Reymsa HFC Series Instruction manual

HFC
Series
Closed Circuit Fluid Cooler
Standard & Low Sound Fans
The
All-Fiberglass
Cooling Towers
Installation, Operation & Maintenance Manual

REYMSA COOLING TOWERS, INC.
www.reymsa.com
The
All-Fiberglass
Cooling Towers
INTRODUCTION
Thank you for choosing REYMSA Cooling Towers as your best Fiberglass Cooling Tower option.
Since 1969, REYMSA Cooling Towers has been providing cost effective heat transfer solutions
for the HVAC, industrial and plastic markets, having more than 5000 installed Cooling Towers
around the world. REYMSA’s towers are manufactured with high quality materials and are
designed to provide years of reliable service when properly operated and maintained.
The following manual has been prepared to support our customers with the installation and
maintenance process of the “state of the art” Closed Circuit Fluid Cooler HFC Series. Our
Installation, Operation & Maintenance manual (IOM) has been written and reviewed by
our engineering department based on theoretical knowledge and practical experience. A
recommended guide is included for the start-up process assuring a secure and optimized
installation. Regarding maintenance, REYMSA Cooling Towers strongly recommends establishing
a scheduled maintenance program and ensure it is followed; this manual could be used as a
guide to establish it.
It is highly recommended that the whole manual and warranty are read before the installation
and start-up.
If you have any doubts or need additional information, please contact your local REYMSA
representative or visit our website.
www.reymsa.com
Introduction

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Index
TABLE OF CONTENTS
A. INSTALLATION 1
A.1. LOCATION 1
A.1.1. RECIRCULATION AND INTERFERENCE 1
A.1.2. ENVIRONMENTAL AND SAFETY 2
A.2. ASSEMBLY INSTRUCTIONS 3
A.2.1. SINGLE FAN TOWERS 3
A.2.2. DOUBLE FAN TOWERS 6
A.2.3. QUADRUPLE FAN TOWERS 9
A.2.4. SINGLE FAN TOWER (GEAR DRIVEN MODELS) 13
A.2.5. SPRAY PUMP 15
A.2.6. COPPER COIL UNIT 16
A.2.7. LOW SOUND FAN CLOSED CIRCUIT FLUID COOLER: FAN ADAPTORS 17
A.2.8. OPTIONAL ACCESSORIES 19
A.2.8.1. ACCESSORIES - SAFETY 19
A.2.8.2. VIBRATION SWITCH 21
A.2.8.3. BASIN HEATER 23
A.2.8.4. ELECTRIC WATER LEVEL CONTROL SYSTEM 25
A.2.8.5. MOTOR SHAFT GROUNDING RING 26
A.3. TOWER SET-UP 27
A.3.1. LEVELING AND TOWER SUPPORTS 27
A.3.2. PIPING CONNECTIONS 27
A.3.3. WIRING 30
A.3.3.1. PROCEDURE TO WIRE THE SPRAY PUMP MOTOR 30
A.3.3.2. PROCEDURE TO WIRE THE FAN MOTOR 31
B. START-UP 32
B.1. FILLING SYSTEM WITH WATER 32
B.2. CONTROLLING WATER LEVEL 32
B.3. SPRAY PUMP 33
B.4. GEAR REDUCER 33
B.5. FAN 34
C. OPERATION 35
C.1. FAN CONTROL - VFD 35
C.1.1. PARAMETERS FOR VFD OPERATION 35
C.1.2. CONFIGURATION AND START-UP FOR ABB ACH550-UH 36
C.2. WATER DISTRIBUTION SYSTEM 39
C.3. WATER TREATMENT AND WATER CHEMESTRY 40
C.3.1. SUSPENDED SOLIDS 41
C.3.2. SCALE FORMATION 41
C.3.3. BIOLOGICAL GROWTH 41
C.3.4 CORROSION 42
C.3.5 AIR POLLUTION 42
C.4. MAKE-UP WATER REQUIREMENTS 42
C.5. COLD WEATHER OPERATION 43
C.5.1. BASIN HEATER OPERATION 44
C.5.2. REMOTE SUMP OPERATION 44
C.5.3. COIL FREEZING PROTECTION 44
C.5.4. PUMP FREEZING PROTECTION 44
C.6. SEASONAL SHUT-DOWN 45
D. MAINTENANCE 46
D.1. TOWER MAINTENANCE SCHEDULE 47
D.2. BASIN 48
D.3. TOWER BODY 49
D.4. FAN MOTOR 50
D.5. GEAR REDUCER 52
D.6. BASIN HEATER 53
D.7. SPRAY PUMP 54
D.8. COPPER COIL UNIT 55
E. TROUBLE-SHOOTING 56
APPENDIX A: EXAMPLE OF STRUCTURAL BASE FOR A REYMSA CLOSED CIRCUIT FLUID COOLER 58
APPENDIX B: EXAMPLES OF ACCESSORIES ASSEMBLY INSTRUCTIONS 61
APPENDIX C: MINIMUM DISTANCE BETWEEN TOWERS AND OBSTRUCTIONS 63
APPENDIX D: WATER MAKE-UP FLOAT VALVE 64
TABLES
Table A-1: Minimum recommended distance between towers 1
Table A-2: Receiving ange type (single fan towers) 5
Table A-3: Receiving ange type (double fan towers) 8
Table A-4: Receiving ange type (quadruple fan towers) 12

