EVAPCO ESW Series Manual

Operation and
Maintenance Instructions
For EVAPCO Clos d Circuit Cool rs and
Evaporativ cond ns rs
for LIFE
Internat iona l Ins titute of
Ammo nia Refrigeration
www.iiar.org
Member of
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†Mark own d by th Cooling T chnology Institut
†

2
for LIFE
Operation and Maintenance Instructions
3 Introduction
3 Safety Precautions
3 Terminology
4 Initial Storage and/or Idle Period Recommendations
5 International Building Code Provision
5 Initial and Seasonal Start-Up C ecklist
6 G n ral
6 Initial and S asonal Start-Up
7 R comm nd d Maint nanc Sch dul
9 S asonal Shut-Down Ch cklist
10 Basic Closed Circuit Cooler/Condenser
Sequence of Operation
11 Fan System
11 Fan Motor B arings
11 Fan Sha Ball B arings
12 Fan B lt Adjustm nt
13 Fan B lt Adjustm nt – Induc d Dra
14 Fan B lt Adjustm nt – Forc d Dra Dra
14 G ar Driv s
14 Air Inl t
14 Coil Inl t
15 Fan Syst m – Capacity Control
15 Fan Motor Cycling
15 S qu nc of Op ration for Fan Motor Cycling
15 Variabl Fr qu ncy Driv s
15 S qu nc of Op rations / Guid lin s for Multi-fan
Units with a VFD during P ak Load
16 Two-Sp d Motors
16 S qu nc of Op ration for Two Fan Units with Two
Sp d Motors during P ak Load
17 Recirculated Water System – Routine Maintenance
17 Suction Strain r in Cold Wat r Basin
18 Cold Wat r Basin
18 Op rating L v l of Wat r in Cold Wat r Basin
19 Wat r Mak Up Valv
19 Pr ssuriz d Wat r Distribution Syst ms
20 Bl d-Off Valv
20 Pump (Wh n Suppli d)
21 Water Treatment and Water C emistry
21 Bl d or Blowdown
21 Galvaniz d St l – Passivation
22 Wat r Ch mistry Param t rs
22 Control of Biological Contamination
23 Gray Wat r and R claim d Wat r
23 Air Contamination
24 Cold Weat er Operation
24 Unit Layout
24 Fr z Prot ction of R circulating Wat r
26 Fr z Prot ction of Clos d Circuit Cool r Coils
27 Unit Acc ssori s
27 Cold Wat r Basin H at rs
27 R mot Sumps
27 El ctric Wat r L v l Control
27 Vibration Cut Out Switch s
27 Capacity Control M thods for Cold W ath r Op ration
27 Induc d Dra Unit Capacity Control
28 Forc d Dra Unit Capacity Control
28 Ic Manag m nt
28 Induc d Dra Units
28 Forc d Dra Units
29 Troubles ooting
32 Replacement Parts
33 Part Id ntification Drawings
33 ATWB/ co-ATWB 3’ Wid Units
34 ATC-E/ATWB/ co-ATWB 4’x4’ & 4’x6’ Wid Units
35 ATC-E/ATWB/ co-ATWB 4’x9’ & 4’x12’ Wid Units
36 ATC-E/ATWB/ co-ATC-A/ co-ATWB 7’ Wid Units
37 ATC-E/ATWB/ co-ATC-A/ co-ATWB 8’ & 8.5’
Wid Units
38 ATC-E/ATWB/ co-ATC-A/ co-ATWB 10’ & 12’
Wid Units
39 co-ATWB-E 8.5’ Wid Units
40 co-ATWB-E 10’ & 12’ Wid Units
41 ESW4 8.5’ Wid Units
42 ESW4 12’ Wid Units
43 co-ATC-H/ co-ATWB-H 8.5’ Wid Units
44 co-ATC-H/ co-ATWB-H 10’ & 12’ Wid Units
45 ESWA 8.5’ Wid Units
46 ESWA 12’ Wid Units
47 LSC-E/LSWE/ co-LSWE 4’ Wid Units
48 LSC-E/LSWE/ co-LSWE 5’ Wid Units
49 LSC-E/LSWE/ co-LSWE 8’ Wid Units
(Singl Sid Fans)
50 LSC-E/LSWE/ co-LSWE 10’ Wid Units
51 LRC/LRWB/ co-LRWB 3’ Wid Units
52 LRC/LRWB/ co-LRWB 5’ Wid Units
53 LRC/LRWB/ co-LRWB 8’ Wid Units
54 PMC-E/ co-PMC 5’ Wid Units
55 PMC-E/ co-PMC 10’ and 12’ Wid Units
56 PHC-S/PHC-L 12’ Wid Singl Sid Air Inl t Units
57 PHC-D 12’ and 14’ Wid Two Sid Air Inl t Units
Table of Contents

