Reymsa RT-404 Instruction manual

The
All-Fiberglass
Cooling Towers
Installation, Operation & Maintenance Manual
RT, RTU, RTG, RTM & RTGM Models
Standard & Low Sound Fans
RT
Series

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” RT Series Towers. It includes the RT, RTU, RTG, RTM &
RTGM models with Standard, Low Sound, and Super Low Sound fans. 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 optimal 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

REYMSA COOLING TOWERS, INC.
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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 FOR RT MODELS 3
A.2.1 SINGLE FAN TOWERS 3
A.2.2 DOUBLE FAN TOWERS 7
A.2.3 QUADRUPLE FAN TOWERS 11
A.3 ASSEMBLY INSTRUCTIONS FOR RTU MODELS 15
A.3.1 SINGLE FAN TOWERS (RTU) 15
A.3.2 DOUBLE FAN TOWERS (RTU) 17
A.3.3 QUADRUPLE FAN TOWERS (RTU) 19
A.4 ASSEMBLY INSTRUCTIONS FOR RTG MODELS 21
A.5 ASSEMBLY INSTRUCTIONS FOR MODULAR TOWERS (RTM) 24
A.5.1 GENERAL PROCEDURE 24
A.5.2 LARGE SIDE ARRANGEMENT FOR A MODULAR TOWER (RTM-L) 26
A.5.3 SHORT SIDE ARRANGEMENT FOR A MODULAR TOWER (RTM-S) 28
A.6 ASSEMBLY INSTRUCTIONS FOR MODULAR TOWERS (RTGM) 31
A.6.1 GENERAL PROCEDURE 31
A.6.2 LARGE SIDE ARRANGEMENT FOR A MODULAR TOWER (RTGM-L) 34
A.6.3 SHORT SIDE ARRANGEMENT FOR A MODULAR TOWER (RTGM-S) 36
A.7 LOW SOUND FAN COOLING TOWERS: FAN ADAPTORS 37
A.8 EQUALIZER LINE INSTALLATION 39
A.9 BOTTOM OUTLET CONNECTION 39
A.10 OPTIONAL EQUIPMENT 41
A.10.1 SAFETY OPTIONAL EQUIPMENT 41
A.10.2 VIBRATION SWITCH 43
A.10.3 BASIN HEATER 45
A.10.4 ELECTRIC WATER LEVEL CONTROL SYSTEM 47
A.10.5 MOTOR SHAFT GROUNDING RING 48
A.11 TOWER SET-UP 49
A.11.1 LEVELING AND TOWER SUPPORTS 49
A.11.2 PIPPING CONNECTIONS 49
A.11.3 WIRING 52
A.11.3.1 PROCEDURE TO WIRE THE FAN MOTOR 53
B. START-UP 54
B.1 FILLING SYSTEM WITH WATER 54
B.2 CONTROLLING WATER LEVEL 54
B.3 PUMP 55
B.4 GEAR REDUCER 55
B.5 FAN 56
C. OPERATION 57
C.1 FAN CONTROL - VFD 57
C.1.1 PARAMETERS FOR VFD OPERATION 57
C.1.2 CONFIGURATION AND START-UP FOR ABB ACH550-UH 58
C.2 WATER DISTRIBUTION SYSTEM 61
C.3 WATER TREATMENT AND WATER CHEMISTRY 62
C.3.1 SUSPENDED SOLIDS 63
C.3.2 SCALE FORMATION 63
C.3.3 BIOLOGICAL GROWTH 63
C.3.4 CORROSION 64
C.3.5 AIR POLLUTION 64
C.4 MAKE-UP WATER REQUIREMENTS 64
C.5 COLD WEATHER OPERATION 65
C.5.1 BASIN HEATER OPERATION 66
C.5.2 REMOTE SUMP OPERATION 66
C.6 SEASONAL SHUT-DOWN 66
D. MAINTENANCE 67
D.1 TOWER MAINTENANCE SCHEDULE 68
D.2 BASIN 69
D.3 TOWER BODY 70
D.4 FAN MOTOR 71
D.5 GEAR REDUCER 73
D.6 BASIN HEATER 74
E. TROUBLE-SHOOTING 75
APPENDIX A: EXAMPLE OF UNLOADING A COOLING TOWER FROM A CONTAINER 77
APPENDIX B: WATER MAKE-UP FLOAT VALVE 79

