MH Fluid Cooler User Manual
Contents
1. and MHF7113 coil volumes are for both coils added together Model Ed con edd ne eal MHF7103___AN 375 MHF7105 CF 867 148 MHF7103 AF 375 110 MHF7107___AN 954 MHF7103 BN 557 MHF7107 AF 954 212 103 BF 557 110 MHF7107___BN 1 43 7 105 AN 500 MHF7107 BF 143 212 MHF7105 AF 500 148 MHF7107___CN 1 65 MHF7105 BN 746 MHF7107 CF 1 65 212 MHF7105 BF 746 148 MHF705 082 144 MHF7105 CN 867 MHF705 122 2 14 Model Wet p Dry vid Model Wet ds Dry ds m m m m MHF7111 AN 2 32 MHF7113 AN 2 79 MHF7111 2 32 504 MHF7113 AF 2 79 538 MHF7111 BN 3 35 7 113 BN 4 05 MHF7111 BF 3 35 504 MHF7113 BF 4 05 538 MHF7111 CN 3 32 MHF7113 4 02 MHF7111 CF 3 32 504 MHF7113 CF 4 02 538 Copper Coil Model Wet xis Dry bus Model Wet Dry m m m MHF7103 ANC 265 MHF7105 507 MHF7103 378 MHF7107 ANC 651 MHF7105 ANC 348 MHF7107 954 MHF7105 507 MHF7107 954 When the use of industrial antifreeze solutions is not possible the system must be operated to meet both of the following conditions 1 Maintain sufficient flow rate through the coil 2 Maintain sufficient heat load on the process fluid Fluid exiting the coil must be maintained at or above 7 C Cycling of the recirculation pump should not be used to contr2. as a minimum routine of scheduled maintenance Always shut off electrical power to the fluid cooler fan motor prior to performing any inspections that may involve physical contact with the mechanical or electrical equipment in or on the fluid cooler Lock out and tag out any electrical switches to prevent others from turning the power back on Service personnel must wear proper personal protective clothing and equipment Weekly Inspect for bacterial growth and general operation conditions Bacterial growth should be reported to your water treatment expert for im mediate attention If equipped the damper actuator and assembly should be cycled open and closed several times Observe the cycle to assure that the blades and linkage move freely Seasonal periods where the damper assembly remains open or closed for months at a time can allow pivot points to scale up causing premature failure Monthly Weekly at start up Observe touch and listen to the fluid cooler Become accustomed to its normal appearance sound and level of vibration Abnormal aspects relating to the rotating equipment should be considered maintenance reason to shut down the fluid cooler until the problem can be located and cor rected Observe operation of the motor coupling or drive shaft Geareducer if equipped and fan Become familiar with the normal operating temperature of the motor s as well as the sight and sound of all components as a whole If equ
3. connections support it externally Normally one of the following inlet arrangements is provided Bevel and groove connection The coil piping connections are beveled for welding and grooved for a mechanical coupling If weld connections used it is recommended that weld areas be protected against corrosion Cold galvanizing is suggested for galvanized coils applied according to the manufacturer s instructions For welded or soldered connections protect adjacent areas from excessive heat and sparks or damage may occur T A Warning Note installation Threaded connection The coil piping connections are fitted with male threads of a specified thread type most commonly NPT or BSP depending on location of installation Copper Soldered connection The piping connections are pipe stubs for field soldering Flanged connection The coil piping connections are designed for flat face flange fittings conforming to 125 ANSI B16 1 specifications and are field installed by others Flange fittings are grooved connection for steel coils and solder connection for copper coils Full faced gaskets and appropriately sized bolts by others must be used for proper function 7 Wire motor s and recirculation pump s in accordance with wiring dia gram For maintenance safety purposes SPX recommends a lockout type disconnect switch for all mechanical equipment In addition to a disconnect switch the motor should be wired to
4. fluid cooler See if surrounding structures are causing recirculation of fluid cooler discharge air Discuss remedy with Marley representative Design wet bulb temperature was too low May have to increase fluid cooler size Discuss remedy with Marley representative Actual process load greater than design May have to increase fluid cooler size Discuss remedy with Marley representative Overpumping Reduce water flow rate over fluid cooler to design conditions Fluid cooler starved for air Check motor current and voltage to be sure of correct contract horsepower Repitch fan blades if necessary Clean louvers fill and eliminators Check to see if nearby structures or enclosing walls are obstructing normal airflow to fluid cooler Discuss remedy with Marley representative Excessive drift exiting fluid cooler Distribution basins overflowing Reduce water flow rate over fluid cooler to design conditions Be sure distribution water basin nozzles are in place and not plugged Faulty drift elimination Check to see that integral fill Louvers and eliminators are clean free of debris and installed correctly If drift eliminators are separate from fill make sure they are correctly installed and in place Clean if necessary Replace damaged or worn out components 43 MH Fluid Cooler user manual SPX COOLING TECHNOLOGIES MALAYSIA Sdn Bhd UNIT 505 BLOCK B PHILEO DAMANSARA 2 NO 15 JALAN 16 11 OFF
5. least 10 times the height of the belt The belts may not be stored for longer than 3 month in an open uncontrolled environment Storage Area The storage area must be dry and dust free Belts may not be kept together with chemicals solvents fuels lubricants acids etc Temperature Belts should be shielded from Radiators and their pipes The distance between radiators and stored equipment must be at least 10 feet Light Belts should be protected from light particularly from direct sunlight and strong artificial light with high ultraviolet content formation of ozone such for example fluorescent tubes installed in open fixtures Ideally room lighting should be normal incandescent bulbs Ozone To counteract the damaging effect of ozone the storage areas may not contain any form of ozone generating equipment such as for example fluorescent light sources mercury vapor lamps or electrical high voltage A Caution maintenance devices Combustion gases and vapors which may lead to ozone formation due to chemical processes must be avoided or removed Dampness Damp storage areas are quite unsuitable It should be ensured that no condensation occurs The relative humidity should be below 65 9 Cleaning Cleaning of dirty belts can be carried out with a mixture of glycerin and spirit in a ratio of 1 10 Benzene benzol turpentine and similar substances may not be used Furthermore sharped objects wire brushes emer
6. maximum charge of 1 ml MHF705 and 42 ml MHF7111 MHF7113 is recommended Models MHF7103 MHF7107 have a grease fitting on each bearing housing with a maximum recommended charge of 15 ml per fitting Chevron SRI 2 grease or equivalent lithium based grease is recommended Semi Annually If equipped check the belt tension and condition If equipped with dampers lubricate jack shaft bearings and tie bar linkage with silicone lubricant If dampers are equipped with pneumatic or electric actua tors the manufacturer s recommended maintenance procedures should be observed If dampers are exposed to heavy dust laden air occasional flushing of the bearings with water is recommended 33 Note 34 maintenance Clean and disinfect fluid cooler with biocides Systems with biofouling high general bacterial counts or positive cultures of legionella may require additional cleaning Refer to Fluid Cooler Cleaning section page 22 Consult your water treatment expert as to prudent biological evaluation testing Geareducer models used on doubleflow MH Fluid Coolers Models MHF706 and MHF707 are designed for 5 year oil change inter vals To maintain five year change intervals use only oil designed specifically for these Geareducers If after five years turbine type mineral oil is used the oil must be changed semiannually Refer to the Geareducer User Manual for oil recommendations and further instructions Annually Rel
7. month 3 hours a month Check for proper operation of temp low water level sensor x Inspect clean buildup of contaminant from sensor x x Structure Inspect tighten all fasteners x x Inspect and touch up all metal surfaces x R Refer to Component User Manual Note It is recommended at least weekly that the general operation and condition be observed Pay attention to any changes in sound or vibration that may signify a need for closer inspection 41 troubleshooting Trouble Cause Remedy Motor will not start Power not available at motor terminals Check power at starter Correct any bad connections between the control apparatus and the motor Check starter contacts and control circuit Reset overloads close contacts reset tripped switches or replace failed control switches If power is not on all leads at starter make sure overload and short circuit devices are in proper condition Wrong connections Check motor and control connections against wiring diagrams Low voltage Check nameplate voltage against power supply Check voltage at motor terminals Open circuit in motor winding Check stator windings for open circuits Motor or fan drive stuck Disconnect motor from load and check motor and fan drive for cause of problem Rotor defective Look for broken bars or rings Unusual motor noise Motor running single phase Check motor and a
