Thermal Care FT Series Instruction Manual

Table of Contents
Foreword .................................................................................................................................................................................................................. 1
Safety Guidelines .................................................................................................................................................................................................. 1
Pre-Installation....................................................................................................................................................................................................... 2
Receiving Inspection .......................................................................................................................................................................................2
Unit Storage........................................................................................................................................................................................................ 2
Installation - Mechanical....................................................................................................................................................................................2
Foundation..........................................................................................................................................................................................................2
Figure 1 –FT8220 Structural Steel Base Frame Dimensions .......................................................................................................3
Figure 2 –FT8250 Structural Steel Base Frame Dimensions .......................................................................................................4
Figure 3 –FT8260. FT8270, and TC8280 Structural Steel Base Frame Dimensions............................................................5
Unit Location ...................................................................................................................................................................................................... 5
Fan Motor and Blade Assembly (FT8220 & FT8250) ..........................................................................................................................5
Fan Motor and Blade Assembly (FT8260 & FT8270) ..........................................................................................................................6
Fan Motor, Fan Blade, and Sprinkler Head Assembly (FT8280) .....................................................................................................6
Inlet Louver Installation (FT8220)...............................................................................................................................................................7
Inlet Louver Installation (FT8250)...............................................................................................................................................................7
Inlet Louver Installation (FT8260-FT8280) .............................................................................................................................................. 8
Lifting.....................................................................................................................................................................................................................8
Figure 4 –FT Series Rigging.....................................................................................................................................................................8
Piping ....................................................................................................................................................................................................................9
Installation - Electrical......................................................................................................................................................................................... 9
Start-Up Procedure .............................................................................................................................................................................................. 9
Step 1 –Flush the Basin ...............................................................................................................................................................................10
Step 2 –Connect Main Power ...................................................................................................................................................................10
Step 3 –Fill Water Circuit ............................................................................................................................................................................10
System Fill Water Chemistry Requirements.....................................................................................................................................10
Table 1 –Fill Water Chemistry Requirements .................................................................................................................................11
Table 2 –Nominal Flow Rates ...............................................................................................................................................................11
Step 4 - Trial Fan Operation.......................................................................................................................................................................11
Operation and Maintenance ..........................................................................................................................................................................12
Fan Motor ..........................................................................................................................................................................................................12
Water Distribution..........................................................................................................................................................................................12
Seasonal Shutdown .......................................................................................................................................................................................12
Freeze Protection............................................................................................................................................................................................12
Calculations...........................................................................................................................................................................................................12
Evaporation Loss.............................................................................................................................................................................................12
Drift Loss ............................................................................................................................................................................................................12
Bleed-Off Rate .................................................................................................................................................................................................12
Number of Concentrations.........................................................................................................................................................................13
Make-Up Water Required ...........................................................................................................................................................................13

Page Intentionally Blank

1
Foreword
The cooling tower consists of evaporative fill
material, a fan, water distribution system, shell, and
water collection basin. The purpose is to provide
evaporative cooling of process water.
This manual is to serve as a guide for installing,
operating, and maintaining the equipment. Improper
installation, operation, and maintenance can lead to
poor performance and/or equipment damage. Use
qualified installers and service technicians for all
installation and maintenance of this equipment.
This manual is for our standard product. The
information in this manual is general in nature. Unit-
specific drawings and supplemental documents are
included with the equipment as needed. Additional
copies of documents are available upon request.
Due to the ever-changing nature of applicable
codes, ordinances, and other local laws pertaining to
the use and operation of this equipment, we do not
reference them in this manual.
The cooling tower is for outdoor installation only.
The use of untreated water in any cooling tower may
cause serious health hazards, including the creation
of conditions conducive to the development of
Legionella bacteria. Use a water treatment program
to stop biological contamination in order to reduce
such hazards. Do not operate this equipment
without a proper water treatment program.
Safety Guidelines
Observe all safety precautions during installation,
start-up, and service of this equipment. The
following is a list of symbols used in this manual and
their meaning.
General Warning
Electricity Warning
Sharp Element Warning
Hot Surface Warning
Flammable Material Warning
General Mandatory Action
Wear Eye Protection
Wear Protective Gloves
Wear Ear Protection
Disconnect Before Carrying Out Maintenance or
Repair
Connect an Earth Terminal to Ground
Only qualified personnel should install, start-up, and
service this equipment. When working on this
equipment, observe precautions in this manual as
well as tags, stickers, and labels on the equipment.
WARNING: Any use or misuse of this equipment
outside of the design intent may cause injury or
harm.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment may contain fan blades
or other sharp edges. Make sure all fan guards and
other protective shields are securely in place.
WARNING: The exposed surfaces of motors can be
very hot and can cause burns if touched with
unprotected hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Shut off the electric power at the main
disconnect before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.

