EVAPCO AT ATLAS User manual

Bulletin ATLAS20RIG
Rigging and
Assembly Instructions
AT ATLAS
Induced Draft, Modular Counterow Cooling Towers
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AT ATLAS Induced Draft Counterow Cooling Towers
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Table of Contents
Introduction............................................................................................3
Shipping ..............................................................................................3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Structural Steel Support .................................................................................4
Rigging Basin Sections ..................................................................................5
Joining Bottom Sections .................................................................................5
Application of Sealer Tape to Basin Sections ................................................................7
Rigging Casing Sections .................................................................................8
Assembly of the Casing Sections to the Basin Sections .......................................................8
Assembly of Bottom Inlet Piping .........................................................................10
Application of Sealer Tape to Casing Sections ..............................................................11
Rigging Fan Sections...................................................................................12
Assembly of the Fan Sections to the Casing Sections........................................................13
Rigging Fan Sections on Multicell Units ...................................................................14
Fan Sealing ...........................................................................................15
Extended Lifts.........................................................................................15
Floating Shaft Installation & Alignment ....................................................................16
Fan Assembly Instructions ..............................................................................17
Rigging Drive Assembly ................................................................................18
Fan Cylinder Assembly .................................................................................19
Fan Cylinder Rigging ...................................................................................20
Fan Cylinder Sealing ...................................................................................21
External Platform and Vertical Ladder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

AT ATLAS Induced Draft Counterow Cooling Towers
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Introduction
Thank you for purchasing your EVAPCO AT ATLAS, counterow, induced draft cooling tower. This manual provides instructions and
recommendations to safely and correctly install all AT ATLAS cooling towers. It is recommended that all instructions provided in this
manual are reviewed prior to rigging and assembly. If at any point specic circumstances not covered by this manual arise please
contact your local EVAPCO representative for assistance.
Proper care must be taken by all parties involved in handling and assembling the equipment to ensure that safe and
thorough installation practices are implemented to prevent damage or injury to the equipment, persons and environment
involved.
Shipping
Unless otherwise noted in the factory submittal, all EVAPCO AT ATLAS towers ship in seven (7) sections per cell plus the drive
system, fan and fan cylinder. Any special shipping congurations will be listed in the factory submittal. Please contact your local
EVAPCO representative for more information on alternate shipping congurations.
Nomenclature
AT 124-4N30-EV
Produc
t
Ty
pe
# of
Cells
Unit
Width
Layers of
Fill Media
Horsepower
Designator
Unit LengthFill
Ty
pe
Product Type
AT – Indicates an Advanced Technology (AT) tower.
# of Cells
Determined by the number of inlet connections, can be 1 or 2 cells.
Unit Width
The total width of the unit, in feet, all cells included.
Layers of Fill Media
Determined by the number of 1 foot tall ll layers. Can be 4 or 5.
Horsepower Designator
Determined by the horsepower per fan motor. Available from N = 40 HP to T = 150 HP.
Unit Length
The total length of the unit, in feet, all cells included.
Fill Type
Indicated the style of heat transfer media in the tower.

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Structural Steel Support
As standard, three structural “I” beams running the length of the unit are required for support of each cell. These beams should
be located underneath the outer anges of the unit (See Figure 1 and 1a). Transverse steel arrangements are also available (see
Figures 1b and 1c). Mounting holes 3/4” (19mm) in diameter are located in the bottom anges of the unit for bolting to the structural
steel (See steel support print in unit submittal for exact bolt hole location). Bolt the bottom sections to the steel support before
rigging the top sections.
Beams should be sized in accordance with accepted structural practices. Maximum deection of the beam under the unit to be
1/360th of the unit length, not to exceed 1/2” (13mm). Deection may be calculated by using 55% of the operating weight of the unit
as a uniform load on each beam (See certied print in unit submittal for operating weight).
The supporting “I” beams should be level before setting the unit. Do not level the unit by shimming between the bottom anges and
the beams as this will not provide proper and continuous longitudinal support. Support beams and anchor bolts are to be furnished
by others.
Please refer to the unit submittal for detailed, project specic steel support arrangement.
24’
48’
30’
30’
Figure 1 - Standard Longitudinal Steel Support Arrangement
for 24’ x 30’ ATLAS
Figure 1b - Standard Transverse Steel Support Arrangement
for 24’ x 30’ ATLAS
Figure 1a - Standard Longitudinal Steel Support Arrange-
ment for 48’ x 30’ ATLAS
Figure 1c - Standard Transverse Steel Support Arrangement
for 48’ x 30’ ATLAS

