Evapco O&M Instruction

Bulletin 116B
Operation and
Maintenance Instructions
FOR EVAPCO INDUCED DRAFT AND FORCED DRAFT CLOSED
CIRCUIT COOLERS AND EVAPORATIVE CONDENSERS
ATC-E/ATWB
PMC-E/PMWQ
ESWA
LSWB/LSCB
LRWB/LRC
WDW
For EVAPCO Authorized Parts and Service, Contact Your Local EVAPCO
Representative or the Local Mr. GoodTower Service Provider
EVAPCO, Inc. World Headquarters & Research/Development Center
EVAPCO, Inc. P.O. Box 1300 Westminster, MD 21158 USA
PHONE: 410-756-2600 FAX: 410-756-6450 E-MAIL: marketing@evapco.com
EVAPCO North America
EVAPCO, Inc.
World Headquarters
P.O. Box 1300
Westminster, MD 21158 USA
Phone: 410-756-2600
Fax: 410-756-6450
E-mail: marketing@evapco.com
EVAPCO East
5151 Allendale Lane
Taneytown, MD 21787 USA
Phone: 410-756-2600
Fax: 410-756-6450
E-mail: marketing@evapco.com
EVAPCO Midwest
1723 York Road
Greenup, IL 62428 USA
Phone: 217-923-3431
Fax: 217-923-3300
E-mail: evapcomw@evapcomw.com
EVAPCO West
1900 West Almond Avenue
Madera, CA 93637 USA
Phone: 559-673-2207
Fax: 559-673-2378
E-mail: contact@evapcowest.com
EVAPCO Iowa
925 Quality Drive
Lake View, IA 51450 USA
Phone: 712-657-3223
Fax: 712-657-3226
EVAPCO Iowa
Sales & Engineering
1234 Brady Boulevard
Owatonna, MN 55060 USA
Phone: 507-446-8005
Fax: 507-446-8239
E-mail: evapcomn@evapcomn.com
EVAPCO Europe
Refrigeration Valves &
Systems Corporation
A wholly owned subsidiary of EVAPCO, Inc.
1520 Crosswind Dr.

Bryan, TX 77808 USA
Phone: 979-778-0095
Fax: 979-778-0030
E-mail: rvs@rvscorp.com
McCormack Coil Company, Inc.
P.O. Box 1727

6333 S.W. Lakeview Boulevard
Lake Oswego, OR 97035 USA
Phone: 503-639-2137
Fax: 503-639-1800
E-mail: mail@mmccoil.com
EvapTech, Inc.
8331 Nieman Road

Lenexa, KS 66214 USA
Phone: 913-322-5165
Fax: 913-322-5166
E-mail: marketing@evaptech.com
Tower Components, Inc.
5960 US HWY 64E

Ramseur, NC 27316
Phone: 336-824-2102
Fax: 336-824-2190
E-mail: mail@towercomponentsinc.com
EVAPCO Newton
701 East Jourdan Street
Newton, IL 62448 USA
Phone: 618-783-3433
Fax: 618-783-3499
E-mail: evapcomw@evapcomw.com
EVAPCO...SPECIALISTS IN HEAT TRANSFER

PRODUCTS AND SERVICES.
EVAPCO Asia/Pacific
EVAPCO Europe, N.V.

European Headquarters
Industrieterrein Oost 4010
3700 Tongeren, Belgium
Phone: (32) 12-395029
Fax: (32) 12-238527
E-mail: evapco.europe@evapco.be
EVAPCO Asia/Pacific Headquarters

1159 Luoning Rd. Baoshan Industrial Zone
Shanghai, P. R. China, Postal Code: 200949
Phone: (86) 21-6687-7786
Fax: (86) 21-6687-7008
E-mail: marketing@evapcochina.com
EVAPCO Europe, S.r.l.

Via Ciro Menotti 10
I-20017 Passirana di Rho
Milan, Italy
Phone: (39) 02-939-9041
Fax: (39) 02-935-00840
E-mail: evapcoeurope@evapco.it
EVAPCO Europe, S.r.l.
Via Dosso 2
23020 Piateda Sondrio, Italy
EVAPCO Europe, GmbH
Bovert 22
D-40670 Meerbusch, Germany
Phone: (49) 2159-69560
Fax: (49) 2159-695611
E-mail: info@evapco.de
Flex coil a/s
Evapco (Shanghai) Refrigeration

Equipment Co., Ltd.
1159 Louning Rd., Baoshan Industrial Zone
Shanghai, P.R. China, Postal Code: 200949
Phone: (86) 21-6687-7786
Fax: (86) 21-6687-7008
E-mail: marketing@evapcochina.com
A subsidiary of EVAPCO, Inc.
Beijing EVAPCO Refrigeration

Equipment Co., Ltd.
Yan Qi Industrial Development District
Huai Rou County
Beijing, P.R. China, Postal Code: 101407
Phone: (86) 10 6166-7238
Fax: (86) 10 6166-7395
E-mail: evapcobj@evapcochina.com
Evapco Australia (Pty.) Ltd.
A licensed manufacturer of EVAPCO, Inc.
Knsgrdvej 115
DK-9440 Aabybro Denmark
Phone: (45) 9824 4999
Fax: (45) 9824 4990
E-mail: info@flexcoil.dk
EVAPCO S.A. (Pty.) Ltd.
34-42 Melbourne St.

P.O. Box 436
Riverstone, N.S.W. Australia 2765
Phone: (61) 29 627-3322
Fax: (61) 29 627-1715
E-mail: sales@evapco.com.au
EvapTech Asia Pacific Sdn. Bhd
18 Quality Road
Isando 1600
Republic of South Africa
Phone: (27) 11 392-6630
Fax: (27) 11-392-6615
E-mail: evapco@icon.co.za
Tiba Engineering Industries Co.
5 Al Nasr Road St.

Nasr City, Cairo, Egypt
Phone: (20) 2-290-7483/(20) 2-291-3610
Fax: (20) 2-404-4667/ (20) 2-290-0892
E-mail: manzgroup@tedata.net.eg
A wholly owned subsidiary of EvapTech, Inc.
IOI Business Park, 2/F Unit 21

Persiaran Puchong Jaya Selatan
Bandar Puchong Jaya,
47170 Puchong, Selangor, Malaysia
Phone: (60-3) 8070 7255
Fax: (60-3) 8070 5731
E-mail: marketing-ap@evaptech.com
Visit EVAPCOs Website at:
http://www.evapco.com
Operation and Maintenance Instructions
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Initial Storage and/or Idle Period Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
International Building Code Provision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Initial and Seasonal Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Initial and Seasonal Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Seasonal Shut-Down Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Basic Closed Circuit Cooler/Condenser Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fan Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fan Shaft Ball Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fan Shaft Sleeve Bearings (4 wide LS units only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gear Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Air Inlet and WDW Dry Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fan System Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fan Motor Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Sequence of Operation for Fan Motor Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Two-Speed Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Sequence of Operation for Two Fan Units with Two Speed Motors during Peak Load . . . . . . . . . . . . .15
Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Sequence of Operations / Guidelines for Multi-fan Units with a VFD during Peak Load . . . . . . . . . . . .15
Recirculated Water System Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Suction Strainer in Cold Water Basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Cold Water Basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Operating Level of Water in Cold Water Basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Water Make Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Pressurized Water Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Bleed-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Pump (When Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Water Treatment and Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Bleed or Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Galvanized Steel Passivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Water Chemistry Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Control of Biological Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Gray Water and Reclaimed Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Unit Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Freeze Protection of Recirculating Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Freeze Protection of Closed Circuit Cooler Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Unit Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Cold Water Basin Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Remote Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Electric Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Vibration Cut Out Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Capacity Control Methods for Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Induced Draft Unit Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Forced Draft Unit Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Ice Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Induced Draft Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Forced Draft Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Part Identification Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
ATW 3 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
ATC/ATW 4x4 & 4x6 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
ATC/ATW 4x9 & 4x12 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
ATC/ATW 8 & 8.5 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
ATC/ATW 10 & 12 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
ESWA 8.5 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ESWA 12 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
ESWA 14 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
WDW Dry Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
WDW Wet Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
LSCB & LSWB 4 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
LSCB & LSWB 5 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
LSCB & LSWB 8 Wide Units (Single Side Fans) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
LSCB & LSWB 10 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
LRC/LRWB 3 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
PMC-E 5 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
PMC-E/PMWQ 10 and 12 Wide Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50, 51
Introduction
Congratulations on the purchase of your EVAPCO evaporative cooling unit. EVAPCO equipment is constructed of the highest
quality materials and designed to provide years of reliable service when properly maintained.
Evaporative cooling equipment is often remotely located and periodic maintenance checks are often overlooked. It is important to
establish a regular maintenance program and be sure that the program is followed. This bulletin should be used as a guide to
establish a program. A clean and properly serviced unit will provide a long service life and operate at peak efficiency.
This bulletin includes recommended maintenance services for unit start up, unit operation and unit shutdown and the frequency of
each. Please note: the recommendations of frequency of service are minimums. Services should be performed more often when
operating conditions necessitate.
Become familiar with your evaporative cooling equipment. Refer to the isometric drawings located on pages 31-49 for information
on the arrangement of components in your equipment.
If you should require any additional information about the operation or maintenance of this equipment, contact your local EVAPCO
representative. You may also visit www.evapco.com or www.mrgoodtower.com for more information.
Safety Precautions
Qualified personnel should use proper care, procedures and tools when operating, maintaining or repairing this equipment in order
to prevent personal injury and/or property damage. The warnings listed below are to be used as guidelines only.
WARNING: This equipment should never be operated without fan screens and access doors properly secured and in place.
WARNING: A lockable disconnect switch should be located within sight of the unit for each fan motor associated with
this equipment. Before performing any type of service or inspection of the unit make certain that all power
has been disconnected and locked in the OFF position.
WARNING: The top horizontal surface of any unit is not intended to be used as a working platform. No routine service
work is required from this area.
WARNING: The recirculating water system may contain chemicals or biological contaminants including Legionella
Pneumophila, which could be harmful if inhaled or ingested. Direct exposure to the discharge airstream and
the associated drift generated during operation of the water distribution system and/or fans, or mists
generated while cleaning components of the water system require respiratory protection equipment
approved for such use by governmental occupational safety and health authorities.
Terminology
Throughout this manual, the terms Induced Draft and Forced Draft are used. Below is a list of EVAPCO Closed Circuit Cooler
and Condenser products offerings and associated terminology.
Induced Draft equipment includes the following Evapco Product Models:

ES Product Lines
ESW Closed Circuit Cooler
ESWA - Closed Circuit Cooler
AT Product Lines
ATW - Closed Circuit Cooler
ATWB - Closed Circuit Cooler
ATC Evaporative Condenser
ATC-B - Evaporative Condenser

ATC-E - Evaporative Condenser
Containerized Product Lines

CATW Closed Circuit Cooler
CATWB - Closed Circuit Cooler
CATC - Evaporative Condenser
WDW Wet/Dry Closed Circuit Cooler
Forced Draft equipment includes the following Evapco Product Models:

LR Product Lines
LRW - Closed Circuit Cooler
LRWB - Closed Circuit Cooler
LRC - Evaporative Condenser
LS Product Lines
LSW - Closed Circuit Cooler
LSWA - Closed Circuit Cooler
LSWB - Closed Circuit Cooler
LSC - Evaporative Condenser
LSCA - Evaporative Condenser
LSCB - Evaporative Condenser
PM Product lines
PMC - Evaporative Condenser
PMC-N - Evaporative Condenser
PMCA - Evaporative Condenser
PMCB - Evaporative Condenser
PMC-E - Evaporative Condenser
PMWQ - Closed Circuit Cooler
Initial Storage and/or Idle Period Recommendations

If the unit will sit for idle periods of time it is recommended that the following be performed in addition to all component
manufacturers recommended maintenance instructions.
The fan bearings and motor bearings need to be turned by hand at least once a month. This can be accomplished by
tagging and locking out the units disconnect, grasping the fan assembly, and rotating it several turns.
If unit sits longer than a few weeks, run gear reducer for 5 minutes weekly.
If unit sits longer than 3 weeks, completely fill gear reducer with oil. Drain to normal level prior to running.
If unit sits longer than one month, insulation test motor windings semi-annually.
If fan motor sits idle for at least 24 hours while the spray pumps are energized distributing water over the coil, motor space
heaters are suggested and (if equipped) should be energized. Alternatively, fan motors may be energized for 10 minutes,
twice daily, to drive any moisture condensation out of the motor windings.
International Building Code Provisions

The International Building Code (IBC) is a comprehensive set of regulations addressing the structural design and installation
requirements for building systems including HVAC and industrial refrigeration equipment. The code provisions require that
evaporative cooling equipment and all other components permanently installed on a structure must meet the same seismic design
criteria as the building.
All items attached to Evapco Closed Circuit Coolers or Evaporative Condensers must be independently reviewed and isolated to
meet applicable wind and seismic loads. This includes piping, ductwork, conduit, and electrical connections. These items must be
flexibly attached to the Evapco unit so as not to transmit additional loads to the equipment as a result of seismic or wind forces.
Initial and Seasonal Start-Up Checklist

General
1.
Verify that the overall installation reects the requirements of the installation guidelines found in EVAPCO Bulletin 311
Equipment Layout Manual available at www.evapco.com.
2.
For multi-speed fan motors, verify that 30 second or greater time delays are provided for speed changes when switching from
high to low speed. Also check to see if interlocks are provided to prevent simultaneously energizing high and low speed, and
confirm both speeds operate in the same direction.
3.
Verify all safety interlocks work properly.
4.
For units operating with a variable frequency drive, make certain that minimum speed requirements have been set. Check with
VFD manufacturer for recommended minimum speeds. Check with VFD manufacturer for recommendations on locking out
resonance frequencies. See Fan System Capacity Control section for more information.
5.
Verify that a water treatment plan has been implemented including passivation of galvanized steel units. See Water
Treatment section for more details.
6.
If the unit is going to sit idle for an extended period of time, follow all manufacturers fan motor and pump instructions for long
term storage. Plastic sheets or tarps should never be used to protect a unit during storage. This practice can trap heat inside
the unit, and could potentially cause damage to plastic components. See your local EVAPCO representative for additional
information on unit storage.
7.
For units subject to freezing climates, high humidity climates, or idle periods lasting 24 hours or more, motor space heaters are
suggested and (if equipped) should be energized. Alternatively, fan motors may be energized for 10 minutes, twice daily, to
drive any moisture condensation out of the motor windings.
BEFORE BEGINNING ANY MAINTENANCE, BE CERTAIN THAT THE POWER IS TURNED OFF
AND THE UNIT IS PROPERLY LOCKED AND TAGGED OUT!
Initial and Seasonal Start-Up

1.
Clean and remove any debris, such as leaves and dirt from the air inlets.
2.
Flush the cold water basin (with the strainer screens in place) to remove any sediment or dirt.
3.
Remove the strainer screen, clean and reinstall.
4.
Check mechanical float valve to see if it operates freely.
5.
Inspect water distribution system nozzles and clean as required. Check for proper orientation.
(This is not required at initial start-up. The nozzles are clean and set at the factory).
6.
Check to ensure drift eliminators are securely in place and in the proper orientation.
7.
Adjust fan belt tension as required. See Fan Belt Adjustment section.
8.
Lubricate fan shaft bearings prior to seasonal start-up.
9.
Turn the fan(s) by hand to insure it turns freely without obstructions.
10. Visually inspect the fan blades. Blade clearance should be approximately 3/8 (1/4 minimum) from tip of blade to the fan cowl.
The fan blades should be securely tightened to the fan hub.
11. If any stagnant water remains in the system including dead legs in the piping, the unit must be disinfected prior to the fans
being energized. Please refer to ASHRAE Guideline 12-2000 and CTI Guideline WTP-148 for more information.
12. Manually fill the cold water basin up to the overflow connection.
13. For closed circuit coolers, fill the heat exchanger coil with the specified fluid and burp air from the system before pressurizing,
using vents on coil inlets. Do not do this for evaporative condensers.
After the unit has been energized, check the following:

1.
Adjust mechanical float valve as required to the proper water level.
2.
Unit basin should be filled to the proper operating level. See Recirculating Water System Operating Levels section for more
details.
3.
Verify fan is rotating in proper direction.
4.
Start the spray water pump and check for proper rotation as indicated by the arrow on the front cover.
5.
Measure voltage and current on all three power leads of pump and fan motor. The current should not exceed the motor
nameplate full load amp rating taking the service factor into account.
6.
Adjust bleed valve to proper flow rate. Maximum bleed off is 3 US GPM per 100 tons. Consult your qualified water treatment
person to fine tune the minimum bleed necessary.
7.
See fan and pump motor manufacturer maintenance and long term storage instructions for more detailed information. The
motors should be lubricated and serviced in accordance with manufacturers instructions.
MAINTENANCE
CHECKLIST
PROCEDURE
1.
Clean pan strainer monthly or as needed
2.
Clean and flush pan* quarterly or as needed
3.
Check bleed-off valve to make sure it is

operative monthly
4.
Lubricate pump and pump motor according to

manufacturers instructions
5.
Check operating level in pan and adjust float

valve if necessary monthly
6.
Check water distribution system and spray

pattern monthly
7.
Check drift eliminators quarterly
8.
Check the fan blades for cracks, missing

balancing weights, and vibrations quarterly
9.
Lubricate fan shaft bearings every 1000

hours of operation or every three months
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
10. Lubricate fan motor bearings see mfgs

instructions. Typically for non-sealed bearings,
every 2-3 years
11. Check belt tension and adjust monthly
12. Inspect and grease sliding motor base
annually or as needed
13. Check fan screens, inlet louvers, fans and dry
cooler coil (WDW only).
Remove any dirt or debris monthly
14. Inspect and clean protective finish annually
- Galvanized: scrape and coat with ZRC
- Stainless: clean and polish with a
stainless steel cleaner.
15. Check water quality for biological contamination.
Clean unit as needed and contact a water
treatment company for recommended water
treatment program* regularly
OPTIONAL ACCESSORIES:
1. Gear Reducer Check oil level with unit
stopped 24 hours after start-up & monthly
2.
Gear Reducer/Piping Do visual inspection

for oil leaks, auditory inspection for unusual
noises and vibrations monthly
3. Gear Reducer Replace oil semi-annually

4.
Oil Pump Do visual inspection for leaks and

proper wiring monthly
5.
Gear Reducer/Coupling Check alignment of

the system 24 hours after start-up & monthly
* Evaporative cooling equipment must be cleaned on a regular basis to prevent the growth of bacteria including Legionella Pneumophila.
NOV
DEC
MAINTENANCE
CHECKLIST
OPTIONAL ACCESSORIES:
6.
Coupling/Shaft Inspect flex elements and

hardware for tightness, proper torque &
crack/deterioration monthly
7.
Heater Controller Inspect controller and

clean probe ends quarterly
8.
Heater Inspect junction box for loose wiring

and moisture one month after start-up and
semi-annually
9.
Heater Inspect elements for scale

build-up quarterly
JAN
FEB
10. Electronic Water Level Controller Inspect

junction box for loose wiring and moisture
semi-annually
11. Electronic Water Level Controller Clean
probe ends of scale build-up quarterly
12. Electronic Water Level Controller Clean
inside the standpipe annually
13. Solenoid Make-up Valve Inspect and clean
valve of debris as needed
14. Vibration Switch (mechanical) Inspect
enclosure for loose wiring and moisture
one month after start-up and monthly
15. Vibration Switch Adjust the sensitivity
during start-up and annually
16. Sump Sweeper Piping Inspect and clean
piping of debris semi-annually
17. Water Level Indicator Inspect and clean
annually
DURING IDLE PERIODS:
1.
Two or more Days: Energize motor

space heaters or run motors for 10 minutes
twice daily
2.
Few Weeks: Run gear reducer for 5 minutes

weekly
3.
Several Weeks: Completely fill gear reducer

with oil. Drain to normal level prior to running.
4.
One Month or longer: Rotate motor shaft/fan

10 turns bi-weekly
5.
One Month or longer: Megger test motor

windings semi-annually
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
Seasonal Shut-Down Checklist

When the system is to be shut down for an extended period of time, the following services should be performed.
1.
2.
3.
4.
5.
6.
7.
8.
9.
The evaporative cooling unit cold water basin should be drained

The cold water basin should be flushed and cleaned with the suction strainer screens in place.
The suction strainer screens should be cleaned and re-installed.
The cold water basin drain should be left open.
The fan shaft bearings and motor base adjusting screws should be lubricated. This should also be performed if the unit is
going to sit idle prior to initial start-up.
The make-up water supply, overflow and drain lines, as well as the recirculating pump and pump piping up to the overflow
level must be heat traced and insulated to account for any residual water.
The finish of the unit should be inspected. Clean and refinish as required.
The fan bearings and motor bearings need to be turned at least once a month by hand. This can be accomplished by
making sure the units disconnect is tagged and locked out, and grasping the fan assembly, rotating it several turns.
Closed Circuit Coolers only - If the recommended minimum fluid flows thru the heat transfer coil cannot be maintained,
and an anti-freeze solution is not in the coil, the coil must be drained immediately whenever the system pumps are shut
down or flow stops during freezing conditions. This is accomplished by having automatic drain valves and air vents in the
piping to and from the cooler. Care must be taken to ensure that the piping is adequately insulated and sized to allow the
water to flow quickly from the coil. This method of protection should be used only in emergency situations and is neither a
practical nor recommended method of freeze protection. Coils should not be drained for an extended period of time, as
internal corrosion may occur. See Cold Weather Operation section of this document for more details.
See fan and pump manufacturer maintenance and long term storage instructions for more detailed instructions.
Basic Closed Circuit Cooler/Condenser Sequence of Operation