2
CAUTION: The equipment will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter elevation
when operating. Wear ear protection as required for
personal comfort when operating or working in close
proximity to the cooling tower.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
Pre-Installation
Receiving Inspection
When the unit arrives, verify the information on the
unit nameplate agrees with the order
acknowledgement and shipping papers. Inspect the
equipment for any visible damage and verify all
items shown on the bill of lading are present. If
damage is evident, document it on the delivery
receipt by clearly marking any item with damage as
“unit damage” and notify the carrier. In addition,
notify our Customer Service Department and they
will provide assistance with preparing and filing
freight damage claims, including arranging for an
estimate on repair costs; however, filing the shipping
damage claim is the responsibility of the receiving
party. Do not install damaged equipment without
getting the equipment repaired.
Shipping damage is the responsibility of the carrier.
To protect against possible loss due to damage
incurred during shipping and to expedite payment
for damages, it is important to follow proper
procedures and keep records. Photographs of
damaged equipment are excellent documentation
for your records.
Start unpacking the unit, inspect for concealed
damage, and take photos of any damage found.
Once received, equipment owners have the
responsibility to provide reasonable evidence that
the damage did not occur after delivery. Photos of
the equipment damage while the equipment is still
partially packed will help in this regard. Refrigerant
lines can be susceptible to damage in transit. Check
for broken lines, oil leaks, damaged controls, or any
other major component torn loose from its
mounting point.
Record any signs of concealed damage and file a
shipping damage claim immediately with the
shipping company. Most carriers require concealed
damages be reported within 15 days of receipt of
the equipment. In addition, notify our Customer
Service Department and they will provide assistance
with preparing and filing freight damage claims,
including arranging for an estimate on repair costs;
however, filing the shipping damage claim is the
responsibility of the receiving party.
Unit Storage
When storing the unit it is important to protect it
from damage. Blow out any water from the unit;
cover it to keep dirt and debris from accumulating or
getting in, and store in an indoor sheltered area that
does not exceed 125°F.
Installation - Mechanical
Foundation
Install the unit on a rigid, non-warping mounting
pad, concrete foundation, or level floor suitable to
support the full operating weight of the equipment.
When installed the equipment must be level within
¼ inch over its length and width. Fasten the tower to
the steel or concrete of the supporting structure. For
units mounted on a roof structure, the base holding
the tower should be elevated above the roof and
attached to the building.

3
Figure 1 –FT8220 Structural Steel Base Frame Dimensions

4
Figure 2 –FT8250 Structural Steel Base Frame Dimensions

5
Figure 3 –FT8260. FT8270, and TC8280 Structural Steel Base Frame Dimensions
Unit Location
The cooling tower is available in different
configurations. Refer to the proposal and order
acknowledgement document for the equipment to
verify the specific design conditions in which it can
operate.
Allow a minimum of 60 inches of clearance between
the cooling tower and any walls or obstructions. For
installations with multiple towers, allow a minimum
of 60 inches between towers.
When locating the tower it is important to consider
accessibility to the components to allow for proper
maintenance and servicing of the unit. Avoid
locating piping or conduit over the unit to ensure
easy access with an overhead crane or lift to lift out
heavier components during replacement or service.
Avoid areas that can create a “micro-climate” such as
an alcove with east, north, and west walls that can be
significantly warmer than surrounding areas. The
cooling tower needs to have unrestricted airways so
it can easily move cool air in and heated air away.
The discharge air must flow upwards without
obstruction. Ensure the air intake is open and free
from obstructions or heat and/or humidity
producing devices. Consider locating the cooling
tower where fan noise and vibration transmission
into nearby workspaces is unlikely.
Fan Motor and Blade Assembly (FT8220 &
FT8250)
In order to prevent possible shipping damage, the
fan motor and fan blade ship unmounted. Use the

