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TTXL Series Installation, Operation and

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1. Y Tower Outperform INDEECO 9KW Heater Voltage And Amp Draw KW Per Voltage of Heaters Element Total Amps Panels needed Panel Amp Rating 208 3 1 9 25 01 1 40 208 3 2 18 50 2 40 208 3 3 27 75 3 40 208 3 4 36 100 4 40 240 3 1 9 21 68 1 40 240 3 2 18 43 36 1 48 2 circuits 240 3 3 277 65 04 2 48 2C amp 40 1 240 3 4 36 86 72 2 48 2 circuits 480 3 1 9 10 84 1 40 2 480 3 2 18 21 68 1 40 2 480 3 3 27 32 52 1 48 4 480 3 4 36 43 36 1 48 4 575 3 1 9 9 05 1 40 2 575 3 2 18 18 1 1 40 2 575 3 3 27 27 15 1 48 4 575 3 4 36 36 2 1 48 4 Stock Control Panel Listing Max Panel Number of Maximum Panel kW Rating Enclosure Amps Circuits Volts 3 Phase Dimensions 40 1 14 2 16 6 33 2 8 x 10 x 6 48 1 17 2 19 9 39 8 10 x 12 x 7 Table 7B Indeeco 9KW Amp Chart Tower Tech Modular Cooling Tower MK9000 12 TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 42 of 130 D Tower Outperform Consult Section 9 4 for information on installation and start up of basin heater Refer to basin heater manufacturer s user manual for complete details on set up validation and operation of the basin heater DANG ER Each heater element contains a fused thermal cutoff device that MUST be wired into the safety circuit as detailed in the installation wiring drawing
2. 84 8 3 2 Multiple Pump Operation Procedure 84 8 3 3 Pump Operation Procedure eere 84 Of Unita Fan Stat paced steel aide sl eee Mea iis 86 8 5 Blow 1 atraer ti 87 Chapter Nine dore ese cease occa 89 9 1 Water FIOW 89 9 2 Water Em 89 9 3 Fan Control 90 94 91 9 4 1 Tower Offline During Cold Weather sees 91 9 4 2 Cold Weather 9 4 3 Basin Heater Installation Testing Start up and Operation 91 95 Water Treatment 103 9 5 Scale Control ERR 103 95 2 Solds Control eT a a otas 104 Tower Tech Modular Cooling Tower Date 09 22 2015 MK9000 12 Page 3 of 130 TTXL Series Installation Operation and Maintenance Manual TOWER Teca Outperform cS 1 1 1 105 9 5 4 Corrosion 1 2200 00 0000000 106 Chapter ee Fe Eo petes ena n Pre E pes ua 107 10 1 Maintenance Schedule essen enema 108 10 1 1 Drift Eliminators
3. Tower Ship Date Warranty Term Tower Tech to complete Address City St Zip Tower Location Contact Tel Fax At Tower Location Office Cell At Tower Location Email Other At Tower Location Start up Completion Date By Tel Email amp Training Completion Date By Tel Email Comments Acknowledged by Filed Tower Tech Warranty Manager Signature amp Date Date Initials Tower Tech Inc N W 5th Stree Oklahoma City Oklahoma 7312 CUSTOMER SERV Main Tel 405 290 Service TowerTechInc com Tower Tech Modular Cooling Tower 9000 12 Date 02 18 2015 Page 79 of 130 TTXL Series Installation Operation and Maintenance Manual i Tow ER Outperform 5 Figure 35 VFD Startup Checklist Appears Below o Tower TECH Tower Start up Warranty Registration Owner Operator training Project S N VFD Who manufactured the VFD Model VFD HP Rating VFD AMP Rating Does the VFD have Bypass Feature Is there a single VFD per Tower Tech module If multiple VFD s per module how many Briefly describe how multiple VFD s are wired to control the fans Is all of the control wiring shielded twisted pair and grounded on one end only lt 2 rH Is the power wiring in separate conduit from control wiring and grounded on both ends o Is a Tower Tech control panel installed with the VFD Please
4. Table 4 Drift Eliminator Data Date 02 18 2015 Page 26 of 130 Tower Tech Modular Cooling Tower MK9000 12 TTXL Series Installation Operation and Maintenance Manual 2 41 Safety Point Brackets The Tower Tech Modular Cooling Tower was designed to reduce maintenance requirements and for routine inspections to be safely performed from ground level The Tower Tech design does not require service personnel to enter the cooling tower for routine inspection or service The maintenance schedule in Section 10 1 only requires service personnel to enter the tower for annual inspections OSHA regulations only require permanent platforms stairways and walkways when routine maintenance is required for an individual more than 6ft of the ground When service personnel have to enter the Tower Tech cooling tower the modular walls served as a fall restraint for the personnel working inside the cooling tower Even with safety being a top consideration in the design of the TTXL Modular Cooling Tower certain service applications required the service technician to adhere to strict fall restraint requirements when accessing the top of the modular cooling tower TTXL modular cooling towers built after October 1 2013 have a safety point bracket mounted inside the tower below each top corner cap The safety point brackets have been tested and certified to hold 5 000 Ibs each A certified engineer must design any fall restraint system t
5. g 9g E 9 RECOMMENDED MAXIMUM OPERATING LEVEL f BOTTOM DF SKIRT r a Figure 3 Sump Level Control Detail CAUTION Operating below recommended operating level of 9 may cause pump surging Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 82 of 130 TTXL Series Installation Operation and Maintenance Manual 1 Tower TECH Outperform CAUTION Do not exceed recommended maximum operating level or sufficient head space may not be available to accommodate water during shutdown Note that the water hold up volume is based on containing the total amount projected to be in the tower s headers laterals and fill and NOT any of the water in piping outside the cooling tower Excess water beyond that which can be contained in the basin or evacuated quickly enough via the overflow pipe will empty into the fan shroud which may cause damage to the fan shroud structure and motor o Overflow is designed to drain water from the basin when water level rises to within 3 3 8 of the Water Collection System 8 3 Hydraulics Refer to Table 11 for respective tower hydraulic data TTXL Model RICE i2 i3 i4 04 i5 i6 06 08 10 154 5s Minimum Flow Rate 200 300 400 400 500 600 600 800 1 000 1 200 GPM m hr o 45 4 68 1 90 8 90 8 113 6 136 3 136 3
6. 1015 ie 255 na 84 0 720 61922 61937 61956 061922 061937 061956 081922 081937 081956 Tower Tech MK9000 12 71 5 16 3 22 13 2 3 0 18 0 84 0 720 a 12 o o Vom ez 92 68 e 285 me ss ane elele irs me me 7 5 81 5 700 190 12 4 992 13 6 108 8 22 17 6 240 84 0 720 380 62 496 6 8 544 NT en Deeper 26 2268 36 288 45 sso aaa maa 4 Modular Cooling Tower TTXL Series Installation Operation and Maintenance Manual 10 250mm Date 02 18 2015 Page 21 of 130 m 150mm 6 150 i Tow ER Outperform 5 Engineering Data 50 Hz 40 C 190V or 380V Model Fan Motors 3 Phase 50 Hz 40 C 190V 380V Connections Nac HP FLA SFA MMC SFA MMC Outlet Overflow jodule Module Module Fan Module Dia Dia m 100 0 10 9 109 0 190 18 8 188 0 20 3 203 0 12 14 2 FNPT 6 10xx37 10 37 370 50 0 190 85 5 700 1 10 9905 ces rm oie etr tem 12xx22 190 2 amp 6 286 0 31 8 318 0 75 750 81 5 700 1 15 380 143 143 0 159 159 0 190 10 0 120 0 10 9 130 8
7. The heater control panel should be within sight of the heater if a disconnect switch option is selected Maintain a water level at least 2 over the heaters using the makeup water controls furnished separately with the equipment or by the user Low water level may lead to overtemperature conditions near the heater Consider additional safety devices overtemperature protection DANG z R Heater element overtemperature can cause a tower fire Optional Immersion Basin Heater Control Panel After selecting the installation site mount the control panel with four 5 16 field supplied bolts through the mounting feet on the enclosure Connect the main incoming power conduit to the main power hub and the heater power conduit to the heater power hubs If alternative conduit hubs are drilled or if supplied hubs are not used replace the plastic protective caps inside the hubs with steel plugs If leakage or condensation is likely to occur in the conduit runs leading to the control panel install a drain in the bottom of the control panel and form a conduit loop Optional Immersion Basin Heater Temperature Low Liquid Level Sensor Mount the combination temperature low liquid level sensor using the factory installed flange which is installed in the basin wall at least 1 above and at least 6 away horizontally from the stainless steel flange s for the heating element s Refer to Figures 15 32 and 33 Tower Tech Modular Cooling Tower
8. Tower Chapter Five Table 8 Weights and Dimensional Data Below TTXL Weights in Lbs Model kg T NEM Preparing for Installation Dimensions per Illustration Below 9470 3 06 6 155 1319xx 2 792 12991 5 905 7 00 213 4 3 06 106 7 dic 7950 16 503 7 00 3 06 3 606 7 501 213 4 106 7 7 800 14 394 3 538 6 543 i5 5 235 23 553 1619 10 706 775 19 587 12 00 4 387 8903 365 8 13 750 24 780 0819xx 3 6237 11264 16 855 29964 12 00 piii 7 645 13 620 365 8 19 700 35 156 8936 15 980 1 i 9 745 20 024 7 00 4 420 9 102 213 4 12 00 365 8 6 00 182 9 2134 3 06 106 7 6 00 182 9 6 00 182 29 12 00 365 8 12 00 365 8 6 00 182 9 cm 10 01 307 3 10 01 307 3 10 01 307 3 9 11 302 3 106 7 3073 40 6 10 01 307 3 9 11 302 3 9 11 302 3 nag 9 cu 3 40 6 pin 9 T pn ee 1 04 4 00 40 6 121 9 40 6 1219 1 04 6 00 40 6 182 9 4 00 121 9 1 04 4 00 40 6 1219 40 6 182 9 17 00 5182 6 00 17 00 Qn 6182 je 6 00 17 00 182 9 5182 17 00 518 2 17 00 518 2 17 00 518 2 13 06 411 5 19 03 586 7 25 00 762 0 13 06 411 5 937 3 36 06 1 112 5
9. 190 100 men Em 5 0 600 55 66 0 2256 20 3 2436 380 9 4 112 8 10 1 121 2 190 286 3432 31 8 381 6 12 127 2 2 FNPT 300mm 300mm x 2 12xx37 12 12xx56 81 5 700 1 15 Baldor motor data SFA MMC refers to Service Factor Amps Maximum Motor Current Size VFD for SFA when motors will be operated by VFD bypass Rating is NEMA nominal efficiency Standard motors TEAO severe duty direct drive with L19 100 000 hour sealed bearings inverter ready with quantum shield wiring class H insulation minimum Motors meet NEMA MG 1 Part 31 requirements for inverter duty use Metric dimensions approximate Flow rates above 2 700 gpm require engineering review and may require two sump containers TTXL 12 requires two sump containers See TTXL 12 drawings for details Table 1 Motor Data 6 Pages Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 22 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform N 7 Fans Figure 9 Typical bladed 7WR Fan High efficiency axial fans with a unique airfoil design are used on all TTXL Series Modular Cooling Towers refer to Figure 9 The fan blades are made of high strength fiberglass reinforced polypropylene held in place by a die cast aluminum silicon alloy hub The high efficiency fan blades are adjustable pitch a
10. Date 02 18 2015 MK9000 12 Page 98 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform lt G R Do not confine or surround the sensor probe with any type of well piping or housing as it may adversely affect its operation Insert the basin heater sensor probe into the Tower Tech installed sensor probe flange only See Figures 15 32 and 33 for location of the probe flange Twist the probe in a counter clockwise movement prior to inserting into the flange so that when the probe is properly seated within the flange its wire rests in a relaxed state rather than twisted state Tighten the locking nut to keep the sensor probe from rotating in the flange Sensor probe connections to the heater control panel are made at the factory No electrical installation is required Optional Immersion Basin Heater Main Power Input Wiring The main incoming power hub and the main power termination points are sized for wires based on the total nameplate kW and voltage The actual load for a particular installation may be less Either compute the actual load on the heater control panel the total kW of all the heaters connected to it or use the nameplate rating in determining the wire size required Calculate the amperage as follows Three Phase Amperage Total kW x 1000 Voltage x 1 732 The field supplied branch circuit disconnect switch and the branch circuit protective devic
11. 081930 i 12 14 2 FNPT mn i 7 i 7 350mm 50mm Fr 081975 i Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 19 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower Outperform Engineering Data Fan Motors 3 Phase 60 Hz 50 C 380V 460V 60 Hz 50 C 380V or 460V Connections 101975 2 7 5 750 380 150 so 123 123 358 DE Jamon xo er 73 ors uo sepe e2 7 wr nz 716 121930 84 121950 in 121975 operated by VFD bypass 865 855 kW kW HP FLA FLA SFA MMC 5 MMC amp TTXL Fans Fan Module Fan Module Module EY 380 6 7 67 0 73 101930 22 220 30 300 84 0 ss s 62 820 380 10 1 101 0 11 3 113 0 101950 10 3 7 37 0 5 0 50 0 92 s 85 5 87 0 167 0 81 5 8 6 096 i ao iso eo 204 Baldor motor data SFA MMC refers to Service Factor Amps Maximum Motor Current Size VFD for SFA when motors will be 6 150 5 gt 12 x2 6 300 300 2 150 Rating is NEMA nominal efficiency Standard motors TEAO severe duty direct drive with _ 100 000 hour sealed bearings inverter re
12. 8 4 Initial Fan Start Up 1 Visually inspect each fan for minimum tip clearance of approximately 1 8 3 175mm before starting fans for first use If clearance is insufficient contact a Tower Tech Representative for further instructions Although tip clearances are quality checked before releasing a TTXL tower re inspect them to ensure there was no movement during shipping Verify that all fan guards are in place and secure Check for proper fan rotation by energizing each fan motor Fans rotate in a clockwise direction and push air upwards Use a qualified electrician to interchange two of the three electrical wires to the motor to correct the rotation if rotation is incorrect Start each fan and measure the motor amperage The amperage should not exceed the motor nameplate rating with service factor as given in Table 1 Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 86 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform Q Motor current may run into the service factor in cold weather operating conditions or when the tower does not have water flowing Motor current should never exceed service factor amps 5 Check the fan staging control to ensure that fans cycle properly Refer to Section 9 3 6 Introduce the heat load after checking all of the items listed above 8 5 Flow Balancing It is often necessary to balance the water flow entering each c
13. Date 02 18 2015 MK9000 12 Page 48 of 130 TTXL Series Installation Operation and Maintenance Manual a gt Tower Outperform 5 2 Tower Location The most suitable location to install a cooling tower from both a performance and safety perspective is a rooftop However when this is not possible use the following guidelines to select a satisfactory location for installation CAUTION Module is designed principally for outdoor installation Contact your Tower Tech Sales Representative for details on indoor use and necessary equipment accommodations 5 2 1 Environmental Safety Considerations A cooling tower module must be installed in a location where contaminated tower discharge air cannot be drawn into any building fresh air ducts The purchaser should obtain the services of a Licensed Professional Engineer or Registered Architect to certify that the location of the tower is in compliance with applicable air pollution fire and clean air codes 5 2 2 Re Circulation Considerations Re circulation is a condition that arises when warm moisture laden exhaust air is inadvertently drawn back into a tower s intake This condition elevates the cooling tower entering wet bulb temperature and affects the tower s capacity to cool to design requirements Re circulation commonly occurs when towers are located within enclosed areas or in close proximity to obstructions and other equipment that exhausts hot humid
14. To lower a fan guard refer to Figure 38 Turn off fan and lock and tag out power 2 Remove the six 1 4 bolts that hold the screen angle to the tower mid basin and perimeter wall using a 7 16 wrench 3 Atthis point you will have full access to the fan and motor TYPICAL TYPICAL BASIN WALL WIND WALL HINGED CLOSED HINGED SCREEN OPEN Figure 45A Opening Full Screen Fan Guard TYPICAL WIND WALL TYPICAL BASIN WALL HINGED SCREENS CLOSED HINGED SCREENS OPEN Figure 45B Opening Split Screen Fan Guard Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 113 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform lt 10 1 5 Fan Inspection and Replacement DAN R When maintenance is required on fan guards fans or fan motors it is imperative that lock out tag out procedures be strictly adhered to prevent damage to equipment or personnel Any dirt ice or other debris on fan blades can affect the balance of the fan Without proper cleaning and maintenance imbalanced fans can cause damage to the motor bearings Fans are pitched and aligned during assembly Recommended clearance between fan shroud and fan tip is 1 16 minimum and 1 2 inch maximum Tower Tech sets fan tip clearance at 1 4 to 3 8 in the factory Fan tip clearance should be checked monthly remove a
15. Outperform Pace 2 JOB NUMBER NO TowER OF Sump PARTS PACKING CHECKLIST 1 Operation Manual One copy per Job 1 Submittal Drawings One Y N copy per Job 1 Copy of the Sump Parts Packing Checklist One per Tower Rapid Link Kit 1 2 Basin Heater Kit Used to heat the Module Cooling Tower water rare auan mopoa Circle Quantity Basin Heater Controller w sensor Quantity varies per Job Check Circle one With Disconnects Without Disconnects Drawings Circle one 208v Heater Element s Circle Quantity 2 SS Heater Flange On Tower Circle Quantity 3 4 Sensor Flange On Tower Circle Quantity 1 Heater Manual If Required Flowline Kit Special Optional Equipment S 1 A L C 52 flowline Controller Box 1 6 Vanstone Flange 1 6 Blind Flange w Threaded 2 Hole and regular 1 Hole 1 Flowline Hardware Kit Comments QCS5028 1 Effective 12 24 03 Figure 33 Sump Parts Packing Checklist Continued Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 69 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform Pace 3 JOB NAME JOB NUMBER MODEL TowER amp OF Sump PARTS PACKING CHECKLIST Control Panel
16. walls structural members and internal components in wetted areas are non corrosive fiberglass various plastics PVC is used exclusively in the hot water distribution system and in other non structural members and stainless steel hardware Non corrosive materials of construction provide long service life in the hostile chemical environments inherent to cooling towers Galvanized metal support systems located in the hot moist air stream and chemical wood treatments are major contributors to environmental and maintenance problems associated with conventional cooling towers Galvanized metals can molecularly break down in the water due to high concentrations of acids and alkalis Conventional wooden towers are often treated with potentially hazardous chemicals to prolong their life These substances also leach into the cooling water The TTXL Series Modular Cooling Tower minimizes these environmental problems by eliminating galvanized metal and treated wood from the wet areas of the cooling tower design The TTXL Series uses impervious plastic pvc coated steel fan guard screens however the fan guard screens are located in the non wetted area below the tower module 3 2 Tower Walls The tower walls provide a perimeter shell around the tower fill media and other internal components The three sections that comprise the walls the Perimeter Basin Wall the Mid Wall and the Top Wall are some of the largest pultruded components in the world
17. 586 7 25 00 762 0 pe 182 9 6 00 182 9 182 9 6 00 17 00 1 04 6 00 40 6 Qu 9 hel 6 00 182 9 5182 1829 5182 6 00 17 00 30 09 937 3 36 06 182 9 182 9 518 2 1 112 5 Dimensions are approximate and should not be used for construction purposes Consult submittals for exact tower data Dimension F may be 1 00 30 5 4 00 121 9 cm 6 00 182 9 8 00 243 8 cm 10 00 304 8 cm or 12 00 365 8 cm depending on project requirements 12 00 365 8 cm may be specified with prior approval of Tower Tech engineeing manager only Dimension F on drawing below is 6 00 182 9 cm 5 Tower weights may vary due to optional equipment residual water from factory testing rain etc Weights shown are guidelines only and do not include sump substructure or other accessories not directly attached to the tower module during shipping c B Es TTXL 1219xx requires two See TTXL 1219xx drawings Tower Tech website N L Figure 20 Dimensional References Tower Tech Modular Cooling Tower MK9000 12 TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 47 of 130 Tower TECH Outperform 5 5 1 Limitations The cooling tower modu
18. Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 61 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform 10 Lift the sump into position and align the four all thread rods and the two 1 2 x 2 bolts into their corresponding holes 5 Loosely attach and hand tighten each of the remaining twenty 1 2 x 2 bolts using one flat washer and one nut per bolt Once all are loosely attached begin to tighten them from the top center Tighten to 30 ft Ibs 11 Through the sump lid opening access insert onto each all thread rod one 3 8 inch 9 5 mm neoprene washer one 2 x 1 2 x 8 5 1 cm x 1 3 cm x 20 3 cm FRP backer support one washer and one nut CAUTION Two FRP backer supports are provided with one backer support having two holes accommodating the two left facing all thread rods and the second backer support accommodating the two right facing all thread rods Sealant must be used between the backer support plate and the sump wall around each hole REFER TO FIGURE 26 12 Setsump screen at the bottom of the sump then attach the ball to the float valve arm using a threadlocking adhesive tape or other self locking mechanism to prevent the ball from vibrating loose and falling off 13 Replace sump lid 3 8 NEO WASHER FACTORY ATTACHED 3 8 SS NUT amp WASHER SUMP LID eas DO NOT REMOVE FACTORY ATTACHED 3 8 SS ALL THREAD WITH PVC SP
19. Z FNPT mns 200mm 250mm 50mm 150mm 51975 Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 17 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform Engineering Data z 40 C 200V 230V 460V o Model Fan Motors 3 Phase 60 Hz 40 C 200V 230V 460V or 575V Connections Ma HP HP FLA FLA SFA MMC SFA MMC Inlet Outlet Makeup Fans Fan Module Fan Module Fan Module Dia Dia Dia 10 250mm 4 6 061950 4 150mm 61930 61950 61975 061930 061975 081930 B e 081950 E 5 150mm 081975 101930 17 1455 Nn i 15 300mm 350mm 150mm 101975 zm zi 1652 xls zw nz 4 6 22 460 se 672 62 575 121050 amp m i 1 15 300 2 50mm 230 24 6 295 2 121975 Fas 123 1476 138 ss ws e ma Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 18 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform Engineering Data 5 Model Fan Motors 3 Phase 60 Hz 50 C 380V or 460V Connections i21930 81 596 we we e ez zs 380 101 202 113 226 e 1
20. 1 Set the tower into position with each footpad on the anchor bolt or location anchor bolt will be installed The size and length of the anchor bolt to be provided by a structural engineer Refer to cooling tower submittal drawings for leg geometric properties Tower Tech can provide seismic and wind loading calculations upon request for each tower model The maximum diameter of the anchor bolt is 1 25 4mm for the square washer provided by Tower Tech to fit onto the anchor bolt Tower Tech requires the anchor bolt Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 54 of 130 TTXL Series Installation Operation and Maintenance Manual gt AK Tower Outperform to extend a minimum of 5 4 139 7mm above the bottom of the footpad as shown in Figure 23 2 Once the sub structure leg is lowered onto its main support beam pier or pad and the footpad is secured then verify the tower is level Refer to Section 5 3 Tolerances for detail 3 Hil the pocket around the anchor bolt to top of two horizontal leg bolts with non shrink grout before installing the square washer Before grout sets install the square washer on top of the two horizontal leg bolts Tighten the anchor nut provided by others and torque to 508 165 Square washer should engage the two horizontal bolts securing the footpad to the leg Re torque to structural engineer s specification after grout has set ANCHOR NUT amp WA
21. 181 7 227 1 272 5 Maximum Flow Rate 600 900 1 200 1 200 1 500 1 800 1 800 2 400 2 700 3 000 GPM m hr 136 3 204 4 272 5 272 5 340 7 408 8 408 8 545 1 613 2 681 4 Basin Capacity 535 810 1 085 760 1 235 1635 1 050 1 325 1 600 1 920 U S Gal m 2 02 3 07 4 11 2 88 4 67 6 19 3 97 5 02 6 06 7 27 Flow rate above 2 700 GPM necessitates the use of two sumps per tower module Rotary Spray Nozzle rotor disc may spin below 100 GPM however this will result in a smaller spray pattern reduced tower performance and efficiency and uneven wear of nozzle components Nozzle operation from 300 GPM to 320 GPM will result in a larger spray pattern The rotor disc will spin freely with flows to approximately 320 GPM however this flow may exceed tower module hydraulic limits consult Tower Tech engineering manager for specifics Nozzle operation above 320 GPM may result in uneven wear of nozzle components Flow rates below 100 GPM and above 300 GPM per nozzle are not allowed Table 12 Tower Hydraulic Data Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 83 of 130 TTXL Series Installation Operation and Maintenance Manual a gt Tower TECH S 32 Outperform 8 3 1 Single Pump Operation Procedure This procedure describes water level balancing for an installation that is operated by a single system pump 1 Open th
