EVAPCO ESW Series User manual

Rigging and
Assembly Instructions
ESW CLOSED
CIRCUIT COOLERS
Bulletin 145-E Metric
EVAPCO, INC. (World Headquarters) P.O. Box 1300, Westminster, Maryland 21158 USA
Phone [phone] Fax [phone]
EVAPCO products are manufactured worldwide:
EVAPCO Europe
Industrieterrein Oost 4010
3700 Tongeren, Belgium
Phone: [phone]
Fax: [phone]
Email: [email protected]e
EVAPCO Europe S.r.l.
Via Ciro Menotti 10
20017 Passirana di Rho (MI), Italy
Phone: [phone]
Fax: [phone]
Email: [email protected]
EVAPCO Europe GmbH
Bovert 22
D-40670 Meerbusch, Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
FOR EVAPCO AUTHORIZED PARTS AND SERVICE, CONTACT YOUR LOCAL
MR. GOODTOWER SERVICE PROVIDER OR THE EVAPCO PLANT NEAREST YOU.

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ESW Closed Circuit Coolers
Method of Shipment
ESW models are shipped with the top section(s) separate
from the bottom section(s). These sections have mating
flanges and will join together in a waterproof joint when
sealed and bolted together as described in the following
instructions. Miscellaneous items, such as sealer tape, bolt
sets and any other required materials, are packaged and
placed inside th0e pan for shipment.
Storage
Do not place tarps or other coverings over the top of the
units if the units are to be stored before installation.
Excessive heat can build up if the units are covered,
causing possible damage to the PVC eliminators, PVC
louvers, or PVC fill. For extended storage beyond six
months, rotate the fan and fan motor shaft(s) monthly.
Also, the fan shaft bearings should be purged and
regreased prior to start-up.
Structural Steel Support
Two structural “I” beams running the length of the unit are
all that is required for support of the units. These beams
should be located underneath the outer flanges of the unit
(see Figure 1). Mounting holes, 19 mm in diameter, are
located in the bottom flange of the unit to provide for bolting
it to the structural steel (see certified print for exact bolt hole
location). Bolt the bottom section to the steel support before
rigging the top section.
Beams should be sized in accordance with accepted
structural practices. Maximum deflection of the beam under
the unit to be 1/360 of the unit length, not to exceed 13 mm.
Deflection may be calculated by using 55% of the operating
weight as a uniform load on each beam (see certified print
for operating weight).
The supporting “I” beams should be level before setting the
unit. Do not level the unit by shimming between the bottom
flange and the beams as this will not provide proper
longitudinal support.
Support beams and anchor bolts are to be furnished by
others. Always refer to certified print for unit weights,
dimensions and technical data.
Figure 1 - Structural Steel Support.
Rigging Bottom Section
Lifting devices are located in the upper corners of the coil as
shown in Figure 2. The hook of the crane must be a
minimum dimension of “H” above the top of the coil to
prevent undue strain on the lifting devices.
See Table 1 for the minimum “H” dimension. These lifting
devices should not be used for extended lifts or where any
hazard exists unless safety slings are employed under the
section. (See “Extended Lifts” on page 4 for proper
arrangement.) Bolt the bottom section to the steel support
before rigging the top section.
Table 1 - Minimum H Dimension for Bottom Sections.
Figure 2 - ESW Bottom Section
Basin Section Length - m MIN. H (Above Coil) - m
2,7 2,1
3,6 3,0
5,4 4,2

