Marley Cooling Tower Basic Control System User Manual
Contents
1. 12 IN 6 Connection Diagram Notes 1 Disconnecting means provided with controller Input Voltage Primary Connections per Transformer Nameplate 8 Customer s Remote Located Equipment Field wiring by others 25 AC Combination Starter 120V Single Phase Single Speed 18 1 120V 1 FOR REMOTE OPTIONS lt 2 2 EU 5 der 8 OFF Sw HAND AUTO 1 3 7 7 ALARM 3 ALARM 8 VV 2 8 aes 120V gt FOR REMOTE lt OPTIONS Connection Diagram Notes 1 Disconnecting means provided with controller 2 Customer s Remote Located Equipment Field wiring by others 26 AC Combination Starter 3 Phase Two Speed One Winding TIME DELAY RELAY 57 9 5 88 66 13 21 31 43 15 12 2 x T 14 22 A1 A2 32 44 TB FU2 3 58 3 qT TP 1 H1 1 VAAN FU3 CPT 4 Tp 2 SEC 18 FU1 5 X2 e GND 1 Disconnecting means provided with controller LI L2 L3 POWER POWER Connection Diagram Notes TERMINAL BLOCK TERMINAL BLOCK T6 T4 T1 T2 T3 2 Input Voltage Primary Connections Transformer Nameplate TO MOTOR 8 Customer s Remote Located Equipment Connection Diagram Field wiring by others See pag2. amp amp 3 amp LOWSPEED 8 F 3 2 Y LOW SPEED TEMPERATURE SWITCH DIAL SETTING PENN BASO Model A28MA 1 Thermostat Adjustable temperature setting Factory set 5 F differential for each stage Factory set 8 F differential between stages Control System Operation 6 TA 8 9 Replace the cover the temperature switch Be sure the gasket is tight against the case to prevent water from entering the switch Press both reset buttons on the outside door of the control panel to reset all overloads to the operating condition Turn the Hand Off Auto selector switch to the off position Clear and remove any lock out tags on the disconnect switch remove any locks and turn the disconnect switch to the on position Be sure all personnel are clear of the rotating equipment Rotate the Hand Off Auto selector switch to the Auto position The fan will now start stop and change speeds automatically based on cold water temperature The water is colder on the louver face than on the eliminator face of the fill in the cooling tower The actual cold water temperature will be between these two extremes For best accuracy we rec ommend the temperature measuring bulb be located near the basin exit in a vertical position Check to be sure the fan rotation is correct You may need to operate the system manually to verify
3. Mount the control panel securely in an upright position The disconnect switch on the control panel must be within sight of the equipment being operated and within 50 feet of that equipment or a separate disconnect switch must be provided The best location will be at the same ambient conditions as the equipment since the overload and the motor are both temperature sensitive devices Mount the temperature switch and the vibration switch if applicable on the tower Refer to the drawings supplied with the tower for details on installation of the switches Install conduit from the bottom of the control panel to the individual pieces of equipment requiring wiring All conduit connections must be completed to provide a continuous raceway for the conductors prior to pulling the conductors through the conduit All conduit must be supported properly in accordance with the National Electrical Code Mark the ends of the conductors for identification and pull them through the conduit Be sure to provide a ground wire to all individual pieces of equipment Connect the conductors to the appropriate terminal points in the control panel Make pigtail connections at the motor using hardware to fasten motor lug to the ring terminal on the power lead wire from the control panel Wrap the pigtail with insulation putty to smooth out the points and edges and wrap the pigtail completely with vinyl electrical tape Connect the ground lead to the