Note: The EVAPCO WDW sequence of operation is unique and is explained in detail in the Sage Panel Control Manual,
EVAPCO Bulletin 117.
System Off / No Load

The system pumps and fans are off. If the basin is full of water a minimum basin water temperature of 40F must be maintained to
prevent freezing. This can be accomplished with the use of optional basin heaters. See the Cold Weather Operation section of
this bulletin for more details on cold weather operation and maintenance.
System/Condensing Temperature Rises

The recirculation pump turns on. The unit will provide approximately 10% cooling capacity with only the pump running. If the unit
has positive closure dampers they should be fully opened before the pumps turn on.
If the system temperature continues to rise, the unit fan is cycled on. For a variable speed controller, the fans are turned on to
minimum speed. See the Fan System Capacity Control section of this bulletin for more details on fan speed control options. If
the system temperature continues to rise, then the fan speed is increased as required, up to full speed.
Note: During sub-freezing weather the minimum recommended speed for variable speed controllers is 50%. ALL FANS IN
OPERATING CELLS OF MULTIPLE CELL UNITS MUST BE CONTROLLED TOGETHER TO PREVENT ICING ON THE FANS.
System Temperature Stabilizes

Control the leaving fluid temperature (closed circuit coolers) or condensing temperature (evaporative condensers) by modulating
the fan speeds with variable speed drives or by cycling fans on and off with single or two-speed drives.
10
System/Condensing Temperature Drops

Decrease the fan speed, as required.
System Off / No Load

The system pump turns off. The starter interlock will energize any optional basin heaters in cold weather.
The recirculation pump should not be used as a means of capacity control, and should not be cycled frequently. Excessive cycling
can lead to scale build-up, and reduce wet and dry performance.
Dry Operation
During colder winter months it is possible to turn off the spray pump, drain the cold water basin, and just cycle the fans. Be sure to
leave the basin drain open during this time to prevent collection of rain water, snow, etc. If the unit has positive closure dampers
they should be fully opened before the fans turn on. If this method will be used on a centrifugal fan, forced draft unit, be sure to
verify that the motor and drives have been properly sized to handle the reduction in static pressure experienced when the spray
water is turned off.
NOTE: MINIMUM CONTROL POINT FOR PROCESS FLUID SHOULD NEVER BE LOWER THAN 42 F.
NOTE: WHEN A UNIT IS PROVIDED WITH A DISCHARGE DAMPER ASSEMBLY, THE CONTROL SEQUENCE SHOULD
CYCLE THE DAMPERS OPEN AND CLOSED ONCE A DAY REGARDLESS OF CAPACITY REQUIRMENTS TO PREVENT
THE ASSEMBLY FROM SEIZING. THE FAN MOTOR SHOULD BE SHUT OFF WHENEVER THE DAMPERS ARE CLOSED.
Fan System
The fan systems of both centrifugal and axial driven units are rugged; however, the fan system must be checked regularly and
lubricated at the proper intervals. The following maintenance schedule is recommended.
Fan Motor Bearings

EVAPCO evaporative cooling units use either a T.E.A.O. (Totally Enclosed Air Over) or a T.E.F.C. (Totally Enclosed Fan Cooled) fan
motor. These motors are built to Cooling Tower Duty specifications. They are supplied with permanently lubricated bearings and
special moisture protection on the bearings, shaft and windings. After extended shut-downs, the motor should be checked with an
insulation tester prior to restarting the motor.
Fan Shaft Ball Bearings

For induced draft units, lubricate the fan shaft bearings every 1,000 hours of operation or every three months. For forced draft
units, lubricate the fan shaft bearings every 2,000 hours of operation or every six months. Use any of the following synthetic
waterproof, polyurea inhibited greases which are suitable for operation between -20F and 350F. (For colder operating
temperatures, contact the factory).
Mobil Polyrex EM
Chevron - SRI
Timken Pillowblock Grease
Feed grease slowly into the bearings or the seals may be damaged. A hand grease gun is recommended for this process.
When introducing new grease, all grease should be purged from the bearings.
Most EVAPCO units are supplied with extended grease lines to allow easy lubrication of the fan shaft bearings as shown in Table 1.
11
Unit Description
Location of Lube Line Fittings
Induced Draft Units:

4 (belt drive), 8, 8.5, 17 wide
Located just beside the fan casing

access door
Induced Draft Units:

10, 12, 14, 24, 28 wide
Located inside the fan casing

access door
Forced Draft Units
Located on the bearing support or

on the side of the unit
Table 1 Location of Grease Lube Line Fittings for Belt Driven Units
Fan Shaft Sleeve Bearings (4 wide LS units only)

Lubricate the intermediate sleeve bearing(s) before unit start up. The reservoir should be checked several times during the first
week to ensure that the oil reserve is brought to full capacity. After the first week of operation, lubricate the bearing(s) every 1,000
hours of operation or every three months (whichever occurs first). High temperatures or poor environmental conditions may
necessitate more frequent lubrication. The oil reservoir consists of a large felt packed cavity within the bearing housing. It is not
necessary to maintain the oil level within the filler cup.
Use one of the following industrial grade, non-detergent mineral oils. Do not use a detergent based oil or oils designated heavy
duty or compounded. Different oils may be required when operating at temperatures below 30F continuously. Table 2 provides a
short list of approved lubricants for each temperature range. Most automotive oils are detergent based and may not be used.
Detergent oils will remove the graphite in the bearing sleeve and cause bearing failure.
Ambient Temp
Texaco
Mobil
Exxon
30F to 100F
Regal R&O 220
DTE Oil BB
Teresstic 220
-25F to 30F
Capella WF 32
DTE Heavy
------------------
Table 2 Sleeve Bearing Lubricants
All bearings used on EVAPCO equipment are factory adjusted and self aligning. Do not disturb bearing alignment by tightening the
sleeve bearing caps.
Oil drippage may result from over-oiling or from using too light of an oil. Should this condition persist with correct oiling, it is
recommended that a heavier weight oil be used.
Fan Belt Adjustment

The fan belt tension should be checked at start up and again after the first 24 hours of operation to correct for any initial stretch. To
properly adjust the belt tension, position the fan motor so that the fan belt will deflect approximately 3/8 when moderate pressure
is applied midway between the sheaves. Figure 1 and Figure 2 show two ways to measure this deflection. Belt tension should be
checked on a monthly basis. A properly tensioned belt will not chirp or squeal when the fan motor is started.
Figure 1 Method 1
Figure 2 Method 2
12
On induced draft belt driven units provided with externally mounted motors (3, 4, 8, 8.5 and 17 foot wide units) and LS Style forced
draft units, both J-type adjustment bolts on the adjustable motor base should have an equal amount of exposed thread for proper
sheave and belt alignment. See Figures 3 and 4.
Figure 3 Externally Mounted Motor, Induced Draft
Figure 4 Externally Mounted Motor, Large LS Units
Figure 6 LR Motor Adjustment
Figure 5 Internally Mounted Motor, Induced Draft
On induced draft belt driven units with internally mounted motors

(10, 12, 14, 20, 24 and 28 foot wide units) and LR units, a motor
adjustment tool is provided on the adjustment nut. See Figures 5
and 6. To use, place the hex end over the adjustment nut and
tension the belt by turning the nut counterclockwise. When the
belts are properly tensioned, tighten the lock nut.
ADJUSTMENT
NUTS
Direct drive units do not require any adjustment.
Figure 7 PM Style Motor Adjustment

13
Gear Drives
Induced draft units with gear drive systems require special maintenance. Please refer to the gear manufacturers recommended
maintenance instructions. These will be enclosed and shipped with the unit.
Air Inlet
Inspect the air inlet louvers (induced draft units) or fan screens (forced draft units) monthly to remove any paper, leaves or other
debris that may be blocking airflow into the unit.
Dry Coil (WDW Only)

Depending on outdoor conditions, the dry coil on the WDW should be cleaned at least twice a year. If the unit is located near trees,
construction, etc., the required cleaning may be more frequent. Per our standard unit maintenance guidelines shown on pages 8 &
9, the coil should be visually inspected monthly along with inlet louvers and inlet screens.
The best cleaning solution for the dry coil is plain water. If the coil has been maintained and cleaned at regular intervals, water is
sufficient to remove dirt and debris from the fins. Heavy build up on the exterior of the fins can be removed with a brush. If a
pressure washer is used, make sure the equipment is set to a low pressure setting and that the nozzle is set to the fan spray, not
stream, otherwise damage to the fins could result. The best method of cleaning the coil is from the inside out. Spraying water from
the outside repeatedly can cause a buildup of debris and airflow restriction.
Fan System Capacity Control

There are several methods for capacity control of the evaporative cooling unit. Methods include: Fan motor cycling, the use of two
speed motors, and the use of variable frequency drives (VFDs).
Fan Motor Cycling

Fan Motor Cycling requires the use of a single stage thermostat which senses the fluid temperature (closed circuit coolers) or
condensing temperature (evaporative condensers). The contacts of the thermostat are wired in series with the fan motors starter
holding coil.
Sequence of Operation for Fan Motor Cycling

Fan Motor Cycling is often found to be inadequate where the load has a wide fluctuation. In this method, there are only two stable
levels of performance: 100% of capacity when the fan is on, and approximately 10% of capacity when the fan is off. Please note
that rapid cycling of the fan motors can cause the fan motor to overheat. Controls should be set to only allow a maximum of six
start/stop cycles per hour. The recirculation pump may not be used as a means of capacity control and should not be cycled
frequently. Excessive cycling can lead to scale build-up, resulting in reduced wet and dry performance.
Two Speed Motors

The use of a two-speed motor provides an additional step of capacity control when used with the fan cycling method. The low
speed of the motor will provide approximately 60% of full speed capacity.
Two-speed capacity control systems require not only a two-speed motor, but also a two-stage thermostat and the proper two-speed
motor starter. The most common two-speed motor is a single winding type. This is also known as a consequent pole design. Two-speed
two-winding motors are also available. All multi-speed motors used in evaporative cooling units should be variable torque design.
It is important to note that when two-speed motors are to be used, the motor starter controls must be equipped with a decelerating
time delay relay. The time delay should be a minimum of 30 seconds when switching from high speed to low speed.
14
Sequence of Operation for Two Cell Units with Two Speed Motors during Peak Load
1.
2.
3.
4.
5.
6.
Both fan motors off Pump running on one cell.