3
Congratulations on th purchas of your EVAPCO vaporativ cooling unit. EVAPCO quipm nt is construct d of th high st quality
mat rials and d sign d to provid y ars of r liabl s rvic wh n prop rly maintain d.
Thoroughly cl an road salt, dirt and d bris from unit imm diat ly a r d liv ry. R sidu l  on product surfac s can caus damag that is
not cov r d by any warranty.
Evaporativ cooling quipm nt is o n r mot ly locat d and p riodic maint nanc ch cks ar o n ov rlook d. It is important to
stablish a r gular maint nanc program and b sur that th program is follow d. This bull tin should b us d as a guid to stablish a
program. A cl an and prop rly s rvic d unit will provid a long s rvic lif and op rat at p ak ffici ncy.
This bull tin includ s r comm nd d maint nanc s rvic s for unit start up, unit op ration and unit shutdown and th fr qu ncy of ach.
Pl as not : th r comm ndations of fr qu ncy of s rvic ar minimums. S rvic s should b p rform d mor o n wh n op rating
conditions n c ssitat .
B com familiar with your vaporativ cooling quipm nt. R f r to th isom tric drawings locat d on pag s 31-52 for information on th
arrang m nt of compon nts in your quipm nt.
If you should r quir any additional information about th op ration or maint nanc of this quipm nt, contact your local EVAPCO
r pr s ntativ . You may also visit www. vapco.com or www.mrgoodtow r.com for mor information.
Qualifi d p rsonn l should us prop r car , proc dur s and tools wh n op rating, maintaining or r pairing this quipm nt in ord r to
pr v nt p rsonal injury and/or prop rty damag . Th warnings list d b low ar to b us d as guid lin s only.
T is equipment s ould never be operated wit out fan screens and access doors properly secured and in place.
A lockable disconnect switc s ould be located wit in sig t of t e unit for eac fan motor associated wit t is
equipment. Before performing any type of service or inspection of t e unit make certain t at all power as been
disconnected and locked in t e “OFF” position.
T e top orizontal surface of any unit is not intended to be used as a working platform. No routine service work is
required from t is area.
Building water systems receive potable and non-potable water from eit er a public or private entity for t eir water
supply. T is water supply for t e building water system can contain various waterborne pat ogens, including
Legionella bacteria, w ic can cause or contribute to various illnesses if aspirated, ingested or in aled. Since
evaporative cooling equipment uses t e same building water, t ere is some potential t at t ese pat ogens mig t
propagate in t e equipment. T erefore, careful consideration s ould be undertaken wit respect to equipment
location and t e implementation of effective water management, inspection and cleaning protocols. (See Control of
Biological Contaminants in t ese Operation and Maintenance Instructions.)
Throughout this manual, th t rms “Induc d Dra” and “Forc d Dra” ar us d. B low is a list of EVAPCO Clos d Circuit Cool r and
Cond ns r products off rings and as sociat d t rminology.
Induced Dra quipm nt includ s th following Evapco Product Mod ls:
<ESW Product Lines
•ESWA - Clos d Circuit Cool r
•ESW4 - Clos d Circuit Cool r
Introduction
Safety Precautions
Terminology

4
<AT Product Lines
•ATWB - Clos d Circuit Cool r
•ATC-E - Evaporativ Cond ns r
•co-ATWB - Clos d Circuit Cool r
•co-ATWB-E - W t/Dry Clos d Circuit Cool r
•co-ATWB-H - W t/Dry Clos d Circuit Cool r
•co-ATC-A - W t/Dry Evaporativ Cond ns r
•co-ATC-H W t/Dry Evaporativ Cond ns r
<PHC - Parallel Hybrid Evaporative Condenser
Forced Dra quipm nt includ s th following Evapco Product Mod ls:
<LR Product Lines
•LRWB - Clos d Circuit Cool r
•LRC - Evaporativ Cond ns r
•co-LRWB - W t/Dry Clos d Circuit Cool r
<LS Product Lines
•LSWE - Clos d Circuit Cool r
•LSC-E - Evaporativ Cond ns r
•co-LSWE - W t/Dry Clos d Circuit Cool r
<PM Product lines
•PMC-E - Evaporativ Cond ns r
•PMC-Q - Evaporativ Cond ns r
•co-PMC - W t/Dry Evaporativ Cond ns r
If th unit will sit for idl p riods of tim it is r comm nd d that th following b p rform d in addition to all compon nt manufactur rs
r comm nd d maint nanc instructions.
•Th fan/motor/pump b arings and motor b arings n d to b turn d by hand at l ast onc a month. This can b accomplish d
by tagging and locking out th unit’s disconn ct, grasping th fan ass mbly (or r moving th pump motor fan guard), and rotating it
s v ral turns.
•If unit sits long r than a f w w ks, run g ar r duc r (if quipp d) for 5 minut s w kly.
•If unit sits long r than 3 w ks, compl t ly fill g ar r duc r with oil. Drain to normal l v l prior to running.
•If unit sits long r than on month, insulation t st motor windings s mi-annually.
•If fan motor sits idl for at l ast 24 hours whil th spray pumps ar n rgiz d distributing wat r ov r th coil, motor spac h at rs
(if quipp d) should b n rgiz d. Alt rnativ ly, fan motors may b n rgiz d for 10 minut s, twic daily, to driv any moistur
cond nsation out of th motor windings.
•If coil sits long r than on month, nitrog n charg th coil.
•En rgiz fan motors spac h at rs.
Initial Storage and/or Idle Period Recommendations