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Rigging Basin Sections
Lifting devices are located along the inside edges of the bottom section for lifting and nal positioning purposes as shown in Figure 2.
The hook of the crane must be a minimum dimension of 26’ above the top of the basin section to prevent undue strain on the lifting
devices. If applicable, see “Extended Lifts” on page 15 for proper arrangement.
Bolt the bottom sections to the steel support before rigging the top sections.
Figure 2 - Rigging Unit Bottom Section - 1 Basin
26' (7.9m)
Joining Bottom Sections
Each 24’ x 30’ ATLAS basin is composed of two (2) 12’ x 30’ sections, connected by three (3) ume boxes for equalization.
In addition to the equalizer umes, these units are provided with horizontal drip channels and vertical splash guards to keep water
from splashing out from between the cells.
The equalizer ume boxes are shipped loose for eld assembly. It is important to connect the equalizer umes to balance the water
level in the basins for proper pump suction operation. The procedures that follow should be performed in sequence.
ATLAS Flume Box Installation Instructions:
1. Rig one of the bottom sections of the cooling tower. Bolt to steel support.
2. One face of the ume box is provided with 3/8” (10mm) welded bolts. Clean the mating ume opening on the rigged bottom
section and apply a layer of sealer tape on this surface, centered between the hole centers and the outside edge. Remove
paper backing strip from sealer tape.
3. Align the bolt holes in the rigged bottom section with the welded 3/8” (10mm) bolts on the ume box.
4. Install 3/8” (10mm) nuts and washers on every bolt around the ume opening and tighten.

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5. Repeat steps 2-4 for all 3 ume boxes.
6. Rig the second basin adjacent to the equalizer ume on the steel support as shown in Figure 3.
7. Clean the mating surfaces of the ume box and the surface of the ume opening on the adjacent section. Apply sealer tape to
the anged ume opening on the adjacent section.
8. Align the bolt holes in the ume box and ume opening with drift pins (by others) while drawing the second bottom section
against the ume box.
9. Install 3/8” (10mm) bolts, nuts, and washers in every hole around the ume opening and tighten.
10. Bolt the second bottom section to the steel support.
Drip Channel and Splash Guard Installation Instructions (this may be completed after the unit is completely rigged):
1. Remove the 1/4” (6mm) hardware which holds the drip channel retaining clips to the side panel. Place the drip channel over
the adjoining basin section anges. Turn around the retaining clips and install them using the same hardware.
2. Apply a single layer of sealer tape to the mating ange of the drip channels (see Figure 3a). Fasten drip channels together
end-to-end by driving a self-tapping 5/16” (8mm) screw through the section end with the larger hole into the mating end with
the smaller hole. Stainless steel units will use 5/16” (8mm) stainless steel nuts and bolts.
3. Add sealer tape to bottom of vertical splash guard. Place the vertical splash guard in the bend of the vertical supports. On
galvanized units, attach the vertical splash guard using 5/16” (8mm) self-tapping screws. On stainless steel units, attach the
vertical splash guards using 5/16” (8mm) stainless steel nuts and bolts. (See Figure 3)
4. Once the bottom of the vertical splash guard has been attached to the drip channel, place the ller cap channel in the upper
anges of the basin as shown in Figure 3. Attach to vertical splash guards using 5/16” (8mm) tappers (for galvanized units) or
stainless steel nuts and bolts (for stainless steel units).
Filler Cap Channel to be installed after the casing sections are rigged.
FILLER CAP
CHANNEL
VERTICAL SPLASH
CHANNEL
EQUALIZER
FLUME BOX
DRIP CHANNEL
VERTICAL SPLASH
CHANNEL
SIDE PANEL
EQUALIZER
FLUME BOX
SEALER TAPE
DRIP CHANNEL
VERTICAL
SPLASH
GUARD
RETAINING
CLIP
Figure 3 - Joining Bottom Sections