22. 7 Check tower for plumb and stability then tighten all hardware at leg braces before detaching the crane 8 Attach the sump box as described in Section 7 1 and proceed with the tower start up operation Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 59 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform C OF TOWER t DF CRANE BDUM 27 CUSTOMER BY CUSTOMER T SLING BY _ CUSTOMER CENTER BEAM ATTACH STRAPS CABLE AS NEEDED TO BEAM VAT TTXL Model Tower Dry L Sling S Spreader Weight in Lbs Length in Feet Beam in Feet m 12 13XXXX 14 04 15 16 08xxxx 10 12 Tower weights may vary due to optional equipment residual water from factory testing rain etc Weights shown are guidelines only and do not include sump substructure or other accessories not directly attached to the tower module during shipping Table 0 Tower Lifting Data Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 60 of 130 TTXL Series Installation Operation and Maintenance Manual 1 Tower TECH Outperform Chapter Seven Tower and Peripherals Installation 7 1 Sump Attachment CAUTION The sum
23. Switch HOAs to AUTO all fan contactors controlled by PLC Set Temp Set Point 10 F C below current temp shown on LCD Verify Fan Staging Sequence Set Temp Set Point 10 F C above current temp shown on LCD Verify Fan de staging Sequence Record amp voltage readings for L1 L2 L3 for each motor NOTE VFD must be in By Pass Mode for these measurements gt Set Temp Set Point to Operating Value Ref Submittal Drawings Inspect the sump screens for start up debris 000000 000 0000000 noo 000000 Verify air is exiting top of tower modules not blocked Verify connections between VFD amp Control Panel Verify all 4 20mA control wires are twisted shielded pair cable grounded on one end Verify VFD Operation of Fan Motors Record VFD Settings amp Operational Values VFD Startup Checklist VFD Startup completed by VFD Certified Technician Oooo nooo VFD Inspected by Printed Name Signature Cell Phone Office Phone Email Company Main Phone A ddress Fax City State Zip Country Comments include VFD Brand Model and qty if not provided by Tower Tech Electrical Inspected By Printed Name Company Date Signature w S Tower Tech Inc 3 of Serv vice TowerTechinc com Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 74 of 130 TTXL Series I
24. This cutoff device is wired in series with any other optional safety devices Immersion basin heaters MUST be deactivated when water is flowing through the cooling tower Failure to do so will result in overheating of the basin heater element and accidental fire For a cooling tower installation having only one pump it is recommended that the heater control system be interlocked with the tower s circulating water pump so the heaters are deactivated when the circulating pump is in operation Doing so provides further protection against overheating of the basin heater element and accidental fire and is also necessary for efficient control of free cooling operations For a cooling tower installation having two or more pumps it is recommended that the heater control system be interfaced to a flow or pressure switch located on the inlet piping to the cooling tower module Doing so provides further protection against overheating of the basin heater element and accidental fire and is also necessary for efficient control of free cooling operations o Tower Tech recommends the electrical contractor installing the basin heater element use a flex loop with additional wiring connected to the element so it can be removed for quick inspection without having to disconnect the wiring Heater element is 22 in length Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 43 of 130 TTXL Series Installation Operation and Maintenanc
25. Typical heights 1 foot 30 5 cm 4 feet 121 9 cm 6 feet 182 9 cm 8 feet 243 8 cm 10 feet 304 8 cm and 12 feet 365 8 cm Footpad e FRP tubular braces Not required for 1 foot 30 5 cm legs e Assembly hardware Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 34 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform 4 2 T9900 Motor Control Panel Figure 15 Typical Motor Control Panel for 10 Fan Cooling Tower Module VIEWSCREEN touch screen standard on all Tower Tech T9900 control panels ordered after August 31 2011 Tower Tech offers a complete line of T9900 optional motor control accessories designed for the TTXL Series Modular Cooling Tower Tower Tech s optional motor control panels come complete and ready for immediate installation Panels require main power feed to the main disconnect switch and a separate 120V control power feed Panels also require connections to the standard pre wired junction box optional individual motor disconnects or pre wired pigtails The T9900 series motor control panels are equipped with a cover mounted lockable main disconnect and individual HAND OFF AUTO controls for each fan motor Each internally mounted combination motor starter adjustable overload protector has an integral lockable circuit breaker to enable individual motor isolation with lock out tag o
26. connection point This 6 connection also serves as the mounting point if tower is equipped with optional electronic liquid level control equipment Refer to Figure 30A 30B or 31 Iowrz Ixcu _ LEVEL SENSOR ASSEMBLY e B le STANDPIPE W FLANGE ai _ TO RECEIVE LEVEL SENSOR ASSEMBLY 9 BASIN WATER LEVEL 0 BOTTOM OF FLOWLINE OF 7 OVERFLOW LEVEL OVERFLOW PIPE 6 BASIN WATER LEVEL MIN FOR am LEVEL READING BOTTOM OF COOLING TOWER BOTTOM OF TOWER SKIRT 2 6 E MINIMUM 6 OVERFLOW RISER INSIDE BOTTOM zi Lum OF BASIN gt EQUALIZATION OVERFLOW PIPE TO EACH CELL SIZED AND PROVIDED BY OWNER MANUFACTURER RECOMMENDS THAT FLOW CONTROL VALVE BE INSTALLED AT EACH CELL S OVERFLOW CONNECTION TO BE PROVIDED BY OTHERS Figure 31A Typical Overflow Equalization Pipe Figure 31B Typical Ultrasonic Stand Pipe with Overflow CAUTION In all cases it is important that the overflow piping be at the specified level P di BOTTOM OF TOWER SKIRT FOR DIMENSION REFERENCE CAUTION overflow lines must be equipped with a siphon breaker to prevent the module from being siphoned dry during overflow situations Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 66 of 130
27. to the full open position and start one pump with a slow ramp time of 1 2 minutes 3 Allow the system to operate until the sump float valve s closes to allow the make up water to replenish the water removed from the basin s by the pump If the pump surges shut off the pump close the make up valve s and adjust the VFD ramp up to alonger time Repeat Steps 1 through 3 Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 85 of 130 TTXL Series Installation Operation and Maintenance Manual 10 11 12 13 Tower TECH Outperform If the pump continues to surge then close the make up valve s adjust the sump water level to a higher setting and repeat Steps 1 through 3 Open the inlet valve s to the module s to the full open position and start the second pump Repeat Steps 3 through 5 Start remaining pumps one at a time by repeating Steps 3 through 5 Verify the operating level in the module s is within the specified range after the system has equalized Shut off one pump with same ramp down time as set for ramp up time Open drain valves on pumps to simulate evaporation When sump float valve s on module s opens shut off second pump Shut down remaining pumps one at a time as the sump float valve s opens Close pump drain valves Check sump water level for overflow If the sump overflows shut off the make up valve lower the float valve setting and repeat Steps 1 through 11
28. 0 00 00000000000 2 109 10 1 2 Media ettet etre ERE eo Even ee 110 10 1 3 Rotary Spray 71 110 Guards used i deett 112 10 1 5 Replacement uoo peii ue ia 113 10 1 6 Fan Blade Replacement sci 115 10 1 7 Fan Blade Pitch Adjustment 115 10 1 8 Fan Motors Removal Installation 116 10 1 9 Fan Motor 117 10 1 10 Mechanical Float Valve esee 117 SCHOEN gases ER 119 10 1 12 Immersion Basin Heater 117 10 1 13 Water Collection iin br Ei ep ER Ee ru ERN eR 119 102 DU or dada cacy eee dE 128 Chapter Eleven Appendix sna n Sees eu ea enes 129 IB MEM oS gni Rem T 129 11 2 Todes of Lables unu 130 11 3 Index of CAPA NS 130 Tower Tech Modular Cooling Tower Date 09 22 2015 MK9000 12 Page 4 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower Outperform Chapter One About This Manual 1 1 Scope Information described herein pertains directly to the installation operation and maintenance of the Tower Tech TTXL Series Modular Cooling Tower The TTXL Series is a forced draft counter flow design that allows modules to be a
29. 1 Installation of Sub Structures Taller Than One Foot 30 5 cm 53 5 4 2 Installation of One Foot 30 5 Sub Structure 54 Chapter Six Rigging amp Handling 45 6 1 Trt POUCH OM i eei ie 56 Tower Tech Modular Cooling Tower Date 09 22 2015 9000 12 Page 2 of 130 TTXL Series Installation Operation and Maintenance Manual 69 Outperform 6 2 Accessory Location CHECK IG c 57 6 3 Proc dure M 57 Chapter Seven Tower amp Peripherals Installation 49 74 Sump Attachment d pep 61 EN EEEiiu mr 61 T2 uDESUn snc M 63 LAL mlet 64 722 Discharge 65 43 Make Up Connection 66 7 2 4 Overflow Equalization Connection eene 66 Chapter Eight Tower 1 ee eee reete ee 67 8 1 Filling System stre 71 8 2 Controlling Water Level iue erect tix RED E vut MEER Le 81 8 3 la 83 8 3 1 Single Pump Operation
30. 49 for up to two hours if the excursion is supported by the fill media manufacturer s recommendations Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 32 of 130 TTXL Series Installation Operation and Maintenance Manual D Tower TECH Outperform TTXL Series internal components are described in Table 6 Fill Media 10 mil PVC std Sub Structure Legs FRP immenso umb 0 Drift Eliminators 10 mil PVC Wind Wall Partitions ABS em Rotary Spray Nozzle HDPE Modular Base Support amp Nylon NNI Mae Water Distribution PVC Fan Shroud Hand Lay Up Chopped Header amp Laterals Fiberglass Strands or Resin Transfer Molded Fiberglass Flame Retardant Water Collection ABS Sump Box PP Extruded pe Rotationally Molded Header Inlet Flange PVC Inspection Ports Nylon _ FRP Fiberglass Reinforced Plastic Pultrusion PVC Poly Vinyl Chloride Self Extinguishing ABS Acrylonitrile 1 3 Butadiene and Styrene Copolymer Flame Retardant PP Polypropylene Table 6 Materials of Construction Internal Components Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 33 of 130 TTXL Series Installation Operation and Maintenance Manual gt AW Tower Outperform Chapter Four Optional Equipment 4 1 Sub Structure Leg Kit FACTORY ASSEMBLED TOWER MODULE x6 SUBSTR
31. 5 6 kW Available at 190V 208V 380V or 415V 50Hz 40 C Available in 2 2 kW 2 9 kW or 3 7 kW Available at 220V 380V or 440V 50Hz 50 C Available in 2 2 kW or 4 5 kW Available at 190V 208V 380V or 415V Motor type and power level depends on tower model selected and required design conditions Refer to Figure 8 for a view of motor mounted to fan shroud Refer to Table 1 for motor data Figure 6 Motor Motor Support Fan Fan Shroud Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 16 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform Engineering Data Hz 40 C 200V 230V 460V o Model Motors 3 Phase 60 Hz 40 C 200V 230V 460V 575V Connections FLA FLA SFA MMC SFA MMC Makeup Overflow TTXL Volts Pan Modale Module aid Dia Dia 200 12 1 242 26 6 T ze n2 224 122 243 45 90 400 220 s 2 35 85 596 8 3 16 6 92 18 4 200mm 6 7 13 4 1 7 15 4 30 0 60 0 33 0 66 0 pes me ma N 121950 8 121975 e zi a m gt 131930 66 0 548 s d 92 27 200mm 200mm 100mm 77 131950 131975 41930 8 10 141950 200 250mm 141975 041930 10 10 6 250 250mm 150mm 041950 041975 151930 10
32. Foot 30 5 cm Sub Structure Installation Detail for Sub Structure Footpad Lifting Bracket Tower Lifting Procedure Sump Installation Detail Standard Piping Connections Connection Flexible Flanges amp Flow Control Valves Discharge Flange and Split Ring Typical Overflow Equalization Pipe Typical Ultrasonic Stand Pipe with Overflow Typical Overflow Equalization Piping Sump Parts Packing Checklist Start up Warranty Activation Owner Operator Training Checklist VFD Startup Checklist Mechanical Float Valve Sump Level Control Detail Typical Flow Balancing Problem Mid Basin Inspection Ports Basin Heater Control Panel Location of Basin Heater Probe amp Element Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 129 of 130 TTXL Series Installation Operation and Maintenance Manual A Tower TECH Outperform Brochure Maintenance amp Service Plans Exploded View of Rotary Spray Nozzle Close Up Fan Guard Hardware Opening Fill Screen Fan Guard Opening Split Screen Fan Gaurd Mechanical Float Valve Sump Layout Sump Screen Detail Water Collection System Close Up View Water Collection System Flow Thru Basin Drainage Perimeter Basin Wall TTXL See Through View of Tower Basin Wall 11 2 Index of Tables Table Number Description Section Motor Data Fan Data Fill Media Data Drift Eliminator Data Motor Data Wall Data Materials of Construction Internal Components Weights and Dimensio
33. LATERAL PATENTED VARIABLE FLOW TM ROTARY SPRAY NOZZLE HOT WATER INLET FILL MEDIA LIFTING LUG PORT PATENTED WATER COLLECTION SYSTEM BASIN HEATER BASIN HEATER SENSOR PERIMETER PROBE ACTUAL LOCATION FLOW THROUGH BASIN LEFT OF SUMP BRACE SPACER MID BASIN __ OVERFLOW EQUALIZATION CONNECTION DIRECT DRIVE MAKE UP FAN ASSEMBLY SUMP DISCHARGE SUMP TANK WATER CONNECTION Figure 1 TTXL 3 D Cut Away View A counter flow cooling tower as opposed to a cross flow cooling tower is distinguished by the airflow and water flow moving in opposite directions in relationship to one another inside the tower In a cross flow tower the air and water flow move perpendicular to one another Figure 2 shows the layout of a Tower Tech counter flow cooling tower compared to a typical cross flow tower Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 8 of 130 TTXL Series Installation Operation and Maintenance Manual Y TOWER Outperform s DIT A H p f j a Figure 2 TTXL versus Conventional Induced Draft Cross Flow Tower The Tower Tech TTXL Series Modular Cooling Tower is characterized as a mechanical forced draft cooling tower Mechanical fans are used to provide a known volume of air through the tower Forced draft towers have the fan located in the cool dry ambient air stream o
34. Maintenance Manual ji TOWER Outperform 5 e Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist Project S N Date OWNER amp OPERATOR TRAININ Needs Good Attention N A Each attendee has seen the cooling tower and its controls beforehand Each attendee has signed in on Tower Tech s Sign In Sheet Tower Tech sales video has been shown to each attendee Chapter by chapter discussion of IO amp M Manual has been completed om B fh Q amp A session has been completed at the conclusion of training oooo ooooo nooo Names of Attendees Comments Trainer Printed Name Date Instructor Signature Company Tel Cell Email Customer Printed Name Signature Company Date Email Office Phone Cell Fax Oklahoma 73127 USA Effective 07 1 CUSTOMER SERV Main Tel 405 290 7 Service TowerTechInc com HOTLINE Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 78 of 130 TTXL Series Installation Operation and Maintenance Manual j TOWER Outperform 5 v Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist Project S N Date ARRANTY REGISTRATION FORM Registration Date Customer End User Tower Location if different than customer Work Order Serial Control Panel S N
35. NEMA 4X wire junction box is integral to the heater element cap See Figure 15 for location of the basin heater element Wiring of both the control panel main input and of the immersion heater must be completed by a licensed electrician Only wiring with a temperature rating of 75 C and rated to carry the quantity of amperage must be used All wiring must comply with NEC CEC as well as local electrical codes Refer to the basin heater manual entitled Cooling Tower Basin Heater Control Panel shipped inside the control panel for details regarding Main Power Input Wiring and Heater Power Wiring Optional Immersion Basin Heater Operating Instructions Before energizing the main supply disconnect visually check that the water level is above the sensor probe and that ice has not formed and adjust the make up water control valve as needed The combination temperature low level control is preset at 45 F and the system will not energize if the water level is too low or if the water temperature is above 45 F Verify all mechanical and electrical systems are working properly Complete the system test procedure to verify proper operation also applies to pre season test when water temperatures exceed 45 F Remove all test jumpers before energizing the system DANG E R Water Level must be above sensor probe to prevent accidental fire Under normal operating conditions the energized heater control panel will automatically cycle the hea
36. Operation if Sensor Probe is Encased in Ice a De energize the heater control panel and tag circuit out for maintenance b Remove the heater control panel enclosure cover c Install a jumper wire between terminals and G2 on the combination temperature low level control circuit board d Install the heater control panel enclosure cover CAUTION Do not operate the system unattended or for an extended period of time with the G1 G2 jumper installed A low liquid level condition could occur and the system will not shut off This could result in damage to the heater s and cooling tower e Energize the system and listen for the contactor closing f Operate the system until the ice is melted around the probe g After operation de energize the circuit remove the jumper check all connections replace the cover and place the system back in service Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 97 of 130 TTXL Series Installation Operation and Maintenance Manual D AD Tower Outperform Optional Immersion Basin Heater Installation This section consists of general information mechanical installation electrical installation and start up Optional Basin Heater Installation General Carefully plan the locations of heaters control panels and probes Measure the factory supplied probe cord length DANG E R Do not attempt to change the supplied probe cord length
37. TO SUBSTRUCTURE amp TOWER AT JOB LOCATION BY OTHERS TRE SUBSTRUCTURE HARDWARE SOME HARDWARE NOT SHOWN FOR CLARITY Figure 22 Installation Detail for Sub Structures Taller Than One Foot 30 5 cm Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 53 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower Outperform Un 4 2 Installation of One Foot 30 5 cm Sub Structure With the cooling tower lifted slightly above the main support beam or pad do the following 1 Attach the 1 tall sub structure leg vertical support beam to the cooling tower s modular base support using two gt x 6 stainless steel hex bolts with washers and nuts per leg finger tighten 2 Once the 1 tall sub structure leg is loosely secured the cooling tower module can be lowered onto its main support beam or pad Upon setting the cooling tower verify that the tower is level Refer to Section 5 3 Tolerances for detail 3 Tighten all 1 dia Bolts to 50 ft 165 Tighten all bolts less than 1 dia To 30 ft Ibs FACTORY ASSEMBLED TOWER MODULE FIBERGLASS LEG ASSEMBLY BOLTED TO TOWER AT JOB LOCATION SOME HARDWARE BY OTHERS NOT SHOWN FOR CLARITY Figure 23 Installation Detail for 1 Sub Structure 5 4 3 Installation and of Sub Structure Footpad With the cooling tower lifted slightly above the main support beam or pad do the following
38. air Pumps control panels piping and buildings can all be impediments to the smooth unimpeded flow of air into a cooling tower To minimize re circulation Tower Tech recommends the following e Position the top of the cooling tower at least as high as any adjacent walls enclosures buildings shrubbery winter snow fall lines or other significant structures Minimize the opportunity for exhaust air to migrate downward by placing tower as close to the interfering structure as possible Note that this should be balanced against the possibility of air restriction e If air restriction is a concern it is recommended that enclosures provide air entry or ventilation via louvers slots or similar openings Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 49 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform 52 3 Interference Considerations Interference is a condition that arises when the cooling tower is situated down wind or in close proximity to a heat emitting source To avoid interference careful locating of the cooling tower is essential Consider the following e cooling tower should be designed for the entering wet bulb temperatures at the proposed tower location rather than ambient wet bulb for the locality e Install the cooling tower upwind of the interference utilizing prevailing summer winds as the guideline e Remove any obstr
39. and other in line physical filtration devices Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 104 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform Undissolved solids serve as physical foulants which can plug fill thereby reducing tower efficiency increase chiller head pressures their deposition increases friction and damage fill and shell structure by weight imposed addition they can contribute to corrosion by preventing the contact of the CI Corrosion Inhibitor to the downstream metal surfaces as well as promote biofilm formation by shielding microbes from biocides Controlling these solids is important in allowing lower and more efficient use of treatment chemicals An undissolved solids level of 100 150 ppm particularly those 10 microns or smaller in size is typically recommended for re circulating systems Usually a physical means is used to remove these solids e g de sludgers cyclones centrifugal separators strainers filters 100 mesh or 150 um particle cut off pressurized media filters sand gravel beds good for most average industrial applications not exceeding 200 ppm and whose particulates do not exceed 10 um and cartridge filters for fine filtering 1 um or less only chemical plants with stringent downstream requirements will need this also HVAC systems incoming water 5 ppm or less are used Q Solids removal is not a st
40. any basin heater s before draining water from the module s basin Failure to do so will result in damage to the module as well as potential for fire to occur 10 1 Maintenance Schedule TTXL Series Modular Cooling Towers are designed to require minimal maintenance However the quality of care they receive will affect their service life The following schedule is given as a minimum checklist to aid in providing the recommended inspection and maintenance of your unit Refer to Table 12 for recommended maintenance of TTXL components Table 13 TTXL Maintenance Schedule Maintenance Frequency Action To Be Taken Reference Section Immersion Basin Heater 12 months prior to cold season Visual Inspection 10 1 12 Water Collection System 6 months Visual Inspection 10 1 13 Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 108 of 130 TTXL Series Installation Operation and Maintenance Manual 4 Tower TECH Outperform Items completed during a single walk around amp under tower module at specified intervals Inspection time is expected to be completed in less than five minutes per tower module Required only if tower is not operated regularly for an extended period of time Required only if motor has tripped more than 3 times within any 30 day period After installation of replacement Fan Assembly Note Issues observed during Visual Inspections need appropri
41. are not designed to safely support the weight of personnel CAUTION The Water Collection System and fill media will support the live load of personnel at 200 Ibs ft to a maximum of 450 Ibs per cooling tower module Tower Tech recommends avoiding walking on the fill media or Water Collection System unless pieces of 1 x 2 plywood used for load distribution to minimize the possibility of damaging fill media and Water Collection System 3 Take note of how the fill media sections are stacked in the tower module 4 Remove the sections of fill media above the area of the Water Collection System that you wish to access and inspect each log for scale dirt and debris Any fill pieces that are heavily contaminated by scale dirt or other debris should be removed from the tower module and power washed Any fill pieces not contaminated by scale dirt and other debris can be stacked temporarily on top of other fill elsewhere in the tower module If necessary additional drift eliminator sections may be removed to make room to stack clean fill pieces elsewhere in the tower module Clean fill media may also be placed temporarily on top of installed drift eliminators provided that no more than one layer of clean fill is placed on top of installed drift eliminators A CAUTION When removing fill media note the location of scale dirt and debris within the fill media from top to bottom i e top layers of fill contained show
