LRC Evaporative Condenser
The LRC is a low noise, low height, forced draft, centrifugal fan design evaporative condenser with a capacity range of 25 to 379 nominal tons (107 to 1622 kW). Standard construction consists of type 304 stainless steel cold water basin and G-235 (Z725 Europe) galvanized steel casing with all type 304 stainless steel construction available.
The LRC Evaporative Condenser product line is a combination of EVAPCO’s extensive forced draft evaporative cooling product experience and engineered solutions design philosophy. Combined with EVAPCO's high-efficiency THERMAL-PAK® coil, the LRC is the most efficient, quietest, and easiest forced-draft condenser in the industry to maintain and operate. The LRC’s engineered design features are described below.
- Principle of Operation
- Thermal-Pak II Coil
- Efficient Drift Eliminators
- Pressurized Water Distribution System
- Sound Attenuation Packages
- LRC Ships Factory Assembled
- Fast, On-Time Shipments
Principle of Operation
The refrigerant is circulated through the coil of the evaporative condenser. Heat from the refrigerant is dissipated through the coil tubes to the water cascading downward over the tubes. Simultaneously, air is forced upward, over the coil opposite the water flow by the fans. A small portion of the water is evaporated which removes the heat. The warm moist air is discharged to the atmosphere while the cooled water drains to the basin at the bottom of the cooler where it is recirculated by the pump up through the water distribution system and back down over the coils. The vertical air discharge of the LRC design and the distance between the discharge air and the fan intake reduce the chance of air recirculation since the warm humid air is directed up and away from the unit. For detailed layout information, please consult EVAPCO’S Equipment Layout Guidelines.
Thermal-Pak II Coil
EVAPCO's Thermal-Pak II coils is designed to assure maximum cooling capacity. The airflow through the coil is counterflow to the fluid flow, providing the most efficient heat transfer process. A special coil design is utilized to reduce the air pressure drop through the unit while maximizing tube surface area and increasing its heat transfer capabilities. The uniquely shaped tubes of the coil are staggered in the direction of airflow to obtain a high film coefficient.
The coils are manufactured from high quality steel tubing following the most stringent quality control procedures. Each circuit is inspected to assure the material quality and then tested before being assembled into a coil. Finally, the assembled coil is pneumatically tested at 400 psig (2758 kPa) under water to ensure it is leak free.
To protect the coil against corrosion, it is placed in a heavy steel frame and then the entire assembly is dipped in molten zinc (hot-dip galvanized) at a temperature of approximately 800°F (427º).
Efficient Drift Eliminators
An extremely efficient drift eliminator system is standard on the LRC Evaporative Condenser. The system removes entrained water droplets from the air stream to limit the drift rate to less than 0.001% of the recirculating water rate. With a low drift rate, the LRC Evaporative Condenser saves valuable water and water treatment chemicals. The LRC can be located in areas where minimum water carryover is critical, such as parking lots.
The drift eliminators are constructed of an inert polyvinyl chloride (PVC) plastic material which effectively eliminates corrosion of these vital components. They are assembled in sections to facilitate easy removal for inspection of the water distribution system.
Pressurized Water Distribution System
Another important part of an evaporative condenser is the water distribution section. The coil must be thoroughly and completely drenched with water at all times, to give the maximum heat transfer and to minimize scaling. The EVAPCO system does this by circulating 6 gallons of water per minute over every square foot (4 liters per second over each square meter) of coil face area.
The water distribution system is greatly simplified if EVAPCO units, wit the largest non-clog water diffusers available for evaporative condensers. The diffusers are threaded into the water distribution header to ensure correct positioning. Also, a collar on the diffuser extends into the header and acts as a sludge ring to reduce the need for maintenance. Excellent flooding of the coil is maintained at all times without numerous small orifice nozzles or complicated troughs.
For corrosion protection the diffusers are made of ABS plastic and distributor pipes are noncorrosive Polyvinyl Cholride (PVC).
Sound Attenuation Packages
The standard LRC is the quietest, low silhouette centrifugal fan evaporative condenser in the industry. This is achieved by providing the first stage of inlet sound attenuation as part of the LRC's standard design. The LRC drive system, including the fan housing(s), electric motors, belts, bearings and drives, is completely enclosed by a protective housing which covers the drive system and also provides a significant level of sound reduction.