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Index
Table A-5: Flanges recommended torque 15
Table B-1: Operation and Start-up basin level 32
Table C-1: Maximum operating temperatures 39
Table C-2: Maximum operating pressure 39
Table C-3: Water chemistry guidelines 40
Table C-4: Cycle of concentration 42
Table C-5: Recommended solution freezing protection temperature 44
Table D-1: Recommended Tower and optional equipment maintenance schedule 47
Table D-2: Oil capacity for gear reducer models 52
Table D-3: Copper coil unit(s) weight by model 55
FIGURES
Figure A-1 : Minimum recommended distance between towers 1
Figure A-2: Recirculation 2
Figure A-3: Single Fan Tower Fork lifting 3
Figure A-4: Single Fan Tower Crane Lifting 3
Figure A-5: Fan Duct Lifting 3
Figure A-6: Typical anchorage for a single fan tower 4
Figure A-7: Upper and lower parts installation 4
Figure A-8: Fan duct assembly for a single tower 5
Figure A-9: Fan duct alignment for a single tower 5
Figure A-10: Double fan tower fork lifting 6
Figure A-11: Double fan tower crane lifting 6
Figure A-12: Fan Duct Lifting 6
Figure A-13: Basin lifting (optional) 7
Figure A-14: Typical anchorage for a double fan tower 7
Figure A-15: Fan duct, upper and lower parts installation 7
Figure A-16: Fan duct assembly for a double fan tower 8
Figure A-17: Fan duct alignment for a double fan tower 8
Figure A-18: Double fan tower fork lifting 9
Figure A-19: Double fan tower crane lifting 9
Figure A-20: Fan duct lifting 9
Figure A-21: Basin lifting (optional) 10
Figure A-22: Typical anchorage for a quadruple fan tower 10
Figure A-23: Lower section installation for quadruple fan tower 10
Figure A-24: Upper section 1 quadruple fan tower 10
Figure A-25: Upper section 1 & 2 for a quadruple fan tower on plane 11
Figure A-26: Fan duct installation for a quadruple fan tower 12
Figure A-27: Fan duct alignment for a quadruple fan tower 12
Figure A-28: Lifting for HFC-F models 13
Figure A-29: Typical anchorage for HFC-F models 13
Figure A-30: Upper body section installation for HFC-F models 14
Figure A-31: Fan duct assembly for HFC-F models 14
Figure A-32: Screen mesh assembly for HFC-F models 14
Figure A-33: Spray pump and water return pipes assembly to tower 15
Figure A-34: Copper coil unit 16
Figure A-35: Fan adaptor in a single fan tower 17
Figure A-36: Fan adaptor installation 17
Figure A-37: Fan adaptor alignment 17
Figure A-38: Fan adaptor 2 installation 18
Figure A-39: Fan duct installation on a fan adaptor 18
Figure A-40: Fan duct alignment 18
Figure A-41: Fan duct installation in a fan adaptor for a quadruple fan tower 18
Figure A-42: Optional accessories by REYMSA 19
Figure A-43: Optional safety accessories 20
Figure A-44: Vibration switch recommended location 21
Figure A-45: Internal switches 21
Figure A-46: Typical electric diagram 21
Figure A-47: Vibration switch detail 22
Figure A-48: Sensitivity adjustment 22
Figure A-49: Basin heater system 23
Figure A-50: Recommended basin heater mounting 23
Figure A-51: Basin heater control panel diagram 24
Figure A-52: Electrical water level control system 25
Figure A-53: Electrical Connections & Water Level Control Parts 25
Figure A-54: Motor Shaft Grounding Ring 26
Figure A-55: Motor Shaft Grounding Ring Path to Ground 26
Figure A-56: Example of a base support 27