42. at least 1 above and 6 horizontally away from heater For best performance probe should be placed between 3 and 6 below water level 3 Heater must be positioned at least 2 above floor of Perimeter Basin Wall and at least 2 from each Perimeter Basin Wall for circulation For best performance heater should be placed midway between Perimeter Basin Walls Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 100 of 130 TTXL Series Installation Operation and Maintenance Manual lt AD Tower Outperform Optional Immersion Basin Heater Start Up and Annual Maintenance Once installation is complete verify proper operation a b c d Check all mechanical and electrical connections to ensure they are tight Make sure all other system components are installed and ready to operate Follow the instructions in the basin heater user s manual Once proper operation has been verified ensure all jumpers and or test resistors are removed and permanent wiring is installed and tightened Optional Immersion Basin Heater Troubleshooting Startup and Maintenance Procedure DANGER Possibly dangerous voltages are present in the equipment Disconnect electrical service at the source and tag circuit out for maintenance before servicing A CAUTION Troubleshooting should only be performed by qualified personnel a b d e Perform a visual inspection of the syst
43. gt Tower TECH Ul Installation Operation and Maintenance Manual TTXL Series Modular Cooling Tower Tower Tech Inc 5400 N W 5th Street Oklahoma City Oklahoma 73127 USA TEL 405 290 7788 FAX 405 979 2131 Sales TowerTechInc com Service TowerTechInc com www TowerTechInc com Y Tower Teca Outperform Table of Contents Chapter One About This Manual 1 1 lor eed 1 2 M ccm 14 Customer Service Support Chapter Two TTXL Series Features 2 1 Model Nomenclature 2 2 Modular Design eR 2 3 2 4 Make Up Connection Float Valve 2 5 Rotary Spray Nozzle beendet redet tete 2D MOTOTS 2 7 com 2 8 F n ONG bU v 2 10 Drift 2 11 Safety Point Brackets bnt 2 12 Power and Control Wiring eese Chapter Three Materials of Construction 3 1 Bac Euro me eee mee ee ete er Co nee RO Lm Bd o Towet Walls 21 Tower Tech Modular Cooling Tower 9000 12 TTXL Series Installation Operation and Ma
44. out the motor fan to be worked on 2 Open fan guard 3 Remove fan 4 Disconnect electrical wiring and conduit 5 Support the weight of the motor 6 Loosen the four bolts that connect the motor to the base plate and remove any shims making note of their placement 7 Remove the connecting bolts while holding the motor steady 8 Slowly lower the motor to the ground CAUTION If any of the wire supplied with a fan motor junction box or safety disconnect requires replacement use replacement wire of the same gauge and type To install a motor reverse the above procedure 10 1 9 Fan Motor Lubrication Standard motors on TTXL Modular Cooling Tower have sealed bearings If the tower is not operated regularly for an extended period of time the motors should be turned on briefly once each month Refer to Table 11 10 1 10 Mechanical Float Valve To remove the float valve Remove sump lid and circular access plate 2 Remove ball and rod assembly from the adjusting arm 3 Using proper sized wrench unscrew the valve from the threaded flange Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 117 of 130 TTXL Series Installation Operation and Maintenance Manual 44 Tower TECH Outperform To install the float valve 1 Attach valve to threaded flange 2 Valve outlet must be pointed straight down 3 Screw rod and float to adjusting arm 4 Adjust float for desi
45. some tower module sizes contact Tower Tech engineering manager for specifics Flows lower than 100 GPM 6 5 LPS are never allowed Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 14 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform Variable Flow Advantages Conventional water distribution in cooling towers sacrifices valuable energy saving opportunities This fact is even more pronounced in today s water filming style heat transfer media The efficiency of evaporative heat transfer is affected by the air to water contact area and the mass flow liquid to gas ratio In general for a given heat load and water mass flow rate the more surface area involved the less required air velocity over the water surface and consequently the less air moving fan horsepower If lower KW ton is desired one must purchase more air to water contact surface area Film media such as the popular PVC cross fluted corrugated film block provided a breakthrough in cooling tower design It greatly increases the contact surface area without increasing the size of the tower box Adversely it suffers quickly from scaling and biomass fouling in very compact air channels that negatively impact the flow of air Precise water treatment is required to prevent bio growth fouling and the fill must remain wetted to avoid evaporative scaling Conventional water distribution uses fixed orifice spray nozz
46. tight amp secure LE o All Heater Element Conduit Openings are Sealed Pump Flow Interlock Installed Prevents Heater Operation with Flowing Water Electrical Energizing Verify that Heater Elements Do NOT Energize with Flowing Water oO Verify that Heater Elements Do NOT Energize without water in Basin Verify Amp draw of Heater Element Li Follow all procedures Basin Heater O amp M Manual oO E Comments Start up Inspector Printed Name Signature Company Phone Cell Email Customer Company Signature Date Email Printed Name Office Phone Cell Fax er Tech Inc JO N W 5th Oklahoma City Oklahoma 73127 USA Effective Main 2 Serv ice TowerTechinc com Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 76 of 130 TTXL Series Installation Operation and Maintenance Manual i Tow ER Outperform 5 e Tower TECH Avere Tower Start up Warranty Registration Owner Operator Training Checklist sketch or insert pictures of cooling tower installation ELEVATION OF TOWER amp SURROUNDING BUILDING EQUIPMENT Include Measurements PIPING DETAILS COMMENTS a Tower Tech Inc 5 of 25 sin Tel 788 Service TowerTechInc com Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 77 of 130 TTXL Series Installation Operation and
47. 0 12 11 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform Each Tower Tech modul is equipped with a terminally mounted outlet sump shown in Figure 6 that is flanged for easy hook up Standard equipment for each sump includes a threaded make up water connection a mechanical float valve a flanged overflow equalization connection and a sump screen to collect large pieces of debris that may have entered the system Sump flange sizes vary depending upon the cooling tower model selected Table 10 lists typical connection sizes for TTXL Series Modular Cooling Towers 24 Make Up Connection Float Valve The TTXL Series Modular Cooling Tower can be supplied with either a one or two inch brass float valve see Figure 7 or no mechanical make up assembly when using an electronic level control or remote sump application The fitting is Female National Pipe Thread FNPT valve components are made of brass or stainless steel The connection flange is made from high quality plastic to eliminate corrosion The maximum rated operating pressure for the valve is 25 psi 1 76 kgf cm You must install a pressure reducer valve if operating pressure exceeds 25 psi 1 76 kgf cm The make up water piping should contain an anti siphon breaker device before the sump connection Refer to local codes for details INTERIOR e SUMP WALL MAKE UP L WATER VAL
48. 00 GPM and above 320 GPM NOTE Tower module hydraulic limits may be exceeded if nozzle is operated above 300 GPM consult Tower Tech engineering manager before attempting operation above 300 GPM per nozzle Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 110 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform STAINLESS STEEL ASSEMBLY BOLT SS WASHER SS SPRING CN NU Lu NC pes NOZZLE BOTTOM SS LOCKING NUT SS WASHER NOZZLE HEAD SS LOCKING NUT 49 poe Figure 43 Exploded View of Rotary Spray Nozzle NOZZLE ROTOR DANG The Rotary Spray Nozzle uses a compressed spring Attempting to disassemble the Rotary Spray Nozzle may cause serious injury Tower Tech sells replacement Rotary Spray Nozzles as complete assemblies only Disassembly of Rotary Spray Nozzle voids nozzle warranty To remove the Rotary Spray Nozzle 1 Expose the Rotary Spray Nozzle by removing the drift eliminators that restrict access 2 Remove the section of fill media directly below the Rotary Spray Nozzle 3 Remove the small set screw in nozzle head that locks the Rotary Spray Nozzle in place 4 Using a strap wrench unscrew the Rotary Spray Nozzle 5 Individual Rotary Spray Nozzle components not sold separately Disassembly of Rotary Spray Nozzle voids nozzle warranty Tower Tech Modular Cooling To
49. 015 MK9000 12 Page 84 of 130 TTXL Series Installation Operation and Maintenance Manual 10 11 12 Tower TECH Outperform Open inlet water valve s to the module s approximately fifty percent 50 open and start one pump Allow the system to operate until the sump float valve s closes to allow the make up water to replenish the water removed from the basin s by the pump If the pump surges shut off the pump close the make up valve s and adjust the sump float valve s to a higher setting Repeat Steps 1 through 3 Open the inlet valve s to the module s to the full open position and start the second pump Repeat Steps 3 through 5 Start remaining pumps one at a time by repeating Steps 3 through 5 Verify the operating level in the module s is within the specified range after the system has equalized Shut off one pump Open drain valves on pumps to simulate evaporation When sump float valve s on module s opens shut off second pump Shut down remaining pumps one at a time as the sump float valve s opens Close pump drain valves Check sump water level for overflow If the sump overflows shut off the make up valve lower the float valve setting and repeat Steps 1 through 11 8 3 3 VFD Pump Operation Procedure To balance the water level in a VFD pump system 1 the make up valve s to the module s to the full open position 2 Open inlet water valve s to the module s
50. 2 Page 67 of 130 TTXL Series Installation Operation and Maintenance Manual g Tower TECH Outperform JoB NUMBER MODEL NO TOWER OF SuMP PARTS PACKING CHECKLIST Leg Kit Used to connect the 1 2 4 6 8 legs to the bottom of the Base Support the 4 corners of the cooling tower Part amp Quantity I 16 1 X 2 1 2 SS Bolts 16 1 SS Nuts 32 1 SS Washers 8 2 4 x 4 x 64 1 4 FRP Brace Part amp 12 1 X 2 1 2 SS Bolts 12 1 SS Nuts 24 1 SS Washers Sump Kit Used to connect the Sump Box to the flange o C Pa ee re Rm 1 Sump Box Size Circle Size 1 Makeup Flange Circle Size 1 Overflow Flange Circle Size 1 Sump Split Ring 2 Pcs Circle Size 8 1 8 Black Plastic Float Ball Provide only for Makeup Valve 1 10 Brass Stem Provide only for Makeup Valve 22 1 2 x 2 SS Bolts 22 1 2 SS Nuts 44 1 2 SS Washers 4 3 8 SS Nuts 8 3 8 SS Washers 8 3 8 SS Neos 2 FRP Sump Spacers 12 SS Sump Screen 1 Tube Clear Silicone aia mam 2 0 x 1 Large Sump Gasket Comments 0 5027 1 Effective 12 24 03 Figure 33 Sump Parts Packing Checklist Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 68 of 130 TTXL Series Installation Operation and Maintenance Manual 44 Tower TECH
51. ACER 4 EA COOLING TOWER BASIN WALL SUMP FLANGE FACTORY ATTACHED 3 8 SS HEX NUT 3 8 NEO WASHER 8 x2 x 1 2 FRP BACKER 2 EA 1 2 x 2 SS HARDWARE SUMP FIELD INSTALLED 22 EA LARGE SUMP FLANGE GASKET FIELD INSTALLED 3 8 SILICONE BEAD FIELD INSTALLED OUTLET FLANG BACKER PLATE Figure 27 Sump Installation Detail Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 62 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 7 2 Piping Connections Standard piping connection locations on a TTXL module are illustrated in Figure 27 Standard dimensions are noted in Table 10 A description of each connection and its related function follows INLET FLANGE MAKE UP CONNECTION 6 EQUALIZER OVERFLOW FLANGE DISCHARGE FLANGE Figure 28 Standard Piping Connections Connections inches TTXL Inlet Outlet Make Up Overflow Equalizer Model Diameter Diameter Diameter Diameter 12 gt N The make up valve located inside the sump box is designed to operate with an inlet pressure of 25 psi Install a pressure reducing valve if local supply pressure exceeds 25 psi TTXL 12 has two sump boxes with 12 outlets however only the first sump box make up and overflow equalization connection is needed The second sump box wil
52. AUTION Waterproof type connectors MUST be used so that water and moisture cannot be drawn into the box or panel when connecting electrical power and control wiring to a junction box or control panel Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 29 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform Figure 13A Standard NEMA 4X Junction Box Optionally available are rotary disconnect switches comprised of NEMA 4X enclosures with auxiliary contacts for remote monitoring refer to Figure 13B Figure 13B Optional Rotary Type NEMA 4X Lockout Disconnect Switches Itis important to follow the pre wire sequence of the motors to the rotary disconnects as defined in tower submittal drawings The order of each motor wiring is critical when connecting to motor starters to insure proper sequence and operation of the motors The Tower module can be pre wired to pigtails length to be specified for onsite connection by others to electrical equipment refer to Figure 13C Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 30 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform Figure 13C Pre wire to Pigtails Chapter Three Materials of Construction 3 1 Background The Tower Tech TTXL Series Modular Cooling Tower is factory pre assembled
53. Circle One With Temp Without Temp Provided only for Temperature Controller Note If a box is marked B O for back order on any item contact the Tower Tech Shipping Dept Manager 405 979 2125 for the status of the B O shipment All items shipped by Tower Tech have been inspected and counted prior to shipment All request for missing or incorrect items must be reported on this form by fax within 24 hours of delivery All request after the 24 hour period will be handled on a billable basis Comments TOWER TECH The Technology Company MODEL MANUFACTURED UNDER U S PATENTS 5 227 095 5 143 657 5 152 458 5 487 849 5 487 531 5 545 356 5 958 306 Other Patents Pending Tower Tech Rotary Spray Nozzle SmarTTower and Water Drop Logo Are All Trademarks of Tower Tech Inc Tower Tech Inc P O Box 891810 Okla City OK 73173 Phone 405 290 7788 QCS5029 0 Effective 04 22 03 Figure 33 Sump Parts Packing Checklist Continued Tower Tech Modular Cooling Tower 9000 12 TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 70 of 130 a gt Tower TECH Outperform The assistance of a factory certified startup technician is required to help ensure initial startup of TTXL Series Modular Cooling Tower is performed in accordance with factory procedures Factory authorized startup is mandatory for warranty validation Factory c
54. FNPT 2 far za d eo RR nd n ont i21975 112 7 5 380 15 0 300 167 e vs 206 67 201 73 219 mu 22 es ELE saos sos 460 5 62 18 3 i31950 37 111 50 a nad 460 8 f 27 6 200mm 8 e in TFNPT 4 200mm 25mm 100mm 10 200mm 250mm 10 250 eo a N 16 7 13 8 50 1 41 4 29 2 ss 15 450 ss ve 2s ae sss 258 22 so o ss 101 404 141950 14 8 20 0 Hatata ofe coo wr sw so er 22 56 224 62 ma 101 aoa 42 rijg Paso 332 92 ss D N tw 2 FNPT 50mm 2 FNPT 50mm 6 150 6 150 rx A HP FLA SFA MMC SFA MMC 1 Outlet Makeup Overflow Fans Fan Module Module Module Dia Dia Dia 10 250mm i51930 8 10 2 FNPT e Ax 200mm 250mm 50mm 150mm 151975 gt o2 44444 10 2 FNPT 250mm 50mm ms 67 2 73 48 ipie pw ao Ea ee OR RE 2 FNPT 50 6 150mm 6 150 6 150mm 1 ws E Bs HEU os o2 52 200mm Em ss aso were 900 102 ws 22 176 30
55. RU BASIN DRAINAGE HOLES IN PRIMARY CHANNEL OF FLOW THRU BASIN Figure 50 Flow Thru Basin Drainage Perimeter Basin Wall Secondary Drainage Channel Drainage Holes Each end of a secondary drainage channel has a drainage hole or notch located between each pair of end caps The drainage hole allows any water flowing in a secondary channel to escape into the perimeter basin beam These holes are hidden from view and can only be felt by hand If a secondary channel s hole or notch becomes plugged by scale dirt or debris water may overflow the secondary channel into the fan area Refer to Figures 48 and 49 Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 123 of 130 TTXL Series Installation Operation and Maintenance Manual v Tower TECH amp Outperform N Figure 51 TTXL See Through View of Tower Basin Wall Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 124 of 130 TTXL Series Installation Operation and Maintenance Manual a gt Tower TECH Outperform CAUTION The ends of Secondary Drainage Channels have been plugged with caulking material at the factory to prevent water leaks If the caulk is removed air moving rapidly within the Perimeter Basin Wall can force water flowing in the Perimeter Basin Wall to flow into the Secondary Drainage Channels quickly filling them to capacity and causing them to overflow Use care when cleaning Secon
56. SHER PROVIDED BY OTHERS 2 3 4 69 9mm x 2 3 4 69 9mm SQUARE WASHER 2 WITH 1 1 8 28 6mm HOLE p PROVIDED BY TOWER TECH ANCHOR BOLT MUST EXTEND AT LEAST 5 1 2 139 7mm ABOVE BOTTOM OF FOOTPAD CONCRETE SLAB OR OTHER MOUNTING STRUCTURE BY OTHERS 7 2 SUBSTRUCTURE LEG amp FOOTPAD Figure 24 Installation Detail for Sub Structure Footpad Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 55 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform Chapter Six Rigging and Handling DANG The lifting points are integral to the tower structure Damage to the tower caused by improper lifting invalidates the cooling tower warranty 6 1 Introduction Factory assembled TTXL Series Modular Cooling Towers shipped on flatbed trailers should be lifted directly from the trailer to the final point of installation Sub structure kit motor control panel sump and sump hardware are shipped on a separate pallet on the same trailer as the tower module Optional accessory equipment will be shipped on separate pallets Refer to Table 9 The owner shall be responsible for lifting and placement of the tower Owner shall furnish all incidental materials required for location of tower in its final position All work shall be in accordance with requirements of local municipal governing authorities and all U S Occupational Safety
57. TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform T Y Figure 32 Typical Overflow Equalization Piping for large tower installations with Electronic Level Control Tower Tech recommends installing additional overflow pipe on multiple tower installations An overflow pipe should be installed for every 4 modular towers LJ i Keep all vents clear and open Stand Pipes must be heat traced and insulated in cold climates Chapter Eight Tower Start Up A CAUTION In addition to the tower module s standard sump screen it is recommended that an additional fine mesh construction start up screen be used during initial cooling tower start up and after every service event Placing this additional screen on top of the tower module s standard sump screen will help prevent any debris that may have entered the cooling tower during manufacture shipment storage installation or service from being ingested into heat exchangers and other downline equipment Monitor the construction start up screen for cleanliness approximately once hourly until satisfied that water stream is clear of debris Clean and replace construction start up screen as needed To ensure all required parts are shipped with each TTXL Series Modular Cooling Tower Tower Tech s Shipping Department uses a Sump Parts Packing Checklist Refer to Figure 32 Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 1
58. The Perimeter Basin Wall serves as both a structural member and a cold water reservoir Walls are joined vertically by tongue and groove joints and are sealed using a polyurethane adhesive vibration dampener and sealant to prevent leaks Transversal Perimeter Basin Walls are joined to longitudinal Perimeter Basin Walls using a fiberglass Corner Enclosure that provides further structural and sealing integrity to the tower box Stainless steel fasteners are used to bolt the walls together and to join them to the Corner Enclosures Coated stainless steel fasteners are employed in areas where water hold up occurs Refer to Table 5 for details on wall design specifications Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 31 of 130 TTXL Series Installation Operation and Maintenance Manual D Tower TECH Outperform Attribute Specification Material Composition Fiberglass Reinforced Plastic Isophthalic Resin Manufacturing Process Pultrusion Material Thickness 6 35mm min Material Thickness 10 12 7mm min Corner Enclosure amp Substructure Flame Spread Rating 94 0 Flammability Classification UL 94 Smoke Rating 650 ASTM E662 Self Extinguishing Yes ASTM D635 UV Inhibitor Yes UV resistant fiber layer employed Table 5 Wall Data 33 Fan Shroud The fan shroud used on TTXL Series Modular Cooling Towers refer to Figure 10 is made using a hand lay up process uti
59. Tower Tech stocks most tower parts for immediate shipment For further information contact a Tower Tech Customer Service Representative at 405 979 2123 or Service TowerTechInc com Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 128 of 130 TTXL Series Installation Operation and Maintenance Manual lt Tower TECH Outperform Chapter Eleven Appendix Description Section TTXL 3 D Cut Away View TTXL versus Conventional Induced Draft Cross Flow Tower TTXL versus Conventional Induced Draft Counter Flow Tower TTXL Series Modular Cooling Tower Installation Water Collection System Flow Thru Basin Mid Basin Motors Fans Sump Layout Mechanical Float Valve Motor Motor Support Fan Fan Shroud Typical 6 Bladed 9WR Fan Fan Shroud Safety Point Bracket Typical Wiring Layout Standard NEMA 4X Junction Box Optional Rotary Type NEMA 4X Lockout Disconnect Switches Optional Pre Wire to Pigtails Tower Sub Structure Typical T9900 Motor Control Panel T2100 Motor Protection Panel Immersion Basin Heater and Sensor Probe Location Ultrasonic Liquid Level Sensor Location Sump Detail with Electronic Level Control Sensor Equalization Overflow Pipe Detail No Ultrasonic Level Sensor Sump Detail No Ultrasonic Level Sensor Dimensional References Multi Tower Layout and Piping Recommendation Installation Detail for Sub Structures Taller Than One Foot 30 5 cm Installation Detail for One
60. UCTURE HARDWARE FRP TUBULAR BRACE SUPPORT BOLTED TO SUBSTRUCTURE amp TOWER AT JOB LOCATION BY OTHERS FRP TUBULAR BRACE SUPPORT BOLTED TO SUBSTRUCTURE amp TOWER AT JOB LOCATION BY OTHERS 1 x 6 P SUBSTRUCTURE HARDWARE FIBERGLASS LEG ASSEMBLY BOLTED TO TOWER AT JOB LOCATION BY OTHERS SOME HARDWARE NOT SHOWN FOR CLARITY Figure 14 Tower Sub Structure Tower Tech offers a pultruded fiberglass substructure connected to each corner of the tower module Refer to Figure 14 When installed on Tower Tech sub structures up to 8 feet 243 8 cm in height the TTXL Series Modular Cooling Tower is certified to withstand 200 mph 41 psf 241 4 KPH 200 KSM wind load and to resist certain seismic forces The sub structure anchors to steel concrete piers or to a concrete slab Braces attach to the Perimeter Basin Walls to provide rigid support Cooling Tower with sub structure is OSHPD certified As a general rule increased leg height will improve tower performance by increasing the air inlet area Use higher sub structure leg heights if obstructions adjacent to the tower reduce airflow to the tower Sub structure leg heights of 6 foot 182 9 cm and 8 foot 243 8 cm are the most common For air inlets above 12 high the preferred method of installation is with 1 foot 30 5 cm sub structure legs stub legs that mount on top of a raised pier or steel Sub structure kit includes e Pultruded fiberglass legs
61. VE l or 2 FPT MAKE UP WATER CONNECTION BALL ADJUSTMENT LOCKING NUT P d _ STEM GASKET 8 POLYPROPYLENE 77 FLOAT BALL Figure 7 Mechanical Float Valve Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 12 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform 5 2 5 Rotary Spray Nozzle Tower Tech s patented variable flow Rotary Spray Nozzle disperses water from the water distribution piping to the fill media nozzle requires less pressure to operate than conventional nozzle is virtually maintenance free and improves tower performance The Rotary Spray Nozzle requires less pressure head to operate than a conventional nozzle by combining a low profile spray pattern with a low pressure orifice Use of a lateral spray pattern allows the nozzle to be positioned as close as one inch above the surface of the fill material saving several feet of pump head In addition the use of a turbine in the nozzle to atomize the flow is much more efficient than the atomization approach used in a conventional nozzle Debris that typically clogs conventional nozzles will pass directly through the Rotary Spray Nozzle This is accomplished by the 4 10 16 cm nozzle throat inlet coupled with the brisk rotating agitation action provided by the nozzle s turbine which spins on a water bearing inside the nozzle The water bearing minimizes wear of nozzle compon