8. pack orientation Replace packs in the reverse procedure explained for removal Place packs in the fluid cooler in the order they were removed Packs should nest tightly with each other leaving a level surface with no gaps Coil Eliminator Removal The coil eliminators are comprised of a series of thermoformed PVC pack as semblies oriented to strip water from the air prior to leaving the fluid cooler They are packed tightly to ensure no water escapes Eliminator edges can be very sharp and could cut skin if prop amp r protection is not used Always wear gloves and sleeves when han dling eliminator packs 23 24 maintenance To remove the eliminators place both hands on the eliminator face and push up this will indicate where one assembly stops and another starts Push a single section up until it hits the top of the metal retaining channel 1 Push the bottom side of the pack down inside the fluid cooler 2 Turn the pack Sideways and remove the eliminator 3 Repeat this procedure for other packs to gain necessary access Proper eliminator pack replacement is essential to operation Incorrect installation may result in excessive drift rates and fan inefficiency To ensure packs are reinstalled in the correct orientation it is recommended that one pack is left in its original location inside the fluid cooler as a reminder of pack orientation Place packs in the fluid cooler in the order they were removed Packs should nest
9. rentrer cenis erect rend 22 LIII 25 Shee Alignment 30 ROUtING MAINtG MANGO sss ccscesezscestz 32 Motor Relubrication external motor option essent 35 Seasonal Shutdown INStruCtiONs sssi itte titt te crecen Prec 36 Long Term Storage Proced res e ttc cin tee in rn ctr ir o 37 Maintenance Schedule etat rep tuit db eoe Eve RE YR UNE ERE 41 Troubleshooting t ce redet e ats atero ient ee ato 42 The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product Indicates presence of a hazard which can cause severe personal injury death or substantial property damage if ignored Indicates presence of a hazard which will or can cause personal injury or property damage if ignored Indicates special instructions on installation operation or mainte nance which are important but not related to personal injury hazards A Warning preparation The Marley MH Fluid Cooler purchased for this installation represents the cur rent state of the art in crossflow induced draft fluid cooler design Thermally and operationally it is one of the most efficient fluid cooler of its class These instructions as well as those offered separately on motors fans Geareducer couplings drive shafts float valves pumps etc are intended to assure that the fluid cool
10. the structural integrity of the fan guard Failure ofthe fan guard could allow operating or maintenance fall into the rotating fan 3 Spin the fan s manually to assure that all fan blades properly clear the inside of the fan cylinder If equipped observe the action of the coupling or drive shaft couplings to be sure that the motor and Geareducer are properly aligned If necessary correct the alignment in accordance with the included manual For belt drive equipped models observe the action of the sheaves and belts to be sure that the motor is properly aligned with the fan sheave See Belt Tensioning and Sheave Alignment on pages 25 and 30 It is essential that the fan cylinder and fan guard be installed in accordance with the drawings shipped with the fluid cooler Do not force the fan cylinder out of round 4 Momentarily bump energize the motor s and observe rotation of the fan s If rotation is backwards shut off the fan and reverse two of the three primary leads supplying power to the motor Iffluid cooler is equipped with a two speed motor check for proper ro tation at both speeds Check also to see that starter is equipped with a 20 second time delay which prevents direct switching from high speed to low speed If the fan is intended to be reversed for deicing purposes make sure that the starter is equipped with a 2 minute time delay between changes of direction These delays will prevent abnormal stress f
11. tightly with each other leaving a level surface with no gaps A Caution Figure 1 maintenance Belt Tensioning Any bolts loosened or removed functioning as mechanical or struc tural hardware should be replaced with the torques specified below Anti seize compound is recommended for stainless steel hardware Fastener Torque Values Machine Bolt Galvanized Stainless Size ft lb N m ft lb N m 8mm 8 10 15 20 10mm 15 20 30 40 12mm 25 35 50 65 16mm 65 85 120 160 20mm 125 170 230 315 See Figure 1 and Figure 2 for model MHF705 Loosen specified hard ware located at the top and bottom of the motor support assembly before adjusting the jacking screws Do not remove the hardware it is re quired to support the motor Tighten the hardware after adjustment Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check tension frequently during the first 24 48 hours of run in operation Over tensioning shortens belt and bearing life Keep belts free from foreign material which may cause slipping Never LOOSEN HARDWARE gt Le JACKING SCREWS MOTOR SINGLE MOTOR TWO FANS MHF705 ONLY 25 Figure 2 Figure 3 26 maintenance apply belt dressing as this will damage the belt and cause early failure A Dodge V Belt Tension Tester is an alternate method for tensioning V belts Check with you local belt supplier LOOSEN HARDWA
12. HAT BOTH ARE FULLY ENGAGED ON THEIR SHAFTS THERE SHOULD BE FOUR POINTS OF CONTACT WHEN A STRAIGHT EDGE IS LAID AROSS THE TOP OF BOTH SHEAVES ALIGN THE BOTTOM EDGES OF THE FAN AND MOTOR SHEAVES WHILE ENSURING THAT BOTH ARE FULLY ENGAGED ON THEIR SHAFTS THERE SHOULD BE FOUR POINTS OF CONTACT WHEN A STRAIGHT EDGE IS LAID AROSS THE BOTTOM OF BOTH SHEAVES SHEAVE ALIGNMENT MHF7103 THRU MHF 7107 ONLY 31 A Warning A Warning 32 maintenance Routine Maintenance Some maintenance procedures may require maintenance personnel to enter the fluid cooler Each cased face of the fluid cooler has a door for access to the interior of the fluid cooler The optional fan deckladder models MHF71 1 1 and 113 designed and intended solely for personnel to gain access to the fan deck The fan deck ladder should not be used to enter or exit the access doors located on the cased face of the fluid cooler unless the optional access door platform is provided The purchaser or owner is responsible for providing a safe method for entering or exiting the access door Use of the fan deck ladder to enter or exit the access doors may result in a fall Included with this instruction packet are separate User Manuals on each major operating component of the fluid cooler and it is recommended that you read them thoroughly Where discrepancies may exist the separate User Manuals will take precedence The following is recommended
13. JALAN DAMANSARA 46350 PETALING JAYA MALASIA P 60 3 7947 7800 F 6 03 7947 7999 spxcooling asiapacinfo spx com In the interest of technological progress all products are subject to design and or material change without notice ISSUED 10 2014 sea_Z0876176 revA COPYRIGHT 2014 SPX Corporation
14. RE JACKING SCREWS MOTOR SINGLE MOTOR SINGLE FAN MHF705 ONLY See Figure 3 for MH Fluid Cooler models MHF7103 thru MHF7107 witha single motor per fan Loosen specified hardware located at the top and bottom of the motor support assembly before adjusting the jacking screws Do not remove the hardware it is required to support the motor Tighten the hardware after adjustment Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check tension frequently during the first 24 48 hours of run in operation Over tensioning shortens belt and bearing life Keep belts free from foreign material which may cause slipping LOOSEN HARDWARE JACKING SCREWS MOTOR SINGLE MOTOR SINGLE FAN MHF7103 THRU MHF7107 ONLY maintenance See Figure 4 and Figure 5 for MH Fluid Cooler models MHF7103 thru MHF7107 for single motor with two fans The belts are adjusted by turning the two acme bolts clockwise to tension the belts keeping the motor plate square to the wall Before tightening or loosening the belts loosen the four motor to motor plate bolts Do not remove the hardware Next loosen the four motor plate to side gusset bolts Do not remove the hardware It may help to grease three radial motor slots before turning the adjustment bolts If one belt is looser than the other the motor should rotate in the greased slots until the tension is approximately equal After achieving proper tension tighten th
15. asonal Startup or Annually Inspect General Condition and Operation x x Observe Operation of Mechanical motor fan and drive mechanism x x Makeup valve if equipped x x Inspect for unusual noise or vibration x x Inspect and Clean Air inlet x x PVC drift eliminators x x Distribution basin nozzles and collection basin x x Fan and pump motor exterior x x Coil surface x Check Collection water basin level x x Blowdown adjust as required x x Geareducer Drive if equipped Check for loose fasteners including oil drain plug x Check oil level check for repair oil leaks x x Change oil R Make sure vent is open x x Check driveshaft or coupling alignment x Check for loose driveshaft or coupling fasteners x Check driveshaft or coupling bushings or flex element for unusual wear x x Lube lines if equipped Check for oil leaks in hoses or fittings x R x Belt drive if equipped Fan shaft bearing lubrication every 3 mo every 3 months every 3 months Check and tighten support fasteners x Check shaft sheave and belt alignment x Check belt tension and condition x x Check sheave bushing fastener torque x Fan Check and tighten blade and hub fasteners x Check fan blade pitch and tip clearance x Check fan cylinder for loose fasteners x Motor Lubricate grease as required R Check mounting bolts for tightness x Operate at least Basin Heater if equipped 3 hours a month 3 hours a
