Sterling Fan 88200440000 User Manual

SF Series  
Fiberglass Cooling Towers  
Part Number: 882.00440.00  
Bulletin Number: SC6-610.5  
Effective: 6/15/07  
Write Down Your Serial Numbers Here For Future Reference:  
_________________________  
_________________________  
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We are committed to a continuing program of product improvement.  
Specifications, appearance, and dimensions described in this manual are subject to change  
without notice.  
DCN No. ____________  
© Copyright 2007  
All rights reserved.  
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Table of Contents  
CHAPTER 1: SAFETY................................................................6  
1-1 How to Use This Manual ................................................................................. 6  
Safety Symbols Used in this Manual.....................................................................6  
1-2 Warnings and Precautions .............................................................................. 7  
1-3 Responsibility.................................................................................................. 7  
CHAPTER 2: FUNCTIONAL DESCRIPTION.............................8  
2-1 Models Covered in This Manual...................................................................... 8  
2-2 General Description ........................................................................................ 8  
2-3 Standard Features .......................................................................................... 8  
Materials of Construction.......................................................................................8  
2-4 Optional Features............................................................................................ 9  
CHAPTER 3: INSTALLATION..................................................10  
3-1 Tower Installation Location............................................................................ 10  
Roof Installation...................................................................................................10  
Ground Installation ..............................................................................................10  
Alternative Installations .......................................................................................10  
3-2 Assembling the Cooling Tower in the Field ................................................... 12  
3-3 Rigging.......................................................................................................... 13  
3-4 Installing the Fan Package............................................................................ 13  
3-5 Installing Piping............................................................................................. 13  
3-6 Setting Up the Water Balancing Valve .......................................................... 16  
3-7 Initial Start-up................................................................................................ 16  
CHAPTER 4: OPERATION.......................................................17  
4-1 Bleed-Off and Evaporation Rates.................................................................. 17  
4-2 Winter Operation Considerations .................................................................. 17  
CHAPTER 5: MAINTENANCE .................................................18  
5-1 Preventative Maintenance............................................................................. 18  
Water Treatment .................................................................................................18  
Routine Maintenance ..........................................................................................18  
5-2 Corrective Maintenance ................................................................................ 19  
Replacing Nozzles and Fill..................................................................................19  
CHAPTER 6: APPENDIX..........................................................20  
6-1 Technical Assistance .................................................................................... 20  
Parts Department ................................................................................................20  
Service Department.............................................................................................20  
Sales Department................................................................................................20  
Contract Department...........................................................................................20  
6-2 Drawings and Specifications ......................................................................... 21  
Fiberglass Cooling Towers  
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6-3 Parts List ....................................................................................................... 24  
6-4 Electrical Schematics.................................................................................... 25  
Fiberglass Cooling Towers  
iv  
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List of Figures  
Figure 1: Structural Steel Support Requirements ......................................................................... 11  
Figure 2: Rigging Arrangement.................................................................................................... 13  
Figure 3: Cooling Tower with Tower Reservoir Piping Diagram................................................ 14  
Figure 4: Cooling Tower with Basin as Reservoir Piping Diagram............................................. 14  
Figure 5: Flexible PVC Outlet Coupler ........................................................................................ 15  
Figure 6: Throttling Valve Pressures............................................................................................ 16  
Figure 7: Dimensions and Weights............................................................................................... 21  
Figure 8: Tower Performancec.................................................................................................... 22  
Figure 9: Cooling Tower Nozzle Capacity................................................................................... 23  
Figure 10: Supplied Parts for Field Assembly.............................................................................. 24  
Figure 11: Spare Parts List............................................................................................................ 24  
Figure 12: Typical Wiring Diagram ............................................................................................. 25  
Fiberglass Cooling Towers  
v
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Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance  
equipment productivity.  
This manual covers only light corrective maintenance. No other maintenance should be  
undertaken without first contacting a service engineer.  
The Functional Description section outlines models covered, standard features, and optional  
features. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, preventive maintenance, and corrective maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the equipment. We can also provide the assistance of a factory-trained technician to help  
train your operator(s) for a nominal charge. This section includes instructions, checks, and  
adjustments that should be followed before commencing with operation of the equipment.  
These instructions are intended to supplement standard shop procedures performed at shift,  
daily, and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the equipment safely and efficiently.  