4. 250V and 31 60 Amps Transformer 240 or 480 Volts 208 Volts Terminal Blocks Fuse Blocks High Low Selector Switch H O A Selector Switch Contact Blocks for Selector Switch Quan Part No A74931 C00683 C00682 B56497 B56498 B56499 B56500 B56501 A74936 A74958 A74959 A74960 A74940 A74941 A74941 A74946 A74947 A74952 A74953 A74961 A74955 A74956 Parts List 10 hp 208V Two Speed 10 hp and 15 hp 240V Two Speed 15 hp 20 hp and 25 hp 480V Two Speed Item Description Quan 1 Contact Kit 2 2 Solid State Overload Relay SQ D Number Type SFB20 FLA 1 5A 4 5A Type SSC20 FLA 3A 9A Type 55020 FLA 6A 18A Type 55120 FLA 9A 27A Type 55220 FLA 15A 45A Type 55320 FLA 30A 90A Type S8420 FLA 45A 135A 3 Magnet Coil Starter 2 4 Pneumatic Timing Relay 120 V 60 Hz 1 5 Magnet Coil Timing Relay 1 6 Snap Switch Timing Relay 1 7 Fuse Clips 250V 31 60 Amps 600V 0 30 Amps 1 600V and 31 60 Amps 1 8 Transformer 240 or 480 Volts 1 208 Volts 1 9 Terminal Blocks 9 10 Fuse Blocks 2 11 High Low Selector Switch 1 12 Selector Switch 1 13 Contact Blocks For Selector Switch 2 Part No A74932 C00683 00682 56497 B56498 B56499 B56500 B56501 A74937 A74958 A74959 A74960 A74941 A74942 A74946 A74947 A74952 A74953 A74961 A74955 A74956 43 44 Parts List 15 hp 20 hp and 25 hp 208V Two Speed 20 hp 25 hp and 30
5. Marley Basic Control System User Manual 92 1320E M Marley N Warning This manual contains vital information for the proper installation and operation of your cooling tower and the basic control system Carefully read the manual before installation or operation of the tower Failure to follow the instructions in this manual may result in substantial personal injury or death Save this manual for future reference Table of Contents oilo g RAD 2 i 3 Factory Installation ntt tr nette ttr 4 Field Connections Sue merenti eh IRI 6 s cann tede eng teg i UR EC E ER MC RR ed 6 NG Tower Standard ia eren ii 7 NC Tower Motor Outside Option serene 7 Tower Modular citi rt c ats 8 Field rinnovo eR E 10 Field Installed Systems Single Speed 10 Field Installed Systems Two Speed 11 Control System Operation titt t teret ec inire 12 Single Speed Mari al te eee tte tte nnn 12 TWO speed Mantl l atii cito citet n RE Rp 13 Dingle Speed Automatic ettet mnes 14 Two Speed Automatic sese 16 System Maintenance trecenti etre ER UR cnc 18 Contacts sitire ai d ana b Rar eir nada de d ie
6. SOLID STATE OVERLAND RELAY 10 POWER POWER TERMINAL BLOCK TERMINAL BLOCK Connection Diagram Notes T11 112 T13 T2 T3 1 Disconnecting means provided with controller 2 Input Voltage Primary Connections per Transformer TO MOTOR Nameplate 8 Customer s Remote Located Equipment Connection Diagram See Page 28 for Elementary Diagram P DN Field wiring by others 29 16 30 STANDARD TEMP CONTROLLER PENN STAT Y LOW HIGH yf 7 RRN e B B BULB SENSOR OPTIONAL TEMP CONTROLLER MARLEY SMART SYSTEM ORANGE ORANGE 14 16 BLUE 24 SENSOR WELL 9 BLUE 14 AC Combination Starter 3 Phase Two Speed Two Winding LOL 5 1 gt gt 2 L ESTA 12 ag L 95 9 amp T3 x L3 11 HOL Tii gt gt E ud 0 0 EET E 73 ag H1 PRI US Se CPT 6 5 x1 sec 2 OFF VIB HIGH LOW HAND AUT SW D AUTO Hi 12 LOL HOL 7 8 9 TR 40 tot tater EN MM BN 1 1 1 SE EN p o 14 i 7 F 141 CONTROL 9 HIGH HIGH ALARM ALARM e lt LOW Port ALARM x I 120V FOR gt CUS