16. ch may result in damage to the equipment and possible injury Mechanical Equipment The fluid cooler is designed to operate at full speed and half speed Warranty is void ifthe fluid cooler is operated at speeds which cause damaging vibrations to the fluid cooler and associated equipment When utilizing a variable frequency drive the fluid cooler must be tested across the full range of speeds and checked against CTI guidelines for excessive vibration Speed ranges not meeting these guidelines must be locked out in the VFD Always shut off electrical power to the fluid cooler fan motor prior to performing any maintenance on the fluid cooler Any electrical switches should be locked out and tagged out to prevent others from turning the power back on 1 If equipped check oil level Although the Geareducer was filled to the proper level the factory tipping during shipment and hoisting may have caused some loss of oil If oil is required fill Geareducer to the proper level with approved lubricant See Geareducer User Manual Check oil level at the Geareducer or dipstick standpipe located on fan deck if so equipped to confirm that the proper level is indicated 2 Ondoubleflow models MHFT7 1 11 and MHF71 13 installthetwo piece fan guard according to the installation drawing shipped with the fluid cooler A Warning Note A Caution Note installation Improper installation of the fan cylinder and fan guard will destroy
17. coil so as to effect nitrogen flushing for about 10 minutes and thus 37 A Caution 38 maintenance to expel all air out of the unit Finally re tighten the inlet nozzle blind flange bolts and let nitrogen pressure build up to 48 kPa inside the tube bundle Disconnect the nitrogen line and plug the isolation valve to avoid any pressure drop in case of valve leak Machinery Components Electric motors All drive motors should be taken down and stored indoors Then every month turn motor shafts to evenly distribute lubricant to the bearing parts Recirculation pumps All pumps and pump motors should be taken down and stored indoors pumps and motors may be stored fully assembled Then every month turn pump impeller shaft to evenly distribute lubricant to the bearing parts Belts Properly stored belts will retain their properties unchanged for several years Under unfavorable storage conditions and with improper handling dete rioration of their physical properties will result These changes can be caused for example oxidation ozone extreme temperatures light damp or solvents It should be ensured that belts are stored stress free which is to say without tension pressure or other causes of deformation as strain causes permanent deformation and failure due to fatigue as well as cracking If for reasons of space they are stored suspended the diameter of the bar from which they are suspended must be equal to at
18. de areas of collection water basin distribution water basins louvers and drift eliminators Make sure that cold water suction screens are clear and properly installed Fill the water system to an approximate depth of 8 in the depressed area of the collection water basin This is the recommended operating water level Adjust the float valve so that it is 75 open at that level Continue filling the system until the water reaches a level approximately 3mm below the lip of the overflow Start your pump s and check for proper rotation as indicated by the ar row on the pump cover observe system operation A certain amount of pump down of the basin water level will occur before water completes the circuit and begins to fall from the fill in the upper module The amount of initial pump down may be insufficient to cause the float valve to open However you can check its operation by pressing down on the operating lever to which the stem of the float valve is attached operation Some trial and error adjustment of the float valve may be required to bal ance the makeup water with fluid cooler operation Ideally the float valve setting will be such that no water is wasted through the overflow at pump shutdown However the water level after pump start up must be deep enough to assure positive pump suction 5 Open the valve on the fluid cooler bleed line and adjust bleed to the recommended rate See Water Treatment section on page 20 6 C
19. dhere to it readily Contact the manufacturer of the coat ing you intend to use for instructions Fluid cooler framework Check structural bolted connections and tighten as required Fans Check fan assembly bolting and tighten as required Use torque values prescribed in the Fan User Manual Fans shaft bearings If equipped lubricate fan shaft bearings at close of each operating season see page 33 Electric motors Clean and lubricate motor at close of each operating season refer to motor manufacturer s recommendations Check motor anchor bolts and tighten as required See Page 35 for fluid coolers with motor located outside the plenum option Do not start motor before determining that there will be no interfer ence with free rotation of the fan drive maintenance The motor s should be operated for three hours at least once a month This serves to dry out windings and re lubricate bearing surfaces Refer to the Marley Electric Motor User Manual Manual 92 1475 available at spxcooling com Atstart of new operating season make sure bearings are adequately lubricated before returning motor to service Long Term Storage Procedures Instructions for protection of non operating equipment for more than 3 months After installation of the Fluid Cooler and completion of the pre startup instruc tions the operational availability of equipment will last for a maximum period of three months Ensure that the fluid cooler and co
20. e Alignment Always shut off electrical power to the fluid cooler fan motor prior to performing any inspections that may involve physical contact with the mechanical or electrical equipment in or on the fluid cooler Lock out and tag out any electrical switches to prevent others from turning the power back on Service personnel must wear proper personal protective clothing and equipment The motor sheave is to be positioned as close as possible to the motor in order to minimize torque on the motor bushings The motor and fan sheaves may have grooves that are not used The bot tom surface of the motor and fan sheaves must be aligned within 3mm of each other and level within 3mm in 30cm in order to not adversely affect belt and sheave life Alignment can be achieved by placing a straight edge across the top of the sheaves making sure that it is level and measuring down to the bot tom surface of both sheaves at four points The number of grooves on the motor and fan sheaves may not match each other or the number of grooves on the belt Always install the belts on the highest grooves on the fan sheave Doing so will reduce the force on the fan shaft bearings thus increasing their life Bushing Fastener Torque N m SH 20 8 SDS 20 8 SD 20 8 SK re 18 18 SF 16 30 13 47 12 88 Figure 7 maintenance ALIGN THE TOP EDGES OF THE FAN AND MOTOR SHEAVES WHILE ENSURING T
21. e hardware LOOSEN HARDWARE ACME BOLT MOTOR SIDE GUSSET Figure 4 SINGLE MOTOR TWO FANS MHF7103 THRU MHF 7107 ONLY Fastener Torque at Motor Only Machine Bolt Galvanized Stainless Size ftlb N m ftlb N m 10mm 30 32 42 43 34 36 46 48 12mm 64 66 87 91 85 90 115 122 16mm 135 140 183 190 125 130 169 176 20mm 220 230 298 312 195 205 264 278 MHF7103 THRU MHF7107 ONLY NON LUBRICATED 4 27 maintenance FAN SHAFT BEARING HOUSING BELT s SIDE GUSSET Figure 5 MOTOR SINGLE MOTOR TWO FANS MHF7103 THRU MHF 7107 ONLY Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check tension frequently during the first 24 48 hours of run in operation Over tensioning shortens belt and bearing life Keep belts free from foreign material which may cause slipping Never apply belt dressing as this will damage the belt and cause early failure A Dodge V Belt Tension Tester is an alternate method for tensioning V belts Check with your local belt supplier Figure 6 STRAIGHT EDGE 28 maintenance See Figure 5 for MH Fluid Cooler models MHF7111 and MHF7113 with belt drive option The belts are adjusted by turning the threaded rod Before tightening or loosening the belt the double nuts holding
22. eater in accordance with the SPX Cooling specification The space heater is to be energized at all times whether actuator motor is operating or not The purpose of the energized space heater is to prevent moisture inside the unit from corroding the internal components Failure to wire and energize the space heater will void the warranty if the actuator fails due to internal corrosion Automatic Electric Actuator must be stored in a dry environment until installed If a unit is going to sit idle prior to startup the actua tor must be removed from the damper and stored appropriately Dry Operation Alsorefertothe Freezing Weather Operation and Protection Against Coil Freezing sections Models equipped with a finned coil s are designed to operate dry without recirculating water during colder weather as heat load and ambient condi tions permit If dry operation is intended and the recirculating water is at risk of freezing the recirculating pump should be turned off and the water in the collection basin pump and make up supply piping should be drained Care must be exercised when cycling the recirculating water pump s fre quent wet dry cycles may lead to premature scaling of the coil surface Note A Caution operation Freezing Weather Operation The Marley film fill system used in the MH Fluid Cooler has air entrance louvers that are molded as an integral part of the fill This feature makes these fluid coolers very forgi