The Maintenance chapter is intended to serve as a source of detailed assembly and  
disassembly instructions for those areas of the equipment requiring service. Preventive  
maintenance sections are included to ensure that your equipment provides excellent, long  
service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, and parts lists. A  
spare parts list with part numbers specific to your machine is provided with your shipping  
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your  
serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
Danger! DANGER indicates an imminently hazardous situation which, if not avoided,  
will result in death or serious injury.  
Warning! WARNING indicates a potentially hazardous situation or practice which, if not  
avoided, could result in death or serious injury.  
Caution! CAUTION indicates a potentially hazardous situation or practice which, if not  
avoided, may result in minor or moderate injury or in property damage.  
Fiberglass Cooling Towers  
Chapter 1: Safety  
Page 6 of 25  
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1-2 Warnings and Precautions  
Our equipment is designed to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety codes.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this equipment, use good judgment and follow these safe practices:  
; Follow all SAFETY CODES.  
; Wear SAFETY GLASSES and WORK GLOVES.  
; Disconnect and/or lock out power before servicing or maintaining the equipment.  
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this  
equipment.  
; Operate this equipment within design specifications.  
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.  
You should remove the fuses and carry them with you.  
; Make sure the equipment and components are properly GROUNDED before you  
switch on power.  
; When welding or brazing in or around this equipment, make sure VENTILATION is  
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with  
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and  
ready for use if needed.  
; Refrigeration systems can develop refrigerant pressures in excess of 500 psi (3,447.5  
kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION SYSTEM. This  
must be performed by a qualified service technician only.  
; Do not restore power until you remove all tools, test equipment, etc., and the  
equipment and related components are fully reassembled.  
; Only PROPERLY TRAINED personnel familiar with the information in this  
manual should work on this equipment.  
We have long recognized the importance of safety and have designed and manufactured our  
equipment with operator safety as a prime consideration. We expect you, as a user, to abide  
by the foregoing recommendations in order to make operator safety a reality.  
1-3 Responsibility  
These machines are constructed for maximum operator safety when used under standard  
operating conditions and when recommended instructions are followed in the maintenance  
and operation of the machine.  
All personnel engaged in the use of the machine should become familiar with its operation as  
described in this manual.  
Proper operation of the machine promotes safety for the operator and all workers in its  
vicinity.  
Each individual must take responsibility for observing the prescribed safety rules as outlined.  
All warning and danger signs must be observed and obeyed. All actual or potential danger  
areas must be reported to your immediate supervisor.  
Fiberglass Cooling Towers  
Chapter 1: Safety  
Page 7 of 25  
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Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual covers fiberglass cooling tower models. Model numbers are listed on the serial  
tag. A model number followed by –Q is specially-constructed, and the information in this  
manual may not apply. Make sure you know the model and serial number of your equipment  
before contacting the manufacturer for parts or service.  
2-2 General Description  
The fiberglass cooling tower system is constructed of lightweight polyester-reinforced  
fiberglass for corrosion resistance and durability. PVC fill material resists decay, corrosion,  
and microorganisms, and handles temperatures up to 130ºF (54ºC). Access panels allow easy  
inspection of fill material. Fan blades are factory-tuned for optimum performance. ABS water  
distribution nozzles are pre-piped and feature a non-clogging design.  
2-3 Standard Features  
Materials of Construction  
Component  
Shell  
Material  
Fiberglass-reinforced polyester  
Aluminum fabrication  
Galvanized, mild steel  
PVC Plastic  
Fan blade  
Fan motor support  
Fill, eliminator  
Louver pack  
Nozzle  
PVC Plastic  
ABS plastic  
Piping assembly  
Fasteners  
Schedule 80 PVC plastic  
Stainless Steel  
Support Feet  
Bottom Outlet  
Fiberglass brackets standard  
Fiberglass  
Water Balancing Valve Aluminum  
Fiberglass Cooling Towers Chapter 2: Functional Description  
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2-4 Optional Features  
Side Outlet. The side outlet is used when the tower basin is used as a reservoir.  
Starter Package. The starter package includes a starter, a remote On/Off switch, a  
thermostat, and a well.  
Basin Reservoir. The basin reservoir includes an automatic float valve, overflow and drain  
connections, and an outlet basket strainer for towers with no inside reservoir.  