6
following steps to install the fan motor and fan blade
assembly.
1. Verify the fan pitch is set so the “0” on the fan
blade lines up with the “0” on the fan hub.
2. Remove motor support frame from top of tower.
3. Set the motor frame up off the ground (use saw
horses or some other means of support).
4. Place the motor with the shaft pointing down
onto the motor frame and bolt the motor to the
frame using the bolts provided.
5. Attach the fan blade to the motor shaft.
6. Remount the entire fan motor and fan assembly
back on top of the cooling tower with the fan
located down inside the tower.
Fan Motor and Blade Assembly (FT8260 &
FT8270)
In order to prevent possible shipping damage, the
fan motor, fan blade, and sprinkler head assembly
ship unmounted. Use the following steps to install
the fan motor, fan blade, and sprinkler head
assembly.
1. Remove motor support frame from top of tower.
2. Place a piece of plywood on top of the fill in the
tower to prevent damage during installation.
3. Position sprinkler arms with studs in end of pipe
positioned at 12 o'clock when viewed from
outside of tower facing center.
4. With the sprinkler arm correctly positioned,
tighten the retaining bolt on the sprinkler head
until snug.
Note: Do not over tighten, as this will crack the
sprinkler arm.
5. Install the “TEE” shaped tension wire support
post on the top of the sprinkler head.
6. Loosen the turnbuckles to open them up all the
way.
7. Hang the turnbuckle from the “TEE” shaped
tension wire support post on top of the sprinkler
head.
8. In the other end of the turnbuckle, tightly wrap
one end of the wire; wrap the opposite end of
the wire around stud and under flat washer.
Tighten nut at the end of the sprinkler pipe.
9. Tighten the turnbuckle until wire is tight and
sprinkler pipe is level.
10. Place the fan motor on the ground with shaft up
and fasten the motor frame with the provided
½" bolts.
11. Align key way and slide the fan hub onto the fan
motor shaft with “U” bolts facing downward.
Tighten fan hub onto motor shaft.
12. Install fan blades in their numerical order with
corresponding number on fan hub making sure
the “0” on the fan blade lines up with the “0” on
the fan hub.
13. Make sure ALL blades are set to the same pitch.
14. Tightly secure the fan blades to the fan hub by
progressively tightening the U-Bolt nuts. If the
U-Bolt does not allow for a tight joint, replace
and repeat the process until properly secured.
15. Recheck the pitch of each blade to ensure it did
not change while tightening the nuts.
16. Remount the entire fan motor assembly on top
of the tower with fan down inside the tower and
bolt it back down.
17. Reinstall the fan guards.
Fan Motor, Fan Blade, and Sprinkler Head
Assembly (FT8280)
In order to prevent possible shipping damage, the
fan motor, fan blade, and sprinkler head assembly
ship uninstalled. Use the following steps for
installing the fan blade, fan motor, and sprinkler
head assembly.
1. Remove motor support frame from top of tower.