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Figure 3a - Drip Channel and Vertical Splash Guard Installation
DRIP CHANNEL
SECTION
5/16"
HARDWARE
SEALER
TAPE
DRIP
CHANNEL
RETAINING
CLIP
SIDE PANEL
TAPPERS (GALVANIZED)
OR STAINLESS STEEL
BOLTS (STAINLESS)
DRILLING IS
REQUIRED
IN THE FIELD
FOR THESE
HOLES
Figure 4 - Sealer Tape on Flange of Basin Section
1LAYER OF SEALER TAPE
CENTERED OVER THE
MOUNTING HOLES
1LAYER OF SEALER TAPE
CENTERED OVER THE
MOUNTING HOLES
END SIDE
Application of Sealer Tape to Basin Sections
Once the basin sections have been set on the support steel and all fasteners are installed, the top anges should be wiped down
to remove any dirt or moisture. Apply one layer of sealer tape along the 12’ and 30’ sides, centered over the mounting hole (see
Figure 4).
The sealer tape should overlap on the corners as shown in Figure 4. Do not splice the sealer tape along the 12’ long end anges.
Sealer tape will need to be spliced and overlapped on the 30’ sides.
Always remove the paper backing from the sealer tape.

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Rigging Casing Sections
Lifting ears are provided in the corners of the casing sections and along the length (4 total lifting ears per side) for lifting and nal
positioning. The hook of the crane must be a minimum dimension 26’ above the casing sections to prevent undue strain on the
lifting ears.
Assembly of the Casing Sections to the Basin Sections
Before securing the casing sections to the basin sections, remove any loose parts shipped in the basin.
Wipe the anges on the bottom of the casing sections. Units are also provided with match markings on each section (i.e. A1 of
basin section should match up with A1 of casing section).
Lower the casing section to within several inches of the basin section making sure the two sections do not touch and the sealer
tape is not disturbed. Lower the casing section the rest of the way and fasten all four corners. See Table 1 for recommended
hardware. Make use of drift pins to simplify the nal positioning process (see Drift Pin explanation below).
Install the remaining fasteners, working from the corners towards the center. Fasteners must be installed in every hole in the anges.
Use of Drift Pins for Final Positioning
Drift pins are tools used to align holes in the anges of the casing and basin sections of the unit prior to nal fastening. They are
occasionally used in the positioning of the basin section as well.
Once the sealer tape is applied and the casing section is hovering over the basin section, a drift pin should be driven into each of
the corner bolt holes. Using drift pins in the corners (at minimum) is meant to restrict the sideways motion of the casing section
relative to the basin section.
A drift pin should be used in intermediate bolt holes in the rigging seams as needed to maintain alignment.
Figure 5 - Rigging a Unit Casing Section
H
26' (7.9m)

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Figure 6 - Assembling Casing and Basin Sections
Notes:
The side anges located in between cells can be accessed from inside the unit.
Bolts can be driven upward through the mating anges if access is restricted.
All rigging hardware is provided by EVAPCO. Drift pins are by others. The recommended drift pin is 3/16” punch size with
10” overall length.
Units Hardware Sizes
All ATLAS Units 3/8” (10mm) Nuts, Bolts & Washers (Galvanized or Stainless)
Table 1 - Hardware Sizes