Basin Heater. The basin heater includes a heater and a low water level heater shutoff. It is  
used on towers with basin reservoirs to guard against freeze-up when your tower system is  
shut down.  
Structural Base. The structural base is a factory-provided structural steel mounting base. It  
speeds tower installation and gives your tower proper support.  
Access Ladder. The access ladder meets OSHA specifications and allows for easier  
maintenance and inspection.  
Fiberglass Cooling Towers Chapter 2: Functional Description  
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Chapter 3: Installation  
3-1 Tower Installation Location  
Roof Installation  
Select a location over or nearest to the heaviest building structural members. These members  
should be outside load-bearing walls, building columns, or roof joists. You may need to  
spread the load over several structural members to provide support without over-stressing any  
one member. See Figure 1 on page 11 for structural steel support requirements. You are  
responsible for contacting a structural engineer to verify support requirements.  
Choose a site with easy access to simplify routine maintenance. This consideration is  
especially important when a tower is located near a roof edge.  
Avoid locations where wind currents can re-circulate tower discharge air.  
Stay clear of roof discharge points. Avoid stacks, exhaust fans, dust collector discharges, or  
any process that can contaminate air circulating through the tower.  
Caution! Multiple tower installations require at least five feet (60”/ 152cm) clearance  
between towers to reduce freeze-ups. The manufacturer is not responsible for  
damages resulting from improper site selection.  
Ground Installation  
Elevate the tower so that positive pressure is on pump suction and to allow maintenance  
access to the underside of the tower cell.  
Alternative Installations  
Outside Installation with the Pump Tank Reservoir Inside. Water exits the tower and  
drains to a pump tank reservoir inside the building below. The tower outlet must be at least  
three feet (approximately 1 meter) above the top of the pump tank. The outside tower basin  
must drain completely when shut down to avoid winter freeze up.  
Outside Installation Using the Tower Basin as a Reservoir. Process pump suction piping  
is directly connected to the bottom outlet on the tower. Install the optional outlet basket filter  
and automatic float assembly. Contact the Sales department for this accessory kit.  
Note: A dimension of 60”is required between the tower air inlet and the wall of a  
building. See above caution for required distance between towers.  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 10 of 25  
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Figure 1: Structural Steel Support Requirements  
Structural steel  
B
B
2 X 2 angle  
to support  
tower basin,  
flush with top  
of structural  
steel rails  
D
A
C
C
C
C
TSE50  
Model  
number  
SF2003  
SF2004  
SF2005  
SF2007  
SF2009  
SF2011  
SF2015  
A
B
C
D
in.  
cm  
in.  
50  
50  
67  
67  
85  
85  
85  
cm  
in.  
cm  
in.  
78  
78  
78  
78  
78  
78  
78  
cm  
52  
52  
68  
68  
87  
87  
87  
132.1  
132.1  
172.7  
172.7  
221.0  
221.0  
221.0  
127.0  
127.0  
170.2  
170.2  
215.9  
215.9  
215.9  
16  
16  
22  
22  
28  
28  
28  
40.6  
40.6  
55.9  
55.9  
71.1  
71.1  
71.1  
175.3  
175.3  
175.3  
175.3  
175.3  
175.3  
175.3  
Note: The illustration in Figure 1 shows structural steel with spacing for two (2) cooling towers. Your  
installation may vary.  
Dimension A – Centerline for fiberglass mounting feet provided with cooling tower. This is so bolt holes  
can be made to secure the tower to the structural support.  
Dimension B & C – Location of basin support steel.  
Dimension D – Provides proper distance of 60” between cooling towers and distance between cooling  
tower and the wall of a building.  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 11 of 25  
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3-2 Assembling the Cooling Tower in the Field  
Your cooling tower may have been shipped on two skids to reduce shipping charges.  
One skid contains the lower section, identified by the black fill wrapped in plastic on the  
inside of the lower section. The second skid contains the top tower section bolted over the  
fan/motor assembly. Perform the following procedure to properly assemble the two sections  
if the sections shipped separately.  
1. Remove the clear plastic protective wrapping from the fill.  
2. Inspect both sections for any damage, and locate the red orientation mark on one of  
the vertical sides of each section.  
3. The manufacturer supplies self-adhesive gasketing material to insure a water-tight  
seal between the top and bottom sections. Install this material on the top of the  
attachment flange on the lower section prior to mating the top and bottom sections.  