23. er serial number from the fluid cooler name plate when ordering parts Periodic maintenance You may wish to contract with SPX Cooling for regularly scheduled visits for the purpose of inspecting and reporting your 4 39 40 maintenance fluid coolers condition to make recommendations intended to prevent emergencies and to perform maintenance considered outside the norm This service is not intended to replace the important function performed by your maintenance staff Their attention assures the fluid coolers s routine operating performance and is invaluable However we recognize that the unusual manner in which a fluid cooler performs its function as well as the unique forces which act upon it may be considerations which occasionally require the services of an expert technician Additional Information Increased load requirements MH Fluid Coolers are designed so that cells of either equal or unequal capacity can be added in the future This al lows you to compensate for the load increases that normally occur with the replacement or addition of production equipment and still retain continuity with respect to your fluid cooler system Fluid cooler rebuilding SPX routinely rebuilds and upgrades fluid cool ers and cooling towers of all materials and manufacture If your product ever reaches the limit of its service life we recommend that you investigate the cost of rebuilding before you routinely order a n
24. er serves you properly for the maximum possible time Since product warranty may well depend upon your actions please read these instructions thoroughly prior to operation If you have questions about the operation and or maintenance of this product and you don t find the answers in this manual please contact your Marley sales representative When writing for information or when ordering parts please mention the product serial number shown on the nameplate located on the access door Safety First The location and orientation of the fluid cooler can affect the safety of those responsible for installing operating or maintaining the fluid cooler However since SPX Cooling Technologies does not determine the location or orienta tion of the fluid cooler we cannot be responsible for addressing those safety issues that are affected by the fluid cooler s location or orientation The following safety issues should be considered by those respon sible for designing the fluid cooler installation access to and from the fan deck access to and from maintenance access doors the possible needfor ladders either portable orpermanent to gain access to the fan deck or maintenance access doors the possible need for handrails around the fan deck the possible need for external access platforms potential access problems due to obstructions surrounding the fluid cooler lockout of mechanical equipment the possible need for safety cag
25. es around ladders the need to avoid exposing maintenance personnel to the potentially unsafe environment inside the fluid cooler Note preparation Itis not intended nor assumed that access to the fan deck on single flow models Models MHF7103 thru MHF7107 and MHF705 is needed or necessary Those are only some ofthe safety issues that may arise in the design process SPX strongly recommends that you consult a safety engi neer to be sure that all safety considerations have been addressed Several options are available that may assist you in addressing some of these personnel safety concerns including Louver face distribution basin access platform with ladder and handrail A handrail system around the perimeter of the fan deck with either one or two ladders for access to the deck Doubleflow models MHF7111 and MHF7113 only Extended fan deck that provides additional access around one end of the fan cylinder opposite the fan deck access ladder Doubleflow models MHF7111 and MHF7113 only Ladder extensions used where the base of the fluid cooler is elevated Safety cages for ladders External lube lines Access door platform Motor located outside the fluid cooler Doubleflow models MHF7111 and MHF7113 with Geareducer drive only External motoraccess platform Doubleflow models MHF7 111 andMHF7113 with Geareducer drive only Plenum walkway Mechanical equipment access platform Fluid Cooler Locatio
26. ew replacement fluid cooler Each MH Fluid Cooler includes a document package containing general orientation drawings and fluid cooler component manuals These documents contain important information relating to safe installation and operation of the fluid cooler Field installation is required for fan guards doubleflow models piping inlets and piping outlets Some optional accessories such as hand rails ladders and safety cages may also require field installation A separate installation drawing or manual for each purchased option is included in the document package along with bills of material If you have purchased an option and can t find the appropriate installation drawing contact your local Marley sales representative before proceeding In addition to these specific documents numerous technical reports are published by SPX including more detailed information on a variety of cooling tower and fluid cooler operation and service topics Your Marley sales rep resentative will be happy to give you copies of these reports at no charge or you can download copies from our website at spxcooling com For complete parts and service assistance contact the Marley sales repre sentative in your area If you need help locating your representative please phone 60 3 7947 7800 or check the internet at spxcooling com maintenance schedule Maintenance Service Monthly Semi annually Se
27. gh level In order to achieve water quality which is acceptable to the fluid cooler the selected water treatment company must work from a relatively constant level of concentrations This stabilization of contaminant concentrations is usually accomplished by blowdown which is the constant discharge of a portion of the circulating water to waste As a rule acceptable levels on which to base a treatment schedule will be in the range of 2 4 concentrations The following table shows the minimum amount of blowdown percent of flow required to maintain different concentrations with various cooling ranges Number of Concentrations 1 5X 2 5X 3 0X 4 0X 3 C 7 38 25 18 11 08 6 C 1 5 78 51 38 25 18 8 C 2 3 1 18 78 58 38 28 11 C 3 1 1 58 1 05 78 51 38 14 C 3 9 1 98 1 32 98 64 48 Cooling Range Multipliers are based on drift of 0 02 of the circulating water rate Range Difference between hot water temperature and cold water temperature EXAMPLE 160 m hr circulating rate 10 C cooling range To maintain 4 concentrations the required blowdown is 0 458 or 00458 times 160 m hr which is 73 m3 hr If fluid cooler is operated at 4 concentrations circulating water will contain four times as much dissolved solid as the makeup water assuming none of the solids form scale or are otherwise removed from the system 21 Note Z Warning 22 maintenance When water treat
28. grease is forced out through relief openings 4 Replace fill plugs and operate mechanical equipment 30 minutes to one hour to purge excess grease at grease relief opening 5 Reinstall grease relief plugs and reinstall guard Resume normal fluid cooler operation 35 A Caution Note A Caution 36 maintenance Seasonal Shutdown Instructions When the system is to be shut down for an extended period of time it is recommended that the recirculation water system be drained Leave the basin drains open Draining the coil is not recommended draining promotes corro sion inside the coil tubes See protecting coil in Freezing weather on page 19 During shutdown clean the fluid cooler see Caution page 22 and make any necessary repairs Eliminators and louvers are easily removed to gain access to the coil Pay particular attention to mechanical equipment supports and sheaves or coupling or drive shafts Following each year s shutdown and cleaning inspect the fluid cooler s metal surfaces for evidence of the need to apply a protective coating Do not mis interpret grime as a need to have the fluid cooler painted If relatively bright metal can be exposed by cleaning consider that the galvanizing has remained effective Unless there is evidence of a generalized failure of the galvanizing localized touch up should be all that is required To the extent that the galvanizing zinc coating still exists paint will not a