Both fan motors off Pump running on both cells.
One fan motor on low speed, one fan motor off Pump running on both cells.
Both fan motors on low speed Pump running on both cells.
One fan motor on high speed, one fan motor on low speed Pump running on both cells.
Both fan motors on full speed Pump running on both cells.
Variable Frequency Drives

The use of a variable frequency drive (VFD) provides the most precise method of capacity control. A VFD is a device that converts
a fixed AC voltage and frequency into an adjustable AC voltage and frequency used to control the speed of an AC motor. By
adjusting the voltage and frequency, the AC induction motor can operate at many different speeds.
The use of VFD technology can benefit the life of the mechanical components with fewer and smoother motor starts and built-in
motor diagnostics. VFD technology has particular benefit on evaporative cooling units operating in cold climates where airflow can
be modulated to minimize icing and reversed at low speed for de-icing cycles. Applications using a VFD for capacity control must
also use an inverter duty motor built in compliance with NEMA standard MG-1. This is an available option from EVAPCO.
NOTE: VFD's should not be used on pump motors. The pumps are designed to be operated at full speed and are not intended to
be used as capacity control.
The type of motor, manufacturer of the VFD, motor lead lengths (between the motor and the VFD), conduit runs and grounding can
dramatically affect the response and life of the motor. Select a high quality VFD that is compatible with the fan motor(s) in the
EVAPCO unit(s). Many variables in the VFD configuration and installation can affect motor and VFD performance. Two particularly
important parameters to consider when choosing and installing a VFD are switching frequency and the distance between the motor
and VFD often referred to as lead length. Consult the VFD manufacturers recommendations for proper installation and
configuration. The motor lead length restrictions can vary with the vendor. Regardless of motor supplier, minimizing lead length
between the motor and drive is good practice.
Sequence of Operations / Guidelines for Multi-fan Units with a VFD during Peak Load
1.
2.
3.
4.
5.
Both fan motors off Pump running on one cell.

Both fan motors off Pump running on both cells.
Both VFDs turn on at the manufacturers recommended minimum operating speed (20-25%) Pump running on both cells.
Both VFDs speed up uniformly (they should be synchronized on start-up) Pump running on both cells.
Both VFDs are on full speed Pump running on both cells.
Note: the VFDs need to have a pre-set shutoff to prevent water temperatures from becoming too cold and to prevent the drive
from trying to turn the fan at near zero speed. Operating below 25% of motor speed achieves very little return in fan energy
savings and capacity control. Check with your VFD supplier if operating below 25% is possible.
For more details on the use of variable frequency drives, please download a copy of EVAPCOs Engineering Bulletin 39 from
www.evapco.com.
15
Recirculated Water System Routine Maintenance

Suction Strainer in Cold Water Basin
The pan strainer as shown in Figures 8, 9, 10 and 11 should be removed and cleaned monthly or as often as necessary. The
suction strainer is the first line of defense in keeping debris out of the system. Make certain that the strainer is properly located over
the pump suction, alongside the anti-vortexing hood.
Figure 8 Single Strainer Assembly
Figure 9 Dual Strainer Assembly
ANTI-VORTEXING
HOOD
ANTI-VORTEXING
HOOD
STRAINER
ASSEMBLY
STRAINER
HANDLE
STRAINER
HANDLE
STRAINER
ASSEMBLY
Figure 10 LSWB/LSCB/PMCE/PMWQ Strainer Assembly
Figure 11 LRWB/LRC Strainer Assembly
Cold Water Basin

The cold water basin should be flushed out quarterly, and checked monthly or more often if necessary, to remove any accumulation
of dirt or sediment which normally collects in the basin. Sediment can become corrosive and cause deterioration of basin materials.
When flushing the basin, it is important to keep the suction strainers in place to prevent any sediment from entering the system.
After the basin has been cleaned, the strainers should be removed and cleaned before refilling the basin with fresh water.
Operating Level of Water in Cold Water Basin

The operating level should be checked monthly to make sure the water level is correct. Refer to Table 3 for unit specific levels.
16
Evaporative Condenser
Model Number
Closed Circuit Cooler

Footprint
Operating
Water Level*
ATC Products
50E to 165E
187E to 3714E
ATW Products
3 and 4 wide units
8.5 wide thru 24 wide
6
11
CATC Products
181 to 504
CATW Products
7.5 wide units
11
LRC Products
25 to 379
LRW Products
3 wide thru 8 wide units
8"
LSC Products
36 to 170
185 to 385
400 to 515, 800 to 1030
550 to 805, 1100 to 1610
LSW Products
4x6 thru 4x12
5.5x12, 5.5x18
8x12, 8x24, 10x12, 10x24
8x18, 8x36, 10x18, 10x36
Dual Fan Sided Units
8x12, 8x24
8x18, 8x36
11
11
12
15
12
12
15
PMC Products
175E to 375E
332E to 1985E
PMWQ Products
10 and 12 wide units
10
14
WDW Products
11
ESWA Products
8.5 wide thru 14 wide units
11
* Measured from lowest point on basin floor.
Table 3 - Recommended Operating Water Level
At initial start up or after the unit has been drained, the unit must be filled to the overflow level. Overflow is above the normal
operating level and accommodates the volume of water normally in suspension in the water distribution system and the riser
piping.
The water level should always be above the strainer. Check by running the pump with the fan motors off and observing the water
level through the access door or remove the air inlet louver.
Water Make Up Valve

A mechanical float valve assembly is provided as standard
equipment on the evaporative cooling unit (unless the unit has
been ordered with an optional electronic water level control
package or the unit is arranged for remote sump operation).
The make up valve is easily accessible from outside the unit
through the access door or removable air inlet louver. The make
up valve is a bronze valve connected to a float arm assembly
and is activated by a large foam filled plastic float. The float is
mounted on an all-thread rod held in place by wing nuts. The
water level in the basin is adjusted by repositioning the float
and all-thread using the wing nuts. Refer to Figure 12 for
details.
Figure 12 Mechanical Water Make Up Valve
17
General Information - Start-up & Maintenance
-The make up valve assembly should be inspected monthly and adjusted as required. The valve should be inspected annually for
leakage and if necessary, the valve seat should be replaced. The make up water pressure for the mechanical valve should be
maintained between 20 and 50 PSIG.
Pressurized Water Distribution Systems

Check the water distribution system monthly to make sure it is operating properly. Always check the spray system with the pump
on and the fans off. On forced draft models, remove one or two eliminator sections from the top of the unit and observe the
operation of the water distribution system. On induced draft models, lifting handles are provided along the top layer of eliminators.
Eliminators can be easily removed from the access door and the distribution system observed. The diffusers are essentially nonclogging and should seldom need cleaning or maintenance.
If the water diffusers are not functioning properly, it is a sign that the pan or system strainer has not been working properly and that
foreign matter or dirt has accumulated in the water distribution pipes. The nozzles can be cleared by taking a small pointed probed
and moving it rapidly back and forth in the diffuser opening.
If an extreme build-up of dirt or foreign matter occurs, remove the end cap in each branch to flush the debris from the header pipe.
The branches or header can be removed for cleaning, but do so only if necessary. Check the strainer in the pan to make sure it is
in good condition and positioned properly so that cavitation or air entrainment does not occur.
All Evaporative Condensers and Closed Circuit Coolers, except the PMC-E Evaporative Condensers and ESWA Closed Circuit
Cooler, are supplied with ZM II spray nozzles as standard. The ZMII spray nozzles do not need to be oriented a specific way to
achieve proper coil coverage. Figure 13 shows the standard orientation of the ZMII spray nozzles.
Figure 13 ZM II Spray Nozzle Orientation

All Coil Products except the ESWA
18
For the ESWA, wide orifice water diffusers are supplied. When inspecting and cleaning the water distribution system, always check
that the orientation of the water diffusers is correct as shown in Figures 14 and 15. For EvapJet nozzles, make sure that the top
edge of the EVAPCO logo is parallel to the top of the water distribution pipe.
THREADED END CAP
Figure 14 Proper Water Diffuser Orientation (2A Nozzles)

ESWA Models (Except 14 Wide Models)
THREADED END CAP
Figure 15 Proper Water Diffuser Orientation (EvapJet)

ESWA 14 Wide Models
Bleed-Off Valve
The bleed-off valve, whether factory or field installed, must be checked weekly to make sure it is functioning and set properly. Keep
the bleed-off valve wide open unless it has been determined that it can be set partially open without causing scaling or corrosion.
Pump (When Supplied)

The pump and pump motor should be lubricated and serviced in accordance with the pump manufacturers instructions as supplied
with the unit. The recirculation pump should not be used as a means of capacity control, used with a VFD or be cycled frequently.
Excessive cycling can lead to scale build-up, and reduce wet and dry performance. On 14' wide ESWA's, which are supplied with
two pumps per cell, both pumps should be energized at the same time. One pump should not be on while the other pump is off.
19
Water Treatment and Water Chemistry

Proper water treatment is an essential part of the maintenance required for evaporative cooling equipment. A well designed and
consistently implemented water treatment program will help to ensure efficient system operation while maximizing the equipments
service life. A qualified water treatment company should design a site specific water treatment protocol based on equipment
(including all metallurgies in the cooling system), location, makeup water quality, and usage.
Bleed or Blowdown
Evaporative cooling equipment rejects heat by evaporating a portion of the recirculated water into the atmosphere as warm,
saturated discharge air. As the pure water evaporates it leaves behind the impurities found in the systems makeup water and any
accumulated airborne contaminants. These impurities and contaminants, which continue to recirculate in the system, must be
controlled to avoid excessive concentration which can lead to corrosion, scale, or biological fouling.
Evaporative cooling equipment requires a bleed or blowdown line, located on the discharge side of the recirculating pump, to
remove concentrated (cycled up) water from the system. EVAPCO recommends an automated conductivity controller to maximize
the water efficiency of your system. Based on recommendations from the water treatment company, the conductivity controller
should open and close a motorized ball or solenoid valve to maintain the conductivity of the recirculating water. If a manual valve is
used to control the rate of bleed it should be set to maintain the conductivity of the recirculating water during periods of peak load
at the maximum level recommended by the water treatment company.
Galvanized Steel Passivation

White Rust is a premature failure of the protective zinc layer on hot dip or mill galvanized steel which can occur as a result of
improper water treatment control during the start-up of new galvanized equipment. The initial commissioning and passivation
period is a critical time for maximizing the service life of galvanized equipment. EVAPCO recommends that the site specific water
treatment protocol includes a passivation procedure which details water chemistry, any necessary chemical addition, and visual
inspections during the first six (6) to twelve (12) weeks of operation. During this passivation period, recirculating water pH should
be maintained above 7.0 and below 8.0 at all times. Since elevated temperatures have a harmful effect on the passivation
process, the new galvanized equipment should be run without load for as much of the passivation period as is practical.
The following water chemistry promotes the formation of white rust and should be avoided during the passivation period:
1.
2.
3.
4.
pH values in the recirculating water greater than 8.3.