7. TEMPERATURE DIAL TEMPERATURE SWITCH SENSING JUMPER BAR BULB 23 3 4 5 120V CPT FOR REMOTE OPTIONS lt 6 6 X2 0x0 71 4 9 c I GND 12 24 edL Ib sn AC Combination Starter 3 Phase Single Speed 1 2 Vis acis SOLID STATE OVERLOAD RELAY ALARM 5b H12 OL MOTOR gt 7 1 5 O M T2 ag m dg M 95 4 so X1 SEC x2 SW HAND AUTO E Gde 11 11 TS 20 e 9 ALARM 3 ALARM eM 5 32 0 4 6 12 nN 6 120V gt FOR REMOTE lt OPTIONS Connection Diagram Notes 1 Disconnecting means provided with controller Input Voltage Primary Connections per Transformer Nameplate 8 Customer s Remote Located Equipment u o o Grounding Service Conductor and Grounding Electrode Conductor Terminals Located in Bottom of Cabinet cuc Field wiring by others AC Combination Starter 208V and 230V Single Phase Single Speed L1 L3 1 in a JEn SO M T2 IO F uf U 2 3 4 H1 PRI SEC 2 GND OFF d AUTO START 1 9 10 6 L MH 5 jid Am k M 9 DB 9 ALARM 3 ALARM ny p
8. Two Speed 1 hp through 5 hp 460V Two Speed Description 1 Contact Kit Quan 2 Solid State Overload Relay SQ D Number 10 11 12 13 Type SFB20 FLA 1 5A 4 5A Type SSC20 FLA 3A 9A Type SS020 FLA 6A 18A Type 55120 FLA 9 27 Type 55220 FLA 15A 45A Type 55320 FLA 30A 90A Type SS420 FLA 45A 135A Magnet Coil Starter Pneumatic Timing Relay 120V 60Hz Magnet Coil Timing Relay Snap Switch Timing Relay Fuse Clips 250V and 0 30 Amps 600V and 0 30 Amps 250V and 31 60 Amps Transformer 240 or 480 Volts 208 Volts Terminal Blocks Fuse Blocks High Low Selector Switch H O A Selector Switch Contact Blocks for Selector Switch Part No A74930 C00683 C00682 B56497 B56498 B56499 B56500 B56501 A74936 A74958 A74959 A74960 A74940 A74941 A74941 A74946 A74947 A74952 A74953 A74961 A74955 A74956 41 42 Parts List 5 hp and 7 1 2 hp 208V Two Speed 5 hp and 7 1 2 hp 240V Two Speed 7 1 2 hp and 10 hp 480V Two Speed Description 1 2 Contact Kit Solid State Overload Relay SO D Number Type SFB20 FLA 1 5A 4 5A Type SSC20 FLA 3A 9A Type SS020 FLA 6A 18A Type 55120 FLA 9 27 Type 55220 FLA 15A 45A Type 55320 FLA 30A 90A Type 55420 FLA 45A 135A Magnet Coil Starter Pneumatic Timing Relay 120V 60Hz Magnet Coil Timing Relay Snap Switch Timing Relay Fuse Clips 250V and 0 30 Amps 600V and 0 30 Amps
9. a short circuit or ground fault condition The thermal overload units are both the solid state relay type and the melting alloy type and are reset by depress ing the reset button Overloads trip most frequently because of mechanical overloads or frequent cycling of the fan motor Visual Inspections Visual inspections should be conducted during installation and at six month intervals Check all connections for tightness Vibration or improper installation can cause loose connections resulting in increased resistance to current flow We recommend the use of copper wire only During the visual inspection we recommend the use of compressed air and brushes to clean dirt from magnetic pole faces and contacts Single Speed Wiring Details 3 Phase INCOMING POWER PANEL L L2 L3 IF MOTOR RUNS lt BACKWARDS SWITCH TERMINAL BLOCK N ANY TWO WIRES GREEN NORMALLY CLOSED VIBRATION SWITCH OR JUMPER AT RED 5 7 Note Terminal block numbers are shown out of order Actual terminals are numbered in sequential order NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED OVