Sulzer EWK User Manual

General introduction to SULZER EWK cooling tower service.

Main components of EWK towers, space-saving design.

Explains the water evaporation process for cooling.

Details EWK tower design, materials, and space efficiency.

Role of fill in heat exchange and its material.

Description of low-noise, easy-maintenance fans.

Explains spray nozzles for water distribution.

Details the three-phase fan motors and their protection.

Details water inlet/outlet, overflow, make-up, and drain connections.

Safety instructions for handling and unloading cooling towers.

Procedures for assembling cooling towers at the installation site.

Step-by-step guide for assembling polyester tower parts.

Instructions for mounting the silencer, with precautions.

Guidance on installing standard and special louvers.

Specific steps for installing special louvers.

Final checks to ensure correct assembly and component placement.

Guidance on selecting suitable locations for cooling towers.

Describes tower placement on a concrete base.

Describes tower placement on a steel support structure.

Specifies minimum distances for operation and maintenance.

Installing towers higher for air exit clearance over obstacles.

Importance of same-height installation for multiple towers.

Evaluating high installation to reduce pump needs.

Advises supports for manifold pipes to prevent breakage.

Avoid sites with dust/organic matter to prevent water contamination.

Warns against dusty areas introducing particles into the water system.

Details the sequence and methods for connecting water and electrical lines.

Presents operational limits for SULZER EWK cooling towers.

Step-by-step guide for initial startup and post-maintenance restart.

Verify motor voltage, current, and connections.

Clean tower if particles detected in water post-startup.

Procedure for stopping motor and addressing fan imbalance.

General safety precautions for operating, servicing, and repairing equipment.

Safety for welding/grinding synthetic parts, fire hazards.

Safety for maintenance: disconnect power, warnings.

Guidelines for connecting water pipes, ensuring hygiene.

Identifies ice formation risks and precautions.

How ice forms in louvers and affects air openings.

Measures to avoid/neutralize ice, ensuring warm water circulation.

Ice from droplet drag at air exit; fan-stopped operation.

Ice in high-temp circuits; solutions like chimneys.

Connect overflow to nearest drainage to prevent ice.

General checks after 24h operation and downtime precautions.

Detailed list of tower checks, cleaning, and component inspections for maintenance.

Instructions for cleaning the filter by removal and washing.

Checking fill for sediments/algae; cleaning/substituting.

Checking and cleaning spray nozzles for uniform water distribution.

Method for cleaning nozzles via inspection windows or manhole.

Procedures for checking and cleaning/substituting drift eliminator.

Checking and cleaning float valve, ensuring proper water level.

How to adjust the float valve position.

Safety and procedures for checking motor consumption and fastening.

Verifying motor mounting screws are tight.

Checking the oil level in the gear reducer.

Safety and procedures for cleaning and checking fan fastening.

Instructions for cleaning louvers, including removal.

Causes for fill clogging: dirt, high air temp, deposits, foreign bodies.

High air temperature affecting tower performance.

Blockages in water circuits due to dirt or deposits.

Foreign objects in air path from fouling or ice.

Lack of proper airflow, affecting cooling efficiency.

Malfunction in the fan's speed or operation regulation.

Issues with the fan's motor or drive system.

Water leakage detected within the cooling tower system.

The electric motor for the fan is not operating.

The fan motor is rotating in the incorrect direction.

Regulation system for fan speed or operation is faulty.

Problems with the combined motor unit.

Malfunction within the gear reducer.

Incorrect time relay setting for the fan motor at low speeds.

Fan imbalance caused by dirt or mechanical failure.

Issues with the motor or fan bearings.

Blockage of the water spray nozzles.

Blockage of the fill material, hindering airflow or water flow.

Recommends resistance for basin to prevent freezing during winter service interruptions.

Automatic activation of electric resistance based on temperature.

Suggests thermostat for maintaining water temp and controlling fan.

Details ladders/platforms for accessing fan drive on large models.

Describes annular silencer design for noise reduction.

Recommends vertical installation close to the fan.

Lists water quality requirements for scale-free service and algae prevention.

Formula to calculate necessary make-up water flow rate.

Discusses blow-down operations with treated water to control salt/algae.