Cooling Tower Water and
Chilled Water Pump Tanks
Part Number: A0552321
Bulletin Number: SC5-605.7
Effective: 4/11/08
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 2008
All rights reserved.
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Table of Contents
CHAPTER 1: SAFETY .................................................................5
1-1 How to Use This Manual ................................................................................. 5
Safety Symbols Used in this Manual.....................................................................5
1-2 Warnings and Precautions .............................................................................. 6
1-3 Responsibility.................................................................................................. 6
CHAPTER 2: FUNCTIONAL DESCRIPTION...............................7
2-1 Models Covered in This Manual...................................................................... 7
2-2 General Description ........................................................................................ 7
2-3 Standard Features .......................................................................................... 8
2-4 Optional Features............................................................................................ 9
CHAPTER 3: INSTALLATION ...................................................10
3-1 Uncrating Your Pump Tank........................................................................... 10
3-2 Installation Location Considerations.............................................................. 10
3-3 Rigging.......................................................................................................... 10
3-4 Installing Separate Tank Ledge Models........................................................ 11
3-5 Installing Optional Equipment........................................................................ 11
3-6 Making Electrical Connections ...................................................................... 11
3-7 Making Piping Connections........................................................................... 12
Tower Tank Piping Connections .........................................................................14
Chilled Water Piping Connections.......................................................................15
3-8 Initial Start-up................................................................................................ 15
CHAPTER 4: OPERATION ........................................................16
4-1 Start-up ......................................................................................................... 16
4-2 Determining Flow Rate.................................................................................. 16
4-3 Stand-by Pump Usage.................................................................................. 17
Single Stand-by pump:........................................................................................17
Dual Stand-By Pump...........................................................................................17
4-4 Shut-down..................................................................................................... 17
CHAPTER 5: MAINTENANCE...................................................18
5-1 Preventative Maintenance............................................................................. 18
Water Treatment .................................................................................................18
Lubricating Pump Motors and Seals....................................................................18
Maintaining Makeup Valve Assemblies...............................................................18
CHAPTER 6: APPENDIX ...........................................................19
6-1 Technical Assistance .................................................................................... 19
Parts Department ................................................................................................19
Service Department.............................................................................................19
6-2 Remote Starters and NEMA Panels.............................................................. 20
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NEMA Panel Standard Features.........................................................................20
NEMA Panel Options ..........................................................................................20
6-3 Drawings and Specifications ......................................................................... 21
Cooling Tower Water Pump Tanks......................................................................21
Chilled Water Pump Tanks..................................................................................23
Process Pump Curves and Specifications...........................................................25
Re-circulation Pump Curves and Specifications..................................................26
6-4 Parts List ....................................................................................................... 27
Recommended Spare Parts................................................................................27
Spare Process Pump Seals and Casing Gaskets ...............................................27
Spare Re-circulating Pump Seals and Casing Gaskets ......................................27
6-5 Optional Assembly Detail Drawings .............................................................. 28
Tank Support Leg Assembly Detail: 4 Legs ........................................................28
Tank Support Leg Assembly Detail: 6 Legs ........................................................29
Tank Support Leg Assembly Detail: 7 Legs ........................................................30
Tank Ladder Assembly Detail..............................................................................31
Sightglass Assembly Detail.................................................................................32
6-6 Typical Piping Diagrams................................................................................ 33
Typical Single Well Cooling Tower Water Pump Tank Piping System................33
Typical Dual Well Cooling Tower Pump Tank Piping System .............................34
Typical Single Well Chilled Water Pump Tank Piping System ............................35
Typical Dual Well Chilled Water Pump Tank Piping System...............................36
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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.
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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.
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Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual covers many models of cooling tower pump tanks and chilled water pump tanks
with operating capacities of 100 to 6,125 gallons (378 to 23,183 liters). Pump tanks are
designed, specified, and engineered to meet the needs of the process specified at the time of
purchase. Model numbers are listed on the serial tag.
Model numbers start with a CT or CW to describe cooling tower or chilled water tank
configurations. The number following is the approximate capacity up to the overflow of the
tank well(s) and a D at the end indicates a dual well configuration. Additional numbers are
added to signify pump horsepower. For example, a CT1600D-20-20-10 pump tank is a
cooling tower tank, 1,615 gallon (6,113 liter) capacity to its overflow, has dual wells, a 20 hp
process pump, a 20 hp dual standby pump and a 10 hp recirculation pump.
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
Single well pump tanks are reservoirs for chilled water and tower cooling water processes.
Process pump(s) deliver water through the chiller or cooling tower as well as through the
process. Dual well tanks have re-circulation pump(s) to deliver water from the hot side to the
chiller or tower. The water then returns to the cold side, where process pump(s) deliver
cooled water directly to process.
Standby pumps may be used as backups for both process and re-circulation during service or
maintenance procedures. Manifolding options provide ease of connection to process and can
ease the transition to standby pumps.
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2-3 Standard Features
All tower and chilled water pump tanks come standard with the following:
• ODP motors and cast iron impellers on standard pumps
• Centrifugal pump(s) with cast iron housings, cast iron impellers and mechanical seals
• Solid diamond-plate pump ledge
• Standard hardware includes thermometer(s), compound liquid-filled pump pressure
gauge(s) with trim, and drain valve
• Heavy gauge 304 stainless steel construction.