If the standard LRC sound pressure level is not quiet enough for certain applications, the should levels can be further reduced by adding various stages of sound attenuation. The sound attenuation options of the LRC can be provided in stages and will provide varying degrees of attenuation based on the stage of attenuation selected. Consult EVAPCO, Inc. for Factory Certified Sound Data for each option.
LRC Ships Factory Assembled
The compact, unitary design of the LRC Evaporative Condenser allows them to be shipped completely assembled. This results in lower transportation costs and no assembly requirements at the job site. Only one lift is required to rig the LRC. Note: Options such as attenuation and discharge hoods will require additional lifts.
Fast, On-Time Shipments
The LRC is a completely factory assembled evaporative condenser manufactured by a dedicated professional workforce, expert in building closed circuit coolers. Factory trained mechanics and EVAPCO's strict quality control and inspection procedures guarantee the quality of every unit shipped.
EVAPCO's controlled factory environment ensures fast on-time shipments, allowing the LRC to be available WHEN THE CUSTOMER WANTS IT!
Designed for easy maintenance, the LRC Evaporative Condenser leads the industry in maintenance friendly features. The three most critical areas for evaporative condenser maintenance are the basin, drive system and coil. The LRC cold water basin is constructed of Type 304 Stainless Steel for low maintenance and long life and is easily accessed from outside the tower. All drive system components are located in the dry, entering air stream and can be serviced from outside the tower without removing the fan screens, even with full sound attenuation! The exclusive THERMAL-PAK II ® coil is designed for trouble-free maintenance and long life straight from the factory.
- Stainless Steel Cold Water Basin
- Stainless Steel Strainers
- Mechanical Drive System Access
- Motor Mount and Belt Alignment
- Fan Access
- End Mounted Recirculating Pump
Stainless Steel Cold Water Basin
The basin of the evaporative condenser is the most susceptible area to accelerated corrosion from turbulent mixing of air and water and silt build-up than any other part of the cooling tower. EVAPCO provides as standard, the most effective corrosion protection available for the basin – type 304 stainless steel construction. The entire cold water basin including the suction strainers are constructed of type 304 stainless steel for maximum protection from the effects of corrosion. Other types of coatings cannot provide the same maintenance-free operation and tower longevity available from the standard stainless steel construction.
Stainless Steel Strainers
The EVAPCO standard for many years, the stainless steel strainer is one component of the evaporative condenser subject to excessive wear and corrosion. With stainless steel construction, this component will last the life of the evaporative condenser.
Mechanical Drive System Access
The LRC mechanical drive system is easy to maintain. Bearing lubrication is made easy with extended lubrication lines brought to the outside of the fan and drive enclosure. These connections are still accessible even with all of the LRC’s additional sound attenuation options. A large motor access door is located on the side of the fan and drive enclosure for quick and easy access to the motor for routine maintenance or removal. There is no need to remove fan screens to maintain the key drive components.
Motor Mount and Belt Alignment
All LRC models have TEFC motors mounted on an adjustable motor base. This adjustable base design allows belt tensioning to be performed externally without removing the fan screens. The locking mechanism used to maintain belt tension can also be used as wrench to adjust belt tension. This screw operated adjustment is extended through the LRC’s optional intake sound attenuator for easy adjustment even with full intake attenuation.
The split fan housing on the LRC allows quick removal of the fans from the front end of the unit. This feature allows for easy fan removal when units are placed side by side where space is minimal.
End Mounted Recirculating Pump
All LRC models feature a horizontal pump mounted at the open, connection end of the unit. This location makes pump maintenance easy as access is free and unobstructed.
All LRC Evaporative Condensers utilize heavy duty totally enclosed (T.E.F.C.) fan motors designed specifically for evaporative condenser applications. In addition to the standard motors provided on each cooling tower, EVAPCO offers many optional motors to meet your specific needs, including:
• Premium Efficiency Motors
• Multi-Speed Motors
• Inverter-Ready Motors
The TEFC motors are mounted horizontally in the fan and drive enclosure, in the dry entering air stream and can be accessed through a side panel door or through the front by removing the air intake screen.
The belt drive system consists of multigrooved V-Belts with high lateral rigidity. The belts are designed for evaporative condenser service, and are constructed of neoprene with polyester cords. The belt drive is sized for 150 percent of the motor nameplate horsepower ensuring long and trouble free operation.