Make sure that the flange is clean, dry, and free of rough spots before applying the  
gasketing material.  
4. Align the holes in the gasket with the bolt holes in the flange, then remove the paper  
on the back side. Cut the gasketing material to fit properly, and apply the gasket to  
the flange as you realign gasket holes with flange holes. Repeat on all four sides of  
the tower.  
5. Apply silicone caulk in cut lines and voids to complete sealing between sections.  
6. Unbolt the top section from the skid and make sure that the flange on the top section  
is clean, dry, and free of rough spots.  
7. Place the upper section on the gasketed lower section, aligning the red orientation  
marks. Take care not to disturb the gasketing and silicone caulk while aligning bolt  
holes.  
8. After aligning, bolt the two sections together with the fasteners provided. Use a flat  
washer under the bolt head on top and a flat washer, a lock washer, and nut on the  
bottom side of the flange.  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 12 of 25  
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3-3 Rigging  
Handle the fiberglass cooling tower shell section very carefully. Until installed and properly  
supported, it is subject to handling damage. See Figure 2 for rigging information.  
Caution! Use an appropriately rated hoist to support the equipment.  
Figure 2: Rigging Arrangement  
Channel  
I-beam  
Spreader bar wide  
enough to protect  
cooling tower shell  
Rope stay  
Caution! Use appropriately rated  
The rope stay goes  
all the way around the  
tower to keep the  
hoist to support equipment.  
vertical rope in position.  
Do not let the rigging transfer any load to the cooling tower shell. Provide support to  
the bottom of the cooling tower when rigging. Do not rig from the corners of the  
optional base. Do not rig less than 8 inches from the corners.  
3-4 Installing the Fan Package  
Install the fan package after the tower is in position.  
1. Remove the dunnage securing the fan package to the pallet.  
2. Carefully rig the package using the lifting eyebolts provided.  
3. Mounting holes have been pre-drilled at the factory; move the package into position  
and fasten it securely with the stainless steel hardware provided.  
3-5 Installing Piping  
Make sure that all piping attached to the cooling tower is externally supported. Do not  
support anything from the cooling tower shell.  
The cooling tower and related fittings and connections are constructed of plastic materials  
and are not designed to bear external weight.  
Do not apply high torque to the fittings that are made up into the tower fittings. Use a backup  
wrench when applying torque to the fittings.  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 13 of 25  
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Install the piping according to the piping diagrams in Figure 3 on page 14, Figure 4 on page  
14, and Figure 5 on page 15.  
Figure 3: Cooling Tower with Tower Reservoir Piping Diagram  
Type 2  
balancing  
valve  
Type 2  
inlet  
Type 2  
pressure  
gauge  
TWR  
P
TWR  
Support piping to eliminate  
load from tower casing  
Caution!  
Do not apply  
excessive torque  
to fittings  
Cooling tower  
Typical bottom outlet  
3/4" constant bleed  
Bypass  
3/8" drain line  
NOTE: Drain line is intended to prevent  
tower freeze-up. Do not valve.  
TWR  
TWS  
Tower water return  
Tower water supply  
TR  
TWS  
Overflow  
City water  
3/4" constant  
bleed  
Strainer basket  
Makeup  
P
Tower water  
reservoir  
Drain  
P-1  
T
To drain  
Figure 4: Cooling Tower with Basin as Reservoir Piping Diagram  
Inlet  
Balancing valve  
1/4" swing check valve  
12" above highest point  
in return line  
Pressure  
gauge  
Bypass  
P
TWR  
TWS  
TWR  
Tower water return  
Tower water supply  
Caution!  
3/4" constant bleed  
Do not apply  
excessive torque  
to fittings  
Overflow  
Makeup  
City water line  
City water  
Cooling  
tower  
Building  
exterior  
TWS  
Side outlet  
Drain  
TR  
To drain  
To drain  
Thermostat-mount  
in piping (1/2" fitting)  
P
Support piping to eliminate  
load from tower casing  
TR  
P-1  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 14 of 25  
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Figure 5: Flexible PVC Outlet Coupler  
Tower outlet  
Flexible PVC  
Coupling  
(from Sterling)  
Clamps  
(from Sterling)  
Outlet pipe must be  
supported from building  
structure or tower steel  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 15 of 25  
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3-6 Setting Up the Water Balancing Valve  
Install the plug provided in the unused water inlet on the side of the tower. Tighten and check  
for leaks.  
