chemical
treatments must be regularly monitored by qualified personnel.
The manufacturer strongly recommends use of EPA-registered microbiocides on a regular
basis. We do NOT recommend use of chlorine or backyard swimming pool chemicals.
Permitting the discharge of such chemicals into a city sewer may violate local, state, and/or
federal laws.
We offer a full-service water treatment program including chemicals, dispensing equipment,
automatic bleed-off, and monthly water analysis. Contact the Parts and Service department
for more information.
Routine Maintenance
• The fan motor has double-sealed bearings and needs no lubrication
• Inspect basket strainers (where used) and clean as needed.
• Check constant bleed back to the tank for flow during operation.
• Check the bleed-off line to verify that water flows to the drain during operation.
• Inspect the tower basin for dirt and debris, and clean as needed.
• Check the tower nozzle(s) for proper operation at full water flow.
• Check the water treatment equipment for proper operation. Refer to the information
supplied with these devices.
• Check the throttling valve pressure gauge. The pressure should be within the
recommendations in section 3-6.
Fiberglass Cooling Towers Chapter 5: Maintenance Page 18 of 25
Page 19
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.
Fiberglass Cooling Towers Chapter 5: Maintenance Page 19 of 25
Page 20
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.
Service Department
Call toll-free 8am–5pm CST [800] 423-3183 or call [262] 641-8610.
Emergency Service is available 24 hours a day. We have a qualified service department ready
to help. Service contracts are available for most of our products.
www.acscustomerservice.com
Sales Department
Call [262] 641-8610 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact
our Sales Department for the name of the sales representative nearest you.
Contract Department
Call [262] 641-8610 Monday–Friday, 8am–5pm CST
Let us install your system. The Contract Department offers any or all of these services:
project planning; system packages including as-built drawings; equipment, labor, and
construction materials; union or non-union installations; and field supervision.
Fiberglass Cooling Towers Chapter 6: Appendix Page 20 of 25
Page 21
6-2 Drawings and Specifications
g
A
A0536711
B
Top View
Fan guard
Fan motor
Fan blade
Motor support
assembly
Supply piping
Access
door
Nozzle
C
Return
E
pipin
Side View Cutaway View
adaptor
Nozzle
Rigid PVC
tower fill
Water
diverter
D
Figure 7: Dimensions and Weights
Dimensions Weights
Model A B C D (supply) E (return) Shipping Operating
number in. cm in. cm in. cm in. mm c in. mm c lbs. kg lbs. kg
SF2003 64 163 64 163 104 264 3” 76.2 mm 4” 101.6 mm 600 273 1,300 591
SF2004 64 163 64 163 125 318 3” 76.2 mm 6” 152.4 mm 750 341 1,700 772
SF2005 82 208 82 208 121 307 4” 101.6 mm 8” 203.2 mm 1,400 636 2,900 1,317
SF2007 82 208 82 208 121 307 4” 101.6 mm 8” 203.2 mm 1,500 681 3,200 1,453
SF2009 100 254 100 254 123 313 4” 101.6 mm 8” 203.2 mm 1,950 886 3,800 1,726
SF2011 100 254 100 254 123 313 4” 101.6 mm 8” 203.2 mm 2,100 954 4,400 1,998
SF2015 100 254 100 254 124 315 4” 101.6 mm 8” 203.2 mm 2,600 1,181 5,200 2,361
c Millimeter measurement is approximate. Customer is responsible for converting to metric piping sizes.
Fiberglass Cooling Towers Chapter 6: Appendix Page 21 of 25
Page 22
Figure 8: Tower Performancec
Cooling Fan NEC Nominal
Model capacity Nozzles motor amp draw air flow
number tons Kcal/hr no. hp kW rpm 460/3/60 cfm cmh
SF2003 50 151,200 1 2 1.5 1,200 3.4 12,000 20,388
SF2004 75 226,800 4 5 3.7 1,200 7.6 18,000 30,582
SF2005 100 302,400 4 5 3.7 900 7.6 23,500 39,926
SF2007 125 378,000 4 5 3.7 900 7.6 26,000 44,174
SF2009 150 453,600 4 10 7.5 900 14.0 30,000 50,970
SF2011 175 529,200 4 10 7.5 900 14.0 33,000 56,067
SF2015 200 604,800 4 15 11.2 900 21.0 43,000 73,057
c Rating conditions are based on 78ºF (26ºC) wet bulb, 95ºF (35ºC) entering water
temperature, and 85ºF (29ºC) leaving water temperature; flow capacity is based on 3
gpm/ton (2.563 lpm per 1,000 Kcal/hr).