5
Th Int rnational Building Cod (IBC) is a compr h nsiv s t of r gulations addr ssing th structural d sign and installation r quir m nts
for building syst ms – including HVAC and industrial r frig ration quipm nt. Th cod provisions r quir that vaporativ cooling
quipm nt and all oth r compon nts p rman ntly install d on a structur must m t th sam s ismic d sign crit ria as th building.
All it ms attach d to Evapco Clos d Circuit Cool rs or Evaporativ Cond ns rs must b ind p nd ntly r vi w d and isolat d to m t
applicabl wind and s ismic loads. This includ s piping, ductwork, conduit, and l ctrical conn ctions. Th s it ms must b fl xibly
attach d to th Evapco unit so as not to transmit additional loads to th quipm nt as a r sult of s ismic or wind forc s.
General
1. V rify that th ov rall installation r fl cts th r quir m nts of th installation guid lin s found in EVAPCO Bull tin 311 –
Equipm nt Layout Manual availabl at www. vapco.com.
2. Fan motor spac h at rs - To pr v nt any moistur buildup in th windings and b arings, spac h at rs ar provid d as
standard on v ry fan motor. Th s should b wir d prior to op ration.
3. For multi-sp d fan motors, v rify that 30 s cond or gr at r tim d lays ar provid d for sp d chang s wh n
switching from high to low sp d. Also ch ck to s if int rlocks ar provid d to pr v nt simultan ously n rgizing high
and low sp d, and confirm both sp ds op rat in th sam dir ction.
4. V rify all saf ty int rlocks work prop rly.
5. For units op rating with a variabl fr qu ncy driv , mak c rtain that minimum sp d r quir m nts hav b n s t.
Ch ck with VFD manufactur r for r comm nd d minimum sp ds. S “Fan Syst m - Capacity Control” s ction for
mor information, and r comm ndations on locking out r sonanc fr qu nci s.
6. V rify that a wat r tr atm nt plan has b n impl m nt d including passivation of galvaniz d st l units. S “Wat r
Tr atm nt” s ction for mor d tails.
7. If th unit is going to sit idl for an xt nd d p riod of tim , follow all manufactur rs’ fan motor and pump instructions
for long t rm storag . Plastic sh ts or tarps should n v r b us d to prot ct a unit during storag . This practic can
trap h at insid th unit, and could pot ntially caus damag to plastic compon nts. S your local EVAPCO
r pr s ntativ for additional information on unit storag .
BEFORE BEGINNING ANY MAINTENANCE, BE CERTAIN THAT THE POWER IS TURNED OFF
AND THE UNIT IS PROPERLY LOCKED AND TAGGED OUT!
Initial and Seasonal Start-Up
1. Cl an and r mov any d bris, such as l av s and dirt from th air inl ts.
2. Flush th cold wat r basin (with th strain r scr ns in plac ) to r mov any s dim nt or dirt.
3. R mov th strain r scr n, cl an and reinstall.
4. Ch ck m chanical float valv to s if it op rat s fr ly.
5. Insp ct wat r distribution syst m nozzl s and cl an as r quir d. Ch ck for prop r ori ntation.
(This is not required at initial start-up. The nozzles are clean and set at the factory).
6. Ch ck to nsur dri liminators ar s cur ly in plac and in th prop r ori ntation.
International Building Code Provisions
Initial and Seasonal Start-Up C ecklist

6
7. Adjust fan b lt t nsion as r quir d. S “Fan B lt Adjustm nt” s ction.
8. Lubricat fan sha b arings prior to s asonal start-up.
9. Turn th fan(s) and pumps by hand to insur it turns fr ly without obstructions.
10. Visually insp ct th fan blad s. Blad cl aranc should b approximat ly 3/8” (1/4” minimum) from tip of blad to th
fan cowl. Th fan blad s should b s cur ly tight n d to th fan hub.
11. If any stagnant wat r r mains in th syst m including “d ad l gs” in th piping, th unit must b disinf ct d prior to th
fans b ing n rgiz d. Pl as r f r to ASHRAE Guid lin 12-2000 and CTI Guid lin WTP-148 for mor information.
12. Manually fill th cold wat r basin up to th ov rflow conn ction.
13. For clos d circuit cool rs, fill th h at xchang r coil with th sp cifi d fluid and “burp” air from th syst m b for
pr ssurizing, using v nts on coil inl ts. Do not do this for vaporativ cond ns rs.
NOTE: Closed circuit coolers s ould only be used on sealed, pressurized systems. Continual aeration of t e water in an open
system can cause corrosion inside t e tubes of t e cooler leading to premature failure.
For clos d circuit cool rs with optional controls, s controls O&M for prop r start up proc dur .
Aer t e unit as been energized, c eck t e following:
1. Adjust m chanical float valv as r quir d to th prop r wat r l v l.
2. Unit basin should b fill d to th prop r op rating l v l. S “R circulating Wat r Syst m Op rating L v ls” s ction for
mor d tails.
3. V rify fan(s) is rotating in prop r dir ction.
4. Start th spray wat r pump(s) and ch ck for prop r rotation as indicat d by th arrow on th front cov r.
5. M asur voltag and curr nt on all thr pow r l ads of pump and fan motor. Th curr nt should not xc d th
motor nam plat full load amp rating taking th s rvic factor into account.
6. Consult your qualifi d wat r tr atm nt company to fin tun th minimum bl d n c ssary, s “Wat r Tr atm nt and
Wat r Ch mistry” s ction.
7. S fan and pump motor manufactur r maint nanc and long t rm storag instructions for mor d tail d information.
Th motors should b lubricat d and s rvic d in accordanc with manufactur r’s instructions.
8. All n w vaporativ cooling quipm nt and associat d piping should b pr -cl an d and flush d to r mov gr as ,
oil, dirt, d bris and oth r susp nd d solids prior to op ration. Any pr -cl aning ch mistry should b compatibl with
th cooling quipm nt’s mat rials of construction. Alkalin formulations should b avoid d for syst ms which includ
galvaniz d mat rials of construction.
Clos d hydronic syst ms conn ct d to ith r a clos d-circuit cool r or dry cool r should b pr -cl an d and flush d
to r mov d bris, gr as , flash rust, oil, and oth r susp nd d solids prior to op ration. Evapco r comm nds th us of
inhibitor ch mistry or inhibit d glycol to minimiz corrosion and scal during normal op ration. EVAPCO r comm nds
a minimum of 25% inhibit d glycol to minimiz corrosion.