62. acity of the fill media is 25 lbs per square foot during tower operation Occasional inspection of the fill surface area to assess fouling is recommended to assure that this bearing capacity is not exceeded Attribute Fill Media Specifications 19mm Cross Fluted Fill Sheet Thickness nom 10 mil std 15 mil opt Material PVC std HPVC opt Standard Fill Log Length 72 in 1800 mm Standard Fill Log Depth 12 in 300 mm Standard Fill Log Width 12 in 300 mm Surface Area 48 Flame Spread Rating 5 ASTM E 84 UV Inhibitor Yes Table 3 Fill Media Data 2 10 Drift Eliminators The TTXL Series Modular Cooling Tower utilizes a low pressure sinusoidal shaped drift eliminator that provides three distinct changes in flow direction to enhance the drift capturing capability of the drift eliminator The PVC material is virtually impervious to rot decay or biological attack An ultraviolet inhibitor manufactured into the product extends the life expectancy Refer to Table 4 for drift eliminator data Attribute Specification Sheet Thickness nom 10 mil std 15 mil opt Material PVC std HPVC opt Standard Module Length Standard Module Depth 36 in 900 mm 5 5 in 139 7 mm Standard Module Width 12 in 304 8 mm Forced Directional Changes 3 Drift Loss 0 0004 or less EPA 13A Flame Spread Rating 15 ASTM E84 UV Inhibitor Yes
63. actory applied caulking material out of the end of the secondary channel Doing so will damage the Water Collection System and result in leaks 5 Use care to avoid cracking or otherwise damaging a damper or collector vane when removing or installing a damper After installing a damper make sure it opens and closes fully and freely 6 Re seal all end caps and areas where sealant may have been removed during your work to prevent leakage Note that during the cleaning process the membranes of sealants and caulks may be breached and may contain small holes that are not easily seen Always use factory approved sealants and caulking materials 7 Reinstall the fan if it was removed and fan screens in their correct operating positions 8 Remove your lock tag from the control panel or cooling tower 9 Check for proper operation of each fan and motor and visually observe each damper for correct operation To access and perform service on the upper section of the Water Collection System 1 Shut off water to from tower module 2 Access to the interior of the tower module is through the top of the module Remove the drift eliminators over the area of the Water Collection System to be accessed Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 126 of 130 TTXL Series Installation Operation and Maintenance Manual 1 Tower TECH Outperform DANGER Do not walk on drift eliminators as they
64. ady with quantum shield wiring class H insulation minimum Motors meet NEMA MG 1 Part 31 requirements for inverter duty use Metric dimensions approximate Flow rates above 2 700 gpm require engineering review and may require two sump containers TTXL 12 requires two sump containers See TTXL 12 drawings for details Tower Tech Modular Cooling Tower 9000 12 TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 20 of 130 j TowER Outperform Engineering Data Model i21922 i21937 i21956 131922 131937 131956 41922 41937 41956 041922 041937 041956 Fan Motors 3 Phase 50 Hz 40 C 190V 380V ERE 572 67 2 di Poo ves sea m es z2 31 5 190 286 858 33 6 100 8 16 8 7 5 81 5 700 14 3 429 16 3 SE SIE ws 2 63 ELE Gm ME M m 2 es 72 OCENE EE n Fase pe Connections TTXL kW d HP FLA FA MMC SFA MMC aoe Overflow Fan Module Module Module Fan Module Dia 1 FNPT 4 25mm 100mm 1 FNPT m 25mm 10 27 FNPT 250mm 50mm e 100mm e 150mm e 150mm 151922 151937 151956 i 380 14 3 572 16 3 65 2 190 12 4 62 0 13 6 68 0 11 0 sm 62 sto 68 s 1 188 940
65. al that the tower be routinely treated with appropriate biocidal control agents specifically designed to control the proliferation of Listeria Experts agree that oxidizing biocides chlorine hypochlorites hydantoins chlorine dioxide sodium bromide with chlorine and ozone are the most effective control agents and should be used at a level sufficient to maintain a 0 5 ppm minimum residual chlorine level at all times CAUTION The tower should be located well away from and downwind of building air intakes to further reduce the potential for aerosol to enter buildings Under no circumstance should a tower be operated without drift eliminators in place and intact It is best to combine a non oxiding and an oxidizing chemical into your cooling water treatment program Generally the oxidizing biocide chlorine or bromine based technologies is administered continually so as to maintain a specific system concentration whilst the non oxidizing chemical DBNPA Quats glutaraldehyde isothiazoline is slug fed at pre defined time intervals Use of both allows for synergisms between their modes of action as well as assurance that an antimicrobially resistant sub population will not occur It is also recommended that a penetrant or biodispersant see fouling section be used in conjunction with the biocide program to enhance the ability of the oxidizing biocide to contact target microbes This is particularly important if the tower is a process tower
66. allation Operation and Maintenance Manual Tower TECH Outperform 4 4 Immersion Basin Heater Tower Tech offers an optional pre engineered basin heater package for TTXL Series Modular Cooling Towers Each package includes Standard stainless steel electric immersion heater UL listed control panel in NEMA 4X enclosure Water level and temperature sensor probe Wiring diagram Installation and operating instructions Required flange fittings for probe and heater pre installed into tower A CAUTION The immersion basin heater is intended to prevent icing of only the basin water when the tower is not in operation SENSOR PROBE HEATER ELEMENT Figure 17 Immersion Basin Heater and Sensor Probe Location For winter operation Tower Tech offers an optional immersion basin heater with a corrosion and liquid proof enclosure The control unit is a combination controller and probe temperature and water level sensor preset to 45 F 7 2 C control panel contains the electronic temperature flow liquid level control control voltage transformer and the magnetic contactor Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 40 of 130 TTXL Series Installation Operation and Maintenance Manual AD used to energize and de energize the heater s The control panel is UL rated NEMA 4X and can control up to four heating units however the heater elements must be located within the same wa
67. amp Health Administration safety guidelines The accompanying lifting diagrams and procedure are for general information purposes only and owner shall have full responsibility for the work CAUTION Do not lift a tower without first removing excess water rainwater snow melt ice from the cooling tower basin which can drastically increase tower weight and cause an imbalance Lift tower slowly to insure one end doesn t tip forward and damage tower CAUTION tower operations must be performed as specified by a site specific safety plan which is the responsibility of the customer Only qualified experienced personnel should perform rigging Use lifting equipment properly sized for the unit being lifted Do not attempt to lift a module during high winds or inclement weather DANGER Inspect each tower module s lifting hardware prior to lifting tower to check for shipping damage and security of lifting hardware Never lift a tower module if its lifting hardware is cracked or loose as damage to the tower may result Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 56 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 2 Accessory Location Checklist Accessories will always ship on pallets and be shipped with the cooling tower unless there are specific request for drop shipping Packaging of accessories will depend on type of accessory the
68. ate Service completed as required 10 1 1 Drift Eliminators TTXL Series Modular Cooling Towers utilize a low pressure three pass drift eliminator that is impervious to rot decay or biological attack An ultraviolet inhibitor is manufactured into the product to extend life expectancy Drift eliminators however should be inspected once a year in conjunction with the nozzle inspection The drift eliminators should be free from any build up of mud or debris If cleaning is required the following procedure should be followed 1 Remove the drift eliminators Place gently on an elevated platform or on the ground 2 Wash the eliminators by spraying with a low pressure water hose 3 Turn the eliminators over and spray until remaining debris is removed 4 Insert the eliminators back into place in the cooling tower Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 109 of 130 TTXL Series Installation Operation and Maintenance Manual D Tower Outperform 10 1 2 Fill Media CAUTION Distribute personnel weight loading on the fill media by placing a flat surface such as a piece of plywood atop the fill media to prevent damage to the fill and Water Collection System while walking on them Inspect the cooling tower fill media regularly depending on the quality of the water being circulated A typical inspection includes removal of pieces of fill media from all fill layers starti
69. aximum water velocity of 6 ft s to prevent excessive suction leading to potential pump cavitation Velocities of 5 ft second or less are preferred Refer to Figure 29 for a detailed view of the discharge flange and its accompanying split ring It is recommended that a shut off valve be installed in the discharge pipe to regulate flow from each module Tighten bolts to 30 ft Ibs Figure 30 Discharge Flange and Split Ring Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 65 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 5 7 2 3 Make Up Connection The standard make up connection is located on the top left corner of the front of the sump Apply Teflon tape to the threads of the make up piping before inserting it into the connection flange to prevent leakage When supplied the make up valve located inside the sump box 15 designed to operate with an inlet pressure of 25 psi Install a pressure reducer if local supply pressure exceeds 25 psi 7 2 4 Overflow Equalization Connection The 6 overflow equalization connection is located on the bottom right corner of the front of the sump Note 2 fan and 3 fan tower modules have a 4 overflow equalization connection In a single module application this connection serves as a basin overflow line In a multi cell application this connection serves as a flow level equalization line as well as a 6 overflow
70. ce of Ye Y BASIN HEATER conventional air inlet louvers and with its EE enclosed design and optional ability to stage fans on and off automatically can often operate in cold weather without significant ice formation However it is Si e recommended that VFD be used in lieu of fan staging to reduce air velocity through the cooling tower and thereby lessen the pt possibility of ice accumulation that could PaL damage the fill media the Water Collection N STNDHRD CORD LENGTH 15 18 OPTIONAL LENGTHS He Suse CONTACT TOWER TECH S SALES System the tower structure and other DEPARTVENT FOR INFORMATION components Figure 40 Basin Heater Control Panel Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 92 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform Maintaining water flow of 200 minimum through each Rotary Spray Nozzle and adhering to the other recommendations in this Chapter when the ambient air temperature is at or below freezing will maintain sufficient heat in the tower module to prevent accumulation of inside or under the tower It is recommended that a Tower Tech factory engineer be consulted about cold climate operations and for other design assistance Variable frequency drives are especially beneficial in preventing tower icing in areas where the ambient ai
71. control panel to plumbing or piping equipment as vibration could cause damage to internal components CAUTION power and motor wiring conduits are to enter and exit the control cabinet at the bottom of the control cabinet Penetration of the top or sides of the control cabinet will void the electronics warranty CAUTION control wiring conduits are to penetrate the control cabinet on the bottom of the control cabinet as close to left hand side as space allows The optional T9900 control panel is available with a Programmable Logic Controller PLC that is programmed to cycle the cooling tower fans to maintain the desired cold water temperature set point entered by an operator through the cover mounted interface LCD panel The PLC can supply an intermittent 4 20 milliamp signal to control an external variable frequency drive VFD The PI D loop being used by the PLC or VFD should be fine tuned for tight control of the exiting cold water temperature in maintaining temperature set point Fans cycling or ramping constantly up and down indicate o The PI D Loop being used by the PLC or VFD should be fined tuned to maintain tight control to the cold water temperature set point Fans cycling or ramping constantly up and down indicate oscillation of the control loop or hunting that can damage motors and potentially void the motor warranty Once the PLC is fine tuned the control loop should maintain a consistent output with tig
72. ction of rotation of the fan with fan operating before removing the fan guard screen 2 Lock out tag out the electrical power supply to the fan motors 3 Remove the fan guard screens from the cells to be worked on 4 Tower Tech fan blades for the TTXL series cooling tower have a set pitch blade that is fixed by the index tab key Pitch should not be adjusted without authorization from the factory When changing blades use the same index tab key to insure proper pitch 5 Remove the fan assembly from the motor 6 Record the location and quantity of all balancing washers and nuts holding the hub shell together along with the individual fan blade location on the hub so that you can return all of the parts to their original location 7 Remove the center Uniboss center hub from the fan shell marking the orientation first 8 Remove the bolts that hold the fan shell halves together Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 115 of 130 TTXL Series Installation Operation and Maintenance Manual 10 11 12 13 14 15 16 17 18 19 Tower Outperform Carefully separate the fan shell halves by removing the upper half to expose the fan blades Locate the index tab on the fan blade exchange with new index tab for the new pitch angle Fan Pitch is determined by which index tab is installed to achieve the correct setting Once the pitch is establis
73. d should be replaced 4 Remove the test resistor and jumper wire reconnect the sensor cord 5 Make sure the liquid level is adequate and at a temperature of 40 or below The green LED light should be ON the red LED light should be OFF and the contactor s should be energized If they are not the cord and sensor are faulty and should be replaced f When the tests are completed and proper operation verified ensure all jumpers and or test resistors are removed and permanent wiring is installed and tightened 2 Replace control panel enclosure cover DANGER Dangerous voltages are present in this equipment Disconnect electrical service of source and tag circuit out before servicing or replacing components Optional Immersion Basin Heater Repair None of the control components are repairable Remove and replace any failed components Optional Immersion Basin Heater Maintenance The system should be inspected annually just prior to the heating season a Visually inspect the system components for physical damage overheating loose connections leaks etc Service as required b Physically check that all wiring insulation is sound and that all wiring connections are tight Repair and tighten as required c Check operation d Maintain proper water quality per recommendations of your water treatment consultant A high chlorine content and or deposit build up on the element tubes may reduce heater life Correct wate
74. dary Drainage Channels and Drainage Holes Do not attempt to force debris from the ends of a Secondary Drainage Channel as doing so may inadvertently dislodge caulking material which helps prevent leaks e Dampers Installed between collector vanes on the bottom of the Water Collection System dampers are designed to open automatically when the fan beneath it is turned ON and to close automatically when the fan beneath it is turned OFF Dampers thereby help contain airborne water drops inside the Water Collection System Dampers require periodic visual inspection to ensure they are opening and closing fully and freely Refer to Figure 41 e Flow Thru Basin Primary Drainage Holes in the Perimeter Basin Wall allow cooled water exiting the Water Collection System to flow into the Flow Thru Basin Refer to Figures 41 42 and 43 e Flow Thru Basin Secondary Drainage Holes in the Perimeter Basin Wall allow any water that escapes primary containment within the collector primary drainage channels to be channeled back into containment within the perimeter basin beam Refer to Figures 42 and 43 To access and perform service on the bottom section of the Water Collection System 1 Disconnect the power to the fan by locking out and tagging out the appropriate motor 2 Open the fan screen remove fan from motor shaft if necessary 3 If a Damper does not fit properly or is sticking remove the damper from the secondary channel Each Damper is h
75. djacent pairs Fans are cycled OFF in reverse order with the fans farthest from the sump end stopping first last on first off Failure to cycle fans in this order will result in water blow by and water leakage above the off line fans nearest the sump end of the tower When operating the tower module with a variable frequency drive VFD all fan motors should be operated all of the time at the same speed and individual motor overload protection MUST be provided Tower Tech motors operated by VFD can be ramped down to a minimal speed of 6hz but Tower Tech recommends a minimum operating speed of 10hz for the best efficiency and energy savings Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 90 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower Outperform For detailed description of the Optional Control Panel see Sec 4 2 For an in depth discussion of the advantages of variable flow cooling tower operation refer to section 2 5 This Manual shows and describes standard power and control wiring and operating procedures only Tower Tech will supply an appropriate technical supplement for non standard power and control wiring and operating procedures upon request 9 4 Cold Weather 9 4 1 Tower Offline During Cold Weather Any TTXL Series Modular Cooling Tower that will not be operated when ambient temperatures are at or below freezing must have elect
76. e Manual 1 Tower TECH Outperform 4 5 Vibration Control It is Tower Tech s position that TTXL Series Modular Cooling Towers do not require vibration switches because of the small motor size inherent structural stability of the modular tower and by using adhesive vibration dampening sealants for many structural connections Vibration isolators are not required or recommended on TTXL Series Modular Cooling Towers for the same reasons DANGER Should a customer wish to use a vibration switch the tower modules must be fitted with a remote method of resetting the vibration switch to ensure that the reset process does not offer a potential for injury The latter is done at owner s own risk and Tower Tech assumes no liability for damages to personnel or property resulting from the use of a vibration switch A CAUTION Vibration Isolators are not required or recommended for the TTXL Series Modular Tower Vibration isolation springs cannot be attached directly to the substructure leg and will void the warranty If specifications or code requires vibration isolation then springs must be attached below an i beam frame that all of the substructure legs attach on top of or vibration pads can be used directly below the substructure legs 4 6 Ultrasonic Liquid Level Sensor As an alternative to Tower Tech s standard mechanical float valve you may select the optional ultrasonic liquid level sensor The mechanical float valv
77. e can be installed as a back up to the electronic level controller The liquid level sensor transmitter should be mounted in a quiescent zone such as a standpipe extension located off of the tower equalization line for most accurate measurement The recommended installation and piping arrangement is shown in Figure 18A The liquid level sensor transmitter is factory calibrated to send a 4 20mA signal for accurate monitoring of the tower module water level see Figure 18B for calibration settings Tower Tech offers an optional continuous relay controller remote unit for proper operation and signal detection The relay controller will provide a signal to a solenoid valve provided and installed by others to provide adequate make up water for maintaining the required operating water level If the optional relay controller is not used the liquid level sensor transmitter must be wired to a building automation system that controls the solenoid valve provided and installed by others for proper make up water Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 44 of 130 TTXL Series Installation Operation and Maintenance Manual LEVEL SENSOR ASSEMBLY STANDPIPE W FLANGE TO RECEIVE od LEVEL SENSOR ASSEMBLY TT OVERFLOW LEVEL 2 6 BOTTOM OF COOLING TOWER Figure 18A Ultrasonic Liquid Level Sensor Location Consult the ultrasonic liquid level sensor manufacturer s user manual for details on set up ca
78. e end of each collector vane One End is also installed at the center of each collector vane Refer to Figures 47 and 48 e Spacers installed 15 apart along the entire length of each collector vane fasten the Water Collection System together Refer to Figures 47 and 48 Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 121 of 130 TTXL Series Installation Operation and Maintenance Manual s Tower Outperform OUTSIDE END PRIMARY DRAINAGE CHANNEL SECONDARY DRAINAGE CHANNELS SEALED AT BOTH ENDS SEE CAUTION NOTE BELOW INSIDE END CAP UPPER DRAINAGE NOTCH IN SECONDARY DRAINAGE CHANNEL Figure 49 Close Up View Water Collection System e Secondary Drainage Channels Located at the bottommost section of a collector vane secondary channels are designed to capture water drops adhering to the exterior surfaces of a collector vane If a secondary drainage channel becomes clogged with scale dirt or debris it is possible that some water may escape containment Secondary drainage channels should be inspected periodically both visually and by feel to ensure they are free of scale dirt and debris Refer to Figure 48 Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 122 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform DRAINAGE HOLES IN SECONDARY CHANNEL OF FLOW TH
79. e heaters are deactivated when the circulating pump is in operation Doing so provides further protection against overheating of the basin heater element and accidental fire and is also necessary for efficient control of free cooling operations For a cooling tower installation having two or more pumps it is recommended that the heater control system be interfaced to a flow or pressure switch located on the inlet piping to the cooling tower module Doing so provides further protection against overheating of the basin heater element and accidental fire and is also necessary for efficient control of free cooling operations The heater control panel contains the electronic temperature low liquid level control control voltage transformer and the magnetic contactor used to energize and de energize the heater element s The control panel may control more than one heater element up to its nameplate voltage phase and kW rating as long as the elements are located in the same tower module basin The electronic temperature low liquid level sensor probe is stainless steel with a 1 2 NPT mounting fitting It is pre connected to the control panel with a UL rated outdoor cord The sensor has an on off relay output that de energizes the heater element s whenever the basin liquid temperature is above 45 F or whenever the sensor probe is not submersed A low voltage 12 VAC is connected across the sensor probe and fitting When the probe is submers