7
2. Place a piece of plywood on top of the fill in the
tower to prevent damage during installation.
3. Position sprinkler arms with studs in end of pipe
positioned at 12 o'clock when viewed from
outside of tower facing center.
4. With the sprinkler arm correctly positioned,
tighten the retaining bolt on the sprinkler head
until snug.
Note: Do not over tighten, as this will crack the
sprinkler arm.
5. Install the “TEE” shaped tension wire support
post on the top of the sprinkler head.
6. Loosen the turnbuckles to open them up all the
way.
7. Hang the turnbuckle from the “TEE” shaped
tension wire support post on top of the sprinkler
head.
8. In the other end of the turnbuckle, tightly wrap
one end of the wire; wrap the opposite end of
the wire around stud and under flat washer.
Tighten nut at the end of the sprinkler pipe.
9. Tighten the turnbuckle until wire is tight and
sprinkler pipe is level.
10. Set the motor frame up off the ground (use saw
horses or some other means of support).
11. Place the motor with the shaft pointing down
onto the motor frame and bolt the motor to the
frame using the ½" bolts provided.
12. Grease the shaft with Anti-seize or some other
type of grease. Slide the split tapered bushing
onto the motor shaft with the shoulder of the
bushing facing towards the motor. The bottom
of the bushing should be flush with the end of
the motor shaft.
13. Slide the tower fan (the top of the fan has the
aluminum spool attached to it) over the split-
tapered bushing.
14. Line up the non-threaded holes of the fan spool
with the threaded holes in the split tapered
bushing.
15. From the underside of the fan, insert the ¼" x 4"
bolts with lock washers provided through the
non-threaded holes in the fan and screw them
into the split-tapered bushing. The bushing
should still be flush with the end of the motor
shaft.
16. Tighten up the bolts in a uniform pattern until
the fan locks onto the fan bushing. Once the
bolts are tight, the fan bushing should still be
flush with the end of the motor shaft.
17. Lift the entire fan motor and frame as one
assembly, place it onto the top of the tower with
the fan blade inside the tower and bolt it back
down.
18. Reinstall the fan guards.
Inlet Louver Installation (FT8220)
In order to prevent possible shipping damage, the
inlet louvers ship uninstalled. Depending on the size
of the cooling tower, you may have either PVC or
galvanized steel casing supports. The casing
supports are located between the basin and the
main casing of the cooling tower.
1. Align inlet louvers between the casing supports
matching edge of inlet louver with holes in
casing support. Use only one hole to fasten
louver.
2. Mark and drill 5/16" holes in the inlet louvers and
use the provided stainless steel nuts and bolts to
secure the inlet louvers to the casing support.
Inlet Louver Installation (FT8250)
In order to prevent possible shipping damage, the
inlet louvers ship uninstalled. Depending on the size
of the cooling tower, you may have either PVC or
galvanized steel casing supports. The casing
supports are located between the basin and the
main casing of the cooling tower.
1. Position the center of the louver over the casing
support. Each end of the louver has a tab on the
top of the louver that tucks under and behind

8
the upper casing lip. Before drilling any holes
and installing the mounting bolts, proceed to
step two.
2. Position the second louver over the casing
support in the same manner as in step one. At
this point, the louvers will overlap one another.
The tab on the louver should be tucked under
and behind the upper casing lip the same as in
step one for the first louver.
3. Install the remaining four louvers in the same
manner until all louvers are in place.
4. All of the louvers should now be overlapping
one another. Before drilling any holes, you may
need to spread the louvers apart or overlap
more to ensure proper fit.
5. Once the louvers are evenly spaced, drill a 5/16”
hole all the way through the upper casing lip
and louver tabs. Fasten the louvers tab to the
casing with a ¼” bolt, two washers, one lock
washer, and one nut provided. One washer on
the bolt head side and one washer and lock
washer on the nut side. For more rigidity, bolt
the overlapping louvers together in the same
fashion as above, but in a vertical pattern.
Inlet Louver Installation (FT8260-FT8280)
In order to prevent possible shipping damage, the
inlet louvers ship uninstalled. Depending on the size
of the cooling tower, you may have either PVC or
galvanized steel casing supports. The casing
supports are located between the basin and the
main casing of the cooling tower.
1. Position the center of the louver over the casing
support as shown. Each end of the louver has a
tab on the top of the louver that tucks under
and behind the upper casing lip. Before drilling
any holes and installing the mounting bolts,
proceed to step two.
2. Position the second louver over the casing
support in the same manner as in step one. At
this point, the louvers will overlap one another.
The tab on the louver should be tucked under
and behind the upper casing lip the same as in
step one for the first louver.
3. Install the remaining louvers in the same manner
until all louvers are in place.
4. The louvers should now be overlapping one
another. Before drilling any holes, you may need
to spread the louvers apart or overlap them
slightly to ensure a proper fit.
5. Once the louvers are evenly spaced, drill a 5/16”
hole all the way through the upper casing lip
and louver tabs. Fasten the louvers with the bolts
provided. For more rigidity, bolt the louvers
together at the bottom, but not to the basin lip.
Lifting
Use only qualified persons using the proper
equipment when lifting and positioning the cooling
tower. Proper rigging methods must be followed to
prevent damage to components.
Avoid impact loading caused by sudden jerking when
lifting or lowering the cooling tower. When abrasive
surface contact is anticipated use pads to protect the
surface of the fiberglass. The use of a spreader bar is
highly recommended. Keep rigging clear of inlet
piping. Do not use the motor support for lifting the
cooling tower.
Figure 4 –FT Series Rigging