7
1. G ar R duc r – Ch ck oil l v l with unit stopp d 24 hours a r start-up & monthly
2. G ar R duc r/Piping – Do visual insp ction for oil l aks, Monthly
auditory insp ction for unusual nois s and vibrations
3. G ar R duc r – R plac oil S mi-annually
4. Oil Pump – Do visual insp ction for l aks and Monthly
prop r wiring
5. G ar R duc r/Coupling – Ch ck alignm nt of 24 hours a r start-up & monthly
th syst m
6. Coupling/Sha – Insp ct fl x l m nts and hardwar Monthly
for tightn ss, prop r torqu & crack/d t rioration
7. H at r Controll r – Insp ct controll r and Quart rly
cl an prob nds
8. H at r – Insp ct junction box for loos wiring and moistur On month a r start-up and s mi-annually
PROCEDURE FREQUENCY
1. Cl an pan strain r Monthly or as n d d
2. Cl an and flush pan** Quart rly or as n d d
3. Ch ck bl d-off valv to mak sur it is op rativ Monthly
4. Ch ck op rating l v l in pan and adjust float valv Monthly
if n c ssary
5. Ch ck wat r distribution syst m and spray patt rn Monthly
6. Ch ck dri liminators Quart rly
7. Ch ck th fan blad s for cracks, missing balancing w ights Quart rly
loos w ight port caps and op n drain hol s
(Sup r Low Sound Fans) and vibrations
8. Ch ck sh av s, bushings, fan shas and fan hubs Annually
for corrosion. Scrap and coat with ZRC
9. Insp ct lubrication lin s to b arings Quart rly
10. Lubricat fan sha b arings* Ev ry 1000 hours of op ration (or v ry thr months)
11. Ch ck b lt t nsion and adjust Monthly
12. Sliding motor bas – Insp ct and gr as Annually or as n d d
13. Ch ck fan scr ns, inl t louv rs and fans. Monthly or as n d d
R mov any dirt or d bris
14. Insp ct and cl an prot ctiv finish Annually
- Galvaniz d: scrap and coat with ZRC
- Stainl ss: cl an and polish with a stainl ss st l cl an r.
15. Ch ck wat r quality for biological contamination. R gularly
Cl an unit as n d d and contact a wat r tr atm nt
company for r comm nd d wat r tr atm nt program**
OPTIONAL ACCESSORIES:
* S maint nanc manual for start-up instructions and lubrication r comm ndations.
** Cooling Tow rs must b cl an d on a r gular basis to pr v nt th growth of bact ria including L gion lla Pn umophila.
Recommended Minimum Maintenance Sc edule

8
9. H at r – Insp ct l m nts for scal build-up Quart rly
10. El ctronic Wat r L v l Controll r – Insp ct junction box S mi-annually
for loos wiring and moistur
11. El ctronic Wat r L v l Controll r – Cl an prob nds Quart rly or as n d d
of scal build-up
12. El ctronic Wat r L v l Controll r – Cl an insid Annually
th standpip
13. Sol noid Mak -up Valv – Insp ct and cl an valv and As n d d
strain r of d bris
14. Vibration Switch (m chanical) – Insp ct nclosur for On month a r start-up and monthly
loos wiring and moistur
15. Vibration Switch – Adjust th s nsitivity During start-up and annually
16. Sump Sw p r Piping – Insp ct and cl an piping S mi-annually
of d bris
17. Wat r L v l Indicator – Insp ct and cl an Annually
18. SUN Solar Pan ls – Insp ct for damag and cl an with S mi-annually
hos and so brush
Idle Period Recommended Action Frequency
Two or Mor Days En rgiz motor spac h at rs -or run motors for 10 minut s Twic daily
F w W ks Run g ar r duc r for 5 minut s W kly
S v ral W ks Compl t ly fill g ar r duc r with oil. Onc
Drain to normal l v l prior to running.
On Month or Long r Rotat motor sha/fan 10 turns Bi-w kly
M gg r t st motor windings S mi-annually
Recommended Maintenance Sc edule (continu d)
OPTIONAL ACCESSORIES:
DURING IDLE PERIODS:

9
Seasonal S ut-Down C ecklist
Wh n th syst m is to b shut down for an xt nd d p riod of tim , th following s rvic s should b p rform d.
1. Th vaporativ cooling unit cold wat r basin should b drain d
2. Th cold wat r basin should b flush d and cl an d with th suction strain r scr ns in plac .
3. Th suction strain r scr ns should b cl an d and r -install d.
4. Th cold wat r basin drain should b l  op n.
5. Th fan sha b arings and motor bas adjusting scr ws should b lubricat d. This should also b p rform d if th unit
is going to sit idl prior to initial start-up.
6. Th mak -up wat r supply, ov rflow and drain lin s, as w ll as th r circulating pump and pump piping up to th
ov rflow l v l must b h at trac d and insulat d to account for any r sidual wat r.
7. Th finish of th unit should b insp ct d. Cl an and r finish as r quir d.
8. Th fan, motor and pump b arings n d to b turn d at l ast onc a month by hand. This can b accomplish d by
making sur th unit’s disconn ct is tagg d and lock d out, and grasping th fan ass mbly, rotating it s v ral turns.
9. En rgiz fan motor spac h at rs.
10. Clos d Circuit Cool rs only - If th r comm nd d minimum fluid flows through th h at transf r coil cannot b
maintain d, and an anti-fr z solution is not in th coil, th coil must b drain d imm diat ly wh n v r th syst m
pumps ar shut down or flow stops during fr zing conditions. This is accomplish d by having automatic drain valv s
and air v nts in th piping to and from th cool r. Car must b tak n to nsur that th piping is ad quat ly insulat d
and siz d to allow th wat r to flow quickly from th coil. This m thod of prot ction should b us d only in m rg ncy
situations and is n ith r a practical nor r comm nd d m thod of fr z prot ction. Coils should not b drain d for an
xt nd d p riod of tim , as int rnal corrosion may occur. S Cold W ath r Op ration s ction of this docum nt for
mor d tails.
See fan and pump manufacturer maintenance and long term storage instructions for more detailed instructions.