80. e make up valve s to the module s to the full open position 2 Open inlet water valve s to the module s approximately fifty percent 50 open 3 Start pump 4 Allow system to operate until the sump float valve s closes to allow the make up water to replenish the water removed from the basin s by the pump 5 If the pump surges shut off the pump close the make up valve s and adjust the sump float valve s to a higher setting 6 Open the make up valve s to the module s to the full open position Repeat Steps 1 through 3 7 Verify the operating level in the module s is within the specified range refer to Figure 36 after the system has equalized 8 Shut off pump and check sump water level for overflow 9 If the sump overflows close the make up valve s lower the float valve s setting and repeat Steps 1 through 8 8 3 2 Multiple Pump Operation Procedure CAUTION Tower Tech cooling towers are designed for variable flow rates so pumps can be sequenced On and Off according to system load requirements In certain applications if pumps are not staged properly pump surging chiller shutdown and or water overflow into the fan shrouds could occur Allow 10 15 minutes staging between start stop of pumps to allow system time to balance water level To balance the water level in a multiple pump system 1 Open the make up valve s to the module s to the full open position Tower Tech Modular Cooling Tower Date 02 18 2
81. ectors to protect each motor against short circuit or thermal overload The manual motor protectors provide overload trip switches for lock out tag out capability of each individual motor Each manual motor protector has an auxiliary relay to monitor the fault status of each motor The NEMA 4X panel also provides a main non fused disconnect with through the door operator handle The MPP is pre wired to the motors and pre mounted on the cooling tower When a VFD is used with the T2100 MPP a temperature input device RTD can be provided that should be installed within 15 feet of the cooling tower outlet flange The RTD should be wired back to the proper terminal in the VFD for the internal PI D closed loop controller to maintain a cold water temperature set point Tower Tech recommends the VFD be equipped with auto bypass to allow across the line voltage to all motors should the VFD trip or fail CAUTION When tower module is more than 6 feet above standing level consideration should be given to service access to the T2100 MPP Options are available for shipping the MPP for field installation to comply with any applicable local state and national codes including but not limited to building electrical and mechanical codes Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 38 of 130 TTXL Series Installation Operation and Maintenance Manual lt Tower Outperform 4 4 Variable Frequency Dr
82. ed a 50 milliamp AC current passes through the conductive liquid from the sensor probe to the mounting fitting completing the circuit A break in this circuit indicates low liquid level and de energizes the heater element s Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 94 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform lt AD DANGER Use only Tower Tech approved combination temperature liquid sensor probes Failure to do so may result in accidental fire Do not cut or change the length of the sensor cable The 24 V transformer in the control panel provides control voltage for the electronic temperature low liquid level control and the magnetic contactor s The magnetic contactor s are used to switch the line voltage to the heater element s The operating coil of the contactor is energized by the output relay on the electronic temperature low liquid level control Basin heaters are factory preset non adjustable to maintain a basin temperature of 45 F Depending on the size of your cooling tower module multiple immersion heater elements may be required Locating Basin Heater Element s and Control Panel Enclosure 1 For multiple tower installations having a back to back end to end configuration where each tower requires multiple immersion basin heater elements verify that a minimum of three 3 feet of access space exists between module
83. ed no sign of scaling but the bottom layer had a slight scale residue Such information may be helpful as you discuss your tower with a water treater or with Tower Tech s customer service staff 5 Inspect the top section of the Water Collection System for scale dirt and debris and remove any scale dirt and debris by power washing 6 Reinstall clean fill media in the tower module in the same way it was installed by the factory 7 Reinstall drift eliminators 8 Turn on water to from tower module Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 127 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 10 2 Spare Parts The inherent redundancy and reliability of the TTXL s multiple fan direct drive design assures customers that tower performance and efficiency will not be materially impaired if one motor fan is offline This redundancy and reliability and Tower Tech s stock of readily available parts enable most customers to avoid stocking spare parts We recommend the following for customers that prefer to maintain a small spare parts inventory Part Description Single Module Multiple Module Installation Installation Fans Motors Rotary Spray Nozzle Table 14 Recommended Spare Parts Inventory The customer is responsible for selecting purchasing and maintaining a parts inventory consistent with its own needs
84. ed orifice spray nozzles they must remain very near design flow to provide the required spray coverage This innovation allows uniform water loading for a wide range of flow rates and significantly increases the part load performance as compared to other towers using conventional fixed orifice nozzles Refer to Section 9 4 1 Cold Weather Operations for important additional information about cold weather operations with a TTXL Series Modular Cooling Tower This uniform spray pattern is accomplished by using a spring loaded orifice plate that provides a varying cross sectional area as flow rate changes This reduces the loss coefficient as flow increases and allows the total pumping pressure of the tower to remain nearly constant from 11 13 feet or 3 4 4 0 meters of head By eliminating the extreme pressure increases associated with increased flow rates the Rotary Spray Nozzle is able to produce a much more consistent spray pattern as flow rates vary Graph 2 illustrates the change in tower piping head pressure observed at varying flow rates when employing the Rotary Spray Nozzle TOWER PRESSURE VS FLOW FT OF HEAD FLOW NOZZLE GPM Graph 2 Tower Pressure versus Flow As can be seen from the graphs above the operating parameters of the Rotary Spray Nozzle must remain between 100 GPM and 300 GPM 6 5 19 5 LPS which is the approximate upper limit established by tower module hydraulics Somewhat higher flows may be possible in
85. eld in place by an F shaped side that hinges loosely on the top of the rear secondary channel Refer to Figures 41 and 43 Always remove all dampers prior to cleaning secondary drainage channels and reinstall once cleaning is completed 4 Clean the bottom side of the Water Collection System with a power washer Clean both sides of the collector vanes all the way up to the bottom of the fill media Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 125 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform 44 AD If necessary to remove additional scale dirt and debris use a straight tool tilt the tool at a 70 80 angle to the direction of the collector vane by sliding the tool down the entire length of the secondary drainage channel and carefully guiding the tool through the end cap Locate the notch in the end of the secondary drainage channel by moving the tool gently along the bottom of the secondary drainage channel then gently dislodge any scale dirt and debris by pulling toward you and removing it or by pushing it gently through the notch located near the end of the secondary drainage channel The end of the secondary drainage channel has been sealed with caulking material at the factory removal of this material during the cleaning process will damage the Water Collection System and result in leaks CAUTION Do not attempt to push or otherwise force the f
86. ell or pair of cells in multi cell installations Tower Tech requires a professional flow balancer set and certify that flows are balanced and correct for cooling towers being started up Remove a section of drift eliminators from the top of each cell to view the water distribution Flow balancing can be simplified by using isolation valves in both the inlet and discharge piping systems of each module A typical flow balancing problem and its solution are given below using Figure 37 25 25 25 255 XI 876 SA 525 Sx a LX lt lt POO 4 lt gt NN CS Figure 38 Typical Flow Balancing Problem Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 87 of 130 TTXL Series Installation Operation and Maintenance Manual D Tower TECH Outperform Flow Balancing Problem Cell 1 L to R does not have enough water flow resulting in dry void regions Cell 2 has the correct water flow Cell 3 has too much water flow resulting in regions of overlapping spray pattern Flow Balancing Solution Close inlet valve to cell 3 slightly until cells 1 and 3 are like cell 2 It may then be necessary to re adjust cells 42 and 3 o Rule of Thumb Always begin flow adjustments with the cell that has the heaviest water flow It is recommended that the flow to each tower be balanced using a flow meteri
87. em to verify 1 Basin has adequate liquid level and is not frozen If liquid level is low check liquid level controls and add water as required If basin is frozen refer to above section entitled Basin Heater Operation if Sensor Probe is Encased in Ice 2 components appear to be undamaged and in sound operating order If the heater has a thermal cutoff check for continuity and replace if open Check voltage on incoming power lines at the heater control panel The voltage on all phases should match the nameplate rating Correct voltage as required Remove the heater control panel enclosure cover Disconnect sensor cord and install test resistor across terminals and T2 jumper across terminals G1 and G2 Energize the system 1 Measure the voltage at terminals N and 24 240 on the circuit board The voltage should be 21 29 volts If not the transformer is faulty and should be replaced Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 101 of 130 TTXL Series Installation Operation and Maintenance Manual lt Tower Outperform 2 Measure the voltage at terminals on the circuit board and NO on the relay The voltage should be between 21 29 volts If not the circuit board is faulty and should be replaced 3 The green LED light should be ON and the red LED light OFF when the contactor s are energized If not the contactor s are faulty an
88. ents thus providing years of virtually maintenance free service NOZZLE SPRAY DISTANCE VERSUS FLOW Tower Tech Rotary Spray Nozzle 100 Fixed Orifice Nozzle 926 DESIGN SPRAY DISTANCE o o 40 20 0 20 40 60 80 100 120 NOZZLE DESIGN FLOW Graph 1 Nozzle Spray Distance versus Flow Significant increases in performance can be achieved with the use of the Rotary Spray Nozzle because of improved fill coverage and control of the flow pattern size The nozzle orifice is shaped to provide a square spray pattern thereby uniformly wetting the entire fill media This improves tower performance and reduces the likelihood of scaling due to the occurrence of dry regions within the fill Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 13 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform The nozzle is also equipped with a spring loaded orifice to allow the nozzle to automatically adjust to changes in the water flow rate As shown in Graph 1 the Rotary Spray Nozzle performs exceptionally well from approximately 100 GPM to 300 GPM 6 5 19 5 LPS which is the approximate upper limit established by tower module hydraulics Somewhat higher flows may be possible in some tower module sizes contact Tower Tech engineering manager for specifics Flows lower than 100 GPM 6 5 LPS are never allowed This flexible capability is not present in fix
89. er 9 1 Water Flow Control The TTXL Series Modular Cooling Tower s Rotary Spray Nozzle makes it possible to supply a wide range of water flow rates to a system The optimum spray pattern for the nozzle is obtained without significant variation in spray pattern or distribution characteristics when operated from 100 GPM to 300 GPM which is the approximate upper limit established by tower module hydraulics Somewhat higher flows may be possible in some tower module sizes contact Tower Tech engineering manager for specifics Due to the Rotary Spray Nozzle s design reduced flow rates during part load conditions can be distributed to all towers eliminating the need to shut down individual modules This allows each module s fill media surface to be fully utilized increasing the efficiency of the system By ensuring full and continual water coverage of the fill media scaling is notably reduced The Rotary Spray Nozzle s rotor disc may spin below 100 GPM however this will cause uneven wear of nozzle components rotor disc will spin freely with flow to approximately 320 GPM however this flow may exceed tower module hydraulic limits consult Tower Tech engineering manager for specifics Nozzle operation above 300 GPM will result in a slightly larger spray pattern Operation above 320 GPM may result in uneven wear of nozzle components Flow rates below 100 GPM and above 300 GPM per nozzle are not allowed o Fill media will scale when allowed to
90. ersion Basin Heater Check the system annually just prior to the start of the winter operating season as well as anytime the tower is drained 1 Visually inspect probe panel and heater for physical damage evidence of overheating loose connections leaks etc 2 Make sure that the conduit plugs are in place for unused connection ports in the heater element wire box 3 Visually inspect all wiring insulation for integrity and connections for tightness 4 Wipe sensor probe to remove any build up 5 Verify that tower water quality is being properly maintained Specific attention should be paid to excessive chlorine levels that may shorten heater lifespan 6 Refer to Section 9 4 3 for details on test procedure to verify that the immersion basin heater energizes properly DANGER Exercise caution when servicing or troubleshooting the immersion basin heater Always refer to the basin heater user s manual before starting work Only qualified personnel should perform maintenance on the immersion basin heater 10 1 13 Water Collection System The TTXL Series Water Collection System is an effective air water separator that will operate trouble free for extended time periods if it is periodically inspected and maintained as prescribed herein The Water Collection System also supports the weight of the fill media and the design water load CAUTION The WCS is permanently installed in the tower module with hardware and caulking
91. erted into the corner base support of the modular tower Drift pins can be used to fully align the holes for easier insertion of the attachment hardware Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 52 of 130 TTXL Series Installation Operation and Maintenance Manual 44 Tower Outperform 5 4 1 Installation of Sub Structures Taller Than One Foot 30 5 cm With the cooling tower lifted slightly above the main support beam or pad do the following 1 Attach each leg vertical support member to the cooling tower s module base support using two gt x 6 stainless steel hex bolts with washers and nuts finger tighten 2 Attach two tubular FRP braces to the cooling tower apron and to each pultruded FRP leg using 1 x 6 stainless steel hex bolts with washers and nuts finger tighten Refer to Section 5 3 Tolerances for detail 3 tower module can be lowered onto its main support beam pier or pad after the legs and braces are attached After setting the tower module verify that it is plumb and square 4 Tighten all 1 dia Bolts to 50 ft lbs Tighten all bolts less than 1 dia To 30 ft 165 FACTORY ASSEMBLED TOWER MODULE FRP TUBULAR BRACE SUPPORT BOLTED TO SUBSTRUCTURE amp TOWER AT JOB LOCATION BY OTHERS FIBERGLASS LEG ASSEMBLY BOLTED TO TOWER AT JOB LOCATION BY OTHERS HARDWARE 1 x 6 e o SUBSTRUCTURE o LJ FRP TUBULAR BRACE SUPPORT BOLTED
92. ertified startup technician will use the following checklist for startup and for classroom and field training of cooling tower operators and maintenance staff Refer to Figure 33 and 34 Figure 34 Start up Warranty Activation Owner Operator Training Checklist Appears Below Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 71 of 130 TTXL Series Installation Operation and Maintenance Manual 5 Submit by Email ji TOWER Outperform v Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist Tower Tech Modular Cooling Tower MK9000 12 Company Name Project Address Date City State Zip Code Country Company Contact Names Cooling Tower Model Cooling Tower S N Ship Date Module Number of Ss Total Number of Modules on Site Warranty Terms GENERAL PRE WATER FAN STARTUP Needs Inspect Sump Installation Ref IO amp M 7 1 Good Attention N A Have construction screens been installed Is there a watertight seal on sump flange gaskets LH LH Are the sump flange bolts secure E Is the fiberglass backing plate sealed LH Are appropriate nuts and bolts coated Oo Verify Piping amp Headers are self supported Ref IO amp M 5 3 4 Is piping independently supported separate from the tower E o Verify Piping Connections Ref amp 7 2 Is check valve ins
93. es fusing or circuit breaker should be sized to carry at least 100 of the current calculated above Wiring with a temperature rating of 75 should be used The wiring should be sized for the quantity of incoming wires in the conduit and the amperage of the branch circuit protective device as directed by the NEC CEC or any other local directives If non metallic conduit is used provide a circuit grounding conductor that meets NEC CEC requirements Ground lugs are provided in the heater control panel Connect the incoming power wire conduit to the incoming power hub provided on the control panel Make sure the connection is water tight and secure Pull the incoming power wire into the control panel enclosure and make the connections per the control panel wiring diagram Optional Immersion Basin Heater Element Power Wiring One heater control panel may control one or more heaters up to the maximum nameplate kW rating The power wiring to the heater s must have an ampacity equal to the branch circuit over current protection device rating or equal to the rating of sub circuit fusing if installed in the Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 99 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform control panel Some exceptions to this requirement may apply to a specific installation such as a tap rules in the NEC CEC heater power w
94. es of operation With part load conditions occurring during the majority of the year namely spring and fall or colder seasons energy savings associated with these conditions can prove very significant In most geographic climates full load conditions occur during less than 1096 of the year Because part load conditions occur more frequently efforts to improve system efficiency during these periods can have significant payback rewards The Optional Control Panel provides a simple pre engineered solution for proper control of the fans It comes complete with a temperature sensor for mounting in a remote thermal well in the discharge water piping of the cooling tower or in the sensor flange provided in the tower module near the discharge sump The sensor provides the Programmable Logic Controller PLC within the panel with the leaving Cold Water Temperature for comparison with the set point for the CWT CAUTION RTDs should be installed in the centerline of a horizontal section of suction piping and no more than 12 from the cooling tower s attached sump outlet flange The PLC software program controls the staging of the fans to achieve the current set point and match the current load The fans must be cycled ON and OFF in adjacent pairs except for the i Line series tower which has a single row of fans always starting the off line fans nearest the sump end of the module first and then working toward the back end of the module in a
95. fan 1 Disconnect power from motor locking out and tagging out the motor fan to be worked on 2 Open the fan guard 3 Support the fan 4 Remove the bolts from the fan bushing 5 Thread the bolts back into the threaded holes that are provided in the bushing 6 Begin tightening the bolts into the bushing evenly until fan is pushed off the bushing Use a gear puller if bushing doesn t come off easily 7 While supporting the fan tap the bushing gently off the motor shaft 8 Remove the set key from the motor shaft 9 Lower the fan to the ground 10 Mark the fan so that it may be re installed on the same motor from which it was removed Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 114 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 10 1 6 Fan Blade Replacement Individual fan blades should not be replaced without rebalancing the fan Replace the fan if damage occurs to the blades 1 Complete steps 1 thru 9 from Checking amp Re Pitching Fan Blades see Section 10 1 7 Transfer the index tab key to replacement fan blade and place new fan blade into bottom of fan shell half making sure that it is correctly orientated Proceed with steps 11 thru 19 from Checking amp Re Pitching Fan Blades see Section 10 1 7 Check fan balance and rebalance fan assembly if needed 10 1 7 Fan Blade Pitch Adjustment 1 Verify the dire
96. fety enable connection to the VFD to insure when the T9900 panels main breaker is turned off the VFD won t try and operate against no load An owner can control the cooling tower through a BAS by connecting to the T9900 series panel without a gateway module It is recommended that the BAS send a remote temperature set point to the PLC by an intermittent 4 20mA analog signal that is calibrated for 45 F 200 F respectively connected to TB2 terminals J63 J64 The PLC will then sends a speed reference signal to the VFD to maintain temperature set point The BAS can also control the VFD directly by sending a remote speed reference signal by an intermittent 4 20mA or 0 10VDC analog signal connected directly to the VFD The PLC has the capability for remote enable disable control through connection to TB2 by replacing jumper J22 J25 with a dry contact signal The dry contact connection from the VFD to the tower PLC will activate the motor starters and initiate VFD control Any VFD with auto bypass feature shutdown will put the PLC into fan cycling control as in the previous sequence This provides redundant control of the cooling tower should the VFD fail while still allowing the BAS to control the desired tower exiting water temperature The T9900 series panel can be equipped with a gateway module for building automation control interfacing Tower Tech s optional gateway module for communication protocol interfacing with Building Automation System provides a
97. hed by installing the correct index tab for all blades of the fan replace upper fan shell half and tighten the hub bolts to hold the blades firmly in place Replace Uniboss center hub and all balancing washers and nuts to their original locations Recheck the blade pitch after tightening the bolts to ensure that the pitch is correct and record the new pitch setting Verify that the shell half bolts and Uniboss hub bolts are torque to specification below using a torque wrench Manufacturer Specifications 5 16 18 Bolts Use 14 ft Ibs of Torque 3 8 16 Bolts Use 19 ft Ibs of Torque Re install the fan assembly onto the motor shaft Check that the fan is not hitting the shroud Verify that the taper lock bushing bolts to Uniboss hub are torqued to 12 ft Ibs using a torque wrench Replace the Fan Guard Screens Remove lock out tag out Check the fan operation for proper rotation to ensure that there are no other problems and return the unit to service 10 1 8 Fan Motors Removal Installation DANG ER Use lock out tag out procedures to prevent damage to equipment or personnel when maintenance is required on fan guards fans or fan motors Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 116 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform lt AD To remove a motor 1 Disconnect power from motor and lock out tag