Note: Despite its name, stainless steel is still susceptible to discoloration. A
stainless steel tank will not “rust through” even though the surface of the
metal may appear to be rust colored. This appearance may be caused by
water quality (high chloride content or increased acidity in the water) or
cross contamination from carbon steel dust in the vicinity of the stainless
steel. The integrity of the stainless steel remains in tact even though its
appearance is not perfectly clean.
• Factory-installed insulation and covers (chilled water pump tanks)
• Water strainer basket on cooling tower water pump tank models
• Threaded (up to 3” and flanged 4” and above) overflow opening, return openings
(chilled water pump tanks), and process water return (dual-well cooling tower pump
tanks)
• 1” automatic water makeup valve for “hands-off” level control
• 1/2” opening for field-installed thermometer
• 2” valved drain connection
• Twin 1/2” plugged openings for sight glasses
• Six 1/2” plugged openings with brackets for optional/future thermostats
• Baffles and sidewall reinforcements on larger models
• Full-size pump trim for maximum efficiency including butterfly valve (less handle)
and reducer (if necessary) on the suction side; increaser, check valve and butterfly
valve (less handle) on the discharge side
• One year warranty on parts and labor (labor in North America only)
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2-4 Optional Features
All cooling tower and chilled water pump tanks are available with the following:
• Standby pump
• Frame reinforcement for supporting other equipment
• Special paint
• Mild steel well and fittings (divider if applicable)
• Second pump ledge
• Support legs
• OSHA handrail and ladder
• Thermostat and thermowell
• Extra thermostats and plugged 1/2” NPT thermostat openings
• High- and/or low-temperature alarm
• High- and/or low-pressure alarm
• High- and/or low-level alarm
• No flow alarm
• Re-circulating (P2) pump (standard on dual well tanks)
• Dual duty (P3) standby pump with isolation valving
• Additional plugged or valved openings
• Clayton float valve
• Discharge manifold with process and re-circulation pump standby butterfly valving
• NEMA 1 pump starter(s), mounted or un-mounted
• NEMA 12-rated central control panel
• Protection for outdoor installation
Chilled water pump tanks are also available with:
• Automatic pressure regulating bypass valve for single well tanks; assures full flow
through the chiller evaporator
Cooling tower water pump tanks are also available with:
• Insulation
• Cover
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Chapter 3: Installation
3-1 Uncrating Your Pump Tank
Caution! Due to the size and weight of larger model pump tanks, the manufacturer
recommends using bonded professional millwrights to unload and move larger
pump tanks.
Rig the pump tank from the frame only and use spreader bars to prevent load transfer to any
pump tank components. Rig the frame from at least four points and balance the load before
lifting to clear the skid.
3-2 Installation Location Considerations
Consider the following points when locating your pump tank:
• Locate close to the chillers and/or cooling towers and the process itself to minimize
field piping expense
• Locate adjacent to drain and city water sources
• Consult a structural engineer to assure that the floor, mounting pad, or structural steel
support is of adequate strength
3-3 Rigging
Due to the large size and weight of the pump tanks, we recommend professional rigging and
installation. We have a nationwide installation organization that can install your system.
Do not remove the base skid until the unit is at the final location. Lower the unit (do not drop
it) from any truck, platform, or shipping dock.
All 150 through 400 Series pump tanks are provided with lifting lugs on the pump tank
frame. All 500 Series and larger tanks are provided with lifting lug brackets on the pump tank
body. When lifting, use adequately rated hoist, lifting straps and/or chains. Avoid transferring
the load to the pumps and any other components.
Metal pump tanks are provided with slots in the frame for use with fork trucks of sufficient
capacity and properly sized forks.
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3-4 Installing Separate Tank Ledge Models
Pump tanks from the 2000, 2700, 3700, and 5100 Series are a two-component design with
separate tank and pump ledge assemblies.
These models include a hardware package and assembly drawing located in the information
packet. The tank and pump ledge were temporarily joined together at the factory, so all
components should line up properly in the field.
General guidelines for installation are the following:
• Two-piece models are not designed to be lifted as a unit. Fully and separately support
both tank and ledge assemblies when they are moved.
• Providing a level area for the tank installation will simplify reconnecting the pump
ledge to the tank.
• Floor mounted tanks and ledges are joined together with support plates and the pump
trim. Gravity and mass provide most of the structural integrity.
• Leg-mounted tanks and ledges are joined together with support plates, the pump trim,
and bolts between the facing surfaces of the tank and ledge. Typically, the tank
assembly is lifted and mounted on the four legs first, then the pump ledge is lifted with
a fork truck, and the two remaining legs are attached. Use the center leg bolt holes and
the facing surface bolts to bring together and align the ledge and the tank. See
assembly drawings on pages 28-30for detailed instructions.
• Butterfly valves bridge the gap between the ledge and tank flanges. These butterfly
valves may be shipped loose or mounted to the pump suction connection to the tank.
• The flanges may not always line up as expected due to the tendency of the metal to
move as it cools. Extra effort may be required to help align the flanges to bring the
tank sections together properly.
Caution! Improper handling may also cause movement of the flanges. Be sure the lifting
lugs or forklift holes are used for moving the tank and base. Do not use any of
the piping as a means of moving the equipment into position.
3-5 Installing Optional Equipment
See pages 28 to 32 in the Appendix for assembly details for the tank legs, ladder, and sight
glass.