29. il are completely drained of all water and process fluid After this initial period of 3 months until the unit is employed into continuous operation the fan shaft should be turned by hand for a few minutes every month after Inject a small amount of grease into ball roller bearings of fan shaft and drive components as per the manufacturer s recommendation attached General Protective Requirements for Fluid Coolers The fan opening at the top of the fluid cooler should be covered with a tarp This will protect the mechanical components from rain as well as keep out dirt trash leaves etc All coils on every fluid cooler model are protected from the environment by the structure of the fluid cooler as well as the PVC air inlet louvers No ex ternal protection of the coil is required for long term storage For those units equipped with dampers the blades of the dampers should be kept in closed position Damper actuators must be removed and stored in a dry location to prevent condensation buildup inside the actuator Internal Protection of Coil All of the coil inlet and outlet connections should be sealed off with blind flanges One flange per coil should be fitted with a valve pressure gage and blocking plug The coils should be charged with nitrogen gas to prevent cor rosion Connect a nitrogen supply line to the blind flange with valve Loosen the bolts at one of the inlet nozzle blind flanges to let air escape Inject inert gas into
30. ipped check Geareducer oil level Shut down the unit and allow 5 min utes for the oil level to stabilize Add oil if required Check for Geareducer oil leaks Check the Geareducer as well as any optional oil lines to external oil dipstick sight glass Inspect louvers drift eliminators and basin trash screens and remove any debris or scale which may have accumulated Replace any damaged or worn out components Use of high pressure water may damage the eliminator and louver material Observe operation of the float valve Depress the operating lever to make sure that the valve is operating freely Inspect the suction screen for plugging Remove any debris that may have accumulated Check for any buildup of silt on the floor of the collection basin Mentally make note of the amount if any so future inspections will enable you to determine the rate at which it is forming If equipped with dampers lubricate the pivot points of the individual blades Observe the area where the steel pivot pins penetrate the assembly s outer frame The pin should rotate freely in the frame In locations with severe hard water supply or climate apply grease to the pivot points and linkage This will both lubricate and seal out oxygen and moisture from the pivot points and help prevent hard water scale build up Every 3 months If equipped lubricate fan shaft bearings While rotating equipment by hand grease the bearings until a bead forms around the seals a
31. l and electrical stress on the motor and mechanical equipment Electrical savings can be large during periods of low ambient temperature when the cooling requirement can be satisfied at reduced speeds To benefit from these advantages it is important that the drive be installed correctly Marley VFD and controls are specifically designed for our cooling products If you have purchased a Marley VFD and or controls package please follow the instructions in the User Manual for that system Most VFD problems can be 4 9 Z Warning A Warning A Caution A Warning 10 installation avoided by purchasing Marley drive systems If you are installing a VFD other than a Marley drive please refer to that drives installation manual Improper use ofa VFD may cause damage to equipment or personal injury Failure to correctly install the VFD drive will automatically void all warranties associated with the motor and any equipment that is either electrically or mechanically directly attached to the VFD drive system The length of this warranty avoidance will be contingent on properly installing the VFD system and repairing any damage that may have occurred during its operation SPX Cooling Technologies does not assume responsibility for any technical sup port or damages for problems associated with non Marley brand VFD systems Changing the operational fan speed from the factory settings could cause the fan to operate in an unstable region whi
32. ld also be placed under the fluid cooler modules Under no circumstances should you combine the top and bottom modules of modular models and attempt to hoist them at the same time by utilizing the hoisting clips alone OFFSET REQUIRED FOR LIFT SINGLE FLOW FLUID COOLER SHOWN Fluid Cooler Installation These installation instructions are intended to help you prepare before your fluid cooler arrives If discrepancies exist between these instructions and those shipped with the fluid cooler the instructions shipped with the fluid cooler will govern 1 Priorto placement ofthe fluid cooler confirm that the supporting platform is level and that the anchor bolt holes are correctly located in accordance with Marley drawings If your installation uses vibration isolators to dampen vibration they must mounted below the supporting steel See support drawings for further information 2 Place bottom module on your prepared supports aligning anchor bolt holes with those in your supporting steel Make sure that the orientation agrees with your intended piping arrangement Attach fluid cooler to sup porting steel with M16 bolts and flat washers by others See support drawing for location and quantity Position flat washers between the bolt head and the fluid cooler basin flange Note A Caution A Caution installation Before setting top module in place on bottom module clean any debris from the underside of the top
33. linders at fan blade plane of rotation and fan blade tips will eventually strike this ring of ice damaging the fan blades or cylinder Ice can also accumulate on fan blades and be thrown off damaging fan cylinder or blades Allow a minimum of 10 minute delay between reverse operation and forward operation during subfreezing weather to permit ice to dissipate from fan blades and fan cylinders See Fan Drive Caution note on page 9 for fan speed change and reversing precautions Intermittent Freezing Weather Operation If periods of shutdown nights weekends etc occur during freezing weather measures must be taken to prevent the water in the cold water basin and all exposed pipework from freezing Several methods are used to combat this including automatic basin heater systems and pump freeze protection systems available from Marley Basin heaters systems will not prevent the coil from freezing Unless some means of freeze prevention is incorporated into your system the fluid cooler basin and exposed pipework should be drained at the beginning of each wintertime shutdown period If fluid cooler basin is drained verify that all basin heaters have been shut off either by automatic cutoff or disconnect switch operation Protection Against Coil Freezing Ethylene and propylene glycol solutions are the best means to protect the coil from freezing The following table provides the coil volume for each MH Fluid Cooler model MHF7111
34. main power supply through short circuit protection and a magnetic starter with overload protection Motor Wiring Wire motor leads as shown on the motor nameplate matching the supply voltage Do not deviate from the motor nameplate wiring Either of following symbols may be shown on the motor nameplate A AA Y or YY These symbols represent how the motor is constructed on the inside and in no way have anything to do with a Delta or Wye electrical distribution system serving the motor When using a starter Set motor overload protection to 110 of motor nameplate amps This setting allows the fan motor to operate during cooler weather During cooler weather it is common for the motor to draw 6 to 1096 higher than nameplate amps High amps are common during fluid cooler commissioning when the fluid cooler is dry and the ambient air temperature is cool Do not start the motor more than four to five times per hour Short cycling the fluid cooler will cause fuses breakers or OLs to oper ate and will decrease motor life Note Note installation When using a two speed starter Motor rotation must be the same at slow speed and high speed Single winding motor requires a starter with a shorting contactor Two winding motor requires a starter with out a shorting contactor All two speed starters must have a 20 second time delay relay when switching from high speed to low speed Do not start the motor more than fou
35. ment chemicals are added they should not be introduced into the circulating water system via the water collec tion basin of the fluid cooler Water velocities are lowest at that point which results in inadequate mixing Ideal locations would be in the redistribution basin above the coil or in the riser pipe above the discharge of the recirculating water pump s Fluid Cooler Cleaning Any evaporative type fluid cooler must be thoroughly cleaned on a regular basis to minimize the growth of bacteria including Legionella Pneumophila to avoid the risk of sickness or death Service personnel must wear proper personal protective equip ment during decontamination Do NOT attempt any service unless the fan motor is locked out Operators of evaporative cooling equipment such as closed circuit fluid cool ers should follow maintenance programs which will reduce to an absolute minimum the opportunity for bacteriological contamination Public Health Service officials have recommended that good housekeeping procedures be followed such as regular inspections for concentrations of dirt scale and algae periodic flushing and cleaning and the following of a complete water treatment program including biocidal treatment The visual inspection should take place at least once a week during the operating season The periodic flushing and cleaning should be done before and after each cooling season but in any event at least twice a year The louvers d