10
System Off / No Load
Th syst m pumps and fans ar off. If th basin is full of wat r a minimum basin wat r t mp ratur of 40ºF must b maintain d to pr v nt
fr zing. This can b accomplish d with th us of optional basin h at rs. S th “Cold W ath r Op ration” s ction of this bull tin for
mor d tails on cold w ath r op ration and maint nanc .
System/Condensing Temperature Rises
Th r circulation pump turns on. Th unit will provid approximat ly 10% cooling capacity with only th pump running. If th unit has
positiv closur damp rs th y should b fully op n d b for th pumps turn on.
If th syst m t mp ratur continu s to ris , th unit fan is cycl d on. For a variabl sp d controll r, th fans ar turn d on to minimum
sp d. S th “Fan Syst m – Capacity Control” s ction of this bull tin for mor d tails on fan sp d control options. If th syst m
t mp ratur continu s to ris , th n th fan sp d is incr as d as r quir d, up to full sp d.
Not : During sub-fr zing w ath r th minimum r comm nd d sp d for variabl sp d controll rs is 50%. ALL FANS IN OPERATING
CELLS OF MULTIPLE CELL UNITS MUST BE CONTROLLED TOGETHER TO PREVENT ICING ON THE FANS.
System/Condensing Temperature Stabilizes
Control th l aving fluid t mp ratur (clos d circuit cool rs) or cond nsing t mp ratur ( vaporativ cond ns rs) by modulating th fan
sp ds with variabl sp d driv s or by cycling fans on and off with singl or two-sp d driv s.
System/Condensing Temperature Drops
D cr as th fan sp d, as r quir d.
System Off / No Load
Th syst m pump turns off. Th start r int rlock will n rgiz any optional basin h at rs in cold w ath r.
Th r circulation pump should not b us d as a m ans of capacity control, and should not b cycl d fr qu ntly. Exc ssiv cycling can
l ad to scal build-up, and r duc w t and dry p rformanc .
Dry Operation
During cold r wint r months it is possibl to turn off th spray pump, drain th cold wat r basin, and just cycl th fans. B sur to l av
th basin drain op n during this tim to pr v nt coll ction of rain wat r, snow, tc. If th unit has positiv closur damp rs th y should b
fully op n d b for th fans turn on. If dry op ration will b us d on a c ntrifugal fan, forc d dra unit, b sur to v rify that th motor
and driv s hav b n prop rly siz d to handl th r duction in static pr ssur xp ri nc d wh n th spray wat r is turn d off.
NOTE: Minimum control point for process fluid s ould never be lower t an 42º F.
NOTE: W en a unit is provided wit a disc arge damper assembly, t e control sequence s ould cycle t e dampers open
and closed once a day regardless of capacity requirments to prevent t e assembly from seizing. T e fan motor s ould be
s ut off w enever t e dampers are closed.
NOTE: ESW4/A or PHC product lines s ould not operate dry.
NOTE: T e eco-ATW/eco-ATWE sequence of operation is unique and is explained in detail in t e Sage2, Sage3Panel
Control Manual.
Basic Closed Circuit Cooler/Condenser Sequence of Operation
for Wet or Evaporative Mode

11
Table 1 – Location of Gr as Lub Lin Fittings for B lt Driv n Units
Unit Description Location of Lube Line Fittings
Induc d Dra Units: Locat d just b sid th fan casing
3’, 4’, 8’, 8.5’, 17’ wid acc ss door
Induc d Dra Units: Locat d insid th fan casing
10’, 12’, 14’, 24’, 28’ wid acc ss door
Forc d Dra Units Locat d on th b aring support or
on th sid of th unit
PHC Units Locat d insid acc ss door at bottom of
casing/abov th fi ld s am
Th fan syst ms of both c ntrifugal and axial driv n units ar rugg d; how v r, th fan syst m must b ch ck d r gularly and lubricat d at
th prop r int rvals. Th following maint nanc sch dul is r comm nd d.
Fan Motor Bearings
EVAPCO vaporativ cooling units us ith r a T.E.A.O. (Totally Enclos d Air Ov r) or a T.E.F.C. (Totally Enclos d Fan Cool d) fan motor.
Th s motors ar built to “Cooling Tow r Duty” sp cifications. Th y ar suppli d with p rman ntly lubricat d b arings and sp cial
moistur prot ction on th b arings, sha and windings. A r xt nd d shut-downs, th motor should b ch ck d with an insulation
t st r prior to r starting th motor.
Fan S a Ball Bearings
For induc d dra units, lubricat th fan sha b arings v ry 1,000 hours of op ration or v ry thr months. For forc d dra units,
lubricat th fan sha b arings v ry 2,000 hours of op ration or v ry six months. Us any of th following synth tic wat rproof, polyur a
inhibit d gr as s which ar suitabl for op ration b tw n -20°F and 350°F. (For cold r op rating t mp ratur s, contact th factory).
Mobil – Polyr x EM Ch vron - SRI Timk n Pillowblock Gr as
Feed grease slowly into t e bearings or t e seals may be damaged. A and grease gun is recommended for t is process.
W en introducing new grease, all grease s ould be purged from t e bearings.
Most EVAPCO units ar suppli d with xt nd d gr as lin s to allow asy lubrication of th fan sha b arings as shown in Tabl 1.
Fan System

12
Fan Belt Adjustment (Dir ct driv units do not r quir any adjustm nt)
Th fan b lt t nsion should b ch ck d at start up and again a r th first 24 hours of op ration to corr ct for any initial str tch. To
prop rly adjust th b lt t nsion, position th fan motor so that th fan b lt will d fl ct approximat ly 3/8” wh n mod rat pr ssur is
appli d midway b tw n th sh av s. Figur 1 and Figur 2 show two ways to m asur this d fl ction. B lt t nsion should b ch ck d on
a monthly basis. A prop rly t nsion d b lt will not “chirp” or “squ al” wh n th fan motor is start d.
Figure 1 – M thod 1
Figure 2 – M thod 2

13
On induc d dra b lt driv n units with int rnally mount d motors (10, 12, 14, 20, 24 and 28 foot wid units). PHC-S, L and D Units, a motor
adjustm nt tool is provid d on th adjustm nt nut. To us , plac th h x nd ov r th adjustm nt nut and t nsion th b lt by turning th nut
count rclockwis . Wh n th b lts ar prop rly t nsion d, tight n th lock nut.
Figure 3 – Ext rnally Mount d Motor, Induc d Dra
Figure 4 – Int rnally Mount d Motor, Induc d Dra
Induced Dra – On induc d dra b lt driv n units provid d with xt rnally mount d motors, s Figur 3.
ADJUSTMENT NUT
ADJUSTMENT
TOOL
Figure 5 – Int rnally Mount d Motor,
PHC-D Unit
ADJUSTMENT
NUT
ADJUSTMENT
TOOL
Figure 6 – Int rnally Mount d Motor,
PHC-S & L Tand m Fan Units