98. ht control to the cold water temperature set point with small variations for a stable rapid response When a is used with this control panel jumper J21 J24 located on Terminal Block 2 TB2 must be replaced with a dry contact connection in the VFD that indicates the operational status of the VFD to the PLC The dry contact must be normally open N O when the VFD is operational active and normally closed N C when the drive is in by pass mode or when Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 36 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform failed When the is online the dry contact must be which tells the control panel PLC to energize all motor starter coils allowing the VFD to maintain the desired cold water temperature set point entered through the control panel without fan cycling from the PLC When the VFD is in by pass mode or when failed the dry contact must be N C which tells the control panel PLC to de energize the starter coils and the PLC will maintain the desired cold water temperature set point entered by an operator through the door mounted LCD interface panel through fan cycling control A separate 120V circuit must be provided for control power within the panel 4 20 milliamp signal wiring must be shielded twisted pair wiring with the shield properly grounded on one end The PLC provides an optional sa
99. in the basin and disable the basin heater When the cooling tower needs to be shut down without draining the basin it is recommended that one or more optionally available basin heaters be installed Any cooling tower that operates in cold weather may experience freezing Overflow equalization piping and stand piping must be heat traced and insulated Additionally a Tower Tech Modular Cooling Tower requires a specific sequence of steps to optimize operations in cold weather To minimize ice formation and accumulation the flow rate through each Rotary Spray Nozzle must be 200 GPM or greater and tower leavin water be maintained at or above 45 F when ambient temperature is below 25 In freezing conditions it may be helpful to cycle the tower fans OFF periodically in an attempt to remove any ice from within the Water Collection System Cycle fans OFF more frequently as ambient temperature decreases and tower leaving water temperature is reduced When temperatures are above 20 F ice accumulates more slowly and longer fan cycle times may be used The temperature to which water can be C cooled without freezing depends on the Sa heat inside the tower module which is a a function of entering hot water temperature SS leaving cold water temperature oS temperature of air flowing through the E tower and water flow The TTXL Series 95 Modular Cooling Tower with its absen
100. intenance Manual Date 09 22 2015 Page 1 of 130 D Tower hf TM Outperform 34 Motor Support iraa na 32 3 5 Tower mteinal Saritan rte R E RR 32 Chapter Four Optional Equipment 34 41 Sub Struct re Leg Kit 34 4 2 T9900 Motor Control 35 4 3 T2100 Motor Protection Panel eene 39 44 Variable Frequency DELE aussen ot tU Reb ep ccm ina im eterne 39 4 5 Immersion Basin Heater cere er te eren 40 4 6 Vibration Control ret Yt 44 4 7 Ultrasonic Liquid Level Sensor anes 44 Chapter Five Preparing for Installation 47 5 1 48 5 2 Tower Location 49 5 2 1 Environmental Safety Considerations esses 49 52 2 Re Circulation 49 5 2 3 Interference Considerations 50 5 3 dell ocu TTE 50 Acn TET 50 5 3 2 Foundation Slab or Pier 50 5 3 3 ERU 51 534 PIPE c 51 5 3 5 Layout Recommendations aceti 51 5 4 Sub Structure Installation XE DRE DUE Ea EV 42 5 4
101. intermittently dry out Scaling affects cooling tower performance CAUTION Restarting the cooling tower without resetting inlet isolation valves to 25 may result in water hammering and cause damage to the tower s hot water distribution system header laterals and or nozzle components 9 2 Water Temperature The PVC fill media and PVC hot water distribution system standard in TTXL Series towers are designed for tower entering hot water temperatures not exceeding 130 F in continuous operation For applications having hot water temperatures of 130 F to 1409 in continuous operation HPVC fill media and a CPVC hot water distribution system are required Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 89 of 130 TTXL Series Installation Operation and Maintenance Manual D AD Tower TECH Outperform 9 3 Fan Control Cooling and cost savings benefits may be obtained from cycling the fans on a cooling tower With the Tower Tech design each module has a combination of fans that can be staged on or off depending on cooling load requirements By allowing the total water flow volume in a system to circulate through all the modules rather than just a few cooling efficiency is increased because of the utilization of the total fill surface area This increase in efficiency also allows the total fan horsepower usage to be further reduced by eliminating the need for some of the fans to run at low usage tim
102. irections as specified in this manual Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 5 of 130 TTXL Series Installation Operation and Maintenance Manual 1 3 Reference Tower TECH Outperform Forms referenced in this instruction can be ordered as follows Post Office Box Street Address Electronic Tower Tech Inc ATTN Publications Distribution Center P O Box 891810 Oklahoma City OK 73189 U S A Tower Tech Inc ATTN Publications Distribution Center 5400 N W 5th Street Oklahoma City OK 73127 U S A ATTN Publications Distribution Center TEL 405 290 7788 FAX 405 979 2131 Literature 9 TowerTechInc com 1 4 Customer Service Support Your satisfaction is important to us Please direct any questions you may have regarding installation operation or maintenance of your Tower Tech Modular Cooling Tower to our knowledgeable Customer Service Support staff E Mail Us at Service 2 TowerTechInc com Call Us at 405 979 2123 Monday through Friday 8 00 a m to 5 00 p m Central Time Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 6 of 130 TTXL Series Installation Operation and Maintenance Manual AD Tower TECH Outperform Chapter Two 2 1 Model Nomenclature Model Designation 2 Fans 1 x 2 Configuration 3 Fans 1 x 3 Configuration 4 Fans 1 x 4 Configuration 4 Fans 2 x 2 Configuration 5 Fa
103. iring should have a temperature rating of 75 C and be rated for the number of wires in the conduit It must comply with any local codes NEC or CEC depending on the installation location If non metallic conduit is used provide a circuit grounding conductor that meets NEC CEC requirements Ground lugs are provided in the heater control panel Connect the heater power wire conduit s to the heater power wire hub s provided on the control panel Make sure the connection is water tight and secure Pull the heater power wire into the control panel enclosure and make the connections per the control panel wiring diagram Conduit connections to multiple heaters should be run so that each individual heater is branched off of the run until the conduit terminates at the last heater Jumpering from one heater to the next is not recommended Optional Immersion Basin Heater Element Safety Wiring Each heater element contains a fused thermal cutoff device that must be wired into the safety circuit Wire the safety control circuit per Class 2 Article 725 of the N E C and or Section 16 of C E C unless wiring is routed in the same conduit as the power wire in which case Class 2 does not apply and the wiring must be Class 1 PROBE MOUNT ING HEATER WIN MOUNT ING Figure 41 Location of Basin Heater Probe amp Element Notes 1 Water level must never fall below 2 above heater elements while heater is energized 2 Probe must be positioned
104. ive Tower Tech motors are inverter duty rated and meet NEMA 1 Part 31 specifications The use of variable frequency drives VFD and mechanical motor protection starters provide the tightest temperature control 0 5 F 28 C is typical in most applications The will speed up or slow down the fans as required to maintain a constant temperature Consult the VFD manufacturer s user manual for details on programming the VFD unit for use and installation Customers are responsible for programming out harmonic and electronic frequencies and for locating appropriate connection points for variable frequency drives not supplied by Tower Tech Tower Tech drawings are typical only control wiring is to be Belden equivalent shielded twisted pair cable properly grounded on one end For a discussion of the advantages of using VFD with variable flow water distribution refer to section 2 5 CAUTION VFD s must have a dv dt Filter VFD rated cable must be used for load cable from the VFD to the motors Failure to meet these requirements will void the motor warranty CAUTION The VFD must be sized to meet the Full Load current demand at 60hz for all motors connected to the drive If individual motors will be turned on off during VFD operation the Locked Rotor Amperage must be included in the total amperage sizing of the VFD Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 39 of 130 TTXL Series Inst
105. l have plugged make up flange and no overflow equalization flange Table 11 Standard Pipe Connections Data Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 63 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform CAUTION Piping should be installed by a licensed plumbing specialist who is familiar with municipal state and federal regulations CAUTION piping must be freestanding and not supported by the cooling tower at any time It is very important that these instructions are followed to prevent damage to the module due to stress and creep CAUTION Over tightening bolts may result in damage to flanges Heavy duty fender washers should be used on all bolts attaching piping flanges to cooling tower flanges Adhere to all torque requirements listed in this manual and submittal drawings CAUTION Avoid blocking cooling tower air inlets with piping or other equipment to prevent air restrictions that could diminish tower performance Avoid installing piping or other equipment underneath the tower that could restrict access to mechanical equipment for service and maintenance 7 21 Inlet Connection The cooling tower inlet connection is located at the top of the module end wall Tower Tech recommends the use of an appropriate flexible flange connection on the header inlet in order to better accommodate minor piping t
106. le must be installed in accordance with the current edition of the following national and local safety codes National Electric Code Local electric utility requirements Local plumbing and waste water codes Other applicable municipal codes Components added to a module to meet local codes are installed at the customer s expense Tower Tech assumes no responsibility for the impact of such components on the thermal performance or the structural integrity and longevity of the tower Please see your Tower Tech Sales Engineer for further details The size of the module for proposed installation should be based on calculations provided by the client owner or owner s agent at the time of tower specification and are made according to generally accepted methods of thermal calculation o The thermal performance of the TTXL Series Modular Cooling Tower is certified by the Cooling Technology Institute in accordance with its standard STD 201 and has been assigned CTI validation number 08 17 06 This certification is your assurance that the proposed capacities accurately reflect actual cooling tower performance CTI certification under STD 201 is limited to thermal operating conditions with entering wet bulb temperatures between 55 F and 90 F 12 8 and 32 2 C a maximum process fluid temperature of 125 F 51 7 C a cooling range of 4 F 2 2 C or greater and a cooling approach of 5 F 2 8 C or greater Tower Tech Modular Cooling Tower
107. les that produce a round pattern above a rectangular fill pack The nozzles are placed in a rectangular overlapping pattern to assure full wetting of the fill at the design water flow rate Water flow rates below the design point will not produce a full spray pattern and void areas will start to appear Any fill s best efficiency is achieved when the liquid to gas ratio is evenly balanced throughout the fill media Short patterns and overlapping patterns cannot accomplish it When a conventional cooling tower system is faced with a variable water flow rate i e multiple pump cycling or variable speed pumping these pattern problems force the operator to isolate whole cooling tower cells to maintain proper water distribution under reduced load in the remaining on line cells If this is not done the tower efficiency will suffer and the fill media will quickly foul Isolating cells takes away air to water contact surface What is needed is a cooling tower water distribution system that is able to respond to variable flow rates and keep all of the fill media evenly wetted and in service This requires a nozzle that responds to flow changes to keep a constant pattern A square pattern that avoids overlap would be best Putting such a system on a three cell tower with three matched pumps would yield the following opportunities typical tower would operate at 0 06 kW ton for the tower alone at full load 0 06 kW ton at 2 3 load two cells operating at 100 a
108. libration and installation Basin Flood 27 17mo5 Overflow 84 15 6mo 10 Oper Level 8 8ma gt 7 Oper level 7 4mo Dry Well 2 5 0mo atum 0 C4 0ma Flow Line Sensor Settings Bottom Of Sensor To Bottom Of Tank 47 4mA 0 20mA 33 Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 45 of 130 TTXL Series Installation Operation and Maintenance Manual Figure 18 Sump Detail With Ultrasonic Liquid Level Sensor 9 BASIN WATER LEVEL BOTTOM OF FLOWLINE OF OVERFLOW PIPE 2 6 6 BASIN WATER LEVEL MIN FOR LEVEL READING 7 BOTTOM OF TOWER SKIRT INSIDE BOTTOM 7 8 ids MINIMUM 6 OVERFLOW RISER OF BASIN EQUALIZATION OVERFLOW PIPE TO EACH CELL SIZED AND PROVIDED BY OWNER MANUFACTURER RECOMMENDS THAT A FLOW CONTROL VALVE BE INSTALLED AT EACH CELL S OVERFLOW CONNECTION TO BE PROVIDED BY OTHERS BOTTOM OF TOWER SKIRT FOR DIMENSION REFERENCE Figure 19A Equalization OverflowPipe Detail No Ultrasonic Level Sensor OVERFLOW LEVEL DASS OVERFLOW LEVEL e 9 9 RECOMMENDED MAXIMUM OPERATING LEVEL umm UF SKIRT 1 44 Figure 19B Sump Detail With Equalization Overflow Pipe No Ultrasonic Level Sensor Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 46 of 130 TTXL Series Installation Operation and Maintenance Manual 5 Outperform
109. lizing fiberglass mat and chopped fiberglass strands or a resin transfer molding process utilizing fiberglass mat Its unique design radius provides a smooth transition for the air entering the fan thus maximizing the fan efficiency and energy savings and likewise reducing extraneous noise Due to the use of fiberglass mat the shroud is very lightweight yet strong and will resist corrosion indefinitely 3 4 Fan Motor Support Fan motor supports are bolted to the fiberglass shrouds refer to Figure 8 thus allowing the motor motor support and shroud to interconnect with a minimum of vibration and a minimum of fan tip tolerance The motor support is manufactured from stainless steel tubing and plate Motors are mounted to a stainless steel plate that is welded onto the motor support framework Stainless steel fasteners are used exclusively in its assembly 3 5 Tower Internals A CAUTION The standard TTXL Series hot water distribution system and fill media are designed for a maximum tower entering hot water temperature of 130 F 54 4 C in continuous operation Excessive tower entering water temperatures will damage the tower s hot water distribution system and fill media For applications having tower entering hot water temperatures ranging from 130 F to 140 F 54 4 C to 60 C degrees CPVC hot water distribution system piping and HPVC fill media are optionally available PVC fill media can tolerate temperature excursions of up to 15 F 9
110. materials Non Tower Tech factory personnel should never attempt to lift or move the Water Collection System as doing so can permanently damage the tower and void the tower warranty Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 120 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 5 The TTXL Series Modular Cooling Tower s Water Collection System is designed so that adjacent fans must be operated in pairs Thus in a four fan tower module fans 1 and 2 should always operate simultaneously and fans 3 and 4 should always operate simultaneously The i Line series modular towers have a single row of fans that aren t operated in pairs SPACERS DAMPER OPEN COLLECTOR VANE DAMPER CLOSED is END CAP PERIMETER BASIN BEAMS Figure 48 Water Collection System The main components of the Water Collection System include e Collector Vanes Each collector vane is approximately 8 wide and 14 high and is installed transversally in the tower module Collector vanes are a series of overlapping chevron shaped troughs that capture cooled water falling from the fill media and channel it into the perimeter basin beams Refer to Figure 47 e End Caps help hold the collector vanes together and secure the Water Collection System to the Perimeter Basin Wall to prevent leaks End caps are installed in pairs 2 5 apart at th
111. modules without Tower Tech engineering review and approval 5 3 4 Piping piping and other equipment external to the TTXL Series cooling tower module must be stand alone or self supported Tower Tech recommends the use of an appropriate flexible flange connection on each tower inlet and outlet connection to better accommodate minor piping tolerances Failure to use a flexible flange may result in damage to the tower structure as well as adjacent piping Final connections to the cooling tower module must be field fitted after tower installation to prevent pipe stress on the tower Heavy duty fender washers should be used on all flange connections to the cooling tower Tighten all connections to proper torque requirements Never support piping ladders walkways or stairways from a TTXL Series cooling tower module Never attach control panels to plumbing or piping as this may induce vibration CAUTION Avoid blocking cooling tower air inlets with piping or other equipment to prevent air restrictions that could diminish tower performance Avoid installing piping or other equipment underneath the tower that could restrict access to mechanical equipment for service and maintenance CAUTION Do not reduce pipe connected to the cooling tower by more than 2 inches 5cm of the tower connection flange size Tower Tech recommends that any pipe reductions occur after the first elbow of the pipe connection Elevation of piping should never e
112. ms Perimeter Basin Walls interconnected to one or more transversal box beams Mid Basins This structure forms the base of each tower module A unique patented Water Collection System located above the fan motors serves as an air water separator capturing cooled water falling from the fill media The WCS channels the cooled water into the Flow Thru Basin and is discharged into a sump located at the either end of the module This unique enclosed system with its high flow velocity 5 7 fps contains no quiescent areas for water to stagnate and scrubs the basin walls and floor continually thereby minimizing the problem of sediment accumulation that is common to all other cooling tower designs Figure 5 shows the placement of the WCS Flow Thru Basin motors and fans within a Tower Tech TTXL Series Modular Cooling Tower Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 10 of 130 TTXL Series Installation Operation and Maintenance Manual a Tower Outperform WATER COLLECTION SYSTEM PERIMETER FLOW THRU BASIN MID BASIN FAN ASSEMBLY Figure 5 Water Collection System Flow Thru Basin Mid Basin Motors Fans 2 3 Sump Design STAINLESS STEEL m sit SUMP SCREEN SUMP FLOAT VALVE ACCESS COVER MAKE UP WATER CONNECTION OVERFLOW EQUALIZATION CONNECTION SUMP OUTLET FLANGE Figure 6 Sump Layout Tower Tech Modular Cooling Tower Date 02 18 2015 900
113. n Turn on Motor Disconnects Verify that the fan motor resets are not tripped Bump Fans in Sequence Verify Fan Rotation Operate fans in HAND MODE Power up the rest of the fan sets in 1 minute intervals in HAND mode Verify Water Collector Dampers open properly Needs Good Attention N A 00000000 0000000 Voltage amp Amperage Measurements readings must be taken across the line with all fans operating Voltages AC L1 L2 L1 L3 L2 L3 Total L1 Incoming Main Fan1 Starter Fan2 Starter Fan3 Starter Fan4 Starter Fan 5 Starter Fan 6 Starter Fan 7 Starter i Fan 8 Starter Fan9 Starter i Fan 10 Starter Fan 11 Starter Fan 12 Starter E 5 5 0 a cA 2 227 5 PLC CONTROL PROGRAMMING RECORDED INPUT VALUES MIPERATURI NUMBER OF FAN STAG ON DEADBAND TIM O DEADBAND TIM ver Tech Inc Serv ice TowerTechInc com Tower Tech Modular Cooling Tower MK9000 12 TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 73 of 130 i Tow ER Outperform 5 e Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist S N Date Needs Fan Startup Auto Mode Good Attention N A Switch HOAs to OFF all fans stop
114. n access point to gateway data mapping that is pre programmed in the PLC while all other setup interfacing and programming for communication with the BAS to be provided by others Optional gateway modules are available for the following communication protocols BACnet IP or BACnet MSTP RS485 LonWorks IP or LonWork MSTP RS485 Modbus TCP IP or Modbus RTU RS485 Tower Tech supplies a complete wiring schematic with all control panels Custom panels and tower wiring requirements are assigned a discrete project number for easy identification Standard factory pre wiring uses shielded 12 4 AWG 460V wiring however other voltages require use of NEC appropriate wire sizes Wiring used in all towers is Alpha brand VFD compatible quantum shielded liquid tight oil resistant flexible cable Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 37 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform 4 3 T2100 Motor Protection Panel 0 Fig 16 T2100 MPP Should Tower Tech s optional T9900 motor control panel not be used then individual motor protection is required Tower Tech offers an optional T2100 Motor Protection Panel refer to Figure 16 The Motor Protection Panel MPP is a UL Rated NEMA 4X FRP and is designed for single point connection The NEMA 4X panel has individual manual motor prot
115. n the entrance face of the tower pushing air through the tower Induced draft towers have the fan located in the hot moist air stream on the exit face of the tower drawing air upwards through the tower Neither the fans nor the motors on a forced draft cooling tower are subjected to the harsh environment encountered in an induced draft cooling tower Figure 3 shows the layout of a Tower Tech mechanical forced draft cooling tower compared to an induced draft counter flow cooling tower Figure 3 TTXL versus Conventional Induced Draft Counter Flow Tower Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 9 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform The Tower Tech TTXL Series Modular Cooling Tower is also distinguished by its modular design as shown in Figure 4 This enables the individual modules to be interconnected in numerous configurations to accommodate virtually any cooling capacity This design is also quickly adaptable to accommodate future expansion of cooling tower capacity L 28 Note Keep all vents clear and open Stand pipes must be heat traced and insulated in cold climates Figure 4 TTXL Series Modular Cooling Tower Installation Flow Thru Basin and Water Collection System The cold water basin in the TTXL Series Modular Cooling Tower is comprised of a unique patented Flow Thru Basin consisting of four perimeter box bea
116. nal Data Accessory Location List Tower Lifting Data Standard Pipe Connections Data Tower Hydraulic Data TTXL Maintenance Schedule Recommended Spare Parts Inventory ROD BOM 11 3 Index of Graphs Graph Number Description Section 1 Nozzle Spray Distance versus Flow 2 5 2 Tower Pressure versus Flow 2 5 Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 130 of 130 TTXL Series Installation Operation and Maintenance Manual
117. nance and repair of this equipment to prevent personal injury and or property damage Tower Tech offers the highest quality replacement parts materials and services to help customers keep their TTXL Series Modular Cooling Towers operating at peak performance For details refer to the Maintenance amp Service Plans brochure located in the flap inside the front cover of this Manual The brochure describes our Preventive Maintenance Inspection PMI Preventive Maintenance Service PMS and Service Inspection SI Refer to Figure 41 Figure 42 Brochure Maintenance amp Service Plans Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 107 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform DANGER electrical mechanical and rotating machinery constitute a potential hazard particularly for those not familiar with the design construction and operation of same Accordingly adequate measures including the use of a protective enclosure when deemed necessary should be taken with this equipment both to safeguard the public from injury and to prevent damage to the equipment and its associated system DANGER Walking on top of the module is dangerous and could result in serious injury or death Adequate safety measures must be taken to prevent injury due to falling See Section 2 11 regarding safety bracket points DANGER Disconnect