36. module fill skid and beams and from the top of the bottom module and remove shipping cover from bottom of top module replace fasteners at side of module to prevent leaks Place top module on the top peripheral bearing surface factory installed gasket of bottom module aligning mating holes as it is set in place Attach top module to bottom module with fasteners provided according to drawings shipped with your fluid cooler Connect the recirculation piping with rubber coupling shipped with the bottom module piping according to drawings shipped with you fluid cooler Attach makeup water supply piping to appropriately sized float valve connection located in collection water basin side wall Install the drain and overflow according to drawings shipped with your fluid cooler If you wish to pipe overflow and drain water to a remote discharge point make those connections at this time also Fasteners and components provided by others that are to be at tached to the fluid cooler must be compatible with the fluid cooler materials i e fasteners in a stainless steel cold water basin must be stainless steel 6 Attach the process fluid supply and return piping to the coil The coil connection type was defined based on customer preference before the tower was ordered The most common connection types are described are as follows Except for the horizontal components of piping do not support your piping from the fluid cooler inlet outlet
37. n Space available around the fluid cooler should be as generous as possible to promote ease of maintenance and to permit freedom of airflow into and through the fluid cooler If you have questions about the adequacy of the avail able space and the intended configuration of the fluid cooler please contact your Marley sales representative for guidance Prepare a stable level support foundation for the fluid cooler utilizing weight wind load and dimensional information appearing on appropriate Marley submittal drawings Supports must be level to insure proper operation of the fluid cooler A Warning A Caution installation The fluid cooler must be located at such distance and direction to avoid the possibility of contaminated fluid cooler discharge air being drawn into building fresh air intake ducts The purchaser should obtain the services of a Licensed Professional Engineer or Registered Architect to certify that the location of the fluid cooler is in compliance with applicable air pollution fire and clean air codes Fluid Cooler Shipment Unless otherwise specified the MH Fluid Cooler ships by truck on flat bed trailers which lets you receive hoist and install the fluid cooler in one continuous operation Single cell single flow fluid coolers ship on one truck Doubleflow and multicell fluid coolers depending on their size may require more than one truck Responsibility for the condition of the fluid cooler upon its a
38. n be accomplished by fan manipulation as outlined in Item 4 under Fluid Cooler Operation 2 As cold air enters the louvers it causes the water flowing over the fill to be drawn inward toward the center of the fluid cooler Thus under fan operation the louvers and lower periphery of the fluid cooler structure remain partly dry seeing only random splashing from within the fluid cooler plus normal atmospheric moisture from the entering air Such lightly wetted areas are most subject to freezing Ts Z Warning Z Warning A Caution Z Warning 18 operation Therefore if excessive ice forms on the louvers stop the fan for a few minutes With the fan off the water flow will increase in the vicinity of the louvers and reduce the ice buildup 3 Under extended extreme cold conditions it may be necessary to operate the fan in reverse This forces warm air out through the louvers melting any accumulated ice adequate heat load must be available Reversal of fan should only be done at half speed or less Reverse operation of the fan should be used sparingly and should only be used to control ice not to prevent it Reverse fan operation should not need to exceed 1 or 2 minutes Monitoring is required to determine the time required to melt accumulated ice Operating the fan in reverse at half speed for prolonged periods during subfreezing weather can cause severe damage to fans and fan cylinders Ice can accumulate inside fan cy
39. n proper alignment and match marks properly matched Repair or replace worn couplings Rebalance drive shaft by adding or removing weights from balancing cap screws See Driveshaft User Manual Fan Make certain all blades are as far from center of fan as safety devices permit All blades must be pitched the same See Fan User Manual Clean off deposit build up on blades Worn Geareducer bearings If equipped Check fan and pinion shaft endplay Replace bearings as necessary Worn fan shaft bearings Belt drive Check fan shaft endplay Replace bearings as necessary Unbalanced motor Disconnect load and operate motor If motor still vibrates rebalance rotor Bent Geareducer shaft If equipped Check fan and pinion shaft with dial indicator Replace if necessary Fan noise Blade rubbing inside of fan cylinder Adjust cylinder to provide blade tip clearance Loose bolts in blade clamps Check and tighten if necessary Fan shaft bearing Belt drive Grease bearings Scale or foreign substance in circulating water system Cold water temperature too warm See Fluid cooler Operation Insufficient blowdown See Water Treatment section of this manual Water treatment deficiency Entering wet bulb temperature is above design Consult competent water treating specialist See Water Treatment section of this manual Check to see if local heat sources are affecting
40. o not start the motor more than four to five times per hour each low speed start and each high speed start count as one start For greater insight on process fluid temperature control please read Marley Technical Report H 001 Cooling Tower Energy Management available at spxcooling com Pump cycling limits Cycling the recirculating water pump s to control process fluid temperature is not typically recommended It is recommended that while process fluid is being circulated through the coil the fluid cooler recirculation water system always be in operation If the recirculating water pumps s are cycled as part of normal system operation care must be exercised frequent wet dry cycles may lead to premature scaling of the coil surface Dampers If equipped the positive closure damper system is designed to help prevent heat loss from the coil due to air movement caused by convection or wind conditions when both the fan and pump are off Upon start up of the fluid cooler fans the damper actuator is energized and rotates the damper assembly blades open The actuator should be wired into the control circuitry of the fan motor Upon system shutdown the damper actuator is de energized and the spring return actuator returns the damper blades to the closed position ML Note Note 16 operation If the dampers are equipped with an automatic electric actuator the actuator electric motor controller will include a 200 volt AC space h
41. oOx WHERE IDEAS MEET INDUSTRY MH Fluid Cooler INSTALLATION OPERATION MAINTENANCE sea_Z0876176 rev A ISSUED 10 2014 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT Marley Note Z Warning A Caution Note contents This manual contains vital information for the proper installation and operation of your fluid cooler Carefully read the manual before installation or operation of the fluid cooler and follow all instruc tions Save this manual for future reference Fluid Cooler tic eran tente ideis tercie 4 Fluid Cooler Oa 5 Receiving Fluid ooler neis E a ndi dnd Dade rud 5 Hoisting Fluid Cooler c dine ai bete a 5 Fluid Cooler Instalatii 6 Motor WING e 9 Mechanical Equlpmiehibzse entere 10 PIMA Cooler Stan Dp iecit re neta rtt tette ducente teinte te ne cin ret entes 12 Fluid Cooler Operatloriss etico eicere t ce cd E 14 Cooling Beto M 16 Freezing Weather Operation retrait ha cnin ded 17 Water Treatment and Blowdown esee 20 Fluid Cooler Cl aMn Grein a raconte tct
42. ol process temperatures 19 A Caution 20 maintenance Draining the coil is not acceptable as a normal method of freeze protection draining promotes corrosion inside the coil tubes Draining is acceptable in an emergency if the coil is not protected by an antifreeze solution It is recommended that you discuss your freeze prevention options with your local Marley sales representative Water Treatment and Blowdown Maintaining Water Quality The steel used in MH Fluid Coolers has been galvanized with a heavy zinc coating averaging 05mm in thickness Other materials used PVC fill drift eliminators and louvers aluminum fans cast iron Geareducer etc are se lected to offer maximum service life in a normal fluid cooler environment defined as follows Recirculating water with a pH between 6 5 and 8 achloride content as NaCl below 500 mg l a sulfate content SO below 250 mg l total alkalinity as below 500 mg l calcium hardness as CaCO above 50 mg l no significant contamination with unusual chemicals or foreign substances and adequate water treatment to minimize scaling Startup Conditions The water conditions during initial fluid cooler opera tion are crucial in preventing premature corrosion of galvanized steel white rust For at least the first eight weeks of operation pH should be controlled between 6 5 and 8 0 with hardness and alkalinity levels between 100 and 300 mg l expressed a