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Assembly of Bottom Inlet Piping
On the ATLAS tower, the inlet connection is located on the bottom as standard. Internal piping is provided that allows the process
water to make its way to the hot water distribution system. Please follow the below steps to complete eld installation of the bottom
inlet after the unit is rigged.
1. On the ATLAS tower, the inlet connection is located on the bottom as standard.
2. Locate the bottom inlet assembly components, namely the riser pipes, two exible reinforced pipe connectors per basin, four
pipe clamps per basin and the lower pipe anged spool. These components are fastened securely in the unit’s basin prior to
shipment.
2a. Remove shipping strap under pipe.
3. Align the riser pipe assembly with the upper pipe section in the bottom of the casing section. Loosen the pipe clamp and slip
the pipe connector up over the upper pipe section.
4. Tighten all pipe clamps (4 per basin: 2 on the upper). A ratchet wrench is recommended (See Figure 7).
5. Repeat this process for each riser pipe.
6. After tower is fully installed, insert the lower pipe anged spool with gaskets between anges, as shown in Figure 8. Use
hardware noted in Table 2
Figure 8 - Installation of Bottom Inlet Piping
UPPER PIPE
CONNECTOR AND
PIPE CLAMPS
LOWER PIPE
FLANGED SPOOL GASKET
Units Hardware Sizes
All ATLAS Units 7/8” (22mm) Nuts, Bolts & Washers (Galvanized or Stainless)
Table 2 - Hardware Sizes
RATCHET
WRENCH
UPPER PIPE
Figure 7 - Casing Bottom Inlet Piping

AT ATLAS Induced Draft Counterow Cooling Towers
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Figure 9 - Fan to Casing Section Sealing
A
DETAIL A
TWO OVERLAPPING LAYERS OF SEALER TAPE
ON FLANGES BETWEEN CASING SECTIONS
FOR CENTER FAN SECTION SEALING
ONE LAYER OF SEALER TAPE
CENTERED OVER THE MOUNTING HOLES
APPLY CAULK INSIDE TO FAN
SECTION TOP AND END SEAMS
AFTER RIGGING
Application of Sealer Tape to Casing Sections
Once the casing sections have been rigged to the basin sections and all fasteners are installed, the top anges should be wiped
down to remove any dirt or moisture. Apply one layer of sealer tape, centered over the mounting holes (see Figure 9). On the
anges between casing sections, apply two strips of sealer tape, one partially overlapping the other on the entire length of the
anges. Apply sealer tape to the entire perimeter of the casing sections. Do not splice the sealer tape along the 12’ long end
anges. Sealer tape will need to be spliced and overlapped on the 30’ sides.
Always remove the paper backing from the sealer tape.

AT ATLAS Induced Draft Counterow Cooling Towers
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Figure 10B - Rigging of End Fan Module
Figure 10A - Rigging of Middle Fan Module
26' (7.9m)
26' (7.9m)
Rigging Fan Sections
Each ATLAS unit has 3 fan sections: left, right and middle. On the middle section, lifting ears are provided for lifting and nal
positioning. For the left and right sections, “U” bolts are provided. The hook of the crane must be a minimum of 26’ above the lifting
device to prevent undue strain on the lifting ears and “U” bolts. See Figures 10A and 10B for the middle section and end sections,
respectively.

AT ATLAS Induced Draft Counterow Cooling Towers
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Assembly of the Fan Sections to the Casing Sections
The fan sections rigging should begin with an end fan module, followed by the middle fan module and nally followed by the last
end fan module.
Drift pins should be used to align the fan section with the casing section. The installer will need to attach the fan section end
panels to the casing section end panels and the fan section side panels to the casing section side panels with 3/8” hardware.
Units are provided with match markings on each section to assist with arrangement (i.e. A1 of casing section should match up with
A1 of fan section).
Figure 11 - Assembling Fan and Casing Sections

AT ATLAS Induced Draft Counterow Cooling Towers
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Figure 12 - Fan and Casing Rigging - Multicell
Rigging Fan Sections on Multicell Units
In multicell installations, placing multiple towers side-by-side will limit access between cells and make rigging more difcult.
Therefore multicell rigging channels will come attached to the inside of the casing and fan section panels, as shown in Figure 12.
Once the sections are mounted, the anges of the rigging channels must be bolted from inside the unit. Use hardware noted in
Table 3. The fasteners in the rigging channels are in addition to the fasteners required around the perimeter of the fan section.
CASING RIGGING CHANNEL
FAN SECTION RIGGING CHANNEL
DETAIL A
SEE DETAIL A
Units Hardware Sizes
All ATLAS Units 3/8” (10mm) Nuts, Bolts & Washers (Galvanized or Stainless)
Table 3 - Hardware Sizes

