KUKEN COOLING TOWER

(Series 07)

TYPE: SKB & KMB

(OPEN & CLOSED TYPE COOLING TOWER)

OPERATING MANUAL
CONTENTS
Prior to operation
Important Notice P2
Warranty P3
Precaution in safety P4
Warning Sticker and Nameplate P5
Other stickers P6
General Notice P7
Cooling Tower Parts P8
Open type Cooling Tower P8
Closed type Cooling Tower P10
Fan unit P12

Precaution in cooling tower operation

Precaution in operation P13
Precaution in trial operation P13
Precaution in starting operation P18
Precaution during winter care P24
Precaution in halting P26
Precaution in long term out of operation P26

Cleaning and Inspection

Thank you very much for purchasing KUKEN
Cleaning and inspection P27
cooling tower. Daily Inspection P28
Regular Inspection P29
Parts replacement P32
 Prior to use of the product, please read this Adjustment procedure P34
manual carefully and fully understand the Cleaning work P37
content. Retaining cooling tower performance P42
Calculation of make up water P42
 Keep this manual handy whenever necessary Water quality control P43
Consumable Parts List P45
for your daily inspection.

For enquiry
For enquiry P47
Troubleshooting P47

Kuken Kogyo Co., Ltd.

Issuing date : 2009. 09 First edition
 Important Notice

 Purpose of use

 Kuken cooling tower is used to cool water coming in from chiller or other equipments. Do
not use it for the purpose/application other than those stipulated in this manual.

 To those whom concerned

 This Operation Manual is directed to those who get involved in operation, maintenance,
and inspection work of this product.

 About this Operation Manual

 This Manual is copyrighted. Duplication of this material(whole or partial) is not permitted

without the consent of Kuken. It is also not permitted to copy the content to rewritable
electric device.

 The product or parts (sketched, illustrated, or pictured) shown in this manual may give a
different view to the actual goods. And some of illustration could somewhat be simplified to
facilitate our task of elucidating cooling tower internal.

 Cooling tower equipped with optional parts may look different from that illustrated in this
manual. (Contact us for further detail on optional parts)

 The manual could be revised without any prior notice.

 If this manual becomes illegible, contact Kuken for a new copy.

 Should you have any enquiry, please contact Kuken head office (indicated on back page.)

 Safety precaution
 We might not be able to foresee every possible occasion of accident in the application of
Kuken cooling tower. In this way, this manual may fall short of covering unexpectable
danger.

 If modification is required, contact Kuken. Improper modification could cause deterioration

of cooling tower performance as well as insecurity of your safety.

2
 Warranty
 We will repair/replace at our own cost for malfunction/damage caused within the period
covered by this warranty provided that the product could have been used as properly as so
indicated in this Operation Manual.

 Consult us for Regular Inspection. Cooling tower is not covered with warranty if the
inspection has not been done properly following the manual.

 The warranty is only valid for the original buyer who purchased the product initially. It is
not applicable for the secondhand buyers.

 Warranty term

 Within 1 year from the commissioning date.

 Escape clause

Any malfunction/damage caused on cooling tower fit into the cases described below is not
subject to our product guarantee as still covered it may be for the time remaining；

 Any malfunction or damage in consequence of applying cooling tower for the purpose other
than that stipulated herein.
 Physical shock accidentally given during relocation/transportation
 In consequence of improper mending or modification
 Caused by abnormal voltage
 Consumable parts for replacement (such as bearing, V-belt, Strainer)
 Claim filed without this warranty certificate
 No information verifying the purchase is available on warranty certificate (Date of
purchase, name of distributor in the warranty certificate) or those have been rewritten,
 Caused by operation and maintenance deliberately done exceeding the capacity limit of the
product.
 Caused by application of replacement parts other than those recommended by Kuken.
 By natural disaster such as earthquake, typhoon, flood, lightening or fire.
 Due to environmental factors (location and its ambient character) enhancing
aging/corrosion.
 After having been resold or relocated.
 Deterioration by aging

3
 Precaution in safety
Prior to operation, read this section for your safety. Instruction herein contains extremely
important notice in regard with safety. Make sure to follow the instruction with the indicated
sign.

 The sign below indicates wounding or extent of physical damage resulting from misuse.

Sign indicating accident resulting injury or death or damage on physical property.

WARNING indicates there is a possibility of serious wounding and death in consequence

of improper usage (handling).

CAUTION indicates there is a possibility of serious damage of equipments and physical

properties in consequence of improper usage (handling).
indicates matter for you to keep in mind.
Note

 The sign indication below shows the “MUST” (some examples are shown below)

(e.g)
Indicating DON’T EVER DO
Illustration indicating DON’T EVER DO are shown inside or
DON’T BREAK DON’T
APART TOUCH nearby mark.
(e.g)
Indicating MUST DO
Illustration indicating MUST DO are shown inside or
PLUG OUT REQUIRES
EARTHING nearby mark.

(e.g)
Indicating CAUTION
Illustration indicating CAUTION are shown inside or
ELECTRIC
SHOCK JAM HANDS nearby mark.

4
 Warning Sticker and Nameplate

5
 EN
 Other stickers

<FAN>

(*1) For Large cooling tower : on the side of Lower basin tank
For Small cooling tower : on Outside Panel

6
 General Notice

Warning
Other than the purpose of inspection, Do not enter (climb up on) tower while fan is
DO NOT
do not enter (or climb up on) tower. DO NOT
in operation.
ENTER If you ignore the warning, you could get ENTER If you ignore the warning, you could get
injured. injured or you could even be in danger of
death.

Products should not be broken apart or More than 2 persons are required on duty for
DON’T
dismantled unless done by an expert MAINTEN safety reason.
BREAK possessing license. ANCE &
INSPECTI
Some parts may accidentally fall down if it is
APART
If you ignore the warning, it could cause ON too heavy for one person to hold. Injury or
a burn, electric shock and wounding. damage on product can be expected.

Make sure to check that Fan, Spray DO NOT touch electric heater even after
POWER pump, Electric heater and others have POWER power was switched off.
OFF
been switched off. CUT
If you ignore the warning, it could cause a
If you ignore the warning, it could cause burn.
a burn or electric shock.
Electric wiring should be done by an Secure foot space and wear protective on the
LICENCE expert possessing license. PROTECT top of cooling tower.
HOLDER
If you ignore the warning, it could cause ION
If you ignore the warning, you could get
electric shock and short circuit. injured.

Make sure to carry out earth-wiring first Make sure that capacity of power supply,
REQUIRES before doing wiring. CHECK control panel, and switching device be
EARTHIN If you ignore the warning, it could cause appropriate.
G
electric shock. If you ignore the warning, it could cause fire,
electric shock due to the excessive current
and short circuit, leading death or wounding.