Calcium hardness (as CaCO3) less than 50 ppm in the recirculating water.
Anions of chlorides or sulfates greater than 250 ppm in the recirculating water.
Alkalinity greater than 300 ppm in the recirculating water regardless of pH value.
Changes in water chemistry control may be considered after the passivation process is complete as evidenced by the galvanized
surfaces taking on a dull gray color. Any changes to the treatment program or control limits should be made slowly, in stages while
documenting the impact of the changes on the passivated zinc surfaces.
Operating galvanized evaporative cooling equipment with a water pH below 6.0 for any period may cause removal of the
protective zinc coating.
Operating galvanized evaporative cooling equipment with a water pH above 9.0 for any period may destabilize the passivated
surface and create white rust.
Re-passivation may be required at any time in the service life of the equipment if an upset condition occurs which
destabilizes the passivated zinc surface.
For more information on passivation and white rust, please download a copy of EVAPCOs Engineering Bulletin 36 at
www.evapco.com.
20
Water Chemistry Parameters

The water treatment program designed for evaporative cooling equipment must be compatible with the units materials of
construction. Control of corrosion and scale will be very difficult if the recirculating water chemistry is not consistently maintained
within the ranges noted in Table 4. In mixed metallurgy systems, the water treatment program should be designed to ensure
protection of all the components used in the cooling water loop.
Property
G-235
Galvanized Steel
Type 304
Stainless Steel
Type 316
Stainless Steel
pH
7.0 8.8
6.0 9.5
6.0 9.5
pH During Passivation
7.0 8.0
N/A
N/A
Total Suspended Solids (ppm)*
< 25
< 25
< 25
Conductivity (Micro-mhos/cm) **
< 2,400
< 4,000
< 5,000
Alkalinity as CaCO3 (ppm)
75 - 400
< 600
< 600
Calcium Hardness CaCO3 (ppm)
50 - 500
< 600
< 600
Chlorides as Cl (ppm) ***
< 300
< 500
< 2,000
Silica (ppm)
< 150
< 150
< 150
Total Bacteria (cfu/ml)
< 10,000
< 10,000
< 10,000
* Based on standard EVAPAK fill

** Based on clean metal surfaces. Accumulations of dirt, deposits, or sludge will increase corrosion potential
*** Based on maximum coil fluid temperatures below 120F (49C)
Table 4 Recommended Water Chemistry Guidelines
If a chemical water treatment program is used, all chemicals selected must be compatible with the units materials of construction
as well as other equipment and piping used in the system. Chemicals should be fed through automatic feed equipment to a point
which ensures proper control and mixing prior to reaching the evaporative cooling equipment. Chemicals should never be batch
fed directly into the basin of the evaporative cooling equipment.
Evapco does not recommend the routine use of acid due to the destructive consequences of improper feeding; however, if acid is
used as part of the site specific treatment protocol, it should be pre-diluted prior to introduction into the cooling water and fed by
automated equipment to an area of the system which ensures adequate mixing. The location of the pH probe and acid feed line
should be designed in conjunction with the automated feedback control to ensure that proper pH levels are consistently maintained
throughout the cooling system. The automated system should be capable of storing and reporting operational data including pH
reading and chemical feed pump activity. Automated pH control systems require frequent calibration to ensure proper operation
and to protect the unit from increased corrosion potential.
The use of acids for cleaning should also be avoided. If acid cleaning is required, extreme caution must be exercised and only
inhibited acids recommended for use with the units materials of construction should be used. Any cleaning protocol, which
includes the use of an acid, shall include a written procedure for neutralizing and flushing the evaporative cooling system at the
completion of the cleaning.
Control of Biological Contamination

Evaporative cooling equipment should be inspected regularly to ensure good microbiological control. Inspections should include
both monitoring of microbial populations via culturing techniques and visual inspections for evidence of biofouling.
Poor microbiological control can result in loss of heat transfer efficiency, increase corrosion potential, and increase the risk of
pathogens such as those that cause Legionnaires disease. The site specific water treatment protocol should include procedures
for routine operation, startup after a shut-down period, and system lay-up, if applicable. If excessive microbiological contamination
is detected, a more aggressive mechanical cleaning and/or water treatment program should be undertaken.
21
It is important that all internal surfaces, particularly the basin, be kept clean of accumulated dirt and sludge. Additionally, drift
eliminators should be inspected and maintained in good operating condition.
Gray Water and Reclaimed Water

The use of water reclaimed from another process as a source of makeup water for evaporative cooling equipment can be
considered as long as the resultant recirculating water chemistry conforms to the parameters noted in Table 4. It should be noted
that using water reclaimed from other processes may increase the potential of corrosion, microbiological fouling, or scale formation.
Gray water or reclaimed water should be avoided unless all of the associated risks are understood and documented as part of the
site specific treatment plan.
Air Contamination
Evaporative cooling equipment draws in air as part of normal operation and can scrub particulates out of the air. Do not locate the
unit next to smokestacks, discharge ducts, vents, flue gas exhausts, etc. because the unit will draw in these fumes which may lead
to accelerated corrosion or deposition potential within the unit. Additionally, it is important to locate the unit away from the
buildings fresh air intakes to prevent any drift, biological activity, or other unit discharge from entering the buildings air system.
Cold Weather Operation

EVAPCO counterow evaporative cooling equipment is well suited to operate in cold weather conditions. The counterow design
encases the heat transfer media (fill and/or coils) completely, and protects it from the outside elements such as wind which can
cause freezing in the unit.
When the evaporative cooling unit is going to be used during cold weather conditions, several items need to be considered
including unit layout, recirculating water, unit recirculating piping, unit heat transfer coils, unit accessories and capacity control of
the units.
Unit Layout
Adequate unobstructed air flow must be provided for both the intake and discharge from the unit. It is imperative that the equipment
minimize the risk of recirculation. Recirculation can result in condensation freezing the inlet louvers, fans and fan screens. The
buildup of ice on these areas can adversely affect air flow and in more severe cases, lead to failure of these components.
Prevailing winds can create icing conditions on the inlet louvers and fan screens adversely affecting airflow to the unit.
For additional information on unit layout, please refer to EVAPCOs Equipment Layout Manual.
Freeze Protection of Recirculating Water

The simplest and most effective way of keeping the recirculated water from freezing is to use a remote sump. With a remote sump,
the recirculating water pump is mounted remotely at the sump and whenever the pump is shut off, all recirculating water drains
back to the sump. Recommendations for sizing the remote sump tank and recirculating water pumps for coil products are
presented for Evaporative Condensers and Closed Circuit Coolers in their respective catalog bulletin. The pressure drop through
the water distribution system measured at the water inlet is as follows in Table 5.
If a remote sump cannot be used, basin heaters are available to keep the recirculating water from freezing when the pump is
turned off. Electric heaters, hot water coils, steam coils or steam injectors may be used to heat the basin water when the unit is
shut down. However, the basin heater will not prevent the external water lines, pump or pump piping from freezing. The make-up
water supply, overflow and drain lines, as well as the pump and pump piping up to the overflow level must be heat traced and
insulated to protect them from damage. Any other connections or accessories at or below the water level, such as electronic water
level controllers, must also be heat traced and insulated.
Note: Using basin heaters will not prevent the fluid in the coils, nor the residual water in the pump or pump piping from
freezing.
A condenser or cooler cannot be operated dry (fans on, pump off) unless the water is completely drained from the pan. The pan
heaters are sized to prevent pan water from freezing only when the unit is completely shut down.
22
Evaporative Condenser
Model Number

Footprint
Required Inlet
Pressure (psi)
ATC Products
50E to 165E
170E to 247E
218E to 305E
246E to 473E
486E to 630E
508E to 755E
643E to 926E
XE298E to XC462E, XE596E to XC925E
XE406E to XC669E, XE812E to XC1340E
428E to 892E
858E to 1784E
857E to 1783E
1879E to 3459E
791E to 967E, 1625E to 1925E
1616E to 1915E, 2855E to 3714E
ATW Products
3 and 4 wide units
8.5x7.5
8.5x9
8.5x10.5, 8.5x12, 8.5x14
8.5x18
8.5x21
17x12, 17x14
10x12, 10x24, 20x12
10x18, 10x36, 20x18
12x12, 12x14, 12x18
12x24 12x28, 12x36
24x12, 24x14, 24x18
24x24, 24x28, 24x36
12x20, 12x40
24x20, 24x40
2.0
2.0
2.0
2.0
3.0
4.0
2.5
3.7
5.7
3.5
2.5
3.0
2.5
3.5
3.2
CATC Products
181 thru 373
362 thru 504
CATW Products
7.5x8, 7.5x12, 7.5x14
7.5x18
2.0
3.0
LRC Products
25 to 72
76 to 114
108 to 183
190 to 246
188 to 379
LRW Products
3 wide units
5x6
5x9
5x12
8 wide units
1.0
2.0
2.0
2.0
2.0
LSC Products
36 to 80
90 to 120
135 to 170
185 to 385
400 to 1610
LSW Products
4x6
4x9
4x12, 4x18
5.5x12, 5.5x18
10x12, 10x18, 10x24, 10x36
8x12, 8x18, 8x24, 8x36
Dual Fan Sided Units
8x12, 8x18, 8x24, 8x36
1.5
1.5
1.5
2.0
2.5
3.0
2.5
ESWA Products
8.5x9
8.5x12
8.5x18
12x12
12x18
14x24, 14x48
3.0
2.5
3.5
3.0
2.5
3.0
PMC Products
175E to 375E
332E to 1556E
420E to 1985E
PMWQ Products
10 wide units
12 wide units
2.0
3.0
3.5
WDW Products
7.9 x 9 wet cell
7.9 x 12 wet cell
7.9 x 14 wet cell
3.0
2.5
2.5
Note: For multi-cell units, the inlet pressure shown is per cell.
Table 5 - Recommended Recirculating Water Pump Sizing for Remote Sump Application - Coil Products Only
23
Freeze Protection of Closed Circuit Cooler Coils