3-6 Making Electrical Connections
Supply electricity of the voltage, phase, and cycle listed on the serial tag. Pump motor voltage
must be within plus or minus ten percent of the nameplate voltages.
Pump Starters. Pump motor starters may be pre-mounted, shipped loose, or not provided,
depending on the options specified on the order.
On/Off Selector Switch. All pump starters are supplied with an on/off selector switch on the
starter enclosure cover.
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3-7 Making Piping Connections
Piping systems vary with process application and pump tank configuration. Typical system
configurations are available in the Appendix, but the details may or may not apply to your
application. Refer to Figure 1 on page 13 for pipe sizing guidelines. Piping systems must be
designed by a person knowledgeable in piping system design and configuration. Our
contracting department can design and install a piping system tailored to your process.
All process piping returning to the pump tank must be equipped with an inverted trap with a
vacuum breaker at the high point of the system to prevent mains from siphoning into the
pump tank.
Run mains full size in order to reduce pressure drop in the system and provide maximum
pressures at the ends of the mains.
Caution! Do not support piping from the tank or from pumps. Do not weld piping or
piping supports to the tank, as epoxy coating on some tank models can be
damaged.
Caution! Customer is responsible for converting connections to metric sizes as needed.
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Figure 1: Pipe Sizing Guide
Pipe Sizing Guide
Pipe Size
Flow-Steel Pipe
Flow-PVC Pipe
1/2
3/4
1
2
5
2
5
10
10
1 1/4
1 1/2
2
20
20
30
30
50
55
2 1/2
3
100
160
320
900
2000
3500
5000
100
160
320
1000
2100
3700
5800
4
6
8
10
12
Based on 10’ head loss/100’ of pipe (new pipe) — open piping systems. A safety factor of 15
to 20% should be added based on local conditions.
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Tower Tank Piping Connections
Return From Process (Single Well). Connect process return piping to the cooling tower
inlet with appropriate balancing valves and gauges. Size this line to the tower flow rate.
Return From Process (Dual Well). Connect process return piping to the hot well. Size
piping to the process flow rate.
Re-circulation Pump Discharge (Dual Well). Connect to the cooling tower inlet with
appropriate balancing valves and gauges. Size according to the pump discharge rate.
Return From Tower. The return from the tower outlet enters the pump tank from above and
terminates above the water level at the water strainer basket location directing flow through
the basket. Cut the end of the line at a 45º angle.
Makeup. Connect a 1” (approximately 25 mm) water line from a city water source to the
makeup inlet to maintain the water level in the pump tank. City water pressure should not
exceed 30 psi pressure. Check local codes. Backflow preventer may be required.
Overflow. Connect the overflow outlet to an approved, trapped drain to permit excess water
in the pump tank to overflow to the drain. Size the overflow line according to the size of the
pump tank. (Consult specifications on page 21.)
To Drain. Connect this outlet to a 2” (approximately 51 mm) line leading to an approved,
trapped drain.
Process Pump Discharge. Connect the pump discharge to the process water supply main.
Size the pipe to the pump discharge rate to the tower.
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Chilled Water Piping Connections
Process Pump Discharge (Single Well). Connect process pump discharge to the chiller
evaporator water inlet. Size to the chilled water flow rate. Chiller evaporator inlet and outlet
should have valves and temperature and pressure gauges. Outlet of the evaporator is
connected to the chilled process water supply.
Process Pump Discharge (Dual Well). Connect directly to the chilled water process supply.
Size according to process flow requirements.
Return (Single Well). Connect the chilled water returning from the process to the pump tank
threaded return inlet. Size this line according to the chilled water flow rate.
Makeup. Connect a 1” (approximately 25 mm) water line from a city water source to the
makeup inlet to maintain the water level in the pump tank.
Overflow. Connect the overflow outlet to an approved, trapped drain to permit excess water
in the pump tank to overflow to the drain. Size the overflow line according to the size of the
pump tank. (Consult specifications on page 23.) Do not connect to draw if glycol is used in
the system.
To Drain. Connect to a 2” (approximately 51 mm) line leading to an approved, trapped drain.
Do not connect to draw if glycol is used in the system.
Bypass (Single Well). Optional: recommended on single pump systems. Pipe full size to the
pressure-regulating valve from the evaporator outlet to allow flow if process does not require
flow, to ensure proper flow through the evaporator at all times.
3-8 Initial Start-up
• Remove all tools, foreign matter and debris from the pump tank reservoir and piping.
• Complete all piping leading to and from the pump tank. Observe all applicable codes.
• Complete all electrical wiring. Observe all applicable codes.
• Prepare all related equipment in the system for operation.
• Leak check piping. Flush and clean system.
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Chapter 4: Operation
4-1 Start-up
1. Close the drain line at the bottom of the pump tank.
2. Open the 1” makeup water valve and allow the tank to fill until the automatic float
valve shuts off. Adjust the float level so the standing water level is 16” from the top
of the tank, 12” on 150 Series pump tanks. Some tower systems may require a lower
level to allow for drawback from the cooling towers.
3. Check all wiring integrity, field installed controls and voltage.
4. Verify pump motor rotation: should be clockwise from the motor end.
5. Open all pump suction valves fully and lock down.
6. If the process piping is not full of water, close the discharge valves of a process pump
and start that pump. Open the discharge valve very slowly to fill the system. Do this
very slowly to prevent the piping from shaking resulting in possible breakage. When
piping is full, the discharge valve can be left fully open, if the pump is a non-
overloading pump. Follow the same procedure for the other process pumps.