During maintenance and inspection Do proper wiring to avoid leaking and short
DURING work, exercise care not to swallow cooling LEAKING circuit of electricity.
WORK
water and not to inhale droplet. / SHORT
CIRCUIT
If you ignore the warning, it could cause
Make sure to gargle and wash hand after electric shock.
inspection work.
If you ignore the warning, it could affect
your health.

Caution
Do not stick hand or foreign substance Make sure to check after wiring.
DO NOT into fan while in operation. WIRIN Improper wiring could cause damage.
STICK IN
If you ignore the caution, it could cause G
CHECK
wounding and damage.

7
 Cooling Tower Parts

Cooling Tower parts are shown below;

 Open Type Cooling Tower

8
[1] Fan Unit [2] Filling
[3] Spray Filling [4] Outside Panel
[5] Louver [6] Upper Basin
[7] Water Distribution Box [8] Inspection Door
[9] Internal Framework [10] Lower Basin Frame
[11] Lower Basin [12] Inspection Board
[13] Ladder [14] Internal Pipe
[15] Strainer [16] Make-up pipe (Auto)
[17] Make-up pipe (Manual) [18] Overflow Pipe

9
 Cooling Tower Parts

 Closed Type Cooling Tower

10
[1] Fan Unit [2] Heat Exchanger (Coil)
[3] Heat Exchanger (Filling) [4] Coil Frame (FRP)
[5] Outside Panel [6] Louver
[7] Upper Basin [8] Water Distribution Box
[9] Inspection Door [10] Framework
[11] Basin Frame [12] Lower Basin (FRP)
[13] Inspection Board [14] Ladder
[15] Header [16] Collection pipe
[17] Spray water Pipe [18] Spray Pump
[19] Strainer [20] Make-up pipe (Auto)
[21] Make-up pipe (Manual) [22] Overflow Pipe

11
 Fan Unit

[1] Fan Casing [2] Fan Blade Assembly (Fan Blade + Hub)

[3] Nose Cone [4] Fan Support

[5] Motor [6] Motor Base

[7] Fan Shaft [8] Belt Cover

[9] Fan Pulley [10] Motor Pulley

[11] V-Belt [12] Fan Guard

12
 Precaution in cooling tower operation

 Precaution in trial operation

Warning
Do not enter (climb up on) tower while fan is in operation.
There is possibility of serious wounding or death.
DO NOT
ENTER

Caution
Do not stick hand or foreign substance Make sure to check before operation.
into fan while in operation.
DO NOT WIRING Improper wiring could cause damage.
STICK
There is a possibility of wounding and CHECK

damage.
Be aware of abnormality in terms of Make sure to check that earth wire is
noise, vibration, electric current, water connected. And switch, fuse and wire is
CAUTION
temperature, waterflow. EARTH adequate for motor capacity.
WIRE
CONNECT Do not do single-phase operation.
If abnormality is found, refer to Trouble ION

shooting (P47) and handle it promptly. Improper earthing could cause the
breakdown /malfunction.

13
Make sure to check the following.
Open Type Cooling Tower

Check the circulation water flow.

1. Open Valve of Make-up water Pipe (Manual.)

 Fill up lower basin with water until it

overflows through Overflow pipes [1].

2. Make sure that no water leakage can be found

from Lower Basin (FRP) and internal pipes.

3. Prior to introducing water in lower basin, make

sure that Adjust Valve [2] equipped on Upper
Basin is “fully opened”.

4. Once circulation water starts running in , turn

the Adjust Valve up and down until water goes
up to the level indicated by Sticker [3].

Note
 Expected cooling capacity might not be
secured if water level is not kept at proper
level.

5. Before driving Fan, make sure that no abnormal

drift loss can be found from louver side.

Note
 Improper amount of circulating water and misplacing of filling/spray filling may increase water
droplets splashing out through louver.

14
 Check the Fan (Motor) operation.

1. Blade tip should not contact fan casing internal.

2. Drive Fan for several seconds and check the rotation direction (clockwise viewed from the top.)

Note
 Fan having anti-clockwise rotation could not secure required air volume for cooling tower.
Rewiring is required.

For 3 leads (3.7 kW and For 6 leads (5.5 kW and For 6 leads (5.5 kW and over)
below) over) (Direct) (Star-delta)

3. Drive fan continuously.

Note
 If voltage is lower than the rated, current tends to be higher.

4. See if no abnormal noise is coming from fan and motor.

5. Make sure that operating current should not be higher than the rated.
(Refer to nameplate on motor).

6. See if no excessive amount of water droplets is coming out of fan top.

Note
 If Fan motor is controlled by inverter controller, add “JUMP” option to inverter controller.
 After about 100 hours’ operation, check the tightness of V belt.
(If V-belt is excessively loose, refer to P36 “V-belt tension adjustment.”)

15
Closed Type Cooling Tower

Check the circulation water flow.

1. Open Valves for Circulation water

(Inlet/Outlet) and for air-purge [1] on header
pipe.
 Water is filled in Header Pipes and Coils

2. Operate Circulation Pumps intermittently.

 Air inside copper coil is pushed out of
air-purge bleeder.
. Note
 With a portion of air still remained inside copper
tube, Closed circuit system fails to perform at its
best.
 Application of Automatic Air purge bleeder is
recommended.

3. Close Air Purge Bleeder [1].

Note
 If air is not fully released, repeat the above procedure several times.

4. Make sure that no water leakage can be found from pipe, joint (KR joint), coil and header.

Check the spraying water flow.

1. Open Make-up water Valve.

 Fill Lower Basin with water until overflows
(through Overflow Pipe [1].)

2. Make sure that no water leakage from

Lower Basin is found.

16
3. Before spraying water, make sure to open
Adjust Valve [2] fully.

4. Run Spray pump for a few seconds to see

the rotation direction (Refer to A, for
Rotation arrow.)

Note
 Counter-rotating operation could negatively
affect performance of pump. Wiring of Spray
pump motor should be positive phase.

5. Run Spray pump continuously.

Note

 See if no abnormal sound is coming from Spray

pump.

 Make sure that operating current should be

equal to the rated or below. (Refer to
nameplate on motor). If voltage is equal to the
rated or below, current becomes higher.

 Once spraying water starts running in, turn

the Adjust Valve until water goes up to the
level indicated by Sticker [2]. Expected cooling
capacity would not be secured if water level is
not equal at each upper basin.

Check the operation of Fan (Motor)

Refer to P15, Open Type, “Cooling tower Check Fan (Motor.) Operation”

17
Precaution in starting operation

Warning
Do not enter (climb up on) tower while fan is in operation.
There is possibility of serious wounding or death.
DO NOT
ENTER

Caution
Do not stick hand or foreign substance Be aware of abnormality in terms of noise,
into fan while in operation. vibration, electric current, water
DO NOT CAUTION
STICK IN There is a possibility of wounding and temperature, water flow.
damage. If abnormality is found, refer to Trouble
shooting (P47) and handle it promptly.