14
Figure 9 – LR Motor Adjustm nt
Forced Dra – LS and PM Styl forc d dra units, both J-typ adjustm nt bolts on th adjustabl motor bas should hav an qual
amount of xpos d thr ad for prop r sh av and b lt alignm nt.
ADJUSTMENT
NUTS
Figure 7 – PM Styl Motor Adjustm nt
Figure 8a – Ext rnally Mount d
Motor, Larg LS, 8X & 3M Units
ADJUSTMENT
NUTS
Figure 8b – Ext rnally Mount d
Motor, Small LS, 4X & 5X Units
Gear Drives
Induc d dra units with g ar driv syst ms r quir sp cial maint nanc . Pl as r f r to th g ar manufactur rs r comm nd d
maint nanc instructions. Th s will b nclos d and shipp d with th unit.
Air Inlet
Insp ct th air inl t louv rs (induc d dra units) or fan scr ns (forc d dra units) monthly to r mov any pap r, l av s or oth r d bris that
may b blocking airflow into th unit.
Coil Inlet
Insp ct th top coil, air inl t and spray s ction on all PHC units monthly.

15
Th r ar s v ral m thods for capacity control of th vaporativ cooling unit. M thods includ : Fan motor cycling, th us of two sp d
motors, and th us of variabl fr qu ncy driv s (VFD’s).
Not : for th co-ATW with Sag 2and co-ATWE with Sag 3consult th manual.
Fan Motor Cycling
Fan Motor Cycling r quir s th us of a singl stag th rmostat which s ns s th fluid t mp ratur (clos d circuit cool rs) or cond nsing
t mp ratur ( vaporativ cond ns rs). Th contacts of th th rmostat ar wir d in s ri s with th fan motor’s start r holding coil. For
individual fan motor cyclings int rlock fan motors b for fan start to pr v nt issu s with r v rsing idl fans.
Sequence of Operation for Fan Motor Cycling
Fan Motor Cycling is o n found to b inad quat wh r th load has a wid fluctuation. In this m thod, th r ar only two stabl l v ls
of p rformanc : 100% of capacity wh n th fan is on, and approximat ly 10% of capacity wh n th fan is off. Pl as not that rapid
cycling of th fan motors can caus th fan motor to ov rh at. Controls should b s t to only allow a maximum of six start/stop cycl s
p r hour. Th r circulation pump may not b us d as a m ans of capacity control and should not b cycl d fr qu ntly. Exc ssiv cycling
can l ad to scal build-up, r sulting in r duc d w t and dry p rformanc .
Variable Frequency Drives
Th us of a variabl fr qu ncy driv (VFD) provid s th most pr cis m thod of capacity control. A VFD is a d vic that conv rts a fix d
AC voltag and fr qu ncy into an adjustabl AC voltag and fr qu ncy us d to control th sp d of an AC motor. By adjusting th
voltag and fr qu ncy, th AC induction motor can op rat at many diff r nt sp ds.
Th us of VFD t chnology can b n fit th lif of th m chanical compon nts with f w r and smooth r motor starts and built-in motor
diagnostics. VFD t chnology has particular b n fit on vaporativ cooling units op rating in cold climat s wh r airflow can b
modulat d to minimiz icing and r v rs d at low sp d for d -icing cycl s. Applications using a VFD for capacity control must also us
an inv rt r capabl motor built in complianc with NEMA standard MG-1.
NOTE: VFD's s ould not be used on pump motors. T e pumps are designed to be operated at full speed and are not
intended to be used as capacity control.
Th typ of motor, manufactur r of th VFD, motor l ad l ngths (b tw n th motor and th VFD), conduit runs and grounding can
dramatically aff ct th r spons and lif of th motor. S l ct a high quality VFD that is compatibl with th fan motor(s) in th EVAPCO
unit(s). Many variabl s in th VFD configuration and installation can aff ct motor and VFD p rformanc . Two particularly important
param t rs to consid r wh n choosing and installing a VFD ar switching fr qu ncy and th distanc b tw n th motor and VFD o n
r f rr d to as l ad l ngth. Consult th VFD manufactur r’s r comm ndations for prop r installation and configuration. Th motor l ad
l ngth r strictions can vary with th v ndor. R gardl ss of motor suppli r, minimizing l ad l ngth b tw n th motor and driv is good
practic .
VFD Lockout Notification
Sequence of Operations / Guidelines for Multi-fan Units wit a VFD during Peak Load
For co-ATWE, s Sag 2/Sag 3control Pan l O&M
1. Both fan motors off – Pump running on on c ll.
2. Both fan motors off – Pump running on both c lls.
3. Both VFDs turn on at th manufactur r’s r comm nd d minimum op rating sp d (25%) – Pump running on both c lls.
4. Both VFDs sp d up uniformly (th y should b synchroniz d on start-up) – Pump running on both c lls.
5. Both VFDs ar on full sp d – Pump running on both c lls.
NOTE: T e VFDs need to ave a pre-set s utoff to prevent water temperatures from becoming too cold and to prevent
t e drive from trying to turn t e fan at near zero speed. Operating below 25% of motor speed ac ieves very little return
in fan energy savings and capacity control. C eck wit your VFD supplier if operating below 25% is possible.
Fan System - Capacity Control

16
Variable Frequency Drive Lock-out Notification
Qualified personnel s ould use proper care, procedures and tools w en maintaining t e Fan/Drive System in order
to prevent personal injury and/or property damage.
Identify and Lock-out Harmful Resonant Frequencies
A Variabl Fr qu ncy Driv (VFD) fan syst m, unlik traditional fix d-sp d syst ms, is d sign d to op rat b tw n 25% (15Hz) and
100% (60Hz) sp ds, which cr at s an opportunity for op ration wh r r sonant fr qu nci s xist. Sustain d op ration at r sonant
fr qu nci s may l ad to xc ssiv vibration, fatigu of structural compon nts, and/or driv syst m nois and failur . Own rs and
op rators must anticipat th xist nc of r sonant fr qu nci s and lock out fr qu nci s during start-up and commissioning in ord r to
pr v nt driv syst m op rational probl ms and structural damag . As a part of th normal start-up and commission proc ss s, r sonant
fr qu nci s should b id ntifi d and lock d-out in th VFD’s sowar .
Th unit’s supporting structur , xt rnal piping, and acc ssori s contribut to th ov rall harmonic mak -up and stiffn ss of th syst m.
Th choic of VFD will also hav a significant influ nc on how th syst m b hav s. Cons qu ntly, not all r sonant fr qu nci s can b
d t rmin d in advanc at th manufactur r’s factory during final insp ction and t sting. R l vant r sonant fr qu nci s (if th y occur) can
only b id ntifi d accurat ly a r th unit installation in th syst m.
To ch ck for r sonant fr qu nci s in th fi ld, a run-up and run-down t st must b p rform d. Additionally, VFD carri r fr qu nci s
should b adjust d to b st align th VFD with th l ctrical syst m. R f r to your driv ’s start-up proc dur s for additional information and
instruction.
Th proc dur of ch cking for r sonant fr qu nci s r quir s st pping through th VFD’s op rating rang at (2) Hz int rvals from th
low st op rating fr qu ncy to full sp d. At ach st p, paus long nough for th fan to r ach st ady-stat . Not chang s in unit
vibration during this tim . R p at from full sp d to minimum sp d. Should vibration-inducing fr qu nci s xist, th run-up and run-
down t st will isolat th r sonant fr qu nci s which th n must th n b lock d-out in th VFD programming.
For mor d tails on th us of variabl fr qu ncy driv s, pl as download a copy of EVAPCO’s Engin ring Bull tin 39 from
vapco.com.
Two Speed Motors
Th us of a two-sp d motor provid s an additional st p of capacity control wh n us d with th fan cycling m thod. Th low sp d of
th motor will provid approximat ly 60% of full sp d capacity.
Two-sp d capacity control syst ms r quir not only a two-sp d motor, but also a two-stag th rmostat and th prop r two-sp d motor
start r. Th most common two-sp d motor is a singl winding typ . This is also known as a cons qu nt pol d sign. Two-sp d two-winding
motors ar also availabl . All multi-sp d motors us d in vaporativ cooling units should b variabl torqu d sign.
NOTE: W en two-speed motors are to be used, t e motor starter controls must be equipped wit a decelerating time delay
relay. T e time delay s ould be a minimum of 30 seconds w en switc ing from ig speed to low speed.
Sequence of Operation for Two Cell Units wit Two Speed Motors during Peak Load
For co-ATWE, s Sag 2/Sag 3control Pan l O&M
1. Both fan motors off – Pump running on on c ll.
2. Both fan motors off – Pump running on both c lls.
3. On fan motor on low sp d, on fan motor off – Pump running on both c lls.
4. Both fan motors on low sp d – Pump running on both c lls.
5. On fan motor on high sp d, on fan motor on low sp d – Pump running on both c lls.
6. Both fan motors on full sp d – Pump running on both c lls.

17
STRAINER
ASSEMBLY
ANTI-VORTEXING
HOOD
STRAINER
HANDLE
Figure 10 – ATC/W Singl Strain r Ass mbly Figure 11 – LSWE/LSC-E/PMC-E Strain r Ass mbly
Figure 12 – LRWB/LRC Strain r Ass mbly
ANTI-VORTEXING
HOOD
STRAINER
HANDLE
STRAINER
ASSEMBLY
Suction Strainer in Cold Water Basin
Th pan strain r as shown in Figur s 10 through 14 should b r mov d and cl an d monthly or as o n as n c ssary. Th suction strain r
is th first lin of d f ns in k ping d bris out of th syst m. Mak c rtain that th strain r is prop rly locat d ov r th pump suction,
alongsid th anti-vort xing hood.
Recirculated Water System - Routine Maintenance
STRAINER
HANDLE
STRAINER
ASSEMBLY
ANTI-VORTEXING
HOOD
ANTI-VORTEXING
HOOD
PUMP HOUSE HIDDEN FOR CLARITY
STRAINER
HANDLE
STRAINER
ASSEMBLY
Figure 13 – PHC-S&L Strain r Ass mbly
Figure 14 – PHC-D Strain r Ass mbly

18
Cold Water Basin
Th cold wat r basin should b flush d out quart rly, and ch ck d monthly or mor o n if n c ssary, to r mov any accumulation of
dirt or s dim nt which normally coll cts in th basin. S dim nt can b com corrosiv and caus d t rioration of basin mat rials. Wh n
flushing th basin, it is important to k p th suction strain rs in plac to pr v nt any s dim nt from nt ring th syst m. A r th basin
has b n cl an d, th strain rs should b r mov d and cl an d b for r filling th basin with fr sh wat r.
Table 3 - R comm nd d Op rating Wat r L v l
Evaporative Condenser Closed Circuit Cooler Operating
Model Number Footprint Water Level*
ATC-E Products
ATWB, eco-ATW & eco-ATWE Products
50E to 165E, 3’ and 4’ wid units** 9”
170E to 3714E 8.5’ wid to “7’ wid thru 24’ wid ” 11”
eco-ATC-H
8.5’ Wid to 24’ Wid 11”
eco-ATC Products eco-ATWB-E
122A to 3846A 8.5’ wid thru 24’ wid 11”
LRC Products LRWB Products
25 to 379 3’ wid thru 8’ wid units 8"
LSC-E Products LSW Products
36 to 170 4’x6’ thru 4’x12’ 11”
185 to 385 5.5’x12’, 5.5’x18’ 11”
400 to 515, 800 to 1030 8’x12’, 8’x24’, 10’x12’, 10’x24’ 12”
550 to 805, 1100 to 1610 8’x18’, 8’x36’, 10’x18’, 10’x36’ 15”
PMC-E, eco-PMC
175E to 375E, 183 to 387 10”
332E to 2019E, 275 to 2191 14”
—ESW4 Products
8.5’ and 14’ wid units 9”
12’ wid unit 10”
–ESWA Products
8.5’ wid thru 12’ wid units 11”
PHC-S, L and D Products
S-208 to S-1182 9”
L-464 to L-842 9”
D-621 to D-2050 10”
Operating Level of Water in Cold Water Basin
Th op rating l v l should b ch ck d monthly to mak sur th wat r l v l is corr ct. R f r to Tabl 3 for unit sp cific l v ls.
* M asur d from low st point on basin floor.
** Not availabl on co-ATWE.
† M asur d from th ov rflow.
At initial start up or a r th unit has b n drain d, th unit must b fill d to th ov rflow l v l. Ov rflow is abov th normal op rating
l v l and accommodat s th volum of wat r normally in susp nsion in th wat r distribution syst m and th ris r piping.
Th wat r l v l should always b abov th strain r. Ch ck by running th pump with th fan motors off and obs rving th wat r l v l
through th acc ss door or r mov th air inl t louv r.