The simplest and most effective way of protecting the heat exchanger coil from freezing is to use an inhibited ethylene or
propylene glycol anti-freeze. If this is not possible, an auxiliary heat load and minimum flow rate must be maintained on the coil
at all times so that the water temperature does not drop below 50F when the cooler is shut down. See Table 6 for recommended
minimum flow rates.
If an anti-freeze solution is not used, the coil must be drained immediately whenever the pumps are shut down or flow stops. This
is accomplished by having automatic drain valves and air vents in the piping to and from the cooler. Care must be taken to ensure
that the piping is adequately insulated and sized to allow the water to flow quickly from the coil. This method of protection should
be used only in emergency situations and is neither a practical nor recommended method of freeze protection. Coils should not be
drained for an extended period of time, as internal corrosion may occur.
When the unit is in operation during freezing weather, some type of capacity control is normally required in order to keep water
temperatures from dropping below 50F. Operating dry with a remote sump is an excellent way of reducing unit capacity at low
temperatures. Other methods of capacity control include two-speed motors, VFDs and fan cycling. These can be used individually
or in combination with dry/remote sump operation.
Minimum Flows
Footprint
ATW Products
3x3
4 wide units
8.5x7.5
8.5x9 to 8.5x21
17x12, 17x14
10x12, 10x18
10x24, 10x36, 20x12, 20x18
20x24, 20x36
12x12, 12x14, 12x18, 12x20
12x24, 12x28, 12x36, 12x40
24x12, 24x14, 24x18, 24x20
24x24, 24x28, 24x36, 24x40
CATW Products
LRW Products
3 wide units
5 wide units
8 wide units
LSW Products
4x6, 4x9, 4x12, 4x18
5.5x12, 5.5x18
8x12, 8x18
8x24, 8x36
10x12, 10x18
10x24, 10x36
Dual Fan Side Units
8x12, 8x18
8x24, 8x36
ESWA Products
8.5x9, 8.5x12, 8.5x18
12x12, 12x18
14x24
14x48
WDW Products
PMWQ Products
10x12, 10x18
10x24, 10x36
12x12, 12x18, 12x20
12x24, 12x36, 12x40
Standard Flow
GPM
Series Flow
GPM
74
148
160
320
188
376
752
232
464
464
928
140
26
37
74
80
160
94
188
376
116
232
232
464
70
60
94
148
30
47
74
66
94
148
296
188
376
30
47
74
148
94
188
132
264
66
132
237
330
708
1416
150
119
165
354
708
210
415
256
511
105
208
128
256
Table 6 - Closed Circuit Cooler Minimum Recommended Flow Rate

24
Unit Accessories
The appropriate accessories to prevent or minimize ice formation during cold weather operation are relatively simple and
inexpensive. These accessories include cold water basin heaters, the use of a remote sump, electric water level control and
vibration cut out switches. Each of these optional accessories ensures that the cooler or condenser will function properly during
cold weather operation.
Cold Water Basin Heaters
Optional basin heaters can be furnished with the unit to prevent the water from freezing in the basin when the unit is idle
during low ambient conditions. The basin heaters are designed to maintain 40F basin water temperature at a 0F
ambient temperature. The heaters are only energized when the recirculating pumps are off and no water is flowing over
the heat exchanger coil. As long as there is a heat load and water is flowing over the heat exchanger coil, the heaters do
not need to operate. Other types of basin heaters to consider would include: hot water coils, steam coils or steam
injectors.
Remote Sumps
A remote sump located in an indoor heated space is an excellent way to prevent freezing in the cold water basin during
idle or no load conditions because the basin and associated piping will drain by gravity whenever the recirculating pump is
idle. EVAPCO units built for remote sump operation do not include recirculating water pumps.
Electric Water Level Control
Optional electric water level control packages can be furnished to replace the standard mechanical float and valve
assembly. The makeup water pressure for electronic water level control should be maintained between 5 and 100 psig.
The electric water level control eliminates the freezing problems experienced by the mechanical float. In addition, it
provides accurate control of the basin water level and does not require field adjustment even under varying load
conditions. Please note: the standpipe assembly, make up piping and solenoid valve must be heat traced and insulated to
prevent them from freezing.
Vibration Cut Out Switches
During severe cold weather conditions, ice can form on the fans of cooling towers causing excessive vibration. The
optional vibration switch shuts the fan off avoiding potential damage to or failure of the drive system.
Capacity Control Methods for Cold Weather Operation

Induced draft and forced draft coolers or condensers require separate guidelines for capacity control during cold weather operation.
The sequence of control for a unit operating at low ambient conditions is much the same as a cooler or condenser operating under
summer conditions provided that the ambient temperature is above freezing. When the ambient temperatures are below freezing,
additional precautions must be taken to avoid the potential for damaging ice formation.
The most effective way to avoid ice formation in and on a closed circuit cooler or condenser during the winter is to run the unit DRY.
In dry operation, the recirculation pump is turned off, the basin drained, and air passes over the coil. Instead of using evaporative
cooling to cool the process fluid or condense the refrigerant, sensible heat transfer is utilized, so there is no recirculation water to
freeze. If this method will be used on a forced draft unit, be sure to verify that the motor and drives have been properly sized to
handle the reduction in static pressure experienced when the spray water is turned off.
It is very important to maintain close control of the cooler or condenser during winter operation. EVAPCO recommends that an
absolute MINIMUM leaving water temperature of 42 F must be maintained for cooler applications. The higher the leaving
temperature from the cooler or condenser, the lower the potential for ice formation.
Induced Draft Unit Capacity Control
The simplest method of capacity control is cycling the fan motor on and off in response to the leaving fluid temperature of
the cooler or condenser. However, this method of control results in larger temperature differentials and longer periods of
down time. During extremely low ambient conditions, the moist air may condense and freeze on the fan drive system.
Therefore, fans must be cycled during extremely low ambient conditions to avoid long periods of idle time when water is
flowing over the coil. The number of start/stop cycles must be limited to no more than six per hour.
A better method of control is the use of two-speed fan motors. This allows an additional step of capacity control. This
additional step reduces the water temperature differential, and therefore, the amount of time the fans are off. In addition,
two-speed motors provide savings in energy costs, since the cooler or condenser has the potential to operate on low
speed for the reduced load requirements.
25
The best method of capacity control during cold weather operation is the use of a variable frequency drive (VFD). This
allows the closest control of the leaving water temperature by allowing the fan(s) to run at the appropriate speed to closely
match the building load. As the building load decreases, the VFD control system may operate for long periods of time at
fan speeds below 50%. Operating a low leaving water temperature and low air velocity through the unit can cause ice to
form. It is recommended that the minimum speed of the VFD be set at 50% of full speed to minimize the potential for ice
to form in the unit.
Forced Draft Unit Capacity Control
The most common methods of capacity control are cycling the single speed fan motors, using two-speed motors or pony
motors and utilizing variable frequency drives to control the cooler or condenser fans. Although capacity control methods
for forced draft units are similar to those used for induced draft units, there are slight variations.
The simplest method of capacity control for forced draft units is to cycle the fan(s) on and off. However, this method of
control results in larger temperature differentials and periods of time with the fans off. When the fans are cycled off, the
water falling through the unit can draw air flow into the fan section. During extremely low ambient conditions, this moist air
may condense and freeze on the cold components of the drive system. When conditions change and cooling is needed,
any amount of ice that has formed on the drive system can severely damage the fans and fan shafts. Therefore, fans
MUST be cycled during low ambient operation to avoid long periods of idle fan operation. Excessive cycling can
damage the fan motors. Limit the number of cycles to a maximum of six per hour.
Two speed or pony motors offer a better method of control. This additional step of capacity control will reduce water
temperature differentials and the amount of time that the fans are off. This method of capacity control has proven effective
for applications where load variations are excessive and cold weather conditions are moderate.
The use of a variable frequency drive provides the most flexible method of capacity control for forced draft units. The VFD
control system allows the fans to run at nearly an infinite range of speeds to match the unit capacity to the system load.
During periods of reduced load and low ambient temperatures, the fans must maintain enough speed to ensure positive
air flow through the unit. This positive air flow in the unit will prevent moist air from migrating towards the cold fan drive
components reducing the potential for condensation to form and freeze on them. The VFD control system should be
implemented for applications that experience fluctuating loads and severe cold weather conditions.
Ice Management
When operating an evaporative cooling unit in extreme ambient conditions, the formation of ice is inevitable. The key to successful
operation is to control or manage the amount of ice that builds up in the unit. If extreme icing occurs, it can lead to severe
operational difficulties as well as potential damage to the unit. Following these guidelines will minimize the amount of ice that forms
in the unit leading to better operation during the cold weather season.
Induced Draft Units
When operating an induced draft unit during the cold weather season, the control sequence must have a method to
manage the formation of ice in the unit. The simplest method of managing the amount of ice buildup is by cycling the fan
motors off while keeping the pump on. During these periods of idle fan operation, the warm water that is absorbing the
building load flows thru the coil to help melt the ice that has formed in the coil, basin or louver areas. Warning: Using this
method during periods of high winds can cause blow thru, resulting in splash-out and ice formation. To help prevent blow
thru and splash-out, maintain a minimum 50% fan speed.
In more severe climates, the incorporation of a defrost cycle can be used to mitigate and/or eliminate any detrimental
effects of ice in the unit. During the defrost cycle, the fans are reversed at half speed while the recirculating pump
flows water through the units water distribution system. Operating the unit in reverse will melt any ice or frost that may
have formed in the unit or on the air intake louvers. The defrost cycle requires the use of two speed motors with
reverse cycle starters or reversible variable frequency drives. All motors supplied by EVAPCO are capable of
reverse operation.
The defrost cycle should be incorporated into the normal control scheme of the cooler or condenser system. The control
system should allow for either a manual or automatic method of controlling frequency and length of time required to
completely defrost the ice from the unit. The frequency and length of the defrost cycle is dependent on the control
methods and ambient cold weather conditions. Some applications will build ice quicker than others which may require
longer and more frequent defrost periods. Frequent inspection of the unit will help fine-tune the length and
frequency of the defrost cycle.
26
Forced Draft Units

Defrost cycles are NOT recommended for forced draft units, since allowing the leaving water temperature set point to rise
causes the fans to be off for very long periods of time. This is not recommended for forced draft coolers or condensers
because of the potential for freezing the fan drive components. Therefore, the defrost cycle is an inappropriate method of
ice management for forced draft units. However, low speed fan operation or variable frequency drives maintain a positive
pressure in the unit which helps prevent ice formation on the fan drive components.
For more information on cold weather operation, please download a copy of EVAPCOs Engineering Bulletin 23 at
www.evapco.com
Troubleshooting
Problem
Possible Cause
Remedy
Overamping Fan Motors
Reduction in air static

pressure
1. On a forced draft unit verify that the pump is on, and water is
flowing over the coil. If the pump is off, and the unit was not sized
for dry operation, the motor may over-amp.
2. If the forced draft unit is ducted, verify that the design ESP
matches the actual ESP.
3. Verify the correct pump rotation direction. If the pump is rotating
incorrectly, it will result in less water flow, and therefore less overall
static pressure.
4. Check the basin water level against the recommended level.
Note: Air density directly affects AMP reading. Low air density
can cause the fans to spin faster, thus increasing the amp draw.
Electrical issue
1. Check voltage across all three legs of the motor.