9
Piping
The PVC piping and connections on the tower are
not designed to support the weight of the external
piping. To prevent stress fractures and leaks ensure
all field piping connections are properly aligned with
the tower connections, there is no piping stress on
the basin connections, and all flanges are properly
aligned with full flange face contact.
Installation - Electrical
All wiring must comply with local codes and the
National Electric Code. Minimum circuit amps (MCA)
and other unit electrical data are on the unit
nameplate. A unit specific electrical schematic ships
with the unit. Measure each leg of the main power
supply voltage at the main power source. Voltage
must be within the voltage utilization range given on
the drawings included with the unit. If the measured
voltage on any leg is not within the specified range,
notify the supplier and correct before operating the
unit. Voltage imbalance must not exceed two
percent. Excessive voltage imbalance between the
phases of a three-phase system can cause motors to
overheat and eventually fail. Voltage imbalance is
determined using the following calculations:
%Imbalance = (Vavg –Vx) x 100 / Vavg
Vavg = (V1 + V2 + V3) / 3
Vx = phase with greatest difference from Vavg
For example, if the three measured voltages were
442, 460, and 454 volts, the average would be:
(442 + 460 + 454) / 3 = 452
The percentage of imbalance is then:
(452 –442) x 100 / 452 = 2.2 %
This exceeds the maximum allowable of 2%.
There is a terminal block for main power connection
to the main power source. The main power source
should be connected to the terminal block through
an appropriate disconnect switch. There is a separate
lug in the main control panel for grounding the unit.
Check the electrical phase sequence at installation
and prior to start-up. Check the phasing with a
phase sequence meter prior to applying power. The
proper sequence should read “ABC” on the meter. If
the meter reads “CBA”, open the main power
disconnect and switch two line leads on the line
power terminal blocks (or the unit mounted
disconnect). Do not interchange any load leads that
are from the unit contactors or the motor terminals.
WARNING: Any use or misuse of this equipment
outside of the design intent may cause injury or
harm.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment may contain fan blades
or other sharp edges. Make sure all fan guards and
other protective shields are securely in place.
WARNING: The exposed surfaces of motors can be
very hot and can cause burns if touched with
unprotected hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Shut off the electric power at the main
disconnect before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: The equipment will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter elevation
when operating. Wear ear protection as required for
personal comfort when operating or working in close
proximity to the cooling tower.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Ground the unit properly and in
compliance with local and national codes.
Start-Up Procedure
Use a qualified technician to perform the start-up
procedure in sequence. The following serves as a
checklist for the initial start-up and for subsequent
start-ups if the cooling tower is out of service for a
prolonged time.
WARNING: Any use or misuse of this equipment
outside of the design intent may cause injury or
harm.

10
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment may contain fan blades
or other sharp edges. Make sure all fan guards and
other protective shields are securely in place.
WARNING: The exposed surfaces of motors can be
very hot and can cause burns if touched with
unprotected hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Shut off the electric power at the main
disconnect before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: The equipment will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter elevation
when operating. Wear ear protection as required for
personal comfort when operating or working in close
proximity to the cooling tower.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Ground the unit properly and in
compliance with local and national codes.
Step 1 –Flush the Basin
Once the tower has been completely assembled and
placed, make sure all disconnects are locked out.
Remove one of the inlet louver sections. Open the
drain and flush the basin with water to remove any
remaining dirt and debris from basin. Check all
fasteners to make sure there are no loose
components.
Step 2 –Connect Main Power
Connect main power properly ensuring it matches
the voltage shown on the nameplate of the unit.
Check the electrical phase sequence prior to start-
up. Check the phasing prior to applying power. The
proper sequence is “ABC”. If the phasing is incorrect,
open the main power disconnect and switch two line
leads on the main power terminal blocks (or the unit
mounted disconnect). All electrical components are
in-phase at the factory. Do not interchange any load
leads that are from the unit contactors or the motor
terminals. After making proper power connection
and grounding, turn the main power on.
Step 3 –Fill Water Circuit
Check to make sure all water piping connections are
secure. Fill the circulation system with water. If the
basin of the cooling tower is fitted with a make-up,
fill the system until the make-up valve is closed.
System Fill Water Chemistry Requirements
The properties of water make it ideal for heat
transfer applications. It is safe, non-flammable, non-
poisonous, easy to handle, widely available, and
inexpensive in most industrialized areas.
When using water as a heat transfer fluid it is
important to keep it within certain chemistry limits to
avoid unwanted side effects. Water is a “universal
solvent” because it can dissolve many solid
substances and absorb gases. As a result, water can
cause the corrosion of metals used in a cooling
system. Often water is in an open system (exposed
to air) and when the water evaporates, the dissolved
minerals remain in the process fluid. When the
concentration exceeds the solubility of some
minerals, scale forms. The life giving properties of
water can also encourage biological growth that can
foul heat transfer surfaces.
To avoid the unwanted side effects associated with
water cooling, proper chemical treatment and
preventive maintenance is required for continuous
plant productivity.
Unwanted Side Effects of Improper Water Quality
•Corrosion
•Scale
•Fouling
•Biological Contamination
Cooling Water Chemistry Properties
•Electrical Conductivity
•pH
•Alkalinity
•Total Hardness
•Dissolved gases
The cooling towers use a PVC evaporative fill media
to spread the water over a wide surface area to
facilitate evaporation and cooling of the water. The
surface area of the fill, as are all heat exchangers, is