19
Water Make Up Valve
A m chanical float valv ass mbly is provid d as standard quipm nt on th
vaporativ cooling unit (unl ss th unit has b n ord r d with an optional
l ctronic wat r l v l control packag or th unit is arrang d for r mot
sump op ration). Th mak up valv is asily acc ssibl from outsid th unit
through th acc ss door or r movabl air inl t louv r. Th mak up valv is a
bronz valv conn ct d to a float arm ass mbly and is activat d by a larg
foam fill d plastic float. Th float is mount d on an all-thr ad rod h ld in
plac by wing nuts. Th wat r l v l in th basin is adjust d by r positioning
th float and all-thr ad using th wing nuts. R f r to Figur 15 for d tails. Th
bottom c nt r of th float should b s t at 1” b low th middl of th
ov rflow. At its high st point, float arm should b parall l to th wat r l v l.
Th mak up valv ass mbly should b insp ct d monthly and adjust d as
r quir d. Th valv should b insp ct d annually for l akag and if
n c ssary, th valv s at should b r plac d. Th mak up wat r pr ssur for
th m chanical valv should b maintain d b tw n 20 and 50 PSIG.
Pressurized Water Distribution Systems
Ch ck th wat r distribution syst m monthly to mak sur it is op rating prop rly. Always ch ck th spray syst m with th pump on and
th fans off. On forc d dra mod ls, r mov on or two liminator s ctions from th top of th unit and obs rv th op ration of th
wat r distribution syst m. On induc d dra mod ls, liing handl s ar provid d along th top lay r of liminators. Eliminators can b
asily r mov d from th acc ss door and th distribution syst m obs rv d. Th diffus rs ar ss ntially non-clogging and should s ldom
n d cl aning or maint nanc .
If th wat r diffus rs ar not functioning prop rly, it is a sign that th pan or syst m strain r has not b n working prop rly and that for ign
matt r or dirt has accumulat d in th wat r distribution pip s. Th nozzl s can b cl ar d by taking a small point d prob and moving it
rapidly back and forth in th diffus r op ning.
If an xtr m build-up of dirt or for ign matt r occurs, r mov th nd cap in ach branch to flush th d bris from th h ad r pip . Th
branch s or h ad r can b r mov d for cl aning, but do so only if n c ssary. Ch ck th strain r in th pan to mak sur it is in good
condition and position d prop rly so that cavitation or air ntrainm nt do s not occur.
All Evaporativ Cond ns rs and Clos d Circuit Cool rs, xc pt th ESWA/4 Clos d Circuit Cool r, ar suppli d with ZMII®spray
nozzl s as standard. Th ZMII®spray nozzl s do not n d to b ori nt d a sp cific way to achi v prop r coil cov rag . Figur 16 shows
th standard ori ntation of th ZMII®spray nozzl s.
ADJUSTMENT
WINGNUTS
FLOAT ARM
FLOAT BALL MAKE-UP
VALVE
Figure 15 – M chanical Wat r Mak Up Valv
Figure 16 – ZMII®Spray Nozzl Ori ntation
All Coil Products xc pt th ESWA/4

20
THREADED END CAP
Figure 17 – Prop r Wat r Diffus r Ori ntation (2A Nozzl s)
ESWA Mod ls
For th ESWA/4, wid orific wat r diffus rs ar suppli d, shown in figur 19. Wh n insp cting and cl aning th wat r distribution syst m,
always ch ck that th ori ntation of th wat r diffus rs is corr ct as shown in Figur s 17 and 18. For EvapJ t nozzl s, mak sur that th top
dg of th “EVAPCO” logo is parall l to th top of th wat r distribution pip .
Figure 18 – Prop r Wat r Diffus r Ori ntation (EvapJ t)
ESW4 Mod ls
Bleed-Off Valve
Th bl d-off valv , wh th r factory or fi ld install d, must b ch ck d w kly to mak sur it is functioning and s t prop rly. Additional
information can b found und r “Wat r Tr atm nt and Wat r Ch mistry”.
Pump (W en Supplied)
Th pump and pump motor should b lubricat d and s rvic d in accordanc with th pump manufactur r’s instructions as suppli d with
th unit. Th r circulation pump should not b us d as a m ans of capacity control, us d with a VFD or b cycl d fr qu ntly. Exc ssiv
cycling can l ad to scal build-up, and r duc w t and dry p rformanc . On 18' long ESW4's suppli d with two pumps p r c ll, both
pumps should b n rgiz d at th sam tim . On pump should not b on whil th oth r pump is off.
Th pump motor sha and imp ll r should b turn d by hand if th pump ass mbly sits idl (for a month or mor ).
Disconn ct th pow r and lockout/tagout th pump disconn ct. R mov th pump motor fan guard and rotat th pump fan/sha
s v ral turns by hand. R ass mbl th fan guard and r turn to s rvic .
NOTE: For t e eco-ATWE, please consult t e Sage2and Sage3manual.
Figure 19 – Gravity F d Distribution Pan
ESW4 Mod ls Only