118. nd thus can be set at various pitch angles to allow for maximum performance After installation the fans are adjusted to allow a nominal 1 4 tip clearance from the throat of the fan shroud Minimum balancing tolerances are based on ISO balancing standard TC 108 DR 1940 A G6 3 balancing grade is used at 860 RPM Three different fan models are used in the TTXL Series and vary based on motor horsepower refer to Table 2 Horsepower No of Blades Pitch Angle Degrees Blade Profile TWR TWR TWR Table 2 Fan Data for 60 Hertz Motors Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 23 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform 2 8 Fan Shroud Figure 10 Fan Shroud The fan shroud used on the TTXL Series towers is made using a hand lay up process using fiberglass mat and chopped fiberglass strands or a resin transfer molding process employing fiberglass mat The shroud s unique design radius refer to figure 10 provides a smooth transition for the air entering the fan maximizing fan efficiency and thereby reducing energy costs Because of the fiberglass construction the shroud is very lightweight strong and resists corrosion indefinitely 2 9 The most important component of a cooling tower may be the heat transfer surface or The fill s efficiency is a function of its ability to promote contact be
119. nd 0 06 kW ton at 1 3 load one cell operating at 100 Under the same conditions a constant pattern variable spray system with variable speed drives on the fan motors would operate at 0 06 kW ton at full load 0 024 kW ton at 2 3 load all cells operating at 2 3 load and 0 005 kW ton at 1 3 load all cells operating at 1 3 load These energy savings can only be achieved through use of the constant pattern variable flow distribution system found only in patented Tower Tech Modular Cooling Towers Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 15 of 130 TTXL Series Installation Operation and Maintenance Manual Y Tower Outperform 2 6 Motors TTXL Series Modular Cooling Towers shipped after October 2010 are equipped with Baldor brand motors that are direct drive totally enclosed air over TEAO 8 pole induction type inverter ready with Class H Class F minimum insulation and Lio sealed bearings rated for 100 000 hour life with sealed case All Baldor motors on TTXL Modular Cooling Towers shipped after October 2014 also meet 55 and NEMA 1 Parts 30 and 31 requirements Standard available motor types 60Hz 40 C Available in 3 0 HP 2 2 kW 5 0 HP 3 7 kW or 7 5 HP 5 6 kW Available at 200V 230V 460V and 575V 60Hz 50 C Available in 2 2 kW 3 0 HP 3 7 kW 5 0 HP or 5 6 kW 7 5 HP Available at 230V 380V or 460V 50Hz 40 C Available in 2 2 kW 2 9 kW 3 7 kW 4 8 kW or
120. ng device such as an ultrasonic meter as small variations in flow rates may not be visually detectable These small variations however may not allow some towers to function properly reducing the thermal performance of the system Once all inlet valves have been adjusted so that each tower receives the same flow rate some attention must be paid to the tower water levels to insure they are consistent In multi cell installations pressure differentials in the piping system may cause variations in the water levels of subsequent towers To equalize these pressure differentials some adjustments to the discharge piping valves if equipped may need to be made By adjusting the discharge piping valves the water levels can be equalized eliminating variations in system performance These adjustments however must be made by qualified personnel to ensure tower performance is not jeopardized o Tower Tech requires a professional flow balance report be provided to insure the pump s are properly operating to provide proper flow to the cooling tower s Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 88 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform lt Chapter Nine Operation Due to the TTXL Series Modular Cooling Tower s advanced design there are several operational conditions that will allow efficiency levels not possible in a conventional cooling tow
121. ng from the top Visually inspect the flute openings on the bottom side of the piece to determine if any build up of algae bacterial slime or solids has occurred If build up is significant it may be necessary to remove the fill media and clean with water and mild detergent as described for the drift eliminators If algal growth or bacterial slime is detected please contact your water treatment professional to control the problem Overzealous cleaning methods may cause damage to cooling tower components CAUTION Bacterial slime can contribute significant weight loads on the tower beyond that for which it was structurally designed Damage to tower internals or shell due to bacterial growth excursion will void the TTXL Series Modular Cooling Tower warranty 10 1 3 Rotary Spray Nozzle TTXL Series Modular Cooling Towers utilize patented Rotary Spray Nozzles This nozzle has a large four inch orifice and a rotating disc that will dislodge nearly all debris commonly seen in cooling towers While it is unlikely that the nozzle will plug during normal use conditions bi annual inspection of the nozzles is recommended Inspecting the Rotary Spray Nozzle consists of visually inspecting the water distribution pattern If sticks or large objects are jammed in the nozzle follow the instructions for removal refer to Figure 36 CAUTION Recommended nozzle operating range is 100 GPM to 300 GPM Damage to nozzles will occur if operated below 1
122. ns 1 x 5 Configuration 6 Fans 1 x 6 Configuration 6 Fans 2 x 3 Configuration 8 Fans 2 x 4 Configuration Model Series TTXL Series Features Fill Media Type 19 CF1900 Cross fluted fill media having a flute diameter of 19 millimeters is the basis of TTXL performance certification by Cooling Technology Institute Motor Power AA Hou oH oH y on How n 10 Fans 2 5 Configuration 12 Fans 2 x 6 Configuration CTI Other fill media types are available however their thermal performance may not certified by CTI 2 2 Modular Design Cooling towers come in a variety of configurations These configurations can vary according to the type of airflow encountered the type of draft used the tower erection site and the materials of construction These characteristics and myriad other design factors are what distinguish one cooling tower design from another The Tower Tech TTXL Series Modular Cooling Tower is characterized as a forced draft counter flow cooling tower A 3 D section view displaying the internal components of a TTXL Series tower is depicted in Figure 1 Date 02 18 2015 Page 7 of 130 Tower Tech Modular Cooling Tower MK9000 12 TTXL Series Installation Operation and Maintenance Manual T Tower Outperform N DRIFT ELIMINATOR A DISTRIBUTION amp DRIFT ELIMINATOR SUPPORT HOT WATER
123. nstallation Operation and Maintenance Manual i Tow ER Outperform 5 exri lt amp Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist Project S N Date ATER STARTUP amp FLOW Filling System Ref IO amp M 8 1 Verify Makeup Water Level Ref IO amp M 8 2 Basin level Startup Valve Settings Ref IO amp M 8 3 1 8 3 2 Hot Water Control Isolation Valve set for soft start up Ref IO amp M 8 3 1 amp 8 3 2 Cold Water Control Isolation Valve s open Ref IO amp M 8 3 1 amp 8 3 2 Overflow Equalization Valve Open Bypass Water Valve Open Water Flowing to Cooling Tower Water Level Control Ref IO amp M 8 2 Make up Water Valve Open Circulating Water Single Pump Operation Verify Water Level Control Ref IO amp M 8 2 gt Slowly Open Hot Water Control Isolation Valve gt Slowly Close Bypass Valve Needs Good Attention N A nuum 0000 20000 Verify Water Flow Values Ref Submittal Drawings Verify Water Collector Operation oO Verify Nozzle Operation Visually Oo m Record Final Valve Settings amp Flow Values Circulating Water Multiple Pump Operation gt Start Additional Pumps After Basin Level Recovers Approx 5 Min Intervals Verify Water Flow Values Ref Submittal Drawings E Verify Water Collector Operation Verify N
124. ntain water level in the tower module Refer to the instructions provided by the manufacturer to properly calibrate the water level for electronically controlled system Note Standard mechanical level control is pre set at factory and should not require modifications to the setting INTERIOR SUMP WALL MAKE UP pn sl WATER VALVE l or 2 FPT MAKE UP WATER CONNECTION BALL ADJUSTMENT LOCKING NUT STEM Pu aper GASKET 8 7 FLOAT BALL Figure 36 Mechanical Float Valve Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 81 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform Use the following procedure to set the mechanical float valve Refer to Figures 29 and 30 Close make up valve s 2 Remove sump lid and make up valve access cover and set aside Check sump water level The proper water level should be within the range of the standard operating level specified in Figure 30 3 Loosen the locking nut on the adjustment bolt for the Ball Stem specified in Figure 35 then loosen the bolt itself Do not remove the bolt 4 Rotate arm and stem to desired water level 5 Tighten adjustment bolt and nut 6 Restore water supply and verify that the water level is at the desired operating level 7 Replace sump lid and make up valve access cover OVERFLOW OVERFLOW LEVEL
125. o meet the customer s requirements along with any local state federal and OSHA requirements The safety bracket is a certified point to which a fall restraint system can be attached SAFETY POINT Figure 11 Safety Point Bracket Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 27 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform CAUTION Safety point bracket is rated not to exceed 5 000 Ibs for a fall protection system DO NOT ATTEMPT TO LIFT TOWER USING THE SAFETY POINT BRACKETS Any attempt to lift tower using these brackets will void the warranty 212 Power and Control Wiring DANGER Install a lockable disconnect switch in close proximity and within sight of the cooling tower to protect authorized service personnel Ensure the switch is separate from all other circuits Do not perform service work on or near the fans without first ensuring the fan motor is electrically disconnected and locked out Only a licensed electrician should attempt to troubleshoot any electrical components on Tower Tech Modular Cooling Towers Field wiring to the module must conform to the provisions of the National Electric Code NEC ANSI NFPA No 70 in U S A current Canadian Electric Code A22 1 in Canada and or local ordinances The unit must be electrically grounded in accordance with the NEC and CEC as specified above and
126. olerances Failure to use a flexible flange connection may result in damage to the tower structure as well as adjacent piping Final connections to the cooling tower module must be field fitted after tower installation to prevent pipe stress on the tower and a compatible gasket should be used between each flange and flexible flange connector to prevent leakage It is also recommended that a shut off valve be installed in each inlet pipe to regulate flow to each module and to provide a means of tower isolation Design the header piping to the inlet connection for a maximum water velocity of 10 ft s Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 64 of 130 TTXL Series Installation Operation and Maintenance Manual o Tower TECH Outperform ISOLATION SHUT OFF um VALVE RECOMMENDED me i TO BE PROVIDED BY OTHERS FLEX FLANGE RECOMMENDED uem TO BE PROVIDED r BY OTHERS ISOLATION SHUT OFF SERVICE VALVE RECOMMENDED FOR MULTI CELL INSTALLATIONS TO BE SIZED AND PROVIDED BY OTHERS FLEX FLANGE RECOMMENDED TO BE PROVIDED BY OTHERS ISOLATION SHUT OFF SERVICE VALVE RECOMMENDED FOR MULTI CELL INSTALLATIONS TO BE SIZED AND PROVIDED BY OTHERS Figure 29 Connection Flexible Flanges amp Flow Control Valves 7 2 2 Discharge Connection The discharge connection is located on the bottom of the sump Design the discharge piping for a m
127. or local ordinances o The end user is responsible for making all field wiring connections Each motor is factory pre wired to a junction box located on the end of the tower module as illustrated in Figure 13A Optional rotary type lockout disconnect switches may be specified as illustrated in Figure 13B motor wiring is 12 4 AWG except 208 230V 7 5 HP motors or 190V 5 6 kW 7 5 HP motors which use 10 4 AWG Wiring is Alpha brand variable frequency drive compatible liquid tight oil resistant quantum shielded flexible cable typical illustration of optional pre wiring layout is shown in Figure 12 Optional pre wiring of motors to pigtails may be specified as illustrated in Figure 13C Tower Tech also offers an optional pre wiring of the motors to a motor protection panel as described and illustrated in Section 4 3 This Manual shows and describes standard power and control wiring and operating procedures only Tower Tech will supply an appropriate technical supplement for non standard power and control wiring and operating procedures upon request Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 28 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform MOTOR TERMINATION BOX MOTOR TYP SHIELDED CABLE Figure 12 Typical Wiring Layout Refer to Table 1 for amperage requirements at various motor power levels C
128. ozzle Operation Visually Balance Hot then Cold Water Flow across tower modules Ref Submittal Drawings 7 Verify Water Level Control Ref IO amp M 8 2 Is Chiller Operational with Load What Brand Chiller Add Heat Load Verify Water Flow Values Ref Submittal Drawings Verify Water Collector System functions without water drips LH Record Final Valve Settings amp Flow Values Comments Inspected By Date Company Tech Inc 73127 USA Effective 07 Main Tel 405 2 Service TowerTechInc com Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 75 of 130 TTXL Series Installation Operation and Maintenance Manual ji TowER Outperform 5 v Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist Project S N Date GENERAL STARTUP Needs Good Attention N A Verify basin walls seams amp joints Verify all water flanges amp gaskets for water tightness Verify tower footpads are securely anchored per IO amp M Verify all braces are securely fastened to legs 00000 00000 0000 Verify all Fan Guard Screens are securely fastened Comments BASIN HEATERS Needs Electrical before Energizing Good Attention N A Verify Electrical Components amp Wiring Ref Submittal Drawings oO All Wiring Terminations
129. p must be installed before piping can be attached to the module piping from the sump must be self supporting Flexible coupling connection must be used Failure to observe these directions may result in leaking or damage to the tower structure CAUTION Attach the sump to the cooling tower module AFTER the tower has been unloaded from the truck and the sub structure legs have been securely attached 7 1 1 Procedure Refer to Figure 26 1 Remove the two wooden plates from the sump flanges 2 Remove the sump lid then remove contents packaged inside 3 Check contents to verify that they are in agreement with packing slip and to ensure that all needed materials are present before proceeding with installation 4 Do not remove nuts used to attach pipe spacers or the white pipe spacers Refer to Figure 26 5 Clean outside surfaces of both sump flanges both the factory installed flange bolted to the tower wall and the factory installed sump flange 6 Apply a 3 8 inch 9 5 mm bead of silicone to the perimeter of each flange 7 Place the large rectangular gasket on the flange attached to the tower wall 8 Place one 3 8 inch 9 5 mm neoprene washer on each of the four all thread rods Orient the washer so that the neoprene faces towards the sump wall 9 Place two 1 2 x 2 bolts in the two outer holes of the flange attached to the tower wall Orient the bolts so that the head of the bolt faces towards the tower wall
130. provide picture of control panel internals if not Tower Tech Are Line Filters installed on the VFD Are Load Reactors installed on the VFD Is there a Building Management System in operation If Yes who is the manufacturer Communications protocol BACnet LONworks etc Is the Building Management connected through Is Remote Enable Disable Active Is Remote Temperature Set Point Active Is Tower Tech RTD installed and used Has the control loop been fine tuned Voltages AC L1 L2 L1 L3 L2 L3 Total Incoming Main NOTES Voltage amp Amperage Measurements In VFD Mode at 60hz Amperages L1 00000 00005 0000000 RS485 ver Tech Inc 400 N W 5th Street Tower Tech Modular Cooling Tower 9000 12 TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 80 of 130 gt Tower TECH Outperform 8 1 Filling System with Water Open make up valve s and allow basin s and piping to fill to the tower overflow 2 Check all flanged connections and piping for leaks 3 Bleed air from piping by opening bleed valve at pump until water flows out in a steady stream without interruption 4 Close bleed valve 8 2 Controlling Water Level The TTXL Series Modular Cooling Tower utilizes either an electronic solenoid valve optional or mechanically standard controlled float valve located in the sump to mai
131. r quality and clean deposits from element tubes as required e Wipe sensor probe to remove any deposit build up Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 102 of 130 TTXL Series Installation Operation and Maintenance Manual a gt Tower TECH Outperform 9 5 Water Treatment DANGER 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 which is known to cause Legionnaire s disease A water treatment program to stop biological contamination must be used for all cooling tower installations in order to reduce such hazards Do not operate this equipment without a proper water treatment program There are numerous chemical and non chemical methods currently available for use in treating cooling water It is beyond the scope of this text to cover the nature and suitability of these methods However some general information on what constitutes an effective and complete water treatment program is provided below In general a complete program must address the following 1 scale control 2 solids control 3 biological control and 4 corrosion control principally for protection of the cooling loop and not the cooling tower 9 5 1 Scale Control Although it is commonly understood that scale accumulation has a tremendous impact on the efficiency of chillers and heat exchange
132. r temperature falls below 25 F for extended periods and or where the cooling tower is expected to produce water colder than 45 F The latter often occurs in applications where a cooling tower is expected to provide free cooling during cold weather operations Tower Tech recommends that a TTXL tower not be expected to produce water cooler than 452 when the ambient air temperature falls below 25 F unless variable frequency drives are utilized in which case it may be possible to achieve 43 F leaving water so long as the ambient air temperature remains above 10 F Operations in colder conditions may be ossible depending on operational variables including but not limited to entering hot water temperature and water flow rate CAUTION It is necessary to flow a minimum of 200 GPM through each Rotary Spray Nozzle when the ambient air temperature is below freezing in order to maintain sufficien water flow rate inside the cooling tower module to prevent accumulation of ice inside the tower 9 4 3 Optional Basin Heater Installation Testing Start up amp Operation Refer to basin heater user s manual for full installation details Optional Basin Heater General Description When operating a cooling tower in extreme cold temperatures it is recommended that users specify the use of an electric immersion heater to protect against accidental basin freezing Tower Tech offers a stainless steel electric immersion heater and cont
133. rease tower weight causing failure of the tower lifting mechanism 3 Inspect the lifting bracket attachment for cracks or loose hardware Refer to Figure 24 Figure 25 Lifting Bracket Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 58 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Ww Outperform 4 Prepare and position lifting item such as clevis lifting cables spreader beam guide rope and or any other incidental items needed for a complete and safe lifting operation Refer to Figure 25 and Table 9 for appropriate lifting cable length and the spreader beam length Spreader bar must run the full length of the tower as shown in Figure 25 and not the short side of the tower Recommended cable and beam lengths are designed to minimize side loading of tower walls Position crane at the center of the tower misaligned lifting will damage the tower shell and or its water tightness 5 Lift the tower module from the trailer and attach the tower sub structure Verify that the cooling tower support platform is level and if not provide ample shimming such that full bearing is achieved under the tower s footpads Uneven tower placement will lead to operational difficulties 6 Lower the tower module to its final position Fully tighten the anchoring bolts Lower the crane and check the tower for stability while it is still attached to the crane
134. red water level refer to Figure 39 for details then tighten adjusting bolt INTERIOR SUMP WALL MAKE UP MT i WATER VALVE 1 or 2 MAKE UP WATER CONNECTION T i 8 POLYPROPYLENE 77 FLOAT BALL Figure 46 Mechanical Float Valve Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 118 of 130 TTXL Series Installation Operation and Maintenance Manual gg Towkn Qufperform 10 1 11 Sump Screen It is important to visually inspect and document contents retrieved from the sump screen as it can provide valuable information in regards to potential damaging contaminants and preventing their future re entry into the system Use a construction start up screen for extra protection anytime fill media is removed from and reinstalled in the cooling tower To remove the sump screen 1 Shut off pump s 2 Remove sump lid 3 Pull screen out of sump 4 Empty contents of screen To install the sump screen reverse steps 1 through 3 SUMP LID STAINLESS STEEL a SUMP SCREEN p e a A a SUMP FLOAT VALVE ACCESS COVER MAKE UP WATER CONNECTION OVERFLOW EQUALIZATION CONNECTION SUMP OUTLET FLANGE Figure 47 Sump Layout Sump Screen Detail Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 119 of 130 TTXL Series Installation Operation and Maintenance Manual i Tower TECH Outperform 10 11 12 Imm
135. resent in the recirculating water Pulp Paper and Steel Mills Applications with generally poorer water quality may specify vertical flute fill media to minimize the potential for fill plugging Such applications may have higher levels of TSS 25500 PPM with no upper limit 1000 PPM if oil or grease are present or if there is no biological control make up water is from surface waters biological or scale control is poor and or oils or grease may be present up to 25 PPM in recirculating water Refer to Table 3 for data on 38mm vertical flute fill e Entering Water Temperatures PVC fill media is recommended for applications in which the temperature of tower entering hot water does not exceed 130 F in continuous operation HPVC fill media is required for applications in which the temperature of tower entering hot water ranges from 130 F to 140 F in continuous operation PVC and HPVC fill media can tolerate temperature excursions of up to 15 F for up to two hours if the excursion is supported by the fill media manufacturer s recommendations Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 25 of 130 TTXL Series Installation Operation and Maintenance Manual 1 Tower TECH Outperform CAUTION The fill bearing capacity can be affected by the accumulation of silt dirt process leaks and debris The fill media is supported by Tower Tech s patented Water Collection System The load bearing cap
136. rical power to all optional basin heaters turned off and the tower cold water basin must be drained To drain remove any of the four Inspection Ports located at each tower module s corners Tower modules manufactured after October 2009 also have two Inspection Ports located on the bottom of each Mid Basin A tower module manufactured after October 2009 also may contain an optional Basin Drain Kit consisting of a 2 stainless steel threaded coupling with plastic plug installed in each of two Inspection Port Covers located underneath tower in opposite corners of basin channel To ensure each tower module drains completely remove any Mid Basin Inspection Port Cover in each tower module or any 2 plastic plug in each tower module Refer to Figure 38 Refer to Section 9 4 2 i HS1 MID BASIN INSPECTION PORT OPTIONAL BASIN DRAIN PORTS 2 5 5 THREADED COUPLING Figure 39 Mid Basin Inspection Ports 6 fan tower module shown Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 91 of 130 TTXL Series Installation Operation and Maintenance Manual i Tow ER Outperform 5 9 4 2 Cold Weather Operations When the tower will be out of service for an extended period the basin must be drained of water Drains are to be located in the tower s supply and discharge piping Also refer to Section 9 4 1 Leave the drain valves open to prevent rain or snow from collecting