43. ontinue pump operation for about 15 minutes after which it is recom mended that the water system be drained flushed and refilled 7 While operating the recirculating water pump s and prior to operating the fluid cooler fan execute one of the two alternative biocidal treatment programs described in the following Resume treatment with the biocide which had been used prior to shut down Utilize the services of the water treatment supplier Maintain the maximum recommended biocide residual for the specific biocide for a sufficient period of time residual and time will vary with the biocide to bring the system under good biological control or Treatthe system with sodium hypochlorite to a level of 4 to 5 mg l free chlorine residual at a pH of 7 0 to 7 6 The chlorine residual must be held at 4 to 5 mg l for six hours measurable with standard commercial water test kits If the fluid cooler has been in operation and then shut down for a dura tion of time and not drained perform one of the two previous biocidal treatment programs directly to the fluid cooler storage vessel collection basin drain down tank etc without circulating stagnant water over the fluid cooler fill or operating the fluid cooler fan After biocidal pretreatment has been successfully completed cooling water may be circulated over the fluid cooler fill with the fan off When biocidal treatment has been maintained at a satisfactory level for at least six hour
44. r to five times per hour each low speed start and each high speed start count as one start When using a VFD Before beginning ensure that the motor is rated for Inverter Duty per NEMA MG 1 part 31 the VFD solid state overload protection to 119 of motor name plate amps and set maximum current parameter in the VFD to motor nameplate amps Maximum current parameter will reduce fan speed and limit amp draw to nameplate amps during cold weather opera tion If furnished with a mechanical OL set this at 11096 over motor nameplate amps Motor rotation must be the same in both VFD mode and bypass mode If cable distance between the VFD and motor is greater than 30m a DV DT output filter is recommended to avoid damage to the motor 100 feet distance is based on our field experience the VFD manufacture may state different distances and distance does vary depending on the VFD manufacturer Program the VFD for variable torque output Flux vector and constant torque modes may damage the gearbox Do not start and stop the motor using the safety switch at the motor If the drive is being commanded to run and the load side is cycled ON and OFF with the safety switch this may damage the VFD Using a VFD in cooling applications has advantages over traditional single or two speed motor control A VFD can reduce the cost of electrical energy being used and provide better temperature control In addition it reduces the mechanica
45. rift eliminators easily accessible fill surfaces and the coil should be flushed by use of a moderate pressure water nozzle being careful not to cause physical damage A reliable water treatment program should be installed and maintained Filtration devices may be employed to reduce the suspended solids concentrations thus increasing the effectiveness of the water treatment program See Fluid Cooler Startup instructions on page 12 Coil Louver Removal The coil inlet louvers are comprised of a series of thermoformed PVC pack assemblies oriented to push water back into the fluid cooler They are packed tightly to ensure no water escapes from the air inlet A Caution A Caution maintenance Louver edges can be very sharp and could cut skin if proper protec tion is not used Always wear gloves and sleeves when handling eliminator packs To remove the louvers place both hands on the louver face and push up this will indicate where one assembly stops and another starts Push a single louver section up until it hits the top of the metal retaining channel 1 Pull the bottom side of the louver out away from the fluid cooler and remove the louver 2 Repeat this procedure for other packs to gain necessary access Proper louver pack replacement is essential to operation To ensure packs are reinstalled in the correct orientation it is recommended that one pack is left in its original location inside the fluid cooler as a reminder of
46. rom being applied to the mechanical equipment and the electrical circuit components 5 Run the motor and observe the operation of the mechanical equipment Operation should be stable and if equipped there should be no evidence of oil leakage from the Geareducer 6 If equipped with belt drive check the torque on the fan and motor sheave after 10 60 hours of operation See Bushing Fastener Torque Values on pages 25 and 30 If the water supply system is not being operated or if there is no heat load on the system motor amps read at this time may indi cate an apparent overload of as much 10 2000 This is because of the increased density of unheated air flowing through the fan Determination of an accurate motor load should await the applica tion of the design heat load A Warning 12 operation Fluid Cooler Start Up Among other sources outbreaks of Legionnaires Disease have reportedly been traced to cooling towers and fluid coolers Main tenance and water treatment procedures that prevent amplification and dissemination of Legionella and other airborne bacteria should beformulated and implemented BEFORE systems are operated and continued regularly thereafter to avoid the risk of sickness or death Water System 1 New installations should be cleaned and treated with biocides by a water treatment expert before startup Remove any and all accumulated debris from fluid cooler Pay particular attention to insi
47. rrival belongs to the trucker as does the coordination of multiple shipments if required Receiving Fluid Cooler Prior to unloading the fluid cooler from the delivering carrier inspect the ship ment for evidence of damage in transit If damage is apparent note the freight bill accordingly This will support your future recovery claim Find and remove the installation instruction drawings and bills of material located in a plastic bag in the water collection basin This information should be kept for future reference and maintenance purposes Hoisting Fluid Cooler All MH Fluid Cooler models must use hoist clips and overhead lifting for handling assembled fluid cooler Fork lifting from base of fluid cooler is not permitted The clips for the top modules are located at the fan deck level The clips for the lower modules are located at the bottom of the mod ules at the water collection basin A Hoisting Installation label which has hoisting dimensional information is located on the side casing near the fluid cooler centerline Remove fluid cooler from the carrier and hoist into place according to the instructions on the label Upper and lower modules must be hoisted and set separately Do not preassemble modules prior to hoisting 11 gt A Warning Note installation Hoisting clips are provided for ease of unloading and positioning the fluid cooler For overhead lifts or where additional safety is required safety slings shou
48. s Too frequent starting or speed changes Deterioration of grease or foreign material in grease Limit cumulative accelerations time to a total of 30 seconds hour Set on off or speed change set points farther apart Consider installing a Marley VFD drive for fine temperature control Flush bearings and relubricate Bearings damaged Replace bearings Motor does not come up to speed Voltage too low at motor terminals because of line drop Check transformer and setting of taps Use higher voltage on transformer erminals or reduce loads Increase wire size or reduce inertia Broken rotor bars Look for cracks near the rings A new rotor may be required Have motor service person check motor Wrong motor rotation Wrong sequence of phases Switch any two of the three motor leads 42 troubleshooting Trouble Cause Remedy Geareducer noise If equipped Geareducer bearings If new see if noise disappears after one week of operation Drain flush and refill Geareducer oil See Geareducer User Manual If still noisy replace Gears Correct tooth engagement Replace badly worn gears Replace gears with broken or damaged teeth Unusual fan drive vibration Loose bolts and cap screws Tighten all bolts and cap screws on all mechanical equipment and supports Unbalanced drive shaft or worn couplings If equipped Make sure motor and Geareducer shafts are i
49. s the fan may be turned on and the system returned to service Resume the standard water treatment program including biocidal treatment 13 14 operation Fluid Cooler Operation General The cold process fluid temperature obtained from an operating fluid cooler will vary with the following influences 1 Heat load With the fan in full operation if the heat load increases cold process fluid temperature will rise If the heat load reduces the cold process fluid temperature will reduce Note that the number of degrees range through which the fluid cooler cools the process fluid is established by the system heat load and the amount of fluid being circulated in accordance with the following for mula formula is only valid for 100 water as process fluid Heat Load kW Range C Water Flow m hr x 1 162 The fluid cooler establishes only the cold process fluid temperature at tainable under any operating circumstance Airwet bulb temperature Cold process fluid temperature will also vary with the wet bulb temperature of the air entering the louvered faces of the fluid cooler Reduced wet bulb temperatures will result in colder process fluid temperatures However the cold process fluid temperature will not vary linearly with the wet bulb For example a 11 C reduction in wet bulb may result in only a 8 C reduction in cold process fluid temperature Fluid flow rate Increasing the process fl