7. Repeat step 6 for re-circulating pumps. Leave pump discharge valve(s) fully open.
Throttle the valves for proper flow and pressure drop. Lock down and mark valve(s)
when complete. (On metal towers, throttle the pump for the flow rate and balance the
valves on the hot basin(s) for proper depth.)
4-2 Determining Flow Rate
1. Close the gauge cock leading to the pump suction side, and open the gauge cock
leading to the pump discharge.
2. Start the pump and make note of the discharge pressure in psi (kPa/bars).
3. Check the pump curve (See page 25) for the appropriate sample curve discharge
pressure in psi (kPa/bars).
4. Project this point down to find the flow in gpm (lpm).
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4-3 Stand-by Pump Usage
All stand-by pumps should be checked intermittently to make sure they are operational for
when they may be required for usage.
Single Stand-by pump:
1. Open the suction valve fully and lock down.
2. Open the discharge valve slowly until it is equal to the pump it will be replacing.
3. Shut down the pump being replaced and make sure the suction and discharge valves
are fully closed.
Dual Stand-By Pump
1. Open the discharge manifold valve on the proper side of the divider for the
pump being replaced. Be sure the opposite discharge manifold valve is fully
closed.
2. Open the suction valve on the proper side of the divider for the pump being
replaced. Be sure the opposite suction valve is fully closed.
3. Open the discharge valve slowly until it is equal to the pump it will be
replacing.
4. Shut down the pump being replaced and make sure the suction and discharge
valves are fully closed.
4-4 Shut-down
1. Prepare all process and related equipment for shutdown.
2. Shut down all pumps
3. Close the water makeup valve.
4. If you are draining the system, open the 2” drain valve.
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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.
Lubricating Pump Motors and Seals
Some pump motors require greasing; use a high grade ball and roller bearing grease such as
Shell Dolium R or Chevron SR1. Motors with regreasable bearings are shipped with a high
quality, wide temperature range grease.
Caution! Pump seals require water for lubrication, so the pumps must never be run dry
or be dead headed.
Always fill the tank before attempting to operate the pumps. Seal failures usually result from
running the pump dry.
Maintaining Makeup Valve Assemblies
Periodically inspect the water makeup valve assembly for proper operation. If the valve no
longer shuts off completely or reliably, replace it. Make sure that the plastic ball float is
buoyant for proper operation.
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Chapter 6: Appendix
6-1 Technical Assistance
Parts Department
[
]
[262]
Call toll-free 7am–5pm CST 800 423-3183 or call 641-8610, Fax [262] 641-8653
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.
Service Department
[
]
[
] 641
Call toll-free 8am–5pm CST 800 423-3183 or call 262
-8610
[
]
Emergencies after 5pm CST, call 847 439-5655
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, fax [262] 641-8653
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.
Contracting Department
Call [262] 641-8610 Monday—Friday, 8am—5pm CST
Let us install your system. The Contracting Department offers any or all of these services: project
planning; system packages including drawings; equipment, labor, and construction materials; and union
or non-union installations.
Sterling, Inc.
5900 S. 160th Street
New Berlin, WI 53151
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6-2 Remote Starters and NEMA Panels
Pump tanks can be provided with electrical controls such as basic motor starters or elaborate
NEMA panels.
Motor starters or NEMA panels can be shipped loose for field installation or pre-mounted for
space saving convenience. Motor starters are equipped with on/off selector switches for
turning the pump on with overload relays to protect the motor when operating. On tower
systems, re-circulating pump and tower fan motor starter are also provided with thermostats
for proper temperature. The chiller provides the temperature control on chilled water
systems.
All starters require a 120-volt power source for the control circuit.
NEMA Panel Standard Features
The NEMA panel is a properly sized enclosure to house all the starters required for each
pump tank system. A control circuit transformer is also provided to create the 120 volt
control circuit needed for starters and thermostats. A power distribution block is provided to
bring in main power to the panel. All internal wiring is provided and selector switches and
indicator lights are provided on the NEMA panel door with labels to indicate each device.
NEMA Panel Options
Each panel can be customized beyond the basic setup. A list of some of the possible additions
are as follows:
• Alarm circuitry with horn and strobe light
• High temperature alarm
• Low pressure alarm
• High pressure alarm
• Low flow alarm
• Low level alarm
• High level alarm
• Digital temperature display
• Amp meters
• Hour meters
• Digital flow meters
• UL panel
• Automatic water make-up
• Variable speed systems
Pump Tanks
Chapter 6: Appendix
20 of 36
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6-3 Drawings and Specifications
Cooling Tower Water Pump Tanks
Side View
Top View
(P2 Pump Shown Only For Clarity)
Front View
American Standards
Maximum
Return
water &
overflow
pumps/ connections
Tank weight
(less pumps)
tower tons c
Capacity
gallons
Maximum
Dimensions
Model
number
CT140 (D)
PT390 (D) d
Single Dual
inches
W
pounds
Shipping Operating
well
25
well Overflow Operating
13
39
ledge
3
3
Inches
3” NPT
L
H
125
390
100
350
72
95
36
56
40
64
600
500
1,800
3,500
78
ℜ 5” CLMP
4” FLG
4” FLG
6” FLG
6” FLG
6” FLG
6” FLG
6” FLG
CT480 (D)
CT720 (D)
CT1080 (D)
CT1620 (D)
CT2040 (D)
CT2700 (D)
CT3670 (D)
CT5130 (D)
90
135
206
310
382
509
698
978
45
68
450
675
360
540
3
4
4
4
5
6
6
7
102
114
114
138
150
150 121
162 121
162 169
49.5
73.5
73.5
73.5
91
52
52
77
77
78
78
90
92
2,000
2,600
3,400
4,000
5,000
6,000
7,000
7,800
6,000
8,600
103
155
191
225
349
489
1,030
1,550
1,910
2,545
3,490
4,890
900
12,400
17,500
22,100
28,500
37,600
50,700
1,345
1,685
2,245
3,140
4,400
ℜ 8” FLG
ℜ 10” FLG
CT6285 (D)
1,257
629
6,285
5,655
9
162 217
94
14,700
69,100
c
d
Based on three (3) gpm per ton and towers being within 25 feet of the tank.