137. rict requirement for the TTXL Series tower unless 1 the tower is located in a high dust environment or 2 the downstream process requires higher than normal quality process cooling water in which case it is recommended Q Blowdown does little in the way of reducing solid loads because there is little chance that particulates will be positioned near the tower s blowdown valve at the time blowdown or bleed occurs Q Cyclone or centrifugal separators as well as other self cleaning impervious filtration technologies are preferred over media beds The latter affords bacteria the opportunity to establish ecological niches insulating them from biocides 9 5 3 Biological Control Biological control is important both for safety e g Legionella thermal performance Pseudomonas or slime formers can plug fill and corrosion control sulfate reducing bacteria nitrifying bacteria and iron reducers can all produce metabolic end products that are damaging to metal surfaces in piping and downstream equipment reasons Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 105 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform DANG Cooling towers as well as other water atomizing devices such as sprinklers misters shower nozzles etc are potential vectors for the spread of Listeria the causative agent of Listeriosis a type of pneumoniae It is cruci
138. rift eliminators can be damaged by the use of some chemicals Always use cleaning and water treatment chemicals in accordance with recommendations of a water treatment contractor In addition to the chemicals described above for scale inhibition and or modification there are numerous non chemically based methods available in the market and the list of emerging technologies grows yearly Oxidation Reduction Redox based alloys copper zinc have had an excellent history of scale control in Tower Tech towers Alternative methods such as ozone must be used with stringent control as ozone radicals are known to embrittle PVC components such as fill media 9 5 2 Solids Control Undissolved solids are a measure of the insoluble substances found in suspension in cooling tower waters Undissolved Solids include larger diameter heavy particles such as bacteria algae clam mussel larvae leaves twigs silt in make up water dust in air migrated corrosion particles free metal oxides It may also include colloids or complexes generated by using treatment compounds e g stabilizing agents for scale control and crystal modifiers The TTXL Series Modular Cooling Tower s absence of side air louvers and open basins dramatically decreases the potential for undissolved solid entry into the circulating loop as compared with conventional tower designs Further the presence of a high velocity perimeter basin permits more effective use of centrifugal separators
139. rol package as optional equipment The package consists of electric immersion heater element s a heater control panel and a combination temperature liquid level sensor This equipment is designed to prevent basin freeze up during shutdown or standby conditions The electric immersion heaters are sized kW rating voltage phase and sensor cord immersion length for the specific tower basin size and climate Both the heater elements and the control panel are in NEMA 4X enclosures suitable for mounting in outdoor locations Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 93 of 130 TTXL Series Installation Operation and Maintenance Manual D Tower Outperform CAUTION The basin heater element s and control panel s are not designed to prevent icing of the tower components during tower operation DANG ER Each heater element contains a fused thermal cutoff device that MUST be wired into the safety circuit as detailed in the installation wiring drawing This cutoff device is wired in series with any other optional safety devices Immersion basin heaters MUST be deactivated when water is flowing through the cooling tower Failure to do so will result in overheating of the basin heater element and accidental fire For a cooling tower installation having only one pump it is recommended that the heater control system be interlocked with the tower s circulating water pump so th
140. rranged in a variety of configurations The design also enables modules to be interconnected to accommodate virtually any cooling load The design allows for the easy addition of new modules to a set of existing modules if the demand for cooling increases 1 2 Use Pay particular attention to the following symbols when reading this manual o NOTE Notes are intended to clarify or make the installation easier CAUTION Cautions are given to prevent equipment damage G E R Danger warnings are given to alert installer and operators that personal injury and or equipment damage may result if correct installation and operational procedures are not followed Read all parts of this manual before installation or operating the tower Contact our Customer Service Department at 405 979 2123 if you have any questions A CAUTION This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes G E R Disconnect and lock out electrical power before attempting to inspect repair or perform maintenance on the module Failure to follow installation instructions specified herein may create a condition whereby the operation of the product could cause personal injury property damage and or death Tower Tech assumes no liability for situations resulting from the failure to follow d
141. rs it is a lesser known truth that scale accumulation has an adverse effect on cooling tower thermal efficiency Even minor visible scale accumulation on cooling tower fill the tower s heat exchange medium can prevent the even distribution of water as a thin film across the fill heat exchange surface In the event that scale accumulation is great it may have a significant impact on static pressures observed within the tower and thus the free and even flow of air through the Water Collection System and fill media Lastly significant scale accumulation can impose weight loads upon the tower sufficient to distort walls leading to seal leaks as well as failures in the water collection system Cooling tower water must be controlled for solids including both dissolved and undissolved solids Dissolved solids include the scaling ions e g magnesium Mg calcium Ca sulfate 50 phosphate PO5 and the non scaling ions e g chloride sodium Na etc Use a tiered approach to control the concentration and impact of dissolved solids on your TTXL Series Modular Cooling Tower and system equipment e g heat exchangers chillers etc 1 use of scale inhibitor s and 2 periodic blowdown or bleed governed by a conductivity or TDS controller A good rule of thumb for operating Cycles of Concentration is to control the tower s recirculating water conductivity TDS at a level which is 3 4 X that measured in the make up water applies to water s of a
142. s in order to install and later remove the heater element for inspection or service 2 The control panel can be safely mounted to the bottom of the tower module s 4 5 high apron however care must be taken to remain within the boundaries of the tower apron avoiding any possibility for penetration of the tower s Perimeter Basin or leaks will result See Figures 17 39 and Tables 7A 7B for information regarding the immersion basin heater control panel Alternatively the immersion basin heater control panel may be mounted to a corner leg of the tower module It is recommended that the panel be bolted to a Unistrut mount which is mounted across the leg brace and the leg If a remote location from the tower is selected for mounting the control panel bear in mind that the unit ships with a standard 12 probe cord length Longer lengths are optionally available up to 100 in length contact your Tower Tech Sales Representative for details DANGER Use only Tower Tech approved combination temperature liquid sensor probes Failure to do so may result in accidental fire 3 Heater element must be inserted into the Tower Tech installed stainless steel flange fitting The heater element is a 6 kW element manufactured of 304 stainless steel Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 95 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform lt AD A
143. size of the component and number of accessories purchased with the modular cooling tower See Table 12 for a general guide to the accessory location o hardware and accessories are inspected and documented prior to shipment When the shipment arrives all components should be inventoried and reconciled with the shipping documents Component Shipping Location Basin Heater Control Panel Bubble Wrapped inside the sump box that is palletized Basin Heater Element s Bubble Wrapped inside the sump box that is palletized Basin Heater Sensor Attached by cable to the Basin Heater Control Panel Electronic Level Control Panel Kit B Bubble Wrapped inside the sump box that is palletized Electronic Level Control Sensor Kit A Bubble Wrapped inside the sump box that is palletized Electronic Level Control Sensor Kit B Inside the Electronic Level Control Panel Electronic Level Sensor Still Well Pipe Bubble Wrapped inside the sump box that is palletized Mechanical Float Ball and Stem Bubble Wrapped inside the sump box that is palletized RTD Temperature Sensor Inside Panel T2100 or T9900 only Substructure Braces and Legs Palletized and shipped on truck bed Substructure Hardware Boxed and placed inside the sump box that is palletized Sump Hardware Boxed and placed inside the sump box that is palletized T2100 Motor Protection Panel Boxed and palleti
144. talled oO oO oO Is there a control isolation valve hot water LH Is there a control isolation valve cold water E Is the overflow equalization piping installed according to IO amp M oO What is the height of the Overflow Pipe from bottom of Tower Does the make up line have maximum 25psi PRV and is it sealed to the fitting LH Is the inlet outlet piping installed according to IO amp M limits LH Inlet Piping Size Outlet Piping Size Verify Electrical Components amp Wiring Ref Submittals Lockable disconnect present within sight of cooling tower If Tower Tech Panel is not installed is there individual motor overload protection LH Verify Proper Direction of Fan Rotation Li Verify Electrical Terminations Tight amp Secure Verify field wiring from motors to J box or Disconnects LH Verify power feed s to tower Control Panel oO Li oO Comments Inspected By Date Company r Tech Inc 5th S homa City TTXL Series Installation Operation and Maintenance Manual Date 02 18 2015 Page 72 of 130 gt Tower TECH Outperform e Tower TECH Tower Start up Warranty Registration Owner Operator Training Checklist Project S N Date ELECTRICAL FAN Fan Startup Hand Mode Without Water Flowing Set HOA switches to OFF Initiate Power to Control Panel Verify settings for Thermal Overload Protectio
145. ter basin as the temperature sensing probe to prevent the possibility of fire element contains a fused thermal cut off device to prevent over heating of the element Refer to location of immersion basin heater and probe in Figure 17 Tower TECH Outperform INDEECO 6KW Heater Voltage And Amp Draw KW Per Total Voltage of Heaters Element Amps Panels needed Panel Amp Rating 208 3 1 6 16 7 1 39 33 208 3 2 12 33 3 1 39 33 208 3 3 18 50 1 1 64 208 3 4 24 66 7 1 80 240 3 1 6 15 1 1 39 33 240 3 2 12 30 2 1 39 33 240 3 3 18 45 2 1 48 240 3 4 24 60 3 1 64 480 3 1 6 7 5 1 14 5 480 3 2 12 15 1 1 39 33 480 3 3 18 22 6 1 39 33 480 3 4 24 30 2 1 39 33 575 3 1 6 5 8 RL 1 14 5 575 3 2 12 11 7 1 14 5 575 3 3 18 17 4 1 39 33 575 3 4 24 23 2 1 39 33 NOTE RL denotes custom panel with the relabeled panel tag Relabeled panel has 40 amp contactor however the tag is rated for 14 5 amps max Stock Control Panel Listing Table 7A Indeeco 6kW Amp Chart Tower Tech Modular Cooling Tower MK9000 12 TTXL Series Installation Operation and Maintenance Manual Max Panel Number of Maximum Panel kW Rating Enclosure Amps Circuits Volts 3 Phase Dimensions 40 1 14 2 16 6 332 8 x 10 x 6 48 1 17 2 19 9 39 8 10 x 12 x7 Date 02 18 2015 Page 41 of 130 Each heater
146. ter element s ON and OFF if the basin liquid temperature is below 45 F DANGER Disconnect the heater control panel at its source and tag the circuit out for maintenance before performing the following steps Optional Immersion Basin Heater Operation above 45 F a Disconnect the heater control panel and tag circuit out for maintenance b Remove the heater control panel enclosure cover c Remove the sensor wires connected to terminals and T2 on the combination temperature low level control and isolate them Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 96 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform d Install the 1 5K ohm test resistor supplied with the heater control panel in bag inside of cover across terminals T1 and T2 e Install the heater control panel enclosure cover f Energize the system You should hear the contactor s close energizing the heater s CAUTION Do not operate system unattended or for extended periods with the resistor across terminals and T2 The excessive water temperature could damage the cooling tower g After operation de energize the circuit remove the resistor and place it back into its storage bag Check all connections reconnect sensor wires per the wiring diagram to terminals T1 and T2 replace the cover and place the system back in service Basin Heater
147. tween the air and water with a minimum resistance impedance to airflow The fill used by Tower Tech meets the rigorous standards of the Cooling Technology Institute STD 136 88 by having uniform thickness and hole air bubble and foreign matter free and free of other manufacturing defects which may adversely affect performance The standard TTXL Series Modular Cooling Tower contains PVC film fill media stacked to a depth of five feet The selection of the type of fill media used will vary from one installation to another due to variances in water quality and or performance requirements Tower Tech Modular Cooling Tower Date 02 18 2015 9000 12 Page 24 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform e Comfort Cooling Utility and Industrial Applications Generally clean to medium quality water applications would benefit from the use of a cross corrugated fill media with a standard flute size to minimize the potential for plugging while maintaining performance efficiency Refer to Table 3 for data on 19mm cross corrugated fill media Generally the selection of CF 1900 is most suitable when 1 Total suspended solids TSS are 25 PPM TSS 100 PPM where bacterial activity is very low 2 Make up water is from uncontaminated sources 3 Biological and scale control is good 4 Cycles of concentration are low 5 Airborne dust is minimal 6 Oils and grease are not p
148. uctions to free flow of exiting air Such obstructions create static pressures that negatively impact air velocity through the tower 5 3 Tolerances 5 3 1 Leveling Use a level slab or piers in conjunction with a support leg for ground level installation The thickness and size of the pad should meet local codes and unit weight requirements Do not tie the slab to a building foundation CAUTION A full level bearing must be provided under each footpad area Failure to provide may result in damage to the tower ranging from seal leaks to loss of structural integrity Maintain level tolerance to 4 inch 6 35 mm maximum across the entire length or width of the module 5 3 2 Foundation Slab or Pier Requirements Weights are provided in the drawings for towers Information provided includes dry shipping weight and operating weight Roof structures must be able to support the maximum weight of the module and its accessories Install the module on a solid steel frame or appropriate substructure Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 50 of 130 TTXL Series Installation Operation and Maintenance Manual D Tower TECH Outperform 5 3 3 Positioning Install modules with a minimum of 2 inches 5 1 cm between them in order to accommodate inherent manufacturing tolerances for the tower and the components CAUTION Do not install towers with more than 6 inches 15 2cm clearance between
149. ut capability The control panel comes completely pre wired Terminal blocks are provided for the main power feed and the individual fan motor connections and any externally mounted control input and outputs The standard enclosure for the optional motor control panel is a NEMA 4 rated powder coated hinged steel box with full back plate and gasket door The T9900 series panels have a preprogrammed PLC and temperature input device to control fan cycling and or a remote variable frequency drive Each motor overload protector is equipped with an auxiliary relay Should a motor overload trip a dry contact signal can be wired in series or parallel back to a Building Management System or Building Automation System BAS for notification Refer to Figure 15 for a typical motor control panel layout VIEWSCREEN touch screen is standard on all Tower Tech T9900 control panels ordered after August 31 2011 The HMI touch screen comes equipped with a protective panel door that is lockable Door is hinged at the top to provide shade from the sunlight thereby making it easier to view the screen Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 35 of 130 TTXL Series Installation Operation and Maintenance Manual lt Tower Outperform CAUTION Do not mount motor control panels on the tower module s basin walls or casing walls as this will cause basin leakage or wall component failure Never mount or attach the
150. verage hardness Exceptions do exist to this rule of thumb depending on the exact chemical nature of the principal scale ions in the system see your professional water treater for details Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 103 of 130 TTXL Series Installation Operation and Maintenance Manual Tower Outperform The TTXL Series Modular Cooling Tower s non reactive composition allows for most industry accepted scale inhibitors to be used Scale inhibitor blends typically used are proprietary mixtures of phosphonates e g AMP HEDP etc and polymers co and terpolymers such as polymaleic acid phosphinocarboxylic acid PCA polycarboxylate copolymer acrylate polymers all of which are effective at scale control and have no negative effect on materials used in Tower Tech TTXL Series Modular Cooling Towers In order for scale control agents to have their best effect it is often necessary to dose the system with acid e g sulfuric acid to maintain the pH range of 6 5 8 5 CAUTION If acid is added to the cooling water loop it must be added using an injection quill positioned at the center of the return pipe to the tower and well upstream of the tower to ensure sufficient mixing before entering tower module Failure to do so may result in damage to cooling tower components which are normally resistant materials CAUTION Cooling tower fill media and d
151. wer Date 02 18 2015 9000 12 Page 111 of 130 TTXL Series Installation Operation and Maintenance Manual 1 Tower TECH Outperform CAUTION If a cooling tower module is valved out seasonally without adjusting flow rates across the remaining cooling tower modules the Rotary Spray Nozzle s upper flow limit of 320 GPM may be exceeded and result in damage to the remaining online nozzles 10 1 4 Fan Guards DAN G E R When maintenance is required on fan guards fans or fan motors it is imperative that lock out tag out procedures be strictly adhered to prevent damage to equipment or personnel Fan guards are mounted in a frame with convenient hinged access Regularly check the guard for large items such as paper or leaves that might be sucked against the guard It is important to the performance of the cooling tower that any air restrictions be removed To replace a fan guard refer to Figure 37 for close up of hinge hardware 1 Turn off fan and lock and tag out power 2 Remove the six 1 4 bolts that hold the screen angle to the tower mid basin and perimeter wall using a 7 16 wrench 3 Unbolt the screen from the hinge by removing the three remaining 1 4 bolts Figure 44 Close Up Fan Guard Hardware Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 112 of 130 TTXL Series Installation Operation and Maintenance Manual 69 Tower Outperform M N
152. wherein organic leaks into the cooling loop are possible 9 5 4 Corrosion Control Corrosion control is necessary in TTXL tower systems not for preventing damage to the cooling tower itself but rather to prevent damage to downstream piping and equipment The cooling water acts as a delivery mechanism for bringing the corrosion inhibitors to the appropriate metal surfaces A discussion of corrosion control is beyond the scope of this document however a few things bear noting A good corrosion inhibitor must 1 protect all metals involved 2 act at low concentrations 3 act under variety of water conditions pH temp other chemicals 4 have minimal adverse environmental impact Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 106 of 130 TTXL Series Installation Operation and Maintenance Manual gt Tower TECH Outperform Chapter Ten Maintenance Adequate knowledge of the operation and maintenance of the Tower Tech TTXL Series Modular Cooling Tower will ensure efficient and safe operation Failure to follow these instructions may result in poor cooling performance and unnecessary equipment failure The operation maintenance and repair of this equipment should be undertaken only by qualified personnel All such personnel should be thoroughly familiar with the equipment the associated system and controls and all procedures dealing with the handling lifting installation operation mainte
153. xceed the tower flange connection height without engineering review and approval Tower Tech Modular Cooling Tower Date 02 18 2015 MK9000 12 Page 51 of 130 TTXL Series Installation Operation and Maintenance Manual Tower TECH Outperform 5 3 5 Multi Tower Configuration Tower Tech recommends a common manifold pipe be installed for the hot water pipe and cold water piping when operating multiple cooling towers A common manifold pipe is critical to balance the flow of the system Figure 21 below illustrates the proper use of a common manifold to eliminate problems with pressure drop across the cooling tower connection flanges It is important to connect the hot water pipe and the cold water pipe to the center of the common manifold for proper equalization The piping layout shown in Figure 21 will help insure the tower with the shortest pipe distance to the pump doesn t pull air into the system during startup or overflow during shutdown of the pumps The common manifold for the hot water piping should be installed to allow for riser connections to the inlet flanges of the cooling tower Figure 21 Multi Tower Layout and Piping Recommendations 5 4 Sub Structure Installation CAUTION If the holes for the substructure legs or bracing do not align with the cooling tower do not drill new holes or bore out the existing holes You can lower the weight of the tower onto the fiberglass leg to insure it has been fully ins
154. zed if not pre mounted on tower T9900 Control Panel Boxed and palletized on individual pallet VFD Controls Boxed and palletized on individual pallet Components and Accessories are optional items and may not be included with each project Table 9 Accessory Location List Tower Tech Modular Cooling Tower MK9000 12 Date 02 18 2015 Page 57 of 130 TTXL Series Installation Operation and Maintenance Manual 1 Tower Outperform 6 3 Procedure DANG E R Under NO circumstance should a tower be lifted above any personnel DANG Never attempt to lift or move a tower module using a forklift as damage to the tower as well as injury to personnel may result CAUTION Excessive side loading can result in leakage caused by broken seals permanent bending of structural members or ultimate failure of the casing panels Place the tower on a sound and level surface whenever ground storage is needed Always use cribbing diagonally across each corner when setting the tower on the ground or other surface without substructure attached to prevent damage to the bottom side of the cooling tower 1 Check the tower s condition prior to lifting Report any damage to the manufacturer prior to the acceptance of the tower 2 Remove any excess water rainwater snow melt ice from the tower module s cold water basin prior to lifting the tower as excess water can drastically inc

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