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The
All-Fiberglass
Cooling Towers
Index
APPENDIX C: EXAMPLE OF STRUCTURAL BASE FOR A REYMSA COOLING TOWER 80
APPENDIX D: EXAMPLE OF ACCESSORIES ASSEMBLY INSTRUCTIONS 83
APPENDIX E: MINIMUM DISTANCE BETWEEN TOWERS AND OBSTRUCTIONS 85
TABLES
Table A-1: Minimum recommended distance between towers 1
Table A-2: Equalizer Connection Sizes 39
Table A-3: Tightening Torque 40
Table C-1: Maximum operating temperatures for different fill media materials 61
Table C-2: Maximum operating pressure 61
Table C-3: Water chemistry guidelines 62
Table C-4: Cycles of concentration 64
Table D-1: Recommended tower and optional equipment maintenance schedule 68
Table D-2: Oil capacity for Gear Reducer models 73
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: Typical anchorage for a Single Fan Tower 4
Figure A-6: Removing U-bolts from basin for a Single Fan Tower 4
Figure A-7: Body and basin sections installation on RT-A, RT-B, and RT-C 4
Figure A-8: Lower body installation for a Single Fan Tower (RT-D) 5
Figure A-9: Removing U-bolts from Lower Body section for a Single Fan Tower (RT-D) 5
Figure A-10: Upper and Lower Body sections installation for a Single Fan Tower (RT-D) 5
Figure A-11: Fan Duct assembly for a Single Fan Tower 6
Figure A-12: Fan Duct alignment for a Single Fan Tower 6
Figure A-13: Double Fan Tower fork lifting 7
Figure A-14: Double Fan Tower crane lifting 7
Figure A-15: Typical anchorage for a Double Fan Tower 7
Figure A-16: Removing U- from basin for a Double Fan Tower 8
Figure A-17: Body and basin sections installation for a Double Fan Tower (RT-A, RT-B, RT-C) 8
Figure A-18: Lower body installation for a Double Fan Tower (RT-D) 9
Figure A-19: Removing U-bolts from Lower Body section for a Double Fan Tower (RT-D) 9
Figure A-20: Upper and Lower Body sections installation for a Double Fan Tower (RT-D) 9
Figure A-21: Fan Duct assembly for a Double Fan Tower 10
Figure A-22: Fan Duct alignment for a Double Fan Tower 10
Figure A-23: Quadruple Fan Tower fork lifting 11
Figure A-24: Quadruple Fan Tower crane lifting 11
Figure A-25: Typical anchorage for a Quadruple Fan Tower 11
Figure A-26: Basin section 2 installation for a Quadruple Fan Tower 12
Figure A-27: Removing U-bolts from basin for a Quadruple Fan Tower 12
Figure A-28: Lower body section 1 installation for a Quadruple Fan Tower (RT-D) 12
Figure A-29: Removing U-bolts from Lower Body section of a Quadruple Fan Tower (RT-D) 12
Figure A-30: Body section 1 (Upper Body section 1 for RT-D) on a Quadruple Fan Tower 13
Figure A-31: Body section 2 (Upper Body section 2 for RT-D) on a Quadruple Fan Tower 13
Figure A-32: Fan Duct installation for a Quadruple Fan Tower 14
Figure A-33: Fan Duct alignment 14
Figure A-34: Single Fan Tower fork and crane lifting 15
Figure A-35: Typical anchorage for a Single Fan Tower 15
Figure A-36: Fan Duct assembly for a Single Fan Tower 16
Figure A-37: Fan Duct alignment for a Single Fan Tower 16
Figure A-38: Double Fan Tower fork and crane lifting 17
Figure A-39: Typical anchorage for a Double Fan Tower 17
Figure A-40: Fan Duct assembly for a Double Fan Tower 18
Figure A-41: Fan Duct alignment for a Double Fan Tower 18
Figure A-42: Quadruple Fan Tower fork and crane lifting 19
Figure A-43: Typical anchorage for a Quadruple Fan Tower 19
Figure A-44: Body section 2 installation for a Quadruple Fan Tower 20
Figure A-45: Fan Duct installation for a Quadruple Fan Tower 20
Figure A-46: Crane lifting for an RTG model 21
Figure A-47: Typical anchorage for an RTG model 21
Figure A-48: Removing U-bolts from basin section of an RTG model 21
Figure A-49: Lower body section installation for an RTG-D & RTG-E models 22
Figure A-50: Upper Body section installation for an RTG-D & RTG-E models 22
Figure A-51: Fan Deck assembly for an RTG model 23
Figure A-52: Screen mesh assembly for an RTG model 23
Figure A-53: Crane lifting for a modular tower (RTM) 24
Figure A-54: Removing U-bolts from basin of a Modular Tower (RTM) 24