AT ATLAS Induced Draft Counterow Cooling Towers
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Extended Lifts
Important: The lifting devices and “U” bolts should be used for nal positioning only and for lifting where no danger
exists. If they are used for extended lifts, safety slings should be provided under the sections.
Safety slings and skids must be removed before nal positioning of the unit.
The preferred method for extended lifts is to use slings under the unit, as shown in Figure 14 below. Spreader bars should always
be used between the cables at the top of the section to prevent damage to the upper anges.
Figure 14 - Extended Lifts
SAFETY SLING
26' (7.9m)
SAFETY SLING
26' (7.9m)
Fan Sealing
After rigging, apply caulk to the top and end seams of the fan sections (Figure 13). This must be done from the inside of the unit.
APPLY CAULK TO FAN
SECTION TOP AND END
SEAMS AFTER RIGGING
Figure 13 - Fan Section Sealing

AT ATLAS Induced Draft Counterow Cooling Towers
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5. Check angular and axial misalignment between the drive shaft and both the motor and gear drive couplings.
6. Check angular misalignment with a dial indicator on gear drive side.
7. Attach the dial indicator support to the drive shaft and position the indicator tip to read off the opposite side ange.
8. With the dial indicator set to zero, rotate the shaft 360° and record the indicator readings at 90° increments.
9. The range between minimum and maximum values should be less than 0.010” (0.25mm). If alignment is out of tolerance, add
shims (not exceeding 1/4”).
10. When the angular alignment is within the acceptable ranges as mentioned in step 9, securely tighten all gear drive hardware.
11. Repeat steps 6 through 10 on the motor side of the drive shaft.
12. Check axial misalignment with a tape measure or dial caliper. Refer to Table 5 for axial alignment gap limits.
Angular Misalignment Axial Misalignment
Table 4 - Torque Requirements for Floating Shaft Assemblies
Shaft Model Torque Requirement
LRR 350 400 in-lbs (33 ft-lb 45 Nm)
LRR 375 400 in-lbs (33 ft-lb 45 Nm)
LRR 450 145 in-lbs (12 ft-lb 16 Nm)
LRA 485 240 in-lbs (20 ft-lb 27 Nm)
Floating Shaft Installation & Alignment
The fan motor and gear reducer will ship mounted to the mechanical equipment support. The system will be prealigned in the
factory, however alignment should be veried prior to rigging the mechanical equipment support to the fan section.
The steps for alignment of the oating shaft are:
1. Mount the drive shaft with the exible element assembly on the gear drive input shaft using the supplied 3/8” (10mm)
hardware. All bolts, lock washers and nuts are supplied with the drive shaft kit.
2. Insert steel bushings into the composite exible elements on the motor side.
3. Mount the drive shaft with the exible element assembly on the motor output shaft using the supplied 3/8” (10mm) hardware.
All bolts, lock washers and nuts are supplied with the drive shaft kit.
4. Torque requirements for the bolts are listed in Table 4 (these values are dependent upon the shaft model). Use a torque
wrench to properly torque all drive shaft bolts.
Table 5 - Axial Alignment Gap Limits
Shaft Model Axial Alignment Gap Limits
LRR 350 0.42-0.44 in. (10.7mm-11.2mm)
LRR 375 0.53-0.55 in. (13.5mm-14.0mm)
LRR 450 0.42-0.44 in. (10.7mm-11.2mm)
LRA 485 0.58-0.62 in. (14.9mm-15.9mm)