Before starting cooling tower after long intermittent, make sure that nothing (that could cause
accident in the future) has happened to cooling tower.

For Open type cooling tower

1. Check bolt connecting each parts is securely fastened.

2. Check fan and V belt.

 There should not be any contact of blade tip to fan casing and any foreign substance adhered to blade.
 Open belt cover to see if V-belt pieces are in conformity in terms of type, length and number.
 Foreign substance such as dust, bird nest should not be found inside Belt cover.
 Grease should not be leaked from bearing.
 Check V-belt tension.
 Fan Pulley and Motor Pulley should be leveled horizontally.
 Blade-fixing bolt should not be loose.
 Re-tighten blade-fixing bolt after first 100 hour of operation, followed by periodical re-tightening
work once in every 3 years (once in every year for cooling tower operating throughout a year.)
(Required torque is 80Nm for M16 bolt, 55Nm for M12 bolt)
 Re-tighten V-belt after the first 100-hour operation. If V belt is loose, please refer to V Belt tension
adjustment Procedure, P36.
 Drive Fan continuously to see if no abnormal sound or vibration is coming out. Also check if motor
amperage is appropriate.
 Amperage marked should be below the rated amperage of motor.

Note:
 Please refer to P36 tension adjustment procedure for V belt tension.
 Keep in mind that the excess in electric current may cause decrease in voltage.

18
3. Clean the followings;

(a) Upper basin

Check and make sure spray holes are not clogged.

Note:
 Algae and small rocks may disturb smooth spray water flow leaving tower suffering from
deficiency in capacity. Upper Basin Cover is recommended.

(b) Lower basin and Strainer

Refer to P37 to 39 for Cleaning Work.

(c) Strainer for Float Valve

Note
 Float-valve equipped in Kuken cooling
tower is pressure-balance type dual ball-
cock valve (small models may not follow
this specification).
 Built-in strainer helps prevent valve-seat
from clogging.
 Strainer can be pulled out along with
cylinder by loosening cap [1] with
spanner.
Make sure to clean it before starting
operation.
 Malfunction of float valve could cause
shortage/excess of circulation water.
 Refer to P41 (Clean Float Valve strainer.)
 Strainer can be removed easily by
loosening cap [1] with spanner.

4. Fill Make-up pipes with water until it

overflows (from Overflow pipe [2].)

19
5. Make sure that Adjust Valve [3] of
Upper Basin is “FULLY OPENED”

6. Once circulation water starts running

in, make sure that water level does not
exceed the level indicated by Sticker
[4].

Note:
If water level exceeds the level, turn
the Adjust Valve [3] up and down until
water goes down to the level indicated
by Sticker [4].

7. Run Circulation water pump

intermittently to push air out of the
strainer [5].

Note:
 FRP strainer has air release hole
on the top. (Air can be released
automatically.) Refer to the sketch
on the right.

 For stainless strainer, air can be

released by taking off plug [6].

20
8. Adjust the position of rod [7] with hexagon
screw [8] to avoid entraining air towards
strainer.

Note:
 Water level eventually becomes stable
by operating continuously. This is the
appropriate operation water level.
 Pressure range of Float valve is from
0.049MPa ~ 0.294MPa.

9. Confirm that there is no water leakage from Lower Basin or Pipes.

10. Start Fan operation (Make sure that no abnormal noise is coming from fan.)

11. Inspect on a daily basis.

Note:
 Refer to P28 “Daily Inspection (In season)” for Items being inspected.
 If water level goes down during the cooling tower operation, air entrainment towards strainers
could occur, causing the normal operation.
In order to be secure the make-up performance for the appropriate water level, check the Float
Valve operation in time of Daily inspection.

21
 For Closed type Cooling Tower
Note the followings for closed-type cooling tower as well as the information given on P18 (Open type Cooing
Tower)

 Again, make sure to let air out of copper coil.

Note :
 Refer to P16 [Check the circulation water
flow.]

 Water in lower basin should be at proper level

up to the top of overflow pipe before starting
spray-water pump.

Note:
 Refer to P16 [Check the spraying water
flow.]
 Spray pump might not be able to run
smoothly if silica or foreign substance
(such as sand particles) is piled up in a
narrow gap between casing and impeller.
 Copper coils may not get wet sufficiently
for a while after restarting cooling tower
operation but it will be sorted out
naturally within a couple of days.
 Condition of spare or emergency-use cooling tower should be checked monthly by running fan and
spray pumps (for about 10 minutes.)
*DO NOT dry-run Spray pump.
 Condition of Spray pump (impeller) should be checked by hand-turning prior to power on. In case
pump impeller cannot be turned by hand, follow Pump unlocking Procedure.

Pump unlocking procedure

Before driving Spray pump, complete the following to unlock the pump;
Note
 What to prepare : Flathead screw driver (1#) Hammer (0.5 pound)

1. Take off rubber cap [1] with Flathead screw

driver [2].

22
2. Stick in flathead screw driver [2]
through hole on pump cover and fit the
tip into castle.

3. Hit top of the driver [2] several times

with hammer [3] while twisting it
counter-clockwise to unlock.

4. Once impeller starts turning by hand,

rotate it with flathead screw driver [2]
2 or 3 times. (Unlocking process
completed.)

5. Fit Rubber Cap back in the hole

without leaving any clearance.
Note
 Clearance causes water invasion to
Spray pump internal (Could cause
spray pump malfunction.)

23
 Precaution during winter care

: CAUTION

DO NOT touch electric heater even after it was switched off.

Or, you could get burnt.
SWITCH
OFF

Note
● Amperage of fan motor tends to mark higher due to the fact that specific weight of air increases as
ambient temp. decreases.

For Open Type cooling tower

For winter time operation, it is
recommended to apply electric heater [1]

Note
 To install electric heater [1], apply
thermostat to avoid unnecessary temp.
rise.
 Turn electric heater on after
heat-generating portion has been soaked
in water. (Float-switch or thermostat is
recommended for the system.)
Make sure to do it in order to avoid fire
and burnout of heater
 Scrub and remove scale sticking around
heater surface with wire brush in
cleaning.
The claggy scale blocks the heat release,
causing electric heater [1] burnt and
damaged.
 For more detail, refer to "Electric Heater
for Cooling Tower Application - Operation
Manual".

For Closed Type cooling tower

It is recommended to apply anti-freeze unit to prevent circulation water from being frozen.
To prevent spray water from being frozen, please refer to “For Open Type cooling tower” above.

Note
 If the ambient temperature comes below -5oC, it is recommended to apply heater for aux pump.
 Apply insulation for pipes for anti-freeze unit or aux pump.

To apply anti-freezing agent for circulation water, note the followings;

Note
 Anti-freeze agent may affect tower performance negatively depending on character and
concentration of the agent in water. Exercise care in selection taking this fact into account. (Such
as Specific heat, Specific gravity, and Freezing temperature, etc )
 Concentration Closed
of the agent
typeincooling
water may happen
tower coiltodrain
be lowered
waterdue to unexpected mishaps such as
procedure
water-leakage. Check the concentration periodically and replenish if necessary.

24
 Closed type cooling tower coil drain water procedure

1. Close Inlet valve [1] and Outlet valve [2] for

Circulation water.

2. Open all Air release valves [3] connected to

coil-header fully.

3. Open Circulation inlet water drain socket [4]

and Circulation outlet water drain socket [5]

 Water is naturally drained out.

Note
 If Valve is equipped, open it fully.
 If water cannot be drained out naturally,
Move to procedure No. 4.

4. Connect compressor to Circulation inlet water

drain socket [4].

Note
 Air purge valves [3] and Circulation outlet
water drain socket [5] should be kept closed.

5. Raise pressure up to 0.3MPa with compressor.

6. Open Circulation outlet water drain socket [5]

immediately.

 Water inside coil will be discharged.

[5]

7. Repeat No. 5 and 6 again and again to remove

water completely.

Note:
 5 times must be enough to discharge water
completely.
[4]

Note:
 Air purge valve [3], Circulation Inlet water Drain plug [4] and Circulation Outlet water Drain plug [5] should be
kept opened until water is filled for upcoming operation.
 Coil unit is designed to have inclination toward louver (outlet header.)
Make sure to drain from Circulation Outlet water Drain.
 Compressed air fails to push water toward drain outlet if drain plug is opened.

25
 Precaution in halting
 Precaution in long term out-of operation
For both Open Type and Closed Type cooling tower

Warning
Do not enter or (climb up on) tower while Make sure to power OFF
fan is in operation. There is possibility of wounding caused by
DO NOT POWER
ENTER There is possibility of serious wounding or CHECK unexpected self-start of tower.
death.

Caution
Make sure that there is NO foreign During the winter season, make sure to drain
substance into cooling tower or pipe. whole water from circulation water pipes and
NO DRAIN
FOREIGN Foreign substance could cause the WATER lower basin.
SUBSTANCE clogging of strainer.
Pipe and Coil can be cracked by freezing.
Therefore, Air purge valve of header, drain
valve, spray pump drain valve should be kept
opened. For more details, refer to Closed type
cooling tower coil drain water procedure (P25)

To keep tower out of operation for long time, proper inspection and maintenance should be carried out
periodically even during the not-in-use period to be ready for upcoming operation.
 Loosen V-belt to avoid deformation and to protect Fan Shaft and Motor bearing from possible
worn-out due to V-belt tension.
 Cover Fan Discharge port.

To start operation after long-time not-in-use period, follow the instructions below.
 Make sure that no loosening of bolt on each connecting portion and no rust appearing on steel parts.
Replace or repair if necessary.
 Check insulation of fan motor, spray water pump, and circulating water pump. The resistance
should be 3MΩ or at 500V megger.
 Also check the followings prior to operation.
 Warning (P7)
 Precaution in trial (P13)
 Precaution in starting (P18)
 Precaution during winter care (P24)

26
 Cleaning and Inspection

Warning
Products should not be broken apart by Other than the purpose of inspection, do
DON’T
anyone other than licensee. DO NOT
not enter (or climb up on) tower.
BREAK The malfunction could cause burn, electric ENTER If you ignore the warning, you could get
APART
shock and wounding. injured.

Make sure to check that Fan, Spray More than 2 persons are required on duty
POWER pump, Electric heater and others have MAINTEN for safety reason.
OFF
been switched off. ANCE &
INSPECTI
Some parts may accidentally fall down if it
If you ignore the warning, it could cause ON is too heavy for one person to hold. Injury or
a burn or electric shock. damage on product can be expected.
During maintenance and inspection Secure foot space and wear protective on the
DURING work, exercise care not to swallow PROTECT top of cooling tower.
WORK
cooling water and not to inhale droplet. ION
If you ignore the warning, you could get
Make sure to gargle and wash hand injured.
after inspection work.
If you ignore the warning, it could affect
your health.

Caution
Make sure that there is NO foreign Inspect and clean upper basin spray holes
NO
substance into cooling tower or pipe. and strainer equipped with Lower basin on
INSPECTI
FOREIGN Foreign substance could cause the ON AND occasion.
SUBSTANC CLEARNI
E clogging of strainer. NG
Clogging of upper basin holes and strainer could
cause deficiency in cooling tower performance
and damage of strainer.
Bearing for Fan shaft and motor A whole set of V-belt should be replaced
bearing are grease-sealing type. REPLACE after 8,000 hrs of operation or every year. If
REPLACEM
ENT Expected life time of bearings is 20,000 MENT damaged piece of V belt is found (cut or
hours. Therefore it should be replaced worn out heavily), change a whole set of V
approximately every 2 years. belt (DO NOT change damaged piece only)
Replace it soon after you hear the Overuse could cause the deficiency in cooling
abnormal noise. tower performance and damage.
Overuse could cause the deficiency in
cooling tower performance and damage.
Spray pump for closed type cooling
tower uses mechanical seal inside. As
REPLACEM
ENT soon as water leakage is found, replace
it immediately.
Even if water leakage is not found, it
should be replaced every year.
Overuse could cause the deficiency in
cooling tower performance and damage.

Note
 Maintenance and Inspection requires special knowledge and skill. Therefore, contact Kuken
(Details are shown on the back cover page.)

27
 Daily inspection
Item to be checked

Surrounding of cooling tower

Check the following;

 air condition is normal nearby cooling tower, and something to block air flow is not left.
 there is nowhere happened to have higher ambient temp nearby cooling tower.
 abnormal noise or excessive vibration is not found on tower body or pipes.
 there is no water-pool created by water leaked from cooling tower.

Cooling tower internal

Check the following;
Lower Basin
 Circulating water level in lower basin is
appropriate. (Up to top of overflow pipe.)
 Foreign substance such as leaves, plastic bag,
etc is not left in lower basin.
 Circulating water does not change in colour.
 Circulating water temperature and water flow
is normal.

Strainer
 No foreign substance is clogged in strainer
net.
 No large vortex of water can be seen above
strainer.

Float Valve
 Make-up water is replenished automatically when the ball goes down.
 Float valve strainer is not clogged.

Cooling tower top

Check the following;

 Water-distribution holes of upper basin are
not clogged.
 Foreign substance is not stuck around fan
blade.

Current
 Check that amperage of FAN and pump motors as per the rated or below.

28
 Regular inspection
In order to extend the life span of cooling tower, refer to the table below for regular inspection for your
reference.