11
susceptible to fouling of heat transfer surfaces due
to scale or debris. Fouling of these surfaces reduces
the heat-transfer surface area and reduces the heat
transfer and affect the efficiency of the cooling
tower.
The complex nature of water chemistry requires a
specialist to evaluate and implement appropriate
sensing, measurement and treatment needed for
satisfactory performance and life. The
recommendations of the specialist may include
filtration, monitoring, treatment and control devices.
With the ever-changing regulations on water usage
and treatment chemicals, the information is
generally up to date when a specialist in the industry
is involved. Table 1 shows the list of water
characteristics and quality limitations.
Table 1 –Fill Water Chemistry Requirements
Water Characteristic
Quality Limitation
Alkalinity (HCO3-)
70-300 ppm
Aluminum (Al)
Less than 0.2 ppm
Ammonium (NH3)
Less than 2 ppm
Chlorides (Cl-)
Less than 300 ppm
Electrical Conductivity
10-500µS/cm
Free (aggressive) Carbon Dioxide (CO2)†
Less than 5 ppm
Free Chlorine(Cl2)
Less than 1 PPM
HCO3-/SO42-
Greater than 1.0
Hydrogen Sulfide (H2S)
Less than 0.05 ppm
Iron (Fe)
Less than 0.2 ppm
Manganese (Mn)
Less than 0.1 ppm
Nitrate (NO3)
Less than 100 ppm
pH
7.5-9.0
Sulfate (SO42-)
Less than 70 ppm
Total Hardness (dH)k
4.0-8.5
† Dissolved carbon dioxide calculation is from the pH
and total alkalinity values shown below or measured
on the site using a test kit. Dissolved Carbon Dioxide,
PPM = TA x 2[(6.3-pH)/0.3] where TA = Total Alkalinity,
PPM as CaCO3
Check tower basin and connections for leaks. Close
discharge valves of pumps completely. Check
rotation of tower pumps by starting them
momentarily. Once proper pump rotation is
established, slowly open each pump discharge valve
to ¼ open and run the pumps for about five minutes
to make sure all air has been removed from the
system. Stop pumps and check tower outlet to make
sure it is still clean and free from debris. Check water
level in the system again to make sure system is still
full. Start pumps again. While pumps are running, set
the flow to the tower by adjusting the discharge
valves of the pumps.
Table 2 –Nominal Flow Rates
Model
Operating
Range (gpm)
Nominal Flow
(gpm)
Inlet Pressure
Required for
Nominal Flow
(psi)
FT8220
60 to 200
114
3
FT8250
90 to 340
180
5
FT8260
180 to 500
240
5
FT8270
180 to 500
300
5
FT8280
180 to 500
360
5
After steady water flow is established, adjust tower
inlet valves to proper pressure.
Stop the pumps and lock out disconnects until ready
to start system.
Step 4 - Trial Fan Operation
Lock out all disconnects before servicing any portion
of the tower. Check for smooth operation and
clearance between blades and tower by manually
turning the fan blade. Clear the air intake and
discharge areas of any foreign material. Check the
power supply for correct voltage, frequency, and
phase. Turn on fan motor for a moment to check fan
rotation to confirm fan will properly discharge air out
of top of tower. If the fan is rotating in the wrong
direction, turn off fan motor, wait for fan to stop, and
lock out disconnect. Rewire fan motor, by switching
any two power leads. Once proper rotation has been
established, operate the fan motor and check the
amp draw to verify that it falls within the nameplate
rating. If amp draw is in excess of the nameplate
amps, call the Customer Service Department for
assistance. Continue to operate the fan motor for
two or three hours. If abnormal vibration or sound
develops, disconnect power and contact the
Customer Service Department for assistance. Stop
fan motor and lock out disconnects until ready to
start the system. Check all fan bolts to assure they
are tight.