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Figure A-57: Pipe connections for a single fan tower 28
Figure A-58: Pipe connections for a double fan tower 28
Figure A-59: Pipe connections for a quadruple fan tower 29
Figure B-1: Float valve installation 32
Figure C-1: VFD operation range 35
Figure C-2: Start-Stop method 36
Figure C-3: Operation method 36
Figure C-4: Measuring range RTD 36
Figure C-5: Recommended connection diagram for ABB ACH550-UH 36
Figure C-6: Water distribution system schematic drawing 39
Figure C-7: Chemical treatment connection installation 40
Figure C-8: Filtration System 41
Figure C-9: Fan discharge covering 45
Figure D-1: Lubrication Points 54
Figure D-2: Copper coil unit pulled out for maintenance purpose when tower is on the ground 55
Figure D-3: Copper coil unit pulled out for maintenance purpose when tower is on the roof 55
Figure AP-1: Float valve parts 64
Index

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All-Fiberglass
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1
A. INSTALLATION
A.1. LOCATION
Location of the Closed Circuit Fluid Cooler is important to assure it achieves its desired performance. A bad
location choice could lead into performance, safety and environmental issues. The following considerations
are meant to be a guideline to avoid such problems.
A.1.1. RECIRCULATION AND INTERFERENCE
Recirculation is the recapture of a portion of warm and humid air by the same tower. Interference is caused
when a Closed Circuit Fluid Cooler is situated downwind or in close proximity to a heat-emitting source, like
another Closed Circuit Fluid Cooler, red heaters, are stacks, boilers, etc. and warm air enters the Closed
Circuit Fluid Cooler. Both phenomena causes a variation in the entering air wet bulb temperature, therefore
affecting the Closed Circuit Fluid Cooler performance. To avoid recirculation and interference, consider the
following guidelines:
▪Remove any obstructions that might prevent the free ow of the entering and exiting air.
▪Make sure that the area provides enough clearance for safe operation. Place towers far enough apart
so that discharge air from one tower is not drawn in by another. See Table A-1 and Figure A-1 for
suggested clearances between towers.
For a complete table of minimum distances between towers and obstructions please refer to “APPENDIX C: MINIMUM
DISTANCE BETWEEN TOWERS AND OBSTRUCTIONS”.
Installation
MODEL MINIMUM
DISTANCE “D”,
FT
HFC HFC-SL
505
6
606
707 707-LS
808 808-LS
810 810-LS
812 812-LS
510
612
714 714-LS
816 816-LS
819 819-LS
822 822-LS
827 827-LS
1010
1212
1414 1414-LS 7
1616 1616-LS
1619 1619-LS
91622 1622-LS
1627 1627-LS
Table A-1: Minimum recommended distance between towers
Figure A-1: Minimum recommended distance between towers
DISTANCE
“D”

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▪Place the Closed Circuit Fluid Cooler where it will have at least the recommended clearance on all sides
for servicing and for adequate air intake. It is important to consider that the top of the tower should be
above the rooine of any adjacent building or other nearby obstructions. This will limit the possibilities
of the air recirculation back into the towers air intake (See Figure A-2).
Use prevailing summer winds as a guideline for placing a tower in a location that minimizes interference.
▪Do not place the Closed Circuit Fluid Cooler near exhaust fans or air intakes.
▪Do not place the Closed Circuit Fluid Cooler near air make-up units where there is a possibility of the
moist tower discharge air mixing with the air being drawn in by it.
A.1.2. ENVIRONMENTAL AND SAFETY
▪Installation of Closed Circuit Fluid Coolers must be carried out strictly in accordance with all applicable
electrical, safety and construction standards as well as state and local standards and codes.
▪Before proceeding with the installation, make sure the area is provided with a grounded power source
supplying the correct voltage (required by the motor and pump). Field wiring should be completed
by qualied personnel. All electrical wiring should comply with the electrical codes. Also see section
“A.3.3. WIRING”, for proper wiring.
▪Place the Closed Circuit Fluid Coolers on a leveled structural surface, capable of supporting the
operational weight of the tower. Refer to section “A.3.1. LEVELING AND TOWER SUPPORTS” of
this manual for more information about leveling and recommended support. Contact your REYMSA
representative with any questions regarding the recommended support for the Closed Circuit Fluid
Cooler.
▪REYMSA Closed Circuit Fluid Coolers are industrial equipment with rotating parts. Care must be taken
to install them in a safe area whose access is restricted only to authorized personnel.
▪Locate the tower where there is a safe access for its maintenance.
▪The Closed Circuit Fluid Cooler must be installed in a location where the tower’s discharge air cannot be
drawn into any surrounding building fresh-air ducts.
▪There is a certain amount of water that can be carried over in the discharge air of all Closed Circuit
Fluid Coolers (drift). Consideration should be given to placing Closed Circuit Fluid Coolers away from
high trafc areas such as entrances and parking lots.
Installation
Figure A-2: Recirculation
INCORRECT CORRECT
AIR OUT BUILDING
AIR IN AIR IN
DISTANCE
DISTANCE
LOUVERS
WALL
“D”
“D”
WARM &
MOIST AIR
AIR OUT