Warning
Make sure to check that Fan, Spray pump, Electric heater and others have been switched off.
POWER OFF Could cause wounding and fire.

Open Type cooling tower

Frequency
PARTS Item Every Every 3 Every Item to check Check point Means
Daily Others
month months year
Visual No breakage, no No breakage, no Repairing,
Check deformation, No deformation, No Replacement
rust rust
Framework
Visual Bolt loosening Bolt loosening Retightening
Check B, NT.
Contact us.
Visual No breakage, no No breakage, no Replacement
Check deformation deformation
Outside
Panel
Visual No loosening No loosening Repairing.
Check Contact us.

Visual No breakage, no No breakage, no Replacement

Check deformation deformation

Upper Basin Visual No sediment, no Spray water Cleaning

Check flotage equally through
Cooling upper basin
Tower holes
Visual No breakage, no No breakage, no Replacement
Check deformation deformation
Spray water Visual Proper water Equal water Adjustment
box Check level being level
indicated on
Upper Basin
Visual No breakage, no No breakage, no Replacement
Check deformation deformation
Visual Smooth air Cleaning,
Louver
Check intake. No Even air flow Replacement
clogging such as No clogging
scale
Visual No breakage, no No breakage, no Replacement
Check deformation deformation
Visual No scale, No No Clogging Cleaning,
Check slime Replacement
Filling
Visual smooth smooth Cleaning,
Check air/water flow air/water flow Replacement
Visual No deformation No deformation Replacement
Check
Visual Appropriate Appropriate Adjusting
Lower Basin Check water level water level Float Valve.
(P21)
Visual Water leakage No water Repairing.
Check leakage Contact us.

Lower Visual Water being No polluted Cleaning

Basin Check dirty, water,
No clogging No clogging
Visual No breakage, no No breakage, no Replacement
Check deformation, No deformation, No Contact us.
rust rust

29
 Frequency
PARTS Item Every Every 3 Every Item to check Check point Means
Daily Others
month months year
Visual No breakage, no No breakage, no Contact us
Check deformation deformation

Visual extraneous No extraneous Cleaning

Fan Blade Check material material
Visual Clearance No contact Contact us
Check between blades
Visual Bolt loosening No Bolt Bolt
Check loosening tightening
Contact us
Visual Appropriate Appropriate Contact us
Blade Angle
Check blade angle blade angle
Visual No breakage, no No breakage, no
Check deformation deformation Replacement
Fan Casing Visual Bolt loosening No Bolt Bolt
Check loosening tightening
Contact us
Visual No breakage, no No breakage, Replacement
Check deformation, No deformation, Bolt
bolt loosening, bolt loosening, tightening
oil leakage oil leakage Contact us
Visual Abnormal noise No Abnormal Contact us
Shaft Check during rotation, noise during
FAN
no vibration rotation, no
vibration
Visual No oil leakage No oil leakage Contact us
Check
Visual No breakage, No breakage, Replacement
Check No No Contact us.
deterioration, deterioration,
No worn out No worn out
Visual No slip No slip Adjust (P34
V-Belt Check ～P35)
Contact us
Visual Abnormal noise No Abnormal
Check during rotation, noise during Adjust (P34
no vibration rotation, no ～P35)
vibration Contact us
Visual No breakage, no No breakage, Replacement
Check deformation No deformation Contact us
Visual No slip No slip Adjust (P34
Check ～P35)
Pulley Contact us
Visual Abnormal noise No Abnormal Adjust (P34
Check during rotation, noise, no ～P35)
no vibration vibration Contact us
Acous Abnormal noise Abnormal noise Contact us
Bearing tic
check
Visual Check Below the rated Contact us
Amperage, Check amperage (indicated on
Voltage during motor
Motor operation nameplate)
Casing, Visual No breakage, no No rust Replacement
Terminal Check deformation, No
Box rust

Visual Bolt loosening No Bolt Bolt

Fixing Bolt
Check loosening tightening

30
 Frequency
PARTS Item Every Every 3 Every Item to check Check point Means
Daily Others
month months year
Visual No breakage, no No breakage, no Replacement
Check deformation deformation
Visual Start/Stop of Start/Stop of Cleaning,
Ball tap Check making up making up Replacement
water/ Normal water/ Normal (P41)
movement of movement of
Accessorie ball tap ball tap
s Visual No breakage, no No breakage, no Replacement
Check deformation deformation
Visual No problem of Cleaning
Strainer Check sucking cooling
water through
Strainer (No
vortex) No clogging
Others Visual No loosening of No loosening of Bolt
Check Anchor bolt Anchor bolt tightening
No breakage, no No breakage, no Replacement
Installation
corrosion corrosion
No cracking on No cracking on
Foundation Foundation
* It varies depending on the specification.

Closed type Cooling Tower

Frequency
Every
Item Every Every Item to check Check point Means
Daily 3 Others
month year
months
Visual Water leakage No water leakage Contact us
Check
Heat
Visual No breakage, no No breakage, no Contact us
exchanger
Check corrosion corrosion
(Coil)
Visual No Scale, no silica No clogging Cleaning,
Check Replacement
Visual Water leakage No water leakage Replacement
Check ( Replace after
every 8000 hours
Spray Pump
operation)
* Other items to check are same as those of motor.

* The above-mentioned items vary depending on the cooling tower specification.

31
 Parts Replacement

Warning
Make sure to check that Fan, Spray pump, Electric heater and others have been switched off.
POWER OFF If you ignore the warning, it could cause a burn or electric shock.

For Open type cooling tower

Inspection
Expected
PARTS Item Every Every 3 Frequency Remarks
Every year lifetime
month months
FAN Fan Blade Visual 5 years Blade : FRP
Check Hub : Cast Iron

Pulley Visual 7 years Cast Iron

Check Manufacturer's
standard paint

V-Belt Inspection 8,000 hours or Synthetic rubber

& approx. 1 year
adjustment operation

Shaft Inspection Shaft bearing (20,000 7 years Casing : Steel

hours or aprox. 2 year Shaft : HDG steel,
operation) Epoxy painting,
Un-refill type

Fan Casing, Visual 10 years Casing : FRP

etc Check Support : Steel
Fan guard : HDG steel
Motor Casing Visual 7 years Steel or Cast iron,
Check manufacturer's
standard paint

Bearing Inspection Bearing (20,000

hours or aprox. 2 year
operation)
Cooling Framework Visual 10 years HDG Steel
Tower Check
Filling Cleaning 7 years PVC

Lower basin Cleaning Visual 10 years Framework : Steel,

Check Tank : FRP,
HDG Steel
Upper Cleaning 10 years FRP
Basin

Outside Visual 5 years PVC

Panel Check

Louver Visual 5 years PVC

Check,
Cleaning
Others Strainer Cleaning Dismantle 5 years Cover : FRP / Stainless
and check Steel,
Mesh : Stainless Steel

Ball tap Cleaning Dismantle 3 years Socket : Bronze,

and check Ball tap : PE

32
For Closed Type cooling tower

Frequency
Every Every Every Expected
Items Replacement period Material
month 3 year lifetime
months
Heat exchanger Visual 10 years Copper tube
(Coil) Check
Visual Mechanical Seal : 8,000 hours or 7 years
Steel or Cast Iron,
Check approx. 1 year operation
Spray Pump Manufacturer's
Bearing : 20,000 hours or aprox. 2
standard paint
year operation

Anti-Corrosion

Note
 Kuken cooling tower comes with Hot Dip Galvanize (350g/m2) applied on steel parts.
 Life span depends largely on Cooling Tower location and operating condition.
Refer to Expected lifetime and replacement period.

Anti-corrosion specification table.

Parts Kuken standard anti-corrosion specification

Framework H.D.G. (Hot Dipped Galvanised)
Lower basin frame Ditto (Including legs)
Fan unit Ditto (Excluding shaft, bearing unit & pulley)
Header for closed type cooling tower Ditto (Joint is brass)

Note
 Touch-up paint should be applied on painted parts or equipment (motor, pump) once every 3 to 5
years.
 Kuken standard specification does not include the painting on the Hot Dip Galvanised parts, resin
parts, Stainless Steel parts and Brass parts. Standard color of paint is Munsel N-5. Dirt should be
removed by thinner and wiped off with clothe.
Rust should be removed off steel parts by scratching with sand paper or wire-brush prior to
applying touch-up paint.

33
 Adjustment procedure
V Pulley, V belt Adjust Procedure

1. Loosen Motor base fixing bolt [1] (2 pcs.)

2. Loosen Adjust bolt [2] (4 pcs.)

3. Slide Motor base [3] toward Fan.

4. Remove V-Belt.

5. Hook new V-Belt.

Note:
 Carefully do the V-Belt replacement
work not to jam your fingers.
 Hook V-belt to motor pulley[5], then to
fan pulley [6] (hook to the lowest groove
first, then proceed to the middle and the
highest)

6. Tighten Adjust bolt [2] (4 pcs.)

Note:
 Do not over-tighten V Belt.

7. Slide Motor base toward motor.

34
 Surface leveling Adjustment of Fan Pulley and Motor Pulley

1. Check surface level of Fan pulley [2] and Motor

pulley [3] with a straight measure [1].

Note:
 Leveling string can also be used for level
check.

2. Adjust level by screwing/or unscrewing Adjust

bolt [4] (Total 4 pcs.)
Note :
 Fan Pulley [2] and Motor Pulley [3] should
eventually be leveled on surface without
leaving inclination.
 If surface cannot be leveled easily, use
Pulley puller to pull up Motor pulley [3] to
facilitate the work.

3. Repeat procedure 2 until both pulleys are

totally leveled at and on surface.

4. Have Fan Pulley rotated by 180 degrees.

Note :
 Check the level of Pulley again.
(Max. acceptable level difference between
the pulleys is 5mm but try to keep it within
3mm.)
If surface cannot be leveled easily, use
Pulley puller to adjust the level of Motor
Pulley [3].

35
 V-Belt tension adjustment procedure

1. Check V-belt tension with tension gauge.

Note :
 To check belt tension, tension gauge
should be pressed against V-belt (through
Reading Port.) For more accurate reading,
target the plain, seamless surface found
when belt-seam comes at the opposite of
the Port.

2. Have Pulley rotated (with V-belt) 7 to 9

times.
 V-belt starts to be conditioned on surface
of pulley.

3. Recheck V-belt tension.

4. Adjust V-belt tension by tightening/loosening Adjust bolt.

Note:
 Check and adjust the tension of top V-belt to keep deflection within the standard.

Diameter Deflection Load Deflection

φ 1200 13mm

φ 1400 15mm

φ 1600 20N 17mm

φ 1800 19mm

φ 2000 21mm

5. Tighten Adjust bolt to fix Motor Stand.

Note:
 Once again check that Pulley level is certainly within the maximum acceptable level difference.
(Refer to P35)
 Drive Fan motor for 30 to 60 minutes. (New belt usually gets loose after first running.
Therefore, it is required to check belt tension again. It also makes belts fit in Pulleys.

6. V-belt tension should be within value above.

Note:
 Once new belt is applied, belt tension has to be checked after approximately 100 hours
operation and adjusted if necessary.
 If tension is not sufficient, re-adjust V-belt tension.

36
 Cleaning work (Open type cooling tower)
Clean Lower basin and Strainer.

Clean Lower Basin once a month.

Especially when algae or silica appears noticeably on Filling, do the cleaning work
immediately.

Note
 Vortex appearing above Strainer is a warning signal from cooling tower.
Stop operation immediately and clean Lower Basin.

1. Close Valve of Inlet/Outlet water pipes.

2. Close Valve of Make-up water pipe

(Auto.)

3. Open all valves or plugs for drain pipes

to drain out Circulation water.

4. Remove floating ball and rod

temporarily from Float valve body.

Note
 Cleaning work without temporal
removal of the ball and rod could
cause the damage.

5. Remove Strainer [3].

37
 6. Wash away dirt sticking around wire
mesh of Strainer with brush[4]

7. Spray water through louver to wash

away dirt precipitated at the bottom of
Filling toward the centre of Lower
basin.

Note
 Use hose or jet-spray.

8. Clean Lower basin pit with brush.

 Remove dirt through drain.

9. Put Strainer [3] back in position.

10. Have rod [2] and float ball connected back on float valve [1].

11. Close drain valve or plug drain.

12. Open make-up water (auto) valve.

 Refill Lower Basin with water.

13. Open all drain valves again when water comes up to overflow level.
 Drain out dirt precipitated at the bottom of Lower basin.

14. Close all drain valves.

 Refill Lower Basin with water again.

15. Close Outlet water valve. Then, start pump.(Open the valve gradually)

Note
 Open valve gradually until required water flow is secured, then run pump for
another 30 seconds.

38
16. Stop Pump.

17. Temporarily try to remove Strainer once it is soaked completely in water.

Note
 The purpose is check clean strainer wire mesh. (Sometimes remaining dirt or scale comes out
after running pump.

18. Open drain valve again.

19. Wash away the dirt around strainer through drain pipes.

20. Close drain valve.

Note
 Pour water up to overflow level. Then, run
pump.
 Make sure that vortex doesn’t appear soon
after starting pump.
 To go back in operation after cleaning
Filling and Lower Basin, start with the
procedure 14.
If Pump is started with drain valve opened,
strainer can be damaged due to the dirt
accumulated on strainer mesh.

39
Cleaning of Filling.

Note
 Filling and lower basin should be cleaned at the same time.
 Apply highly pressurized water through Louver.
Clean it with appropriate water pressure and volume in order not to damage Filling block.

When scale appears heavily on filling

1. Remove Louver blades.

2. Remove Filling block from Louver side.

Note
 With heavy Pile-up of dirt on surface, filling block tends to be heavier in weight.

3. Have Filling blocks dried naturally.

Note
 Dry for about 2 hours (in Summer time), 5 hours (in Winter time.)

4. Place Filling blocks on a sheet specially arranged for protection, then wrap it.

5. Slap lightly each filling block entirely over the protection sheet to have dried silica come off.

Note
 Slapping without protection sheet may break Filling.

6. Clean the filling block with Highly-Pressurized (jet spray) water. Then put it back where it was.

Note
 If scale cannot be fully removed, use scale-remover.
 To operate cooling tower after cleaning Filling and Lower Basin, follow the procedure from No.
14 in “Clean Lower basin and Strainer”.(P37~39)
If Pump is started with drain valve opened, strainer can be damaged due to the dirt
accumulated on strainer mesh.

40
Cleaning float valve strainer

1. Close Make-up water (auto) Valve.

2. Loose the valve Cap [1] with spanner.

Note
 If air release holes of cap [1] are clogged,
remove foreign substance.

3. Remove Strainer [2].

Note
 Wash away dirt sticking around wire
mesh with brush.

4. Place strainer [2] back in position

5. Fix Cap [1] with spanner.

6. Open Make-up water (auto) Valve.

7. Have Rod [3] go up and down.

Note
 Check the operation of making-up water.

41
 Retaining cooling tower performance
Performance of cooling tower is totally dependent on mutual inter-relationship of factors such as
circulating water flow, inlet and outlet temp., ambient wet bulb temp., air volume, etc. It is not
appropriate to evaluate a tower performance simply by temp. difference of inlet and outlet.

The ideal way of evaluating performance of cooling tower is to focus on outlet temp. by comparing with
that of design condition having rest of the factors(water flow, spraying water flow, inlet temp., wet bulb,
and air flow) completely fixed to be exactly same in figure.

Generally, tower performance tends to be influenced by the factors shown the table below.
Large temp. difference inlet and outlet Small temp. difference inlet and outlet
High heat load Low heat load.
Small water flow Large water flow
Large temp. difference between inlet and wet Small temp. difference between inlet and wet
bulb bulb
High inlet temp. (*) Low inlet temp.
* Inlet in extremely high temp. could soften and deform Filling. (Inlet temp. <45oC)

 Calculation of make-up water

Volume of circulating or spraying water decreases in due course because of the following reasons:
 Cooling tower is designed to cool water taking advantage of principle of evaporation.
 Water droplets are carried away in open air by strong wind generated by fan (“Drift loss”).
 A part of water must be drained out to keep proper circulation/spray water quality in tower to be
replenished with fresh water as much, “blow-down”.

To calculate make-up water volume, follow the equation below:

(1) Evaporation loss (WE) kg/h

WE = (tw1— tw2)×L×Cp÷2520
tw1 : Inlet water temperature(oC), tw2 : Outlet water temperature(oC),
L : Flow rate (kg/h), Cp : Specific heat of water (Kcal/kg oC),
2520 : Latent heat incidental to water evaporation (kJ/kg oC)
If the difference between inlet and outlet temp. is 5 oC, evaporation will be approx. 0.83%
according to the above equation.

(2) Drift loss (WD) kg/h

It varies depending on tower structure and air-flow velocity. Normally it is about 0.3%.
Make-up water (ΔL) kg/h
In total,
ΔL = WE + WD＝ 0.83 ＋ 0.3 ＝ 1.13%

Note:
 Make-up of 1.5~1.7% is recommended in actual operation.

(For reference) Blow-down

The amount required for Blow-down varies depending on amount of pollutant in the air,
amount of make-up water and multiples of concentration of make-up water. Normally it is
about 0.3% against circulation water.

42
 Water quality control
Cooling tower operation with highly-concentrated circulating water causes the negative effect to open
type cooling tower such as corrosion, scale, and slime.
This effect is also applicable to cooling tower operation with highly-concentrated spraying water to
closed-type cooling tower.
The water suitable for cooling tower application is shown below (code JRA-GL-02-1994) for reference
issued by Japan Refrigeration Association (JRA)

[Standard value for circulating water] Value in Round bracket () shows the JRA standard value for
spraying water (closed-type cooling tower)
Tendency
Items Criteria
Corrosion Scale
pH [at 25oC] 6.5 ~ 8.2 (7.0 ~ 8.0) ○ ○
Conductivity [at 25oC] (mS/m) 80 or less (30 or less) ○ ○
Chloride ion (mgCl- /l) 200 or less (50 or less) ○
Sulfate ion (mgSO42- /l) 200 or less (50 or less) ○
Standard
Acid consumption [pH 4.8] (mgCaCO3/l) 100 or less (50 or less) ○
Total hardness (mgCaCO3/l) 200 or less (70 or less) ○
Calcium hardness (mgCaCO3/l) 150 or less (50 or less) ○
Silica (mgSiO2/l) 50 or less (30 or less) ○
Iron (mgFe/l) 1.0 or less (1.0 or less) ○ ○
Copper (mgCu/l) 0.3 or less (1.0 or less) ○
Sulfide ion (mgS2-/l) Shall not be detected (Ditto) ○
Reference Ammonium ion (mgNH4+/l) 1.0 or less (0.3 or less) ○
Residual chlorine (mgCl/l) 0.3 or less (0.25 or less) ○
Isolation carbon (mgCO2/l) 4.0 or less (0.4 or less) ○
Stability exponent 6.0~7.0 (-) ○ ○
Note
 "○" indicates the marked item is a strong influential factor to from corrosion or scale.
 The items listed above are the major factors having tendency for forming corrosion or scale.
 Item and its unit are in conformity of JIS code K0101-1979.Acid-consumption [pH4.8]
is also referred to as Total alkalinity, or M-alkalinity.

[Standard value for make-up water] Value in Round bracket () shows the JRA
standard value for make-up water (closed-type cooling tower)
Items Criteria
pH [at 25oC] 6.0 ~ 8.0 (7.0 ~ 8.0)
Conductivity [at 25oC] (mS/m) 30 or less (30 or less)
Chloride ion (mgCl- /l) 50 or less (50 or less)
Sulfate ion (mgSO42- /l) 50 or less (50 or less)
Standard
Acid consumption [pH 4.8] (mgCaCO3/l) 50 or less (50 or less)
Total hardness (mgCaCO3/l) 70 or less (70 or less)
Calcium hardness (mgCaCO3/l) 50 or less (50 or less)
Silica (mgSiO2/l) 30 or less (30 or less)
Iron (mgFe/l) 0.3 or less (0.3 or less)
Copper (mgCu/l) 0.1 or less (0.1 or less)
Sulfide ion (mgS2-/l) Shall not be detected (Ditto)
Reference
Ammonium ion (mgNH4+/l) 0.1 or less (0.1 or less)
Residual chlorine (mgCl-/l) 0.3 or less (0.3 or less)
Isolation carbon (mgCO2/l) 4.0 or less (4.0 or less)

43
 Calculation of multiple of concentration and blow-down

Heat-exchange is done by having part of circulating (spray) water evaporated. Thus, the leftover portion
of the remaining water is quite concentrated. The dissolved ratio between make-up water and the
remaining water is called "Multiple of concentration".