Centrifugal Fans and Drives
The LRC features forwardly curved centrifugal fan wheels constructed of hot-dip galvanized steel for strength and efficiency. All fans are statically and dynamically balanced and mounted in a hot-dip galvanized steel housing designed and manufactured by EVAPCO. The drive sheaves are located in the dry entering air stream for longer life and are accessible from the side of the fan and drive enclosure.
Fan Shaft and Bearings
All LRC models feature a solid steel shaft for long, reliable shaft life. Other brands may use shafts with welded journals that can make the shaft weaker and prone to failure. The shaft is supported with heavy duty end bearings and no center bearing thereby simplifying maintenance concerns.
(5) Five Year Drive Warranty
EVAPCO provides a standard (5) five year motor and drive warranty on all LRC products. This unique warranty is designed to offer the end user optimum protection against fan drive and motor failure. It is a comprehensive plan which includes the fan(s), fan shaft, belts, sheaves, shaft bearings and motor."
The standard design of the EVAPCO LRC provides the customer with the easiest Evaporative Condensers to maintain in the industry. There are additional options which can make maintenance easier, and extend the life, or enhance the performance capabilities of the Evaporative Condensers. These options are listed below.
- Evapco Manufactured 304 Stainless Steel Coils
- Sound Attenuation
- Extended Surface Coil
- Electric Heaters
- Electric Water Level Control
- Other Options
Evapco Manufactured 304 Stainless Steel Coils
The Evapco manufactured Stainless Steel Coil is an elliptical tube, continuous return bend, 304 stainless steel coil. It is available in both the Patented Thermal Pak Coil design used on AT, UB, LR and LS coolers and condensers and in the patent pending SensiCoil design used in the ESWA.
This option has superior corrosion resistance for Open Systems and Hostile Environments and is available with the Standard Evapco Lead Time! For more detail on the corrosion resistant properties of 304 stainless steel, see Evapco's Maintenance Instruction Bulletin, 112AA.
The Evapco 304 SST coil option can be manufactured as an ASME coil and is CTI certified on the ESWA closed circuit cooler.
If the standard LRC sound pressure level is not quiet enough for certain applications, the sound levels can be further reduced by adding various stages of sound attenuation. The sound attenuation options of the LRC can be provided in stages and will provide varying degrees of attenuation based on the stage of attenuation selected. Consult the factory for Factory Certified Sound Data for each option.
Fan Side Inlet Attenuation
Reduces sound radiated from the fan side air intakes and has an open bottom to allow for air entry. This attenuation package ships loose to be mounted in the field on each side of the cooling tower over the fan intakes.
Fan End Inlet Attenuation
Reduces sound radiated through the far end air intake. It consists of baffled panels to change the path of the air entry and to capture the radiated noise thus reducing the overall sound levels generated. In addition, the external belt adjustment mechanism is extended through the inlet attenuator to allow easy belt adjustment without having to enter the unit.
The discharge attenuation hood features a straight sided design with insulated baffles to reduce the overall sound levels of the discharge air. The discharge attenuation incorporates a large access panel to allow entry to the drift eliminators and water distribution system. If a higher discharge velocity is required, a tapered discharge hood providing minimal sound attenuation is available.
Extended Surface Coil
The LRC can be provided with spiral fins on the heat exchanger coil to increase the dry performance of the unit. Dry performance is accomplished by rejecting heat to the atmosphere without the use of the spray pump and the evaporation process. Dry operation can be practical in cold climates and/or when reduced winter loads exist. The number of fins per inch and and quantity of rows finned can be varied to obtain different dry performances. Dry operation requires the next larger size fan motor. Consult the factory for sizing.
Electric immersion heaters are available as an option and are located in the basin of the cooler. They are sized to maintain a +40° F (4,4º C) pan water temperature at 0°F (-18º C) ambient with the fans off *. They are furnished with a combination thermostat/low water protection device to cycle the heater on when required and to prevent the heater elements from energizing unless they are completely submerged. All components are enclosed in rugged, weather proof enclosures for outdoor use. Heater control packages that include contactor, transformer or disconnects are available.
(*) - Electric heater selection based on 0°F (-18º C) ambient temperature. For alternate low ambient heater selections consult the factory.
Electric Water Level Control
EVAPCO evaporative condensers are available with an optional electric water level control system in place of the standard mechanical makeup valve and float assembly. This package provides very accurate control for the basin water level and does not require field adjustment, even under varying operating conditions.