To prevent damage to the tower fill material, use the water throttling valve and pressure  
gauge to regulate the water pressure to the tower spray nozzle(s). The recommended  
throttling valve is a butterfly-type valve that can be locked in the correct position with a  
locknut. See Figure 6 for recommended throttling valve pressures.  
Figure 6: Throttling Valve Pressures  
Model  
Pressure  
psig  
KPa  
SF2003 10 psig 68.95  
SF2004 7 psig  
Sf2005 3 psig  
48.26  
10.68  
34.47  
41.37  
55.16  
SF2007 5 psig  
SF2009 6 psig  
SF2011 8 psig  
SF2015 10 psig 68.95  
Warning! Exceeding these pressure limits will damage the tower fill and nozzle and void  
the tower warranty.  
3-7 Initial Start-up  
Check for proper rotation on all fan and pump motors. Refer to the arrows atop the tower and  
on pump housings.  
Fill the system with water and adjust the float valve if you are using a float. Maintain a water  
level in the tower basin approximately one inch (25 mm) below the overflow opening.  
The tower basin acts as a sump to maintain water level. Towers using inside tanks do not  
carry water in the basin.  
Fiberglass Cooling Towers  
Chapter 3: Installation  
Page 16 of 25  
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Chapter 4: Operation  
4-1 Bleed-Off and Evaporation Rates  
A proper bleed-off rate is important to limit the concentration of minerals and foreign  
materials in re-circulated water. A bleed-off equal to the evaporation rate, normally about two  
gallons per hour per ton (7.57 liters per hour per 3,780 Kcal/hr), is sufficient for many  
makeup water conditions. Refer to the suggested bleed-off arrangements in Figure 3 and  
Figure 4 on pages 14 and 14 for more information. For automatic bleed rate control, a  
conductivity controller is available through the Sales department.  
4-2 Winter Operation Considerations  
All cooling towers are subject to ice formation in sub-freezing weather. Your cooling tower  
requires a certain amount of attention and maintenance to prevent damage during these  
operating conditions.  
Follow these guidelines to reduce the chance of ice buildup:  
Maintain full design flow. Any reduction in water flow greatly increases the  
probability of ice forming on and around the air inlet louvers.  
Do not use free cooling applications during freezing weather. Reduced water  
temperatures or loading dramatically increases the chance of ice formation. Make sure  
that the leaving water temperature is set above 80ºF (27ºC) during sub-freezing  
weather so heat from the water warms the air inlet louvers and reduces ice formation  
when the fan is off. Using a thermostat to control fan cycling by leaving water  
temperature is mandatory.  
Do not run fans backward to thaw ice. Ice can form on the fan ring, fan guard, and  
support structures, and can severely damage fan blades. Reversed airflow can also  
blow water vapor out onto the roof and create ice fields around the cooling tower.  
Maintain a heat load of at least 60% of tower capacity at all times during operation in  
freezing weather. A lack of substantial load can create uneven temperatures in the  
tower and cause freezing.  
If you shut down your cooling tower during freezing weather, you must drain it  
completely. We recommend that you use an indoor reservoir tank to permit water to  
drain into the tank on system shutdown, whether for emergencies or actual planned  
shutdowns.  
An alternative is to use basin heaters if a tower basin is used as a sump. Basin heaters  
are available as an option. However, basin heaters can permit freeze-up during power  
failures if water remains in the sump. The customer is responsible for determining risk  
factors for each specific application.  
Fiberglass Cooling Towers  
Chapter 4: Operation  
Page 17 of 25  
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Chapter 5: Maintenance  
5-1 Preventative Maintenance  
Water Treatment  
Control of slime, algae, and bacteria growth is extremely important. Cooling towers and  
reservoir pump tanks are superb environments for microorganism growth. Warm water,  
organic debris, and air encourage bacterial growth. Treat your system with chemicals  
(microbiocides) to control microorganism growth.  
Caution! Uncontrolled microorganism growth causes system problems such as fouling  
and corrosion, and can spread bacterially-transmitted diseases.  
You must reduce slime growth and bacterial contamination to eliminate disease-causing  
bacteria.  