“P” signifies molded polyethylene tank.
ℜ PT390 = 6” CLMP, CT5130 = 6” FLG, CT6285 = 8” FLG overflow connections only.
Metric Standards
Maximum
Return
Tank weight
tower cooling c
Capacity
Maximum
water &
overflow
Dimensions
cm
(less pumps)
Model
number
Single
well
Dual
well
liters
pumps/ connections
ledge
Kg
Overflow Operating
mm
L
W
H
Shipping Operating
CT140 (D)
PT390 (D) d
CT480 (D)
CT720 (D)
CT1080 (D)
CT1620 (D)
CT2040 (D)
CT2700 (D)
CT3670 (D)
CT5130 (D)
CT6285 (D)
94,615
49,200
147,599
170,303
257,353
389,814
586,613
722,859
965,073
473
1,476
1,703
2,555
3,899
5,867
7,229
9,633
378
1,325
1,362
2,044
3,407
5,091
6,378
8,497
11,885
16,654
21,404
3
3
3
4
4
4
5
6
6
7
9
76 mm
183
91 102
273
227
908
817
1,588
2,722
3,901
5,625
295,200
340,619
510,921
779,628
1,173,195
1,445,717
1,926,361
2,641,651 1,320,825 13,209
3,701,339 1,850,669 18,509
4,757,242 2,380,513 23,789
241 142 162
259 126 132
289 187 132
289 187 195
350 187 195
381 231 198
381 307 198
411 307 229
411 429 234
411 551 239
ℜ 127 mm
102 mm
102 mm
152 mm
152 mm
152 mm
152 mm
152 mm
ℜ 203 mm
ℜ 254 mm
1,180
1,543
1,815
2,268
2,722
3,176
3,539
6,668
7,938
10,025
12,928
17,056
22,998
31,344
c
In Kcal/hr, calculated for cooling tower water, based on 3 lpm per 1,000 Kcal/hr and towers being within eight (8) meters of the
tank.
d
“P” signifies molded polyethylene tank.
ℜ PT390 = 152mm, CT5130 = 152mm, CT6285 = 203mm overflow connections only.
Pump Tanks
Chapter 6: Appendix
21 of 36
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Figure 2: Standard Pumps and Trim Based on Cooling Tower Capacities
(Flow Based on 3 gpm per Ton)
American Standards
Capacity
Trim
size
inches
2½”
2½”
3”
Process
pump
hp
Recirculating
Nominal
cooling tower tons
Nominal flow
gallons
60
pump
hp
3
20
30
40
5
90
120
150
7½
7½
10
3
5
5
50
3”
60
180
4”
10
5
75
80
225
240
300
375
450
525
600
750
4”
4”
4”
6”
6”
6”
6”
6”
15
15
20
20
25
30
30
40
7½
7½
7½
10
10
15
15
20
20
100
125
150
175
200
250
300
900
6”
50
Pump horsepower
Amp draw 460/3/60
Shipping weight (lbs.)
1½
2.6
—
60
3
4.8
95
90
5
7.6
115
115
7½
11
125
275
10
14
165
320
15
21
180
425
20
27
300
510
25
34
310
630
30
40
400
670
40
52
465
—
50
65
710
—
60
77
730
—
• P1
• P2
Trim size (inches)
Maximum flow (gpm)
Shipping weight (lbs.)
2
50
25
2½
90
35
3
160
50
4
320
75
6
900
120
8
2,000
165
Metric Standards
Capacity
Trim
Process
pump
Recirculating
pump
Nominal refrigeration
Tower water, Kcal/hr
75,600
Nominal flow
liters
227
size
mm Dia.