The control was designed by EVAPCO and is manufactured exclusively for EVAPCO. It consists of multiple heavy duty stainless steel electrodes. These electrodes are mounted external to the unit in a vertical stand pipe. For winter operation, the stand pipe must be wrapped with electric heating cable and insulated to protect it from freezing.
The weather protected slow closing solenoid valve(s) for the makeup water connection is factory supplied and is ready for piping to a water supply with a pressure between 25 and 50 psig (138 kPa and 345 kPa).
• Capacity Dampers
• Pony Motors
• Additional Stainless Steel Material Options
• Stainless Steel Fan Shafts
• Solid Screened Bottom Panels
• Hot Water or Steam Coils
• Steam Injectors
• Vibration Switches
• Remote Sump Configuration
• C.R.N. Condensing Coil
• A.S.M.E. Condensing Coil
• Motors– Energy Efficient / Inverter Duty /
2S/1W and 2S/2W / Mill and Chem Duty
Automotive Duty and Many More, Consult the Factory
Furnish and install, as shown on the plans, an EVAPCO model ____________ evaporative condenser. Each unit shall have condensing capacity of _________ BTUH heat rejection, operating with ____________ refrigerant at _____ °F condensing temperature and _____ °F design wet bulb temperature.
Cold Water Basin
The complete cold water basin shall be constructed of Type 304 stainless steel for long life and durability. Standard cold water basin accessories shall include Type 304 stainless steel overflow, drain, anti-vortexing hood, strainers, brass make-up valve with unsinkable, foam filled plastic float and wastewater bleed line with adjustable valve.
Casing and Fan Section
The casing and fan section shall be constructed of G-235 galvanized steel for long life and durability. Fan section shall include fans, motors and drives. The entire drive system (including fans, motors, sheaves and belts) shall be located in the dry entering airstream.
Centrifugal Fans and Drives
Fans shall be forwardly curved centrifugal type of hot-dip galvanized steel construction. The fans shall be factory installed, statically and dynamically balanced for vibration free operation. The fans shall be mounted on either a solid steel shaft or a hollow steel foam filled shaft with forged bearing journals. The fan shaft shall be supported by heay-duty self-aligning bearings with cast iron housings and lubrication fittings extended to to the outdside of the unit for ease of maintenance. The fan drive shall be a V-Belt type with taper lock sheaves designed for 150% of the motor nameplate horsepower. Drives are mounted and aligned at the factory.
Fan motor(s) shall be ___ Horsepower T.E.F.C. design with 1.15 service factor and suitable for outdoor installation on ___ volts, ___ hertz, and ___ phase electrical service. Motor(s) shall be mounted on an adjustable base.
Water Recirculation Pump
The pump shall be a close-coupled, centrifugal type with a mechanical seal. Pump motor shall be ___ Horsepower T.E.F.C. design suitable for outdoor installation on ___ volts, ___ hertz, and ___ phase electrical service.
Heat Transfer Coil
The coil(s) shall be all prime surafce steel, encased in steel framework with the entire assembly hot-dip galvanized after fabrication. Coil(s) shall be designed with sloping tubes for free drainage of liquid and tested to 400 psig air pressure under water.
Water Distribution System
The system shall provide a water flow rate of not less than 6 GPM over each square foot of unit face area to ensure proper flooding of the coil. The spray header shall be constructed of schedule 40 polyvinyl chloride pipe for corrosion resistance. All spray branches shall be removable and include a threaded end plug for cleaning. The water shall be distributed over the entire coil surface by precision molded ABS spray nozzles (1” x 1/2” orifice) with an internal sludge ring to eliminate clogging. Nozzles shall be threaded into the spray header to provide easy removal for maintenance.
The eliminators shall be constructed of inert polyvinyl chloride that has been specially treated to resist UV degredation. Assembled in easily handled sections, the eliminators shall incorporate three changes in air direction to assure removal of entrained moisture from the discharge airstream. The maximum drift rate shall not exceed 0.001% of the recirculated water rate.
The complete cold water basin shall be constructed of Type 304 stainless steel for maximum corrosion protection. The casing and fan section shall be constructed of G-235 heavy gauge mill hot-dip galavanized steel. During fabrication, all panel edges shall be coated with a 95% pure zinc compound.
Mechanical Equipment Warranty
The fan motor and drive system shall carry a 5 year warranty from the date of shipment, against defects in materials and workmanship including the fan(s), bearings, sheaves, shafts, fan motors(s) and mechanical equipment supports.
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