REYMSA COOLING TOWERS, INC.
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Index
Figure A-55: Body section assemble for a Modular Tower (RTM-B) 25
Figure A-56: Lower Body section assemble for a Modular Tower (RTM-D) 25
Figure A-57: Removing U-bolts from Lower Body section of a Modular Tower (RTM-D) 25
Figure A-58: Upper Body section assemble for a Modular Tower (RTM-D) 25
Figure A-59: T1 module lifting and installation (RTM-B-L) 26
Figure A-60: T1 module lifting and installation (RTM-D-L) 26
Figure A-61: T2 module lifting and installation (RTM-B-L) 26
Figure A-62: T2 module lifting and installation (RTM-D-L) 26
Figure A-63: Fan Duct installation for a Modular Tower (RTM-B-L) 27
Figure A-64: Fan Duct installation for a Modular Tower (RTM-D-L) 27
Figure A-65: Fan Duct alignment for a Modular Tower 27
Figure A-66: Modular Tower installed by large side arrangement (-L) 27
Figure A-67: First module lifting for a short side arrangement (RTM-B-S) 28
Figure A-68: Second module lifting for a short side arrangement (RTM-B-S) 28
Figure A-69: Last module lifting for a short side arrangement (RTM-B-S) 29
Figure A-70: Fan Duct installation for a Modular Tower (RTM-B-S) 29
Figure A-71: Fan Duct alignment for a Modular Tower (RTM-B-S) 30
Figure A-72: Fan Duct installation for a Modular Tower (RTM-B-S) 30
Figure A-73: Crane lifting for a Modular Tower (RTGM) 31
Figure A-74: Removing the U-bolts from basin of a Modular Tower (RTGM) 31
Figure A-75: Body section installation for a modular tower (RTGM-B) 32
Figure A-76: Lower body section assembly for a modular tower (RTGM-D & RTGM-E) 32
Figure A-77: Removing U-bolts from the Lower Body section for a modular tower (RTGM-D & RTGM-E) 32
Figure A-78: Upper Body section installation for a modular tower (RTGM-D & RTGM-E) 32
Figure A-79: Removing U-bolts from the Upper Body section of a modular tower (RTGM-D & RTGM-E) 32
Figure A-80: Fan Deck section assemble for an RTG model 33
Figure A-81: Screen mesh assembly for an RTG model 33
Figure A-82: T1 module lifting and installation (RTGM-B-L) 34
Figure A-83: T1 module lifting and installation (RTGM-D-L & RTGM-E-L) 34
Figure A-84: Typical anchorage for a modular tower (RTGM) 34
Figure A-85: T2 Module lifting and installation (RTGM-B-L) 35
Figure A-86: T2 Module lifting and installation (RTGM-D-L & RTGM-E-L) 35
Figure A-87: T1 Module lifting and installation (RTGM-B-L) 35
Figure A-88: T1 Module lifting and installation (RTGM-D-L & RTGM-E-L) 35
Figure A-89: First T1 Module lifting and installation for a modular tower (RTGM-B-S) 36
Figure A-90: Second T1 Module lifting and installation for a modular tower (RTGM-B-S) 36
Figure A-91: Last T1 Module lifting and installation for a modular tower (RTGM-B-S) 36
Figure A-92: Fan adaptor on a Single Fan Tower 37
Figure A-93: Fan adaptor installation 37
Figure A-94: Fan adaptor alignment 37
Figure A-95: Fan adaptor 2 installation on a Double Fan Tower 37
Figure A-96: Fan Duct installation on a fan adaptor 38
Figure A-97: Fan Duct alignment 38
Figure A-98: Fan Duct installation on a fan adaptor for a Quadruple Fan Tower 38
Figure A-99: Equalizer line installation 39
Figure A-100: Bottom outlet connection view 39
Figure A-101: Tightening sequence 40
Figure A-102: Optional equipment by REYMSA 41
Figure A-103: Safety optional accessories 42
Figure A-104: Vibration Switch recommended location 43
Figure A-105: Internal switches 43
Figure A-106: Vibration Switch Electric Diagram 43
Figure A-107: Vibration Switch detail 44
Figure A-108: Sensitivity adjustment 44
Figure A-109: Basin heater system 45
Figure A-110: Recommended basin heater mounting 45
Figure A-111: Basin heater control panel diagram 46
Figure A-112: Electric Water Level Control System 47
Figure A-113: Electrical Connections & Water Level Control Parts 47
Figure A-114: Motor Shaft Grounding Ring 48
Figure A-115: Motor Shaft Grounding Ring Path to Ground 48
Figure A-116: Example of base support 49
Figure A-117: Pipe connections for a Single Fan Tower 50
Figure A-118: Pipe connections for a Double Fan Tower (RT-D) 50
Figure A-119: Pipe connections for a Quadruple Fan Tower (RT-D) 51
Figure A-120: Example of equalization line 52
Figure B-1: Float valve installation 54
Figure C-1: VFD operating range 57