Applying Sealer Tape
Once the bottom section has been set on the supporting steel and
bolted in place, the top flanges should be wiped down to remove any
dirt or moisture. Sealer tape should be placed over the mounting hole
centerline on the side flanges. Apply two strips of sealer tape, one
partially overlapping the other, on the end flanges.
The sealer tape should overlap on the corners as shown in Figure 3.
Do not splice the sealer tape along the end flanges and preferably not
on the side flanges if it can be avoided. Always remove the paper
backing from the sealer tape.
Figure 3 - Proper Sealer Tape Application
Top Section
“U” bolts are provided in the four corners of the top section
for lifting and final positioning (See Figure 4). The hook of
the crane must be a minimum dimension “H” above the top
section being lifted to prevent undue strain on the “U” bolts.
See Table 2 for the minimum “H” dimension.
Table 2 -Minimum H Dimension for Top Sections.
UNIT NO. MIN. H - m
ESW 72 models 2,7
ESW 96 models 3,6
ESW 142 models 5,1
ESW 144 models 3,6
ESW 216 models 5,1
Figure 4 - ESW Top Section.
ESW Closed Circuit Coolers
Assembly of the Top Section to the Bottom
Section
Before assembling the top section to the bottom section,
remove any loose parts shipped in the pan.
Wipe the flanges on the bottom of the top section. Check to
see that the water distribution connection on the top section is
in the correct position relative to the bottom section (see
certified unit drawing). Units are also provided with match
markings on each section (i.e. A1 of bottom section should
match up with A1 of top section).
Lower the top section to within several inches of the bottom
section making sure the two sections do not touch and the
sealer is not disturbed. Using suitably sized drift pins to
assure proper alignment, lower the top section down onto the
bottom section. Fasten all four corners. Install the remaining
fasteners, working from the corners toward the center, using
drift pins to align the holes. Fasteners must be installed in
every hole on the side flange. None are required on the end
flanges. Galvanized units will use 5/16” self tapping screws
and stainless steel units will use 8 mm nuts, bolts and
washers. See Figure 5.
Note: 8 mm stainless steel nuts, bolts and washers are
used on stainless steel models.
Figure 5 - Mating Upper Section to Bottom Section.
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Extended Lifts
Important: The lifting devices and “U” bolts should be
used for final positioning only and for lifting where no
danger exists. If they are used for extended lifts, safety
slings should be provided under the sections.
The preferred method for extended lifts is to use slings
under the unit (see Figures 5, 6, 7). Spreader bars should
always be used between the cables at the top of the section
to prevent damage to the upper flanges or fan cylinders.
Safety slings and skids should be removed before final positioning of the unit.
ESW Closed Circuit Coolers
Figure 8 - Proper Rigging Method for Extended Lifts. (5,4 m long units)
Figure 6 -ESW Top Section
Figure 7 - Proper Rigging Method for Extended Lifts. (2,7 & 3,6 m long units)

Figure 9 - Attaching Fan Screen to Cylinder
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ESW Closed Circuit Coolers
Mounting Fan Screens
3,6 m Wide Models
In certain situations some units may be shipped with the fan
screens in the basin. Under these circumstances, use the
following procedures to mount the fan screen on the discharge
cylinder.
WARNING: DO NOT WALK ON THE FAN SCREENS AT
ANY TIME!
1. Place both halves of the fan screen on top of the
discharge cylinder. Each half will be tagged to match
markings on the cylinder. Align the eyelets of the fan
screen with the holes tha\t can be found on the
perimeter of the discharge cylinder.
2. At each hole, attach the fan screen to the discharge
cylinder as shown in Figure 9.
3. Join the two screen halves with wire clips (Figure 10).
There should be 3 wire clips on each side of the fan
screen. Space the wire clips evenly across the
radius of the fan screen as shown in Figure 11.
Figure 10 - \\\Wire Clip Arrangement
Figure 11- Wire Clip Spacing
Mounting Fan Screens
3,6 m Wide by 5,4 m Long Models
On these models, the fan screen is supported from underneath
by an “X” shaped support frame.
1. Set the support frame across the top of the discharge
cylinder (See Figure 12).
2. Place both halves of the fan screen on top of the support
frame. Each half will be tagged to match markings on the
cylinder. Align the eyelets of the fan screen with the holes
on the cylinder perimeter.
3. Join the two screen halves with wire clips (See Figure 10).
There should be four clips on either side of the fan screen.
Space them evenly as shown in Figure 11.
4. At each hole, attach the fan screen to the discharge
cylinder as shown in Figure 9. At the four points where the
support frame meets the cylinder, bolt the support frame to
the cylinder together with the fan screen.
Figure 12 - Support Frame Installation

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ESW Closed Circuit Coolers
Optional Motor and Gear Box Davit
This accessory is available to aid in the removal of fan
motors and gear boxes. The assembly consists of a davit
and a mounting base that is attached to the side of the unit
next to the access door. Both of these items will ship loose
in the unit’s basin. There are two types of motor davits:
single point davits provided on units with the Powerband
Belt Drive System (Figure 12) and dual point davits provided
on units with the optional gear drive system (Figure 13).
Use the following procedure to install the mounting base.
1. Place the mounting base on the 8 mm studs protruding
from the fan section near the access door.
2. Use 8 mm lockwashers and nuts to secure the mounting
base to the unit (See Figure 14). Figure 13 - Dual Point Davit Arrangement
Figure 12 - Single Point Davit Arrangement Figure 14 - Mounting Base Installation
Rigging Hardware Parts List
The following table lists those parts which are shipped together
with the unit(s) for field assembly and/or spare parts.
Notes:
1. 5/16 x 1” Tapper. Stainless units use 8 mm nuts and bolts.
ESW Model
Box
Size (m)
Self
Tappers1
Sealer
Tape Nozzles
ESW 72 Models 2,4 x 2,7 45 4 2
ESW 96 Models 2,4 x 3,6 60 5 2
ESW 142 Models 2,4 x 5,4 90 5 2
ESW 144 Models 3,6 x 3,6 60 5 2
ESW 216 Models 3,6 x 5,4 90 6 3
General Information - Start-up & Maintenance
Table 5 – Rigging Hardware