2. Verify that the motor is wired per the wiring diagram, and
connections are tight.
Fan rotation
Verify that the fan is rotating in the correct direction. If not, switch the
leads so it runs correctly.
Mechanical failure
Verify that the fan and motor turn freely by hand. If not, there may be
damage to the internal motor components or bearings.
Belt tension
Check for proper belt tension. Extreme belt tension can cause the
motor to overamp.
Motor running singlephase
Stop motor and attempt to start it. Motor will not start again if single
phased. Check wiring, controls and motor.
Motor leads connected

incorrectly
Check motor connections against wiring diagram on motor.
Bad bearings
Check lubrication. Replace bad bearings.
Electrical unbalance
Check voltage and current of all three lines. Correct if required.
Air gap not uniform
Check and correct bracket fits or bearing.
Rotor unbalance
Rebalance.
Cooling fan hitting end

bell guard
Reinstall or replace fan.
Nozzles clogged
Remove nozzles and clean. Flush water distribution system.
Pump running
backwards
Visually verify pump rotor rotation by turning pump off and then on.
Verify amp draw.
Inadequate pump flow

for remote sump
Confirm inlet pressure at header meets required valves.
Strainer clogged
Remove strainer and clean.
Unusual Motor Noise
Incomplete Spray
Pattern
27
Problem
Possible Cause
Remedy
Fan Noise
Blade rubbing inside of

fan cylinder (induced
draft models)
Adjust cylinder to provide blade tip clearance.
Scaled Inlet Louvers on

AT Units
Improper water
treatment, insufficient
bleed rates or excessive
cycling of the fan
motors, or high
concentrations of solids
in water.
Scale should not be removed using a power washer or wire brush

because it could damage the louvers. Remove the louver assemblies
and let them soak in the cold water basin of the unit. The water
treatment chemicals in the unit will neutralize and dissolve the buildup
of scale. Please note that the time required for soaking the inlet
louvers depends on the severity of the scale buildup.
Note: This assumes chemicals are being used.
Overamping Pump
Motors
Initial start-up
If the unit has only run for a few hours, the pump may overamp until
the pump wear ring has worn in. In this case, it would only be small
percentages, not 15 or 20%. Normally, after a few hours, the pump
amp readings will reduce and level off.
Mechanical failure
Verify that the pump can turn freely by hand. If not, pump most likely
needs to be replaced.
Electrical issue
Verify that the pump has been wired properly. Verify that the voltage
supplying the pump is correct.
Misconception of head
increase or decrease
Note: Increase or decrease in pump flow as a result of clogged or blown

out nozzles or headers should NOT cause the pump to over amp.
Make-up water pressure

too high
Mechanical make-up valve water pressure must be between 20 and

50psi. If pressure is too high, the valve will not close. A pressure
reducing valve can be added to lower the pressure. For the 3 and 5
Probe Electronic Water Level Control Package, the electrical actuator
has a 5 to 100 psi water pressure requirement.
Debris in solenoid
Clean out solenoid of any debris.
Frozen float ball
Inspect, and if so, float or valve may need to be replaced.
Float ball is full of water
Check ball for leaks and replace.
This can happen on

forced draft units due to
the positive pressure in
the casing section.
Overflow connection has
not been piped at all or
properly
Pipe the overflow with a P-trap to an appropriate drain.
Incorrect water level
Verify actual operating level versus O&M recommended levels
Water Intermittently
Blowing Out Overflow
Connection
This is normal
This is normal. The bleed line for the unit is piped to the overflow
connection
Cold Water Basin

Overflowing
Problem with make-up

line.
Refer to Makeup Valve or Electronic Water Level section.
If multi-cell unit, there

may be an elevation
problem.
Make sure that multi-cell units are installed level to one another. If
they are not, it can cause overflowing in one cell.
Makeup Valve Will Not

Shut Off
Water Constantly
Blowing Out Overflow
Connection
28
Problem
Possible Cause
Remedy
Low Pan Water Level
Electronic Water Level

Control
See EWLC Section
Float Ball not set

correctly
Adjust float ball up or down to obtain proper water level. Note: The
float ball is set to the operating level at the factory.
Rusting Stainless Steel
Foreign material on
surface of SS
Rust spots that show up on the surface of the unit are typically not
signs of the base stainless steel material corroding. Often, they are
foreign material, such as welding slag, that has collected on the
surface of the unit. The rust spots will be located around where there
has been welding. These areas may include the coil connections, the
cold water basin near the support steel, and around field erected
platforms and catwalks. The rust spots can be removed with a good
cleaning. EVAPCO recommends using either Naval Jelly or a good
stainless steel cleaner, such as Mothers Wax in conjunction with a
Scotch-Brite pad. Maintenance of the units surface should be done
on a regular basis.
Cracking Fluid Cooler

Insulation
Cracking paint
Most of the time, it is the paint that is cracking and not the insulation.
If the paint is degrading, it should be touched up to maintain the finish
on the insulation. It is recommended that maintaining the finish of the
insulation paint be a part of the standard maintenance program. If the
insulation is cracking, see your local Evapco representative for further
guidance.
Electric Water Level

Control Not Working
The valve won't open or

close
1.
2.
3.
4.
5.
INTEGRAL LEVEL
PROBE/RELAY IN A NEMA 4
POLYCARBONATE
ENCLOSURE 017-00182P
L1
L2
NC
NO
ELECTRIC MAKE-UP VALVE

(NORMALLY CLOSED) 120v
POWER REQUIRED TO OPEN
Verify that water pressure is above 5psi and below 100psi.

Verify wiring with wiring diagram. Check supply voltage.
Verify that there is not a blockage in the Y-Strainer
Confirm the probes are not dirty.
Check Red LED on circuit board. If it is on, the valve should be
closed.
For a 3-Probe Assembly:
Simulate "Low Water Condition" - LED OFF

After cleaning the probes, lift probe assembly out of the stand pipe.
This will simulate a "low water condition". Check the contacts for
proper position.
- The contact between "C" and "NC" should now be closed and water
makeup valve should be energized (valve open)
Simulate "High Water Condition" - LED ON
- Connect a jumper wire between the longest probe and the shortest
probe. The contact between "C" and "NC" should now be open and
the water makeup valve should be de-energized (valve closed)
29
Problem
Possible Cause
Electric Water Level

Control Not Working
L1
L2
NC
For a 5-Probe Assembly:
INTEGRAL LEVEL
PROBE/RELAY
IN A NEMA 4
POLYCARBONATE
ENCLOSURE
017-00299P
120 VAC/60Hz
NO
Remedy
NC
NO
LOW ALARM
ALARM CIRCUIT
VOLTAGE
(AS DESIRED)
NC
NO
HIGH ALARM
ELECTRIC MAKE-UP
VALVE (NORMALLY
CLOSED) 120v
POWER REQUIRED
TO OPEN
Simulate "Low Water Condition"

After cleaning the probes, lift probe assembly out of the stand pipe.
This will simulate a "low water condition". Check the contacts for
proper position.
- Differential Contacts: C to NC - closed - Water make-up valve
energized - LED = OFF
- High Alarm Contacts: C to NO - open - High alarm circuit
de-energized - LED = OFF
- Low Alarm Contacts: C to NC - closed - Low alarm circuit
energized - LED = OFF
Simulate "High Water Condition"

Connect a jumper wire between the longest probe (ground) and all
other probes (high limit, high alarm, and low alarm). Check the
contacts for proper position.
- Differential Contacts: C to NC - open - Water make-up valve deenergized - LED = ON
- High Alarm Contacts: C to NO - closed - High alarm circuit
energized - LED = ON
- Low Alarm Contacts: C to NC - open - Low alarm circuit deenergized - LED = ON
Replacement Parts
EVAPCO has replacement parts available for immediate shipment. Most orders ship within 24 hours from time of order!
The following pages contain exploded view drawings of all current Evapco closed circuit coolers and condensers. Please use these
drawings to help identify the major parts of your unit. To order replacement parts, please contact your local EVAPCO representative
or Mr. GoodTower Service Center. The EVAPCO representative contact information is located on the units nameplate or can be
found by visiting either www.evapco.com or www.mrgoodtower.com.
Additionally, your local EVAPCO representative or Mr. GoodTower Service Center can provide FREE unit inspections to help
ensure your equipment operates at peak performance regardless of the original manufacturer!
30
ATW 3 Wide Units

FAN & COIL CASING SECTION
FAN SCREEN
FAN CYLINDER
FAN
BELT GUARD
TEFC FAN MOTOR

WATER INLET
CONNECTION
DRIFT ELIMINATOR
PUMP RISER PIPING

COIL
COIL CONNECTIONS
PAN SECTION
MAKE-UP VALVE
WITH ADJUSTABLE FLOAT
PUMP RISER PIPING

AIR INLET LOUVER
RECIRCULATING PUMP/
MOTOR ASSEMBLY
STRAINER
31
ATC/ATW 4x4 & 4x6 Wide Units

FAN SCREEN
FAN CYLINDER
FAN
DRIFT ELIMINATOR
BELT GUARD
WATER INLET
CONNECTION
TEFC FAN MOTOR

PUMP RISER PIPING
COIL
COIL CONNECTIONS
PAN SECTION
MAKE-UP VALVE
PUMP RISER PIPING

AIR INLET LOUVER
RECIRCULATING PUMP/
MOTOR ASSEMBLY
STRAINER
32
ATC/ATW 4x9 & 4x12 Wide Units

FAN SCREEN
FAN
FAN CYLINDER
BELT GUARD
WATER INLET
CONNECTION
DRIFT ELIMINATOR
PUMP RISER PIPING
TEFC FAN MOTOR
COIL
PAN SECTION
MAKE-UP VALVE
PUMP RISER PIPING

AIR INLET LOUVER
RECIRCULATING PUMP/
MOTOR ASSEMBLY
STRAINER
33
ATC/ATW 8 & 8.5 Wide Units

BEARING SUPPORT
FAN SCREEN
FAN SCREEN SUPPORT
FAN
DRIFT ELIMINATORS
FAN CYLINDER
ACCESS DOOR
SWING OUT
MOTOR COVER
TEFC FAN MOTOR

PUMP RISER PIPING
COIL
COIL CONNECTIONS
PAN SECTION
MAKE-UP VALVE
COLD WATER BASIN
FRAMED AIR
INLET LOUVER
RECIRCULATING PUMP/
MOTOR ASSEMBLY
SUCTION HOOD & STRAINER
PUMP RISER PIPING
BLEEDLINE AND VALVE
AIR INLET LOUVER MEDIA
LOUVER RETAINER
34
ATC/ATW 10 & 12 Wide Units

FAN SCREEN
FAN SCREEN SUPPORT
FAN
TEAO FAN MOTOR
FAN CYLINDER
SLIDING MOTOR BASE
ACCESS DOOR
MECHANICAL EQUIPMENT
SUPPORT
DRIFT ELIMINATORS
COIL CONNECTIONS
WATER DISTRIBUTION
SPRAY BRANCH
PUMP RISER PIPING
COIL
PAN SECTION
MAKE-UP VALVE
COLD WATER BASIN
RECIRCULATING PUMP/
MOTOR ASSEMBLY
FRAMED AIR
INLET LOUVER

PUMP RISER PIPING
BLEEDLINE AND VALVE

LOUVER RETAINER
35
ESWA 8.5 Wide Units

FAN & FILL CASING SECTION
FAN SCREEN
FAN SCREEN
SUPPORT
BEARING SUPPORT
FAN
FAN CYLINDER
FAN SHAFT
BEARING
DRIFT ELIMINATORS
SWING OUT
MOTOR COVER
TEFC FAN MOTOR