64
hp
5
kW
3.73
5.59
5.59
hp
kW
3
3
2.24
2.24
113,400
151,200
189,000
341
454
568
64
76
76
7½
7½
10
5
3.73
7.50
5
3.73
226,800
283,500
302,400
378,000
472,500
567,000
661,500
756,000
682
852
909
1,135
1,419
1,703
1,987
2,271
2,839
3,406
102
102
102
102
152
152
152
152
152
152
10
15
15
20
20
25
30
30
40
50
7.50
5
3.73
5.59
5.59
5.59
7.50
7.50
11.19
11.19
14.91
14.91
11.19
11.19
14.91
14.91
18.64
22.37
22.37
29.93
37.29
7½
7½
7½
10
10
15
15
20
20
945,000
1,134,000
Pump
horsepower/kW
1½/1.12 3/2.24 5/3.73 7½/5.59 10/7.5 15/11.19 20/14.91 25/18.64 30/22.37 40/29.93 50/37.29 60/44.7
4
Amp draw 460/3/60
Ship weight (Kg) • P1
• P2
2.6
—
28
4.8
44
41
7.6
53
53
11
57
125
14
75
146
21
82
193
27
137
232
34
141
286
40
182
304
52
211
—
65
323
—
77
332
—
Trim size (inches)
Maximum flow (lpm)
Shipping weight (Kg)
2
189
12
2½
340
16
3
624
23
4
6
8
1,211
35
3,406
55
7,570
75
Pump Tanks
Chapter 6: Appendix
22 of 36
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Chilled Water Pump Tanks
Side View
(P2 Pump Shown Only For Clarity)
Top View
Front View
American Standards
Maximum tons
Return
water &
overflow
Tank weight
(less pumps)
chilled H2O c
Capacity
gallons
Maximum
Dimensions
Model
number
Single Dual
well
47
Pumps/ Connections
inches
W
pounds
Shipping Operating
well Overflow Operating
23
73
Ledge
inches
3” NPT
ℜ 5” CLMP
4” FLG
4” FLG
6” FLG
6” FLG
6” FLG
6” FLG
6” FLG
L
H
CW140 (D)
PC390 (D) d
CW480 (D)
CW720 (D)
CW1080 (D)
CW1620 (D)
CW2040 (D)
CW2700 (D)
CW3670 (D)
CW5130 (D)
CW6285 (D)
125
390
110
350
3
3
3
4
4
4
5
6
6
7
9
72
95
36
56
40
64
52
52
77
77
78
78
90
92
94
600
500
1,800
3,500
146
175
87
450
420
102
114
114
138
150
150 121
162 121
162 169
162 217
49.5
73.5
73.5
73.5
91
2,000
2,600
3,400
4,000
5,000
6,000
7,000
7,800
14,700
6,000
8,600
262
411
617
771
1,029
1,418
1,985
131
206
309
386
514
709
993
675
630
1,030
1,550
1,910
2,545
3,490
4,890
6,285
990
12,400
17,500
22,100
28,500
37,600
50,700
69,100
1,480
1,850
2,470
3,405
4,765
6,125
ℜ 8” FLG
ℜ 10” FLG
2,553 1,276
c
d
Based on 2.4 gpm per ton.
“P” signifies molded polyethylene tank.
ℜ PC390 = 6” CLMP, CW5130 = 6” FLG, CW6285 = 8” FLG overflow connections only.
Metric Standards
Maximum cooling,
Return
water &
overflow
Tank weight
(less pumps)
chilled H2O c
Capacity
Maximum
Dimensions
cm
Model
number
Single
well
Dual
well
liters
pumps/ connections
Kg
Overflow Operating
ledge
mm
L
W
H
Shipping Operating
CW140 (D)
PC390 (D) d
CW480 (D)
CW720 (D)
CW1080 (D)
CW1620 (D)
CW2040 (D)
CW2700 (D)
CW3670 (D)
CW5130 (D)
CW6285 (D)
177,876
552,552
662,305
991,565
1,555,471
2,335,098 1,169,441
2,917,927 1,460,856
3,894,353 1,945,284
87,046
276,276
329,260
495,783
779,628
473
1,476
1,703
2,555
3,849
5,867
7,229
9,633
416
1,325
1,590
2,385
3,747
5,602
7,002
9,349
12,888
18,036
23,183
3
3
3
4
4
4
5
6
6
7
9
76 mm
183
91 102
273
227
908
817
1,588
2,722
3,901
5,625
241 142 162
259 126 132
289 187 132
289 187 195
350 187 195
381 231 198
381 307 198
411 307 229
411 429 234
411 551 239
ℜ 127 mm
102 mm
102 mm
152 mm
152 mm
152 mm
152 mm
152 mm
ℜ 203 mm
ℜ 254 mm
1,180
1,543
1,815
2,268
2,722
3,176
3,539
6,668
7,938
10,025
12,928
17,056
22,998
31,344
5,366,263 2,683,281 13,209
7,512,431 3,758,108 18,509
9,662,084 4,829,150 23,789
c
In Kcal/hr, calculated for chilled water, based on 3 lpm per 1,000 Kcal/hr.
d
“P” signifies molded polyethylene tank.
ℜ
PC390 = 152mm, CW5130 = 152mm, CW6285 = 203mm overflow connections only.
Pump Tanks
Chapter 6: Appendix
23 of 36
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Figure 3: Standard Pumps and Trim Based on Chiller Capacities
(Flow based on 2.4 gpm per ton)
American Standards
Capacity
Trim
size
inches
2½”
2½”
3”
Process
pump
hp
Recirculating
Nominal
refrigeration tons
Nominal flow
gallons
60
pump
hp
3
25
35
5
84
120
144
7½
7½
10
3
5
5
50
60
3”
75
180
4”
10
5
90
216
240
300
372
444
528
600
744
4”
4”
4”
6”
6”
6”
6”
6”
15
15
20
20
25
30
30
40
7½
7½
7½
10
10
15
15
20
20
100
125
155
185
220
250
310
375
900
6”
50
Pump horsepower
Amp draw 460/3/60
Shipping weight (lbs.)