Fiberglass Cooling Towers Chapter 6: Appendix Page 22 of 25
Page 23
Figure 9: Cooling Tower Nozzle Capacity
Fiberglass Cooling Towers Chapter 6: Appendix Page 23 of 25
Page 24
6-3 Parts List
Figure 10: Supplied Parts for Field Assembly
Part Number Quantity Description
A0101485 1 Silicone
A0533163 110 Stainless steel flat washers, 5/16”
A0539417 55 Stainless steel screws, 5/16”-18 x 1 3/4”
A0533167 55 Stainless steel hex nut, 5/16”-18
A0534122 55 Stainless steel split lock washers, 3/8”
A0539598 40 ft. FG Tower gasketing
Figure 11: Spare Parts List
Part
description qty Part no. qty Part no. qty Part no. qty Part no. qty Part no. qty Part no. qty Part no.
Shell, top section 1 A0533079 1 A0539552 1 A0536702 1 A0536702 1 A0535879 1 A0535879 1 A0539581
Shell, side outlet 1 A0533078 1 A0539550 1 A0536700 1 A0536700 1 A0535880 1 A0535880 1 A0539582
Shell, bottom outlet 1 A0536666 1 A0539551 1 A0536701 1 A0536701 1 A0536668 1 A0536668 1 A0539583
Tower access door 1 A0533082 1 A0533082 2 A0533082 2 A0533082 2 A0533082 2 A0533082 2 A0533082
Motor support assy. 1 A0533090 1 A0533090 1 A0536712 1 A0536712 1 A0539586 1 A0539586 1 A0539586
Fan Motor Spcr. Brkt. 1 A0539566 -- --- 1 A0536717 -- -- -- -- -- -- -- --
Fan guard 1 A0533092 1 A0533092 1 A0536706 1 A0536706 1 A0535883 1 A0535883 1 A0535883
Fan motor e
Fan blade 1 A0533097 1 A0539556 1 A0547121 1 A0536708 1 A0541387 1 A0541387 1 A0539576
PVC fill e
Eliminator e
Louver 16 A0533106 16 A0539559 20 A0533106 20 A0533106 24 A0533106 24 A0533106 28 A0539580
Nozzle e
Nozzle adaptere
Nozzle 4
Nozzle adapter 4
PVC plug 6
Flexible coupling 1 A0502553 1 A0502554 1 A0535957 1 A0535957 1 A0535957 1 A0535957 1 A0535957
Balancing valve 6
Pressure gauge 1 A0102314 1 A0102314 2 A0102314 2 A0102314 2 A0102314 2 A0102314 2 A0102314
Strainer basket 1 A0500860 1 A0539574 1 A0535956 1 A0535956 1 A0535956 1 A0535956 1 A0535956
Float valve assy. 1 A0076209 1 A0076209 1 A0076029 1 A0538700 1 A0538700 1 A0538700 1 A0538700
Starter kit, 208 VAC 1 A0518023 1 A0518055 1 A0538701 1 A0538704 1 A0518030 1 A0518030 1 A0518059
Starter kit, 230 VAC 1 A0518024 4 A0518056 4 A0538702 4 A0538705 4 A0518031 4 A0518031 4 A0518060
Starter kit, 460 VAC 1 A0518025 4 A0518057 4 A0538703 4 A0538706 4 A0518032 4 A0518032 4 A0518061
c Fan motor spacer bracket part no. A0539566; available on FG2003 models only.
d Fan motor spacer bracket part no. A0536717; available on FG2005 models only.
e Recommended spare parts prior to April 2002.
4 Recommended spare parts list after 2002.
5 Recommended spare parts prior to February 2005 (A0504421 and A0064023)
6 Recommended spare parts list after February 2005
SF2003 c 5 SF2004 5 SF2005 d
1 A0533094 1 A0539555 1 A0536709
10 A0533101 15 A0539557 26 A0533099
5 A0533104 5 A0539558 13 A0533103
1 A0064022 4 A0539572 4 A0064022
1 A0101006 4 A0101006 4 A0101006
1 A0547133 4 A0547131 4 A0547131
1 A0547130 4 A0547130 4 A0547130
1 A0500867 1 A0500867 2 A0500867
1 A0504422 2 A0504422 2 A0504422
SF2007 SF2009 SF2011 SF2015
1 A0536710 1 A0547120 1 A0547120 1 A0539577
39 A0533099 32 A0533099 48 A0533099 48 A0539578
13 A0533103 16 A0533103 16 A0533103 16 A0539579
4 A0064022 4 A0064022 4 A0064022 4 A0064022
4 A0101006 4 A0101006 4 A0101006 4 A0101006
4 A0547132 4 A0547132 4 A0547133 4 A0547133
4 A0547130 4 A0547130 4 A0547130 4 A0547130
2 A0500867 2 A0500867 2 A0500867 2 A0500867
2 A0504422 2 A0504422 2 A0504422 2 A0504422
Fiberglass Cooling Towers Chapter 6: Appendix Page 24 of 25
Page 25
6-4 Electrical Schematics
Figure 12: Typical Wiring Diagram
Fused
disconnect
switch
ON/OFF
switch
Immerse
bulb in tank
Thermostat
115/1/60
208-230-460/3/60
M
Starter with
overloads
Non-fused
disconnect
at tower
Fan
Fiberglass Cooling Towers Chapter 6: Appendix Page 25 of 25
Loading...