Sterling SC6-610.6 User Manual
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:
_________________________ _________________________
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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, 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
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
6-3 Parts List.......................................................................................................24
6-4 Electrical Schematics....................................................................................25
Fiberglass Cooling Towers iv
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
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
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
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
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