AT ATLAS Induced Draft Counterow Cooling Towers
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Fan Assembly Instructions
Once the gear drive has been aligned the fan should be assembled onto the mechanical equipment assembly. This simplies
assembly by completing it at ground level and reducing the number of lifts required.
Hudson Fan:
Please see “Tuf-Lite® III Fans 4000KW Series Hub Installation Manual” and Figure 15.
H
LOCKING COLLAR
BUSHING
FAN BLADE
TOP OF GEAR BEARING
GEAR SHAFT
HUB
Figure 15 - Hudson Fan Mounting
Table 7 -Moore Fan Hub Distance
Table 6 -Hudson Fan Hub Distance
Gear Drive “H”
1008 8.5”
1110 7”
1311 6”
Gear Drive “H”
1008 7”
1110 6”
1311 5”
Figure 16 - Moore Fan Mounting
Moore Fan (Class 10000):
Please see “Moore Fans Class 10000 Fans Owners Manual” and Figure 16.
H
TOP OF GEAR BEARING
LOCKING COLLAR
BUSHING
GEAR SHAFT
HUB
GEAR DRIVE H
1008 7”
6”
5”
1110
1311
The relevant, above-mentioned manuals will be sent along with the tower.

AT ATLAS Induced Draft Counterow Cooling Towers
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Units Hardware Sizes
All ATLAS Units 1/2” (13mm) Nuts, Bolts & Washers (Galvanized or Stainless)
Table 8 - Hardware Sizes
Rigging Drive Assembly
Once the gear drive has been aligned and the fan assembled onto the gear output shaft, the entire assembly should be lifted
onto the fan section (Figure 17). The hook of the crane must be a minimum of 17’ above the lifting ears. See Table 8 for hardware
required to attach the drive assembly to the fan deck. Be sure to position the lifting cables between fan blades so as not to damage
the fan during the lift.
17'-0" (5.2m)
Figure 17 - Rigging Drive System

AT ATLAS Induced Draft Counterow Cooling Towers
19
Figure 18 - Fan Cylinder Assembly
Fan Cylinder Assembly
The fan cylinder will ship in 10 sections for assembly and installation in the eld. Each section will be joined with a ange as shown
in Figure 18. Fan cylinder assembly should be performed on the ground with one person holding the sections up until the assembly
is able to stand alone. See Table 9 below for hardware required to assemble the fan cylinder.
Lifting devices to be installed in between cylinder sections during assembly. Remove lifting device after installing fan cylinder if the
tower has a Super Low Sound Fan.
Flanges should be cleaned prior to assembly. Each cylinder should have 5 lifting devices total, installed in every other cylinder
panel seam.
ASSEMBLE CYLINDER PANELS USING
PROVIDED 3/8" HARDWARE
(SEE DETAIL A)
A
DETAIL A
(TYPICAL)
*ASSEMBLE CYLINDER PANELS
WITH LIFTING DEVICE SANDWICHED
BETWEEN EVERY OTHER PANEL
3/8" NYLOCK NUT
3/8" FENDER WASHER
3/8" FENDER WASHER
3/8" DIA X 1 3/4" BOLT
*REMOVE LIFTER AFTER INSTALLING CYLINDER
Units Hardware Sizes
All ATLAS Units 3/8” (10mm) Nuts, Bolts & Washers
Table 9 - Hardware Sizes

AT ATLAS Induced Draft Counterow Cooling Towers
20
Fan Cylinder Rigging
Lower cylinder carefully around fan and drive shaft using the provided lifting ears. The hook of the crane must be a minimum of
17’ above the lifting ears. Make sure fan assembly is centered within the cylinder before attaching to fan section. Measure the
clearance between each fan tip and the cylinder with a tape measure, making sure it is 7/8” (22mm) or less.
Fasten to fan deck using hardware in Table 10. Holes are to be drilled through the cylinder and fan deck in the eld from outside
the tower.
17'-0" (5.2m)
Figure 19 - Fan Cylinder Rigging
Units Hardware Sizes
All ATLAS Units 3/8” (10mm) Nuts, Bolts & Washers (Galvanized or Stainless)
Table 10 - Hardware Sizes