FILL
FAN MOTOR SHEAVE

FAN BELT
SPRAY BRANCH
ACCESS DOOR
PAN SECTION
COIL
SUCTION HOOD
& STRAINER
PUMP RISER PIPING
RECIRCULATING
PUMP/
MOTOR
ASSEMBLY
COLD WATER
BASIN
AIR INLET
LOUVER MEDIA
COIL CONNECTIONS
BLEED LINE AND VALVE
36
ESWA 12 Wide Units

FAN SCREEN
FAN SCREEN SUPPORT
FAN
FAN CYLINDER
MECHANICAL
EQUIPMENT SUPPORT
DRIFT ELIMINATORS
FILL
ALUMINUM FAN SHEAVE
SLIDING MOTOR BASE
FAN BELT
TEAO FAN MOTOR
WATER DISTRIBUTION
SPRAY BRANCH
ACCESS DOOR
PAN SECTION
COIL
SUCTION HOOD
& STRAINER
RECIRCULATING PUMP/
MOTOR ASSEMBLY
COLD WATER
BASIN
AIR INLET
LOUVER MEDIA
PUMP RISER PIPING
COIL CONNECTIONS
BLEEDLINE AND VALVE
37
ESWA 14 Wide Units

FAN SCREEN SUPPORT

FAN CYLINDER
TEAO FAN MOTOR
FAN
DRIFT
ELIMINATORS
FILL
SLIDING MOTOR BASE

MECHANICAL
EQUIPMENT SUPPORT
WATER DISTRIBUTION
SPRAY BRANCH
PAN SECTION
COIL
BLEEDLINE AND VALVE

COIL CONNECTIONS
MAKE-UP VALVE
SUCTION HOOD
& STRAINER
AIR INLET
LOUVER MEDIA
PUMP RISER PIPING

RECIRCULATING PUMP/
MOTOR ASSEMBLY
COLD WATER
BASIN
SUCTION HOOD
& STRAINER
38
WDW Dry Cell

FAN SECTION
BEARING SUPPORT
FAN SCREEN SUPPORT
FAN SCREEN
DRIFT ELIMINATORS
FAN
FAN CYLINDER
ACCESS DOOR
SWING OUT
MOTOR COVER
TEFC FAN MOTOR
COIL SECTION
COIL
ACCESS DOOR
COIL CONNECTIONS
TO WET COIL
COIL
COIL CONNECTIONS
TO DRY COIL
39
WDW Wet Cell

BEARING SUPPORT
FAN SCREEN
FAN SCREEN SUPPORT
FAN
DRIFT ELIMINATORS
FAN CYLINDER
COIL
CONNECTIONS
THIS END
ACCESS DOOR
SWING OUT
MOTOR COVER
TEFC FAN MOTOR
PUMP RISER PIPING

COIL
PAN SECTION
MAKE-UP VALVE
COLD WATER BASIN
FRAMED AIR
INLET LOUVER
RECIRCULATING PUMP/
MOTOR ASSEMBLY
PUMP RISER PIPING
BLEEDLINE AND VALVE
LOUVER RETAINER
40
LSCB & LSWB 4 Wide Units

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
WATER DISTRIBUTION
SPRAY BRANCH SUPPORT
DRIFT ELIMINATOR
SUPPORT
COIL CONNECTIONS
COIL
PUMP RISER PIPING
PAN SECTION
ACCESS
DOOR
MIGRATION
BAFFLE
WRAPPER
MAKE-UP VALVE WITH
ADJUSTABLE FLOAT
SUCTION STRAINER
BEARING
SUPPORT
FAN HOUSING
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
MOTOR BASE
MOTOR COVER
41

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
WATER DISTRIBUTION
DRIFT ELIMINATOR
SUPPORT
COIL
COIL CONNECTIONS
PUMP RISER PIPING
PAN SECTION
MIGRATION BAFFLE
MAKE-UP VALVE
WRAPPER
SUCTION STRAINER
ACCESS DOOR
BEARING
SUPPORT
FAN HOUSING
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
MOTOR BASE
MOTOR COVER
42
LSCB & LSWB 8 Wide Units (Single Side Fans)

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
WATER DISTRIBUTION
COIL CONNECTIONS
DRIFT ELIMINATOR
SUPPORT
COIL
PUMP RISER PIPING
PAN SECTION
MIGRATION BAFFLE
MAKE-UP VALVE WITH

ADJUSTABLE FLOAT
WRAPPER
ACCESS DOOR
MOTOR BASE
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
BEARING SUPPORT
FAN HOUSING
SUCTION HOOD
& STRAINER
43

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
WATER DISTRIBUTION
COIL CONNECTIONS
DRIFT ELIMINATOR
SUPPORT
PUMP RISER PIPING
COIL
PAN SECTION
MIGRATION BAFFLE
SUCTION HOOD
& STRAINER
WRAPPER
ACCESS DOOR
MOTOR BASE
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
BEARING SUPPORT
44
FAN HOUSING
LRC/LRWB 3 Wide Units

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
DRIFT ELIMINATOR
SUPPORT
COIL
WATER DISTRIBUTION
PUMP RISER PIPING
COIL CONNECTIONS
PAN SECTION
FAN HOUSING
FAN SHEAVE
FAN WHEEL
FAN WRAPPER
FAN BELT
SUCTION HOOD
TEFC FAN MOTOR
SUCTION STRAINER
MOTOR
ACCESS DOOR
PUMP RISER PIPING
ACCESS DOOR
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
MAKE-UP VALVE
COLD WATER BASIN
45

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
DRIFT ELIMINATOR
SUPPORT
WATER DISTRIBUTION
PUMP RISER PIPING
COIL
COIL CONNECTIONS
PAN SECTION
FAN HOUSING
FAN SHEAVE
FAN WRAPPER
FAN BELT
SUCTION HOOD
SUCTION STRAINER

MOTOR ACCESS DOOR
TEFC FAN MOTOR
FAN WHEEL
ACCESS DOOR
PUMP RISER PIPING
MAKE-UP VALVE
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
COLD WATER BASIN
46

COIL CASING SECTION
DRIFT ELIMINATORS
DRIFT ELIMINATOR
SUPPORT
COIL
WATER DISTRIBUTION
SPRAY BRANCH
PUMP RISER PIPING
WATER DISTRIBUTION
COIL CONNECTIONS
PAN SECTION
FAN HOUSING
FAN WHEEL
FAN WRAPPER
FAN BELT
SUCTION HOOD
SUCTION STRAINER
FAN SHEAVE
PUMP RISER PIPING
MOTOR ACCESS DOOR

TEFC FAN MOTOR
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
ACCESS DOOR
MAKE-UP VALVE

COLD WATER BASIN
47
PMC-E 5 Wide Units

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
DRIFT ELIMINATOR
SUPPORT
COIL
COIL
CONNECTIONS
WATER DISTRIBUTION
PUMP RISER PIPING
PAN SECTION
FAN CYLINDER
SUCTION STRAINER
COLD WATER BASIN

FAN BELT
ACCESS DOOR
TEFC FAN MOTOR
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
FAN
MAKE-UP VALVE
PUMP RISER PIPE
BLEED LINE & VALVE
48
ADJUSTABLE MOTOR BASE
PMC-E/PMWQ 10 and 12 Wide Units

COIL CASING SECTION
DRIFT ELIMINATORS
WATER DISTRIBUTION
SPRAY BRANCH
COIL
CONNECTIONS
DRIFT ELIMINATOR
SUPPORT
PUMP RISER PIPING
COIL
WATER DISTRIBUTION
PAN SECTION
COLD WATER BASIN

FAN CYLINDER
PUMP RISER PIPE
ACCESS DOOR
FAN BELT
TEFC FAN MOTOR
ADJUSTABLE MOTOR BASE
BLEED LINE
AND VAVLE
RECIRCULATOR PUMP/
MOTOR ASSEMBLY
FAN (PMWQ STANDARD

WITH SUPER LOW SOUND FAN)
MAKE-UP VAVLE
SUCTION STRAINER
49
Notes:
50
Notes:
51
EVAPCO, Inc. P.O. Box 1300 Westminster, MD 21158 USA

PHONE: 410-756-2600 FAX: 410-756-6450 E-MAIL: marketing@evapco.com
2010 EVAPCO, Inc.
Printed on recycled paper
using soy-based ink

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Bulletin 116B

1520 Crosswind Dr.

P.O. Box 1727

8331 Nieman Road

5960 US HWY 64E

EVAPCO...SPECIALISTS IN HEAT TRANSFER

EVAPCO Europe, N.V.

EVAPCO Asia/Pacific Headquarters

EVAPCO Europe, S.r.l.

Evapco (Shanghai) Refrigeration

A subsidiary of EVAPCO, Inc.

Beijing EVAPCO Refrigeration

34-42 Melbourne St.

A licensed manufacturer of EVAPCO, Inc.

EvapTech Asia Pacific Sdn. Bhd

5 Al Nasr Road St.

A wholly owned subsidiary of EvapTech, Inc.

IOI Business Park, 2/F Unit 21

Visit EVAPCOs Website at:

Operation and Maintenance Instructions

Operation and Maintenance Instructions

Capacity Control Methods for Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Operation and Maintenance Instructions

Induced Draft equipment includes the following Evapco Product Models:

Operation and Maintenance Instructions

ATC-B - Evaporative Condenser

Containerized Product Lines

WDW Wet/Dry Closed Circuit Cooler

Forced Draft equipment includes the following Evapco Product Models:

Initial Storage and/or Idle Period Recommendations

Operation and Maintenance Instructions

International Building Code Provisions

Initial and Seasonal Start-Up Checklist

Verify all safety interlocks work properly.

Initial and Seasonal Start-Up

Remove the strainer screen, clean and reinstall.

Check mechanical float valve to see if it operates freely.

Lubricate fan shaft bearings prior to seasonal start-up.

Turn the fan(s) by hand to insure it turns freely without obstructions.

Operation and Maintenance Instructions

After the unit has been energized, check the following:

Adjust mechanical float valve as required to the proper water level.

Verify fan is rotating in proper direction.

Operation and Maintenance Instructions

Clean pan strainer monthly or as needed

Clean and flush pan* quarterly or as needed

Check bleed-off valve to make sure it is

Lubricate pump and pump motor according to

Check operating level in pan and adjust float

Check water distribution system and spray

Check drift eliminators quarterly

Check the fan blades for cracks, missing

Lubricate fan shaft bearings every 1000

10. Lubricate fan motor bearings see mfgs

Gear Reducer/Piping Do visual inspection

3. Gear Reducer Replace oil semi-annually

Oil Pump Do visual inspection for leaks and

Gear Reducer/Coupling Check alignment of

Operation and Maintenance Instructions

Coupling/Shaft Inspect flex elements and