12
Operation and Maintenance
Fan Motor
The motor should bring the fan up to full speed in
less than five seconds. If it does not, check
connections, fuses, overloads, and voltage at the
motor terminals. If everything does not properly
check out, call the Customer Service Department for
assistance.
WARNING: If vibration occurs, shut the fan off
immediately. Check the motor mounting and make
sure all fasteners are tight. If everything is tight,
remove fan blade assembly from motor and start
without the fan blade. If the motor vibrates, contact
the Customer Service Department for instructions. If
the vibration is not in the motor, check the alignment
of motor with mechanical equipment and the balance
of the fan blade. Make sure all fan blades are secure
and complete. If source of vibration cannot be isolated,
contact the Customer Service Department for
assistance. An optional vibration switch wired in series
with the fan motor contactor will protect the tower
from potential damage caused by vibration.
WARNING: Do not cycle a motor on and off more than
necessary. Frequent cycling may cause the windings to
burn out. Generally, the total of the starting times
should not exceed 12 starts per hour. When changing
fan direction, allow a minimum of two minutes before
reenergizing the motor.
Water Distribution
Scale or sludge buildup will impede the proper
operation of the sprinkler arms. If the sprinkler arms
slow or stop, check the water flow to make sure it is
correct. If it is not correct, dismantle and clean the
sprinkler arms. Clean spray arm openings with plastic
bottlebrush and cleaning solution. Do not soak
sprinkler arms in cleaning solution. Only use a
cleaning solution with a pH of 3.0 or greater.
Seasonal Shutdown
If the tower will be shutdown during the winter, it is
recommended that the motor be run for three hours
a month to keep the bearings lubricated and the
windings dry. Be sure to inspect motor before
bringing it back into full operation. Check basin for
debris, clean if required. Inspect fill for
contamination, change fill if needed.
Freeze Protection
When cooling towers are subjected to intermittent
shutdown (nights, weekends, etc.) during cold
weather, or when operating against minimum loads,
the opportunity for freezing of the water contained
in the water basin and internal piping within the
tower exists. Maintain freedom of fan rotation. Do
not operate if snow, ice, or other obstructions will
interfere with fan rotation.
An indoor auxiliary sump is the best means of
avoiding tower freeze-up. With a properly piped
remote sump system the water within the tower
basin and internal piping of the tower is allowed to
drain to the indoor sump whenever the recirculation
water pump is stopped.
Where a remote sump is impractical because of
tower location or space limitation, heat must be
supplied to the water in the tower basin through the
use of electric immersion heaters. Basin heater
packages are available.
Calculations
Evaporation Loss
If exact evaporation losses are not known, an
approximation can be obtained by using the
following formula (see ASHRAE Equipment
1992, 39.11):
Evaporative Loss (GPM) = Range x GPM x .0008
Range = water in (°F) less water out (°F)
GPM = gallons per minute through tower
Drift Loss
Drift loss can be approximated from the equation
below which assumes a loss of .02% of the water
flowing through the tower.
Drift Loss (GPM) = GPM x .0002
Bleed-Off Rate
The bleed-off rate required is dependent on the
condition of the make-up water and the number of
concentrations desired. The bleed-off rate should
therefore be calculated by the company providing
the water treatment equipment.

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Number of Concentrations
The number of concentrations present in the system
is the measure of how concentrated the level of
dissolved solids in the water.
Number of = Evaporation + Drift + Bleed-Off
Concentrations Drift + Bleed-Off
Make-Up Water Required
The amount of make-up water required is
dependent on a number of factors
Make-up water required (GPM) = E + D + B
E = Evaporative Loss in Gallons per Minute
D = Drift Loss in Gallons per Minute
B = Bleed-Off Rate in Gallons per Minute

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Notes

5680 W. Jarvis Ave. •Niles, IL 60714
New Equipment Sales
Customer Service
Parts Department
847-966-2260 •[e-mail]
847-966-2260 •847-966-9358(fax)
847-966-2636
847-966-8560 •847-966-9358(fax)
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