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A.2. ASSEMBLY INSTRUCTIONS
A.2.1. SINGLE FAN TOWERS
Follow this procedure to assemble and install single fan Closed Circuit Fluid Cooler with Direct Drive.
A.Upon the equipment arrives with the end user, check any abnormality or apparent damage in the
packaging before any landing maneuver of the Closed Circuit Fluid Cooler and its components. The
packing list must match the goods received. Any absence or abnormality of the equipment should be
reported immediately and directly to your local REYMSA representative.
B. After verifying the equipment is received in proper conditions, proceed to unload it piece by piece, with a
crane or forklift of the appropriate capacity (see Figure A-3, Figure A-4 and Figure A-5 for reference).
C.For crane lifting, it is recommended to use a minimum elevation angle of 60 ° between the belt and
the horizontal, also pay special attention when lifting the bottom of the tower (basin with copper coil),
because it does not count with lifting brackets due to their weight. Explicit instructions are described below.
D. Surround the lower section of the tower with the straps, placing them through the basin openings (as shown
in Figure A-4), it’s important to use a spreader bar to avoid damage on the upper edge of the tower,
when lifting don’t balance until tensing the straps (see Figure A-4), pad the strap areas on the tower to
avoid scratching.
E. Remove the plastic wrap that surrounds the tower and its components, loosen the nuts and bolts that keep
the basin section attached to the wooden pallet (the body comes unattached), the nuts and bolts are
located at the bottom of the basin (some models comes totally unattached to the pallet).
F. Before tower’s assembly, REYMSA recommends to install a steel base structure that supports the tower’s
operational weight; also place an isolation pad (supplied by others) between the tower and the base
structure for support purposes. Verify that the base structure has the proper dimensions (for construction,
refer to factory certied drawings). For more information, see section “A.3.1. LEVELING AND TOWER
SUPPORTS”.
G. Place the lower section of the tower (basin with copper coil) on top of the isolation pad and the steel
base structure, making sure that the anchorage holes on the bottom of the tower are aligned with the
perforations of the base. Then proceed to bolt it down and secure it with stainless steel nut and bolt sets
(supplied by others, see Figure A-6 ).
Installation
Figure A-3: Single fan tower fork lifting Figure A-4: Single fan tower crane lifting Figure A-5: Fan duct lifting
Straps
Straps
Spreader
Bar
BASIN BASIN BODY BODY DUCT
Cable
Cable
Rope
FORK EXTENSIONS
6 FT MINIMUM PALLET
LENGTH

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H.Assemble the upper section with the lower section, the upper section comes assembled with u-bolts for
lifting; then using a crane assemble both parts, use a guide pin to align bolt holes as the sections are being
set (See gure A-7). Make sure that the recirculation water inlet, and the recirculation water outlet are on
the same side of the tower when assembled.
2
3
4
5
6
1
RECIRCULATION WATER INLET
UPPER SECTION
ASSEMBLY HOLES
1. 1/2” x 2.5” BOLT
2. 1/2” FLAT WASHER
3. 5/8 HOLE
4. 1/2 FLAT WASHER
5. 1/2” LOCK WASHER
6. 1/2 NUT
(SUPPLIED BY OTHERS)
LOWER SECTION
RECIRCULATION WATER OUTLET
STEEL BASE STRUCTURE
(SUPPLIED BY OTHERS)
Figure A-7: Upper and lower parts installation
Installation
1
2
3
78
1
23
4
6
7
8
5
5
4 ANCHORAGE HOLES
(ONE ON EACH CORNER)
1. 3/4” NUT
2. 3/4” LOCK WASHER
3. 3/4” FLAT WASHER
4. 3/4” ANCHORAGE HOLES
5. ISOLATION PAD
6. ≈1” HOLE
7. 3/4” FLAT WASHER
8. 3/4” X 3” BOLT
(SUPPLIED BY OTHERS)
STEEL BASE SUPPORT
(SUPPLIED BY OTHERS)
Figure A-6: Typical anchorage for a single fan tower.