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All-Fiberglass
Cooling Towers
Figure C-2: Start-Stop method 58
Figure C-3: Operation method 58
Figure C-4: Measuring range RTD 58
Figure C-5: Recommended Connection Diagram for ABB ACH550-UH 58
Figure C-6: Water distribution system schematic drawing 61
Figure C-7: Filtration systems 63
Figure C-8: Fan discharge covering 66
Figure AP-1: Unloading a Cooling Tower from a container 77
Figure AP-2: Unloading the fan duct from a container 77
Figure AP-3: Lifting the fan duct with a forklift 78
Figure AP-4: Pulling the basin out from a container 78
Figure AP-5: Unloading the basin with two forklifts 78
Figure AP-6: Positioning the body section with a crane 78
Figure AP-7: Float Valve Parts 79
Index

REYMSA COOLING TOWERS, INC.
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Notes
INSTALLATION, OPERATION & MAINTENANCE
MANUAL
Cooling Towers (RT Series)

REYMSA COOLING TOWERS, INC.
www.reymsa.com
The
All-Fiberglass
Cooling Towers
1
A. INSTALLATION
A.1 LOCATION
Location of the Cooling Tower 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 Cooling Tower is situated downwind or in close proximity to a heat-emitting source, like
another Cooling Tower, fired heaters, flare stacks, boilers, and warm air enters the Cooling Tower. Both
phenomena causes a variation in the entering air wet bulb temperature, therefore affecting the Cooling
Tower performance. To avoid recirculation and interference, consider the following guidelines:
▪Remove any obstructions that might prevent the free flow 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
recommended clearances between towers.
For a complete table of minimum distances between towers and obstructions please refer to “APPENDIX E: MINIMUM
DISTANCE BETWEEN TOWERS AND OBSTRUCTIONS”.
Table A-1: Minimum recommended distance between towers
Figure A-1: Minimum recommended distance between towers
Distance
“D”
Installation
MODEL MINIMUM
DISTANCE “D” (ft)
RT
303
3
404
505
606
707
708 4
709 5
808 4
810 5
812 6
714
816 7
819 8
822
824
9827
1414
1616 10
1619 11
1622 13
1624 14
1627
MODEL MINIMUM DISTANCE
“D” (ft)
RTG
812 9
1012
1014 10
1016
1018 12
1020 13
1212 10
1214 11
1216 12
1218 13
1220 14
1222
16
1223

REYMSA COOLING TOWERS, INC.
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2
▪Place the Cooling Tower where it will have at least the recommended clearance on all sides for servicing
and for adequate air intake. It is advisable and preferred to have the top of the Tower above the
roofline 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 Cooling Tower near exhaust fans or air intakes.
▪Do not place the Cooling Tower 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
▪Cooling Towers must be installed in accordance to all applicable construction, electrical and safety
standards, as well as State and Local regulations 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 qualified personnel. All electrical wiring should comply with the electrical codes. Also see section
“A.11.3.1 PROCEDURE TO WIRE THE FAN MOTOR”.
▪Place the Cooling Towers on a leveled structural surface, capable of supporting the operational weight
of the Tower. Refer to section “A.11.1 LEVELING AND TOWER SUPPORTS” of this manual for information
about leveling and recommended support. Contact your REYMSA representative with any questions
regarding the recommended support for the Cooling Tower.
▪REYMSA Cooling Towers are industrial pieces of equipment with rotating parts. Care should be taken in
placing them in a secure area where unauthorized access is minimized.
▪Locate the Tower where there is a safe access for its maintenance.
▪The Cooling Tower 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 Cooling Towers
(drift). Consideration should be given to placing Cooling Towers away from high traffic areas such as
entrances and parking lots.
Figure A-2: Recirculation
CORRECTINCORRECT
Air out
Building
Air in
Air in
Air in
Distance
Distance
Louvers
Wall
“D”
“D”
Warm &
moist air
Air out
Installation