Properly used, environmentally approved microbiocide controls system bacteria. Chemical  
treatments must be regularly monitored by qualified personnel.  
The manufacturer strongly recommends use of EPA-registered microbiocides on a regular  
basis. We do NOT recommend use of chlorine or backyard swimming pool chemicals.  
Permitting the discharge of such chemicals into a city sewer may violate local, state, and/or  
federal laws.  
We offer a full-service water treatment program including chemicals, dispensing equipment,  
automatic bleed-off, and monthly water analysis. Contact the Parts and Service department  
for more information.  
Routine Maintenance  
The fan motor has double-sealed bearings and needs no lubrication  
Inspect basket strainers (where used) and clean as needed.  
Check constant bleed back to the tank for flow during operation.  
Check the bleed-off line to verify that water flows to the drain during operation.  
Inspect the tower basin for dirt and debris, and clean as needed.  
Check the tower nozzle(s) for proper operation at full water flow.  
Check the water treatment equipment for proper operation. Refer to the information  
supplied with these devices.  
Check the throttling valve pressure gauge. The pressure should be within the  
recommendations in section 3-6.  
Fiberglass Cooling Towers  
Chapter 5: Maintenance  
Page 18 of 25  
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5-2 Corrective Maintenance  
Replacing Nozzles and Fill  
The PVC fill used in these cooling towers provides years of maintenance-free service under  
normal conditions. If you discover dirty water or defective nozzle(s) damage the fill, you can  
order a replacement kit from the parts department.  
You can easily remove and replace the fill by removing the tower access door on the side of  
the tower. Open the door to gain access to the nozzle system.  
Fiberglass Cooling Towers  
Chapter 5: Maintenance  
Page 19 of 25  
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Chapter 6: Appendix  
6-1 Technical Assistance  
Parts Department  
[
]
[
]
Call Toll-Free 7am–6pm CST 800 423-3183 or call 262 641-8610  
Our Parts Department is ready to provide the parts to keep your systems up and running.  
OEM replacement parts ensure operation at design specifications. Please have the model and  
serial number of your equipment when you call. Consult the Customer Parts List included in  
your information packet for replacement part numbers.  
Service Department  
[
]
[
]
Call toll-free 8am–5pm CST 800 783-7835 or call 262 641-8610. Emergency Service is  
available 24 hours a day. We have a qualified service department ready to help. Service  
contracts are available for most of our products. www.acscustomerservice.com  
Sales Department  
[
]
Call 262 641-8610 Monday–Friday, 8am–5pm CST  
Our products are sold by a world-wide network of independent sales representatives. Contact  
our Sales Department for the name of the sales representative nearest you.  
Contract Department  
[
]
Call 262 641-8610 Monday–Friday, 8am–5pm CST  
Let us install your system. The Contract Department offers any or all of these services:  
project planning; system packages including as-built drawings; equipment, labor, and  
construction materials; union or non-union installations; and field supervision.  
Fiberglass Cooling Towers  
Chapter 6: Appendix  
Page 20 of 25  
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6-2 Drawings and Specifications  
A
A0536711  
B
Fan motor  
Fan guard  
Top View  
Motor support  
assembly  
Fan blade  
Supply piping  
D
Access  
door  
Nozzle  
adaptor  
C
Nozzle  
Rigid PVC  
tower fill  
Water  
diverter  
Return  
piping  
E
Side View  
Cutaway View  
Figure 7: Dimensions and Weights  
Dimensions  
Weights  
Operating  
Model  
A
B
C
D (supply)  
cm in. mm c  
E (return)  
in. mm c  
Shipping  
number in. cm  
SF2003 64 163  
SF2004 64 163  
SF2005 82 208  
SF2007 82 208  
in.  
cm  
in.  
lbs.  
600  
750  
kg  
lbs.  
273 1,300  
341 1,700  
kg  
64 163 104 264 3” 76.2 mm 4” 101.6 mm  
64 163 125 318 3” 76.2 mm 6” 152.4 mm  
591  
772  
82 208 121 307 4” 101.6 mm 8” 203.2 mm 1,400  
82 208 121 307 4” 101.6 mm 8” 203.2 mm 1,500  
636 2,900 1,317  
681 3,200 1,453  
886 3,800 1,726  
954 4,400 1,998  
SF2009 100 254 100 254 123 313 4” 101.6 mm 8” 203.2 mm 1,950  
SF2011 100 254 100 254 123 313 4” 101.6 mm 8” 203.2 mm 2,100  
SF2015 100 254 100 254 124 315 4” 101.6 mm 8” 203.2 mm 2,600 1,181 5,200 2,361  
c Millimeter measurement is approximate. Customer is responsible for converting to metric piping sizes.  