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ESW Closed Circuit Coolers
Figure 16 - Motor Guard and Powerband Belt Installation
Figure 17 - Sheave Alignment Check
Figure 15 - External Motor Installation
External Motor Installation
2,4 m Wide Models
1. Study Figure 15 before installing the motor base on the unit.
2. Insert the lifting device into “U” bolt Aon motor base B.
3. Lift the motor base and insert the pivot pin Cdown into
hole Eand pivot pin Finto hole D.
4. Install washer and nut (do not overtighten) on pivot pins.
Install jam nut on pivot pin C.
5. Insert “J” bolts Ginto holes H. Install flat washers and
cotter pins. Place nuts and washers on threaded portion of
“J” bolts. These will be behind the motor base installed in
the next step.
6. Insert “J” bolts into holes Jin the motor base. Install flat
washers, lock washer and nuts. Remove lifting device from
the “U” bolt on the motor base. Position motor base toward
casing of unit for belt installation.
7. Install Powerband belt K(Figure 16) around fan sheave
and otor sheave. Tighten belt by adjusting nuts on “J”
bolts. Do not over tighten the belts. The center of the belt
should deflect approximately 19 mm with moderate hand
pressure.
8. Measure to see that the top and bottom of the motor base
are the same distance out from the casing of the unit. This
should ensure that the sheaves are properly aligned as
they have been pre-set at the factory.
9. As a final check, lay a straight edge from sheave to
sheave. There should be four point contact. (See Figure
17.) Adjust the position of the motor sheave as necessary.
10. To install Motor Guard L, match up hinges and install
hinge pins M. (See Figure 16.)
11. Close Motor Guard and install (2) wing bolts N.

ESW Closed Circuit Coolers
Float Valve Adjustment
The float valve is pre-set at the factory; however, adjustment
should be checked after rigging. The float valve should be
adjusted so that the centerline of the float is at the
measurement shown in Table 3 from the basin bottom.
Raise or lower the float by using the wing nuts on the
vertical threaded rod only. Do not adjust the horizontal rod.
Maintenance
Once the installation is complete and the unit is turned on, it
is important that it be properly maintained. Maintenance is
not difficult or time-consuming but must be done regularly to
assure full performance of the unit. Refer to the
maintenance instructions enclosed with the unit for proper
maintenance procedures.
Freeze Protection
Proper freeze protection must be provided if the unit is
located in a cold climate. Refer to maintenance instructions
as well as product bulletins for further information.
Starting Sequence
Before starting the unit, check that all access openings,
safety screens and covers are in place. Start the unit as
outlined below:
1. Fill the pan to the overflow level.
2. Bump start and check the spray water pump(s) for proper
rotation. Directional arrows are found on the pump
impeller housing.
3. Bump start and check the fan(s) for proper rotation.
Directional arrows are placed on the side of the fan
cylinder.
Unit Length Level (mm)
All Models 340
Table 3– Recommended Water Level
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Start-up Details
Shipping Chocks and Debris
Remove any chocks that have been placed inside the unit
for shipping purposes. Be sure to remove the chocks from
between the fan and fan guard if applicable. Clean all debris
from the basin prior to start-up. Close and secure all access
doors.
Pump Discharge Line
Connect the riser pipe from the pump discharge on the
basin section to the riser pipe on the coil/fan section using
the flexible connection and hose clamps provided.
Bleed-off Line
A bleed-off line and valve are installed on the unit when
shipped with a pump. On units shipped without a pump
(remote sump applications) make sure a bleed-off line and
valve are properly sized and installed on the discharge side
of the pump and connected to a convenient drain. In either
case, the bleed-off valve should be fully open.
Strainer
Check the strainers, if applicable, in the basin section to
make certain they are in the proper location over the pump
suction, along side of the anti-vortex hood. (See Figure 17.)
Figure 18 - Strainer Location
Screens
Protective fan screens are provided across the top of the fan
cylinders of all models. Check and tighten all bolts.
© 2007 EVAPCO, Inc. Bulletin 145-E Metric – 0707
Note: Closed circuit coolers should be used on sealed,
pressurized systems. Continual aeration of the water in
an open system can cause corrosion inside the tubes of
the cooler, leading to premature failure.