To retain cooling tower performance, cooling tower should be operated with water within the limit of
multiples of concentration.
Blow-down and Make-up water is required as per the amount calculated following the equation below.
ΔL : Make-up water (kg/h)
ΔL = WE + WD + WB
WE : Evaporation loss (kg/h)
WD : Drift loss (kg/h)
WB : Blow down (kg/h)

N : Concentration multiple
N = (WE + WD + WB) / (WD + WB)

From the above, following equation is applicable:

WB = [WE / (N-1)] – WD (1)
ΔL = WE ×N / (N – 1) (2)

For example, if evaporation loss is 0.83% of circulating water amount, correspondence of Multiples of
concentration (N) and Make-up water (ΔL) is figured out according by equation (2) above

[Multiple of concentration and Make-up water amount]

Concentration multiple (N) 2 3 4 5 ∞
Make-up water amount (ΔL) kg/h
12 9 8 7.5 6
per RT

Note:
 It is possible to check Multiples of concentration of circulating and make-up
water by lab analysis. Periodical water sampling is recommended.

Generally, Multiples of concentration is obtained from the following equation applying sodium
ion concentration value obtained from lab analysis.

N = CR / CM
C R : Sodium ion concentration of circulating (spraying) water (mgCl- /l)
CM : Sodium ion concentration of make-up water (mg Cl- /l)

It varies depending on make-up water quality and system.

There are some ways to blow down;

 Equip valve for circulating or make-up water pipe and have the valve kept slightly open to let
some water go out.
 Let some water go out through overflow pipe during cooling tower operation by making up
water manually.
 Install Auto-blow device.
(Kuken under-flow pipe (optional) is recommended to use along with auto-blow device.)

Note :
 Chemical application is also one of the ways to control water quality
(consult chemical supplier for further reference.)

44
 Consumable Parts List
Note
 Contact us after confirmed the serial no. and manufacturing date indicated on nameplate.

No. Consumable Parts Parts Size and Model

1 Fan bearing Fan P12 Name plate indicated on Inspection Door
[7] Fan shaft
2 V-belt Fan P12
[11] V-belt

3 Fan Pulley Fan P12

[9] Fan Pulley

e.g.) 22B3 -> pulley sized 22 inches in dia.

B- type belt ×3 pcs applicable

4 Motor Pulley Fan P12

[10] Motor Pulley

e.g.) NBK 4B3F -> B type 3 pcs 4 inches

Note) “F” stands for “FLAT” in shape.
“Boss-shaped” if no letter indication

45
No. Consumable Parts Parts Size and Model
5 Motor bearing  Fan Unit (P12) Indicated on motor name plate
[5] Motor

6 Spray pump bearing  Closed Type Indicated on Spray pump name plate
Cooling Tower (P10)
[18] Spray Pump

46
 For enquiry
 Trouble shooting
The table below is quick reference to use when you encounter cooling tower trouble.
If direct contact is needed for trouble shooting, check the following information beforehand;
 Items to be specified in Nameplate (Especially “Serial no.” (Refer to P5))
 Specify the troubled parts and detailed description of actual trouble
 Contact person
 “Serial no.” of each motor and spray pump indicated on its nameplate. (P8 ~P12)

Type
Trouble Refer
Ope Clos Cause Countermeasure
details ence
n ed
Check bolts for looseness and
○ ○ Bolts loosening.
tighten loosened ones.
○ ○ Inadequate tension of V-belts. Adjust the tension. P36
Contact of fan blade tips & fan Back
○ ○ Contact us.
Abnormal casing. cover
sound & Back
○ ○ Defective shaft or bearings. Contact us.
vibration cover
Back
○ ○ Defective motor. Contact us.
cover
Reverse rotation of spraying water
○ Wire correctly.
pump.
Check & measure the voltage and
○ ○ Voltage drop.
contact power supplier.
Back
○ ○ Incorrect setting of fan blade angle Contact us.
cover
Electric over
Back
current ○ ○ Defective motor. Contact us.
cover
Back
○ ○ Defective shaft or bearings. Contact us.
cover
○ Defective spraying water pump. Check strainer & spraying pomp.
○ ○ Excessive flow rate. Adjust flow rate in specified value.
○ ○ Imbalanced water. Clean upper basin. Adjust valves.
○ Imbalanced water into cooling coils. Adjust valves.
Insufficient air purge out of cooling Purge air out completely out of
○
coils. coils from purge valve on header.
Abnormal
increase of Remove obstacles for air intake.
○ ○ Insufficient air volume.
outlet water Check V-belts.
temperature Deflected air intake into cooling Improve the remove obstacle for
○ ○
tower. ventilation.
Improve the remove obstacle for
○ ○ Recirculation of discharge air. ventilation. Contact the
distributor.
○ ○ Loosened or slip off of V-belts. Adjust the tension. P36
○ ○ Clogged strainers. Clean strainers. P37
Decrease of water level in lower Check and adjust make-up water
Decrease of ○ ○
basin. float valve.
circulating
○ ○ Defective drain valve. Check drain valve.
water
Insufficient capacity of circulating
○ Replace sufficient capacity pump.
water pump.
○ ○ Excessive flow rate. Adjust flow rate specified value.
Excessive ○ ○ Imbalanced water. Clean upper basin. Adjust valves.
drift loss Excessive air volume into cooling Back
○ ○ Contact us.
tower. cover
Install electric heater or inject
anti-freeze fluid. Install electric P24
Damage to heater or inject anti-freeze fluid.
○ Insufficient draining in cold season.
cooling coils Make sure to open drain valves Back
and purge valves. cover
Contact us.

47
Please fill in the form below soon after receipt of cooling tower.

Type Open / Closed type Cooling Tower Operation Manual

Serial Number
Date of Purchase DATE/MONTH/YEAR / /

Distributor and address

TEL :

Contact us

Should you have any enquiry or something, do not hesitate to contact us.

KUKEN KOGYO CO., LTD.

EXPORT DIVISION

2-39 OHORI-KOEN, CHUO-KU,

FUKUOKA, 810-0051 JAPAN

TEL : +81-(92)-741-5361
FAX : +81-(92)-715-0891
URL : http://www.kuken.com/
E-mail : export@kukenkogyo.co.jp

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