Fiberglass Cooling Towers  
Chapter 6: Appendix  
Page 21 of 25  
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Figure 8: Tower Performancec  
Cooling  
capacity  
number tons Kcal/hr  
Fan  
motor  
hp kW  
NEC  
amp draw  
460/3/60  
3.4  
Nominal  
air flow  
Model  
Nozzles  
no.  
1
4
4
4
4
4
4
rpm  
cfm  
cmh  
SF2003  
SF2004  
SF2005  
SF2007  
SF2009  
SF2011  
SF2015  
50 151,200  
75 226,800  
100 302,400  
125 378,000  
150 453,600  
175 529,200  
200 604,800  
2
5
5
5
10  
10  
1.5 1,200  
3.7 1,200  
3.7  
3.7  
7.5  
7.5  
12,000 20,388  
18,000 30,582  
23,500 39,926  
26,000 44,174  
30,000 50,970  
33,000 56,067  
43,000 73,057  
7.6  
7.6  
7.6  
14.0  
14.0  
21.0  
900  
900  
900  
900  
900  
15 11.2  
c Rating conditions are based on 78ºF (26ºC) wet bulb, 95ºF (35ºC) entering water  
temperature, and 85ºF (29ºC) leaving water temperature; flow capacity is based on 3  
gpm/ton (2.563 lpm per 1,000 Kcal/hr).  
Fiberglass Cooling Towers  
Chapter 6: Appendix  
Page 22 of 25  
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Figure 9: Cooling Tower Nozzle Capacity  
Flow rate in Flow rate  
cu. meters/sec.  
in gpm  
.0119  
190  
180  
170  
160  
150  
140  
130  
120  
110  
100  
90  
.0113  
.0107  
.0101  
.0094  
.0088  
.0082  
.0075  
.0069  
.0063  
.0056  
.0050  
.0044  
.0037  
.0031  
.0025  
.0019  
.0013  
Nozzle 1D  
Nozzle 1B  
80  
70  
60  
50  
40  
30  
20  
2
3
4
5
6
7
8
9
10  
(max.)  
Water pressure in psi  
13.8 20.7 27.6 34.4 41.3 48.2 55.1 62.0 68.9  
Water pressure in kPa  
(max.)  
Fiberglass Cooling Towers  
Chapter 6: Appendix  
Page 23 of 25  
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6-3 Parts List  
Figure 10: Supplied Parts for Field Assembly  
Part Number  
Quantity  
Description  
A0101485  
A0533163  
A0539417  
A0533167  
A0534122  
A0539598  
1
110  
55  
55  
55  
Silicone  
Stainless steel flat washers, 5/16”  
Stainless steel screws, 5/16”-18 x 1 3/4”  
Stainless steel hex nut, 5/16”-18  
Stainless steel split lock washers, 3/8”  
FG Tower gasketing  
40 ft.  
Figure 11: Spare Parts List  
Part  
description  
Shell, top section  
Shell, side outlet  
Shell, bottom outlet  
SF2003 c 5  
SF2004 5  
qty Part no.  
SF2005 d  
SF2007  
Part no.  
A0536702  
A0536700  
A0536701  
SF2009  
Part no.  
A0535879  
A0535880  
A0536668  
SF2011  
Part no.  
A0535879  
A0535880  
A0536668  
SF2015  
Part no.  
A0539581  
A0539582  
A0539583  
qty  
Part no.  
A0533079  
A0533078  
A0536666  
qty  
Part no.  
A0536702  
A0536700  
A0536701  
qty  
1
1
qty  
1
1
qty  
1
1
qty  
1
1
1
1
1
1
1
1
A0539552  
A0539550  
A0539551  
1
1
1
1
1
1
1
Tower access door  
Motor support assy.  
Fan Motor Spcr. Brkt.  
1
1
1
A0533082  
A0533090  
A0539566  
1
1
--  
A0533082  
A0533090  
---  
2
1
1
A0533082  
A0536712  
A0536717  
2
1
--  
A0533082  
A0536712  
--  
2
1
--  
A0533082  
A0539586  
--  
2
1
--  
A0533082  
A0539586  
--  
2
1
--  
A0533082  
A0539586  
--  
Fan guard  
Fan motor e  
Fan blade  
1
1
1
A0533092  
A0533094  
A0533097  
1
1
1
A0533092  
A0539555  
A0539556  
1
1
1
A0536706  
A0536709  
A0547121  
1
1
1
A0536706  
A0536710  
A0536708  
1
1
1
A0535883  
A0547120  
A0541387  
1
1
1
A0535883  
A0547120  
A0541387  
1
1
1
A0535883  
A0539577  
A0539576  
PVC fill e  
Eliminator e  
Louver  
10 A0533101 15 A0539557 26 A0533099 39 A0533099 32 A0533099 48 A0533099 48 A0539578  
A0533104 A0539558 13 A0533103 13 A0533103 16 A0533103 16 A0533103 16 A0539579  
16 A0533106 16 A0539559 20 A0533106 20 A0533106 24 A0533106 24 A0533106 28 A0539580  
5
5
Nozzle e  
Nozzle adaptere  
1
1
A0064022  
A0101006  
4
4
A0539572  
A0101006  
4
4
A0064022  
A0101006  
4
4
A0064022  
A0101006  
4
4
A0064022  
A0101006  
4
4
A0064022  
A0101006  
4
4
A0064022  
A0101006  
Nozzle 4  
Nozzle adapter 4  
1
1
A0547133  
A0547130  
4
4
A0547131  
A0547130  
4
4
A0547131  
A0547130  
4
4
A0547132  
A0547130  
4
4
A0547132  
A0547130  
4
4
A0547133  
A0547130  
4
4
A0547133  
A0547130  
PVC plug 6  
Flexible coupling  
Balancing valve 6  
Pressure gauge  
1
1
1
1
1
1
1
1
1
A0500867  
A0502553  
A0504422  
A0102314  
A0500860  
A0076209  
A0518023  
A0518024  
A0518025  
1
1
2
1
1
1
1
4
4
A0500867  
A0502554  
A0504422  
A0102314  
A0539574  
A0076209  
A0518055  
A0518056  
A0518057  
2
1
2
2
1
1
1
4
4
A0500867  
A0535957  
A0504422  
A0102314  
A0535956  
A0076029  
A0538701  
A0538702  
A0538703  
2
1
2
2
1
1
1
4
4
A0500867  
A0535957  
A0504422  
A0102314  
A0535956  
A0538700  
A0538704  
A0538705  
A0538706  
2
1
2
2
1
1
1
4
4
A0500867  
A0535957  
A0504422  
A0102314  
A0535956  
A0538700  
A0518030  
A0518031  
A0518032  
2
1
2
2
1
1
1
4
4
A0500867  
A0535957  
A0504422  
A0102314  
A0535956  
A0538700  
A0518030  
A0518031  
A0518032  
2
1
2
2
1
1
1
4
4
A0500867  
A0535957  
A0504422  
A0102314  
A0535956  
A0538700  
A0518059  
A0518060  
A0518061  
Strainer basket  
Float valve assy.  
Starter kit, 208 VAC  
Starter kit, 230 VAC  
Starter kit, 460 VAC  
c
d
e
4
5
6
Fan motor spacer bracket part no. A0539566; available on FG2003 models only.  
Fan motor spacer bracket part no. A0536717; available on FG2005 models only.  
Recommended spare parts prior to April 2002.  
Recommended spare parts list after 2002.  
Recommended spare parts prior to February 2005 (A0504421 and A0064023)  
Recommended spare parts list after February 2005  
Fiberglass Cooling Towers  
Chapter 6: Appendix  
Page 24 of 25  
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6-4 Electrical Schematics  
Figure 12: Typical Wiring Diagram  
115/1/60  
208-230-460/3/60  
Fused  
disconnect  
switch  
ON/OFF  
switch  
Thermostat  
M
Immerse  
bulb in tank  
Starter with  
overloads  
Non-fused  
disconnect  
at tower  
Fan  
Fiberglass Cooling Towers  
Chapter 6: Appendix  
Page 25 of 25  
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