50. s CaCO3 Chlorine if used shall be added intermittently with a free residual not to exceed 1 mg I maintained for short periods Excessive chlorine levels may deteriorate sealants and other materials of construction An atmosphere surrounding the fluid cooler no worse than moderate industrial where rainfall and fog are no more than slightly acid and they do not contain significant chlorides or hydrogen sulfide H3S Many proprietary chemicals exist for control of scale corrosion and biologi cal growth and should be used prudently Also combinations of chemicals may cause reactions which reduce treatment effectiveness and certain chemicals such as surfactants biodispersants and antifoams may increase drift rate Note maintenance The structure and coil of your fluid cooler consists primarily of galvanized steel therefore your water treatment program must be compatible with zinc In working with your water treatment supplier it is important that you recognize the potential effects on zinc of the specific treatment program you choose Blowdown A fluid cooler cools water by continuously causing a portion of it to evaporate Although the water lost by evaporation is replenished by the makeup system it exits the fluid cooler as pure water leaving behind its burden of dissolved solids to concentrate in the remaining water Given no means of control this increasing concentration of contaminants can reach a very hi
51. the motor support in place must be loosened There are two jam nuts at the end of the rod next to the casing Turn the nut closest to the end of the rod to tighten the belt Turn the other nut to loosen the belt After achieving proper tension tighten the double nuts located on the fan side of the motor support against the motor support to maintain belt tension then retighten the motor support nuts Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check tension frequently during the first 24 48 hours of run in operation Over tensioning shortens belt and bearing life Keep belts free from foreign material which may cause slipping Never apply belt dressing as this will damage the belt and cause early failure A Dodge V Belt Tension Tester is an alternate method for tensioning V belts Check with your local belt supplier New belts operating less than 8 hours should be tensioned to the maximum value Tension after this period should use no less than the minimum value If the belt span was measured in millimeters then use the Newton force values If specific tensioning instructions are provided with your tensioning tool those instructions should be used instead Belt Tension Motor Sheave Used V Belt New V Belt diameter minimum maximum 85 110mm 22N 32N 112 145mm 32N 47N 147 220mm 38N 56N 29 A Warning Bushing Fastener Torque Values 30 maintenance Sheav
52. ttempt to start it Motor will not start 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 voltages and currents 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 belt guard Reinstall or replace fan Motor runs hot Wrong voltage or unbalanced voltage Check voltage and current of all three lines against nameplate values Overload Check fan blade pitch See Fan User Manual Check for drag in fan drivetrain as from damaged bearings Wrong motor RPM Check nameplate against power supply Check RPM of motor and drive ratio Bearing over greased Remove bearing reliefs Run motor up to speed to purge excessive grease Wrong lubricant in bearings Change to proper lubricant See motor manufacturer s instructions One phase open Stop motor and attempt to start it Motor will not stat if single phased Check wiring controls and motor Poor ventilation Clean motor and check ventilation openings Allow ample ventilation around motor Winding fault Bent motor shaft Check with ohmmeter Straighten or replace shaft Insufficient grease Remove plugs and regrease bearing
53. ubricate motor s according to the manufacturer s instructions See instructions on the next page for fluid coolers with the motor located outside the plenum option Check to see that all bolts are tight in the fan and mechanical equipment region including the fan cylinder and fan guard Refer to Component User Manuals for torque values Inspect the fluid cooler thoroughly making maximum use of instructions given inthe separate User Manuals Check structural bolted connections and tighten as required Make preventive maintenance repairs as necessary Check to see that all bolts are tight in the fan and mechanical equipment region including the fan cylinder and fan guard Refer to Component User Manuals for torque values Every 5 Years If equipped 7111 113 change Geareducer oil Refer to the Geareducer User Manual for instructions Figure 7 maintenance Motor Relubrication Instructions Motor located outside plenum option Doubleflow models MHF7111 and MHF7113 only Open and lock out disconnect switch to make certain motor can not be started 1 Remove guard as shown in Figure 7 Opposite end motor bearing is accessible from outside the fluid cooler 2 Remove grease fill and relief plugs at both shaft extension end and opposite end bearings and remove hardened grease using clean wire Steel Side Casing Grease Relief Plug 3 Insert grease fittings in grease fill openings and add grease until
54. uid flow rate m3 hr will cause a slight elevation in cold process fluid temperature while reducing the fluid flow rate will cause the cold process fluid temperature to decrease slightly However at a given heat load see formula above process fluid flow reductions also cause an increase in the incoming hot process fluid temperature and thermal range Air flow rate Reducing air flow through the fluid cooler causes the cold process fluid temperature to rise This is the recommended method by which to control leaving process fluid temperature If your fluid cooler is equipped with a single speed motor the motor may be shut off when the process fluid temperature becomes too cold This will cause the process fluid temperature to rise When the fluid temperature then becomes too warm for your process the motor can be restarted Note Note operation Fan cycling limits Considering the normal fan and motor sizes utilized on MH Fluid Coolers anticipate that approximately 4 to 5 starts per hour are allowable If your fluid cooler is equipped with a two speed motor s you will have an opportunity for process temperature control When the process fluid temperature becomes too cold switching the fan to half speed will cause the cold process fluid temperature to rise stabilizing at a temperature a few degrees higher than before With a further reduction in fluid tem perature the fan may be cycled alternately from half speed to off D
55. ving of cold weather operation even at the low temperature and reduced load conditions encountered in low temperature applications Nevertheless during operation in subfreezing weather the opportunity exists for ice to form in the colder regions of the fluid cooler Slushy transitory ice forms routinely in the colder regions of the fill of low temperature fluid coolers and is visible through the fluid cooler louvers Such ice normally has no adverse effect on fluid cooler operation but its appearance should be a signal to the op erator to undertake ice control procedures Itis the operator s responsibility to prevent the formation of destruc tive hard ice on the fluid cooler fill Certain guidelines should be followed 1 Do not allow the fluid cooler s leaving process fluid temperature to drop below 7 C If such low temperature operation is necessary or beneficial to your process establish the minimum allowable level as follows During the coldest days of the first winter of operation observe whether any ice is forming on the louver face particularly near the bottom part of the louver face If hard ice is present on the louvers you must increase the allowable cold water temperature If the minimum allowable cold process fluid temperature is es tablished at or near minimum heat load it should be safe for all operating conditions Having established the minimum allowable cold water temperature maintaining that temperature ca
56. y paper etc may not be used as they will cause mechanical damage to the belts Bearings Every month turn the fan shaft and rotate by hand to distribute grease evenly over the bearing parts Then every three months inject grease to prevent any blocking of the lubrication lines possibly due to grease hard ening Whenever the fan shaft has been turned it is a must to secure them at a standstill Fans See Fan User Manual for instructions SPX Cooling Technologies Services Our interest in your MH Fluid Cooler does not end with the sale Having con ceived designed and manufactured the most reliable and longest lasting fluid cooler of its class we want to make sure that you gain the maximum possible benefit from its purchase Therefore the following services are available which are intended to assure the maximum possible service life under your operating conditions tailor the operating characteristics to your specific needs and maintain consistently optimum thermal performance capability They are available by contacting your Marley sales representative Replacement parts complete stock of parts and components is maintained at one or more of the various Marley plants In cases of emergency they can normally be shipped within 24 hours by air freight if necessary However you would obviously benefit from anticipating your need in advance thus avoiding the cost of special handling Be sure to mention your fluid cool
Download Pdf Manuals
Related Search