1½
2.6
—
60
3
4.8
95
90
5
7½
10
14
165
320
15
21
180
425
20
27
300
510
25
34
310
630
30
40
400
670
40
52
465
—
50
65
710
—
60
77
730
—
7.6
115
115
11
125
275
• P1
• P2
Trim size (inches)
Maximum flow (gpm)
Shipping weight (lbs.)
2
50
25
2½
90
35
3
160
50
4
320
75
6
900
120
8
2,000
165
Metric Standards
Capacity
Trim
size
mm dia.
64 mm
64 mm
76 mm
Process
pump
Recirculating
pump
Nominal refrigeration,
chilled water, Kcal/hr
75,600
Nominal flow
liters
227
hp
5
kW
3.73
5.59
5.59
hp
kW
3
3
2.24
2.24
105,840
151,200
181,440
318
454
545
7½
7½
10
5
3.73
76 mm
7.50
5
3.73
226,800
272,160
302,400
378,000
468,720
559,440
665,280
756,000
681
818
908
1,136
1,408
1,680
1,998
2,271
2,816
3,407
102 mm
102 mm
102 mm
102 mm
152 mm
152 mm
152 mm
152 mm
152 mm
152 mm
10
15
15
20
20
25
30
30
40
50
7.50
5
3.73
5.59
5.59
5.59
7.50
7.50
11.19
11.19
14.91
14.91
11.19
11.19
14.91
14.91
18.64
22.37
22.37
29.93
37.29
7½
7½
7½
10
10
15
15
20
20
937,440
1,134,000
Pump horsepower/kW 1½/1.1 3/2.24 5/3.73 7½/5.5 10/7.5 15/11.1 20/14.9 25/18.6 30/22.3 40/29.9 50/37.2 60/44.7
2
9
9
1
4
7
3
9
4
Amp draw 460/3/60
Ship weight (Kg) • P1
• P2
2.6
—
28
4.8
44
41
7.6
53
53
11
57
125
14
75
146
21
82
193
27
137
232
34
141
286
40
182
304
52
211
—
65
323
—
77
332
—
Trim size (mm)
Maximum flow (lpm)
Shipping weight (Kg)
51 mm
189
12
64 mm
340
16
76 mm
624
23
102 mm
1,211
35
152 mm
3,406
55
203 mm
7,570
75
Pump Tanks
Chapter 6: Appendix
24 of 36
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Process Pump Curves and Specifications
TOTAL HEAD
KG/
CM
P1 PROCESS PUMP CURVES - 60 CYCLE
PSI FEET
2
100
220
7
6.5
6
90
200
80
5.5
5
180
60 HP
50 HP
70
60
50
40
160
140
120
100
15 HP
20 HP
4.5
4
25 HP
10 HP
30 HP
3.5
3
5 HP
40 HP
7 1/2 HP
3 HP
100
2.5
U.S. GALLONS
PER MINUTE
200
300
1000
400
1500
500
600
700
2500
800
3000
900
3500
1000
LITERS
PER MINUTE
500
2000
4000
A0548756
Pump Information
Final discharge
trim size ℵ
inches
Pump ship
wt.
Trim ship
wt.
lbs. kg
Pump
rpm
Model
16
50
52
52
54F
55F
56F
57
57
63
IMP.
5.2”
6.0”
5.75”
6.5”
6.5”
6.5”
6.3”
6.4”
6.87”
7.5”
8.2”
hp
3
5
7½
kW
2.24
3.73
5.59
7.46
11.19
14.92
18.65
22.38
29.84
37.30
44.76
lbs.
95
kg
44
3,500
3,500
3,500
3,500
3,500
3,500
3,500
3,500
3,500
3,500
3,500
2” NPT
25
35
50
50
75
75
95
95
12
16
23
23
35
35
44
44
55
55
75
2½” flange
3” flange
3” flange
4” flange
4” flange
6” flange
6” flange
6” flange
6” flange
8” flange
115
125
165
180
300
310
400
465
710
730
53
57
75
10
15
20
25
30
40
50
60
82
137
141
182
212 120
323 120
332 165
63
ℵ
Weld slip-on flange sent at discharge termination for flanged trim. 2” terminates at valve connection.
Pump Tanks
Chapter 6: Appendix
25 of 36
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Re-circulation Pump Curves and Specifications
TOTAL HEAD
KG/
P2 RECIRCULATING PUMP CURVES - 60 CYCLE
PSI FEET
2
CM
110
45
100
3
40
90
2.5
35
80
3 HP
70
60
50
40
30
25
20
2
30 HP
20 HP
25 HP
5 HP
15 HP
1.5
7 1/2 HP
10 HP
1 1/2 HP
U.S. GALLONS
PER MINUTE
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
LITERS
PER MINUTE
3500
4000
4500
5000
500
1000
1500
2000
2500
3000
A0548756
Pump Information
Final discharge
trim size ℵ
inches
Pump ship
wt.
Trim ship
wt.
Pump
rpm
Model
60
IMP.
4.6”
hp
1½
kW
lbs.
60
kg
28
lbs.
kg
1.19 3,500
2.24 3,500
3.73 3,500
5.59 1,750
7.46 1,750
11.19 1,750
14.92 1,750
18.65 1,750
22.38 1,750
2” NPT
25 12
50 23
75 35
75 35
95 44
120 55
120 55
165 75
165 75
16
17
103
104
95
96
96
96
5.2”
3
2½” flange
3” flange
4” flange
6” flange
6” flange
6” flange
8” flange
8” flange
90
41
53
5.3125”
8.0”
5
7½
115
275
320
425
510
630
670
125
146
193
232
287
305
8.0”
10
8.6”
8.9”
9.37”
9.75”
15
20
25
30
ℵ Weld slip-on flange sent at discharge termination for flanged trim. 2” terminates at valve connection.
Pump Tanks
Chapter 6: Appendix
26 of 36
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6-4 Parts List
Recommended Spare Parts
Part number Quantity
Description
A0550190
A0501073
A0069286
A0069285
A0102396
A0069538
A0102394
1
1
Pressure gauge
Temperature gauge
1 (if required) Strainer basket, 12” (approx. 30.5 cm)
1 (if required) Strainer basket, 18” (approx. 45.7 cm)
1
1
1
Float valve, 1” (approx. 25.4 mm)
Plastic ball float, 6” (approx. 15.2 mm)
Float rod, 10” (approx. 25.4 cm)
Spare Process Pump Seals and Casing Gaskets
Process pump
power
Pump seals
Pump casing gaskets
Pump
Model
hp
3
kW
2.24
Part number
A05100581
A05100581
A05100581
A05100581
A05100581
A05100581
A05100581
A05104591
A05104591
A05104591
A05104591
Qty
Part number Qty
A0101975
A0103509
A0103509
A0103509
A0103509
A0103509
A0103509
A0524321
A0524321
A0530385
A0530385
16
50
52
52
54F
55F
56F
57
57
63
5
3.73
7½
10
15
20
25
30
40
50
60
5.59
7.46
11.19
14.92
18.65
22.38
29.84
37.30
44.76
63
Spare Re-circulating Pump Seals and Casing Gaskets
Re-circulating
pump power
Pump seals
Pump casing gaskets
Pump
Model
hp
1½
3
kW
Part number
A0101975
A0100581
A0100581
A0104591
A0104591
A0104591
A0104591
A0104591
A0104591
Qty
Part number Qty
A0101582
A0101975
A0101975
A0104830
A0104830
A0530386
A0530386
A0530386
60
16
17
103
104
95
96
96
1.19
2.24
3.73
5.59
7.46
11.19
14.92
18.65
22.38
5
7½
10
15
20
25
30
96
A0530386
Pump Tanks
Chapter 6: Appendix
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6-5 Optional Assembly Detail Drawings
Tank Support Leg Assembly Detail: 4 Legs
Pump Tanks
Chapter 6: Appendix
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Tank Support Leg Assembly Detail: 6 Legs
Pump Tanks
Chapter 6: Appendix
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Tank Support Leg Assembly Detail: 7 Legs
Pump Tanks
Chapter 6: Appendix
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Tank Ladder Assembly Detail
Pump Tanks
Chapter 6: Appendix
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Sightglass Assembly Detail
Pump Tanks
Chapter 6: Appendix
32 of 36
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6-6 Typical Piping Diagrams
Typical Single Well Cooling Tower Water Pump Tank Piping System
P
P
Cooling tower
3/8" drain intended to
prevent tower freeze-up.
Do NOT valve.
Bypass
3/4" constant bleed
Tower process water return
Tower process water supply
Backflow preventer
(by others)
Strainer basket
Overflow
Makeup
Cooling tower
fan control
(optional)
Single
tower water
reservoir
T
Drain
P-1
To sewer
Pump Tanks
Chapter 6: Appendix
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Typical Dual Well Cooling Tower Pump Tank Piping System
P
P
Cooling tower
3/8" drain intended to
prevent tower freeze-up.
Do NOT valve.
1/4" swing check valve mounted 12"
above highest point in return piping
Bypass
3/4" constant bleed
Tower water return
Tower water supply
Backflow preventer
(by others)
Overflow
Strainer basket
Makeup
Dual well
tower water
reservoir
Cooling tower fan
control (optional)
Recirc. pump motor
control (standard)
T
T
Cold side
Hot side
Return
Drain
P
P
P
P-1
P-2
P-3
To drain
Standby
Pump Tanks
Chapter 6: Appendix
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Typical Single Well Chilled Water Pump Tank Piping System
1/4" swing check valve located 12"
Tower water return and supply
above highest point in return line
Bypass
Chilled water return
Chilled water supply
Backflow preventer
(by others)
Overflow
P
P
T
T
Evaporator
Single chilled
water reservoir
Makeup
Condenser
Chiller
Return
Drain
T
P
P-1
To container
(by others)
Auto pressure
regulating valve
assembly (optional)
Caution! Do not connect city water makeup if glycol is used in the system
Caution! Do not connect to draw if glycol is used in the system. Pipe to catch drum or
overflow tank.
Pump Tanks
Chapter 6: Appendix
35 of 36
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Typical Dual Well Chilled Water Pump Tank Piping System
1/4" swing check valve located 12"
Tower water return and supply
above highest point in return line
Bypass
Chilled water return
Chilled water supply
Backflow preventer
(by others)
Overflow
P
P
T
T
Makeup
Return
Evaporator
Dual chilled
water reservoir
Condenser
Chiller
T
T
Cold side
P-1
Hot side
P-3
Return
Drain
P
P
P
P-2
To container
(by others)
Standby
Caution! Do not connect city water makeup if glycol is used in the system
Caution! Do not connect to draw if glycol is used in the system. Pipe to catch drum or
overflow tank.
Pump Tanks
Chapter 6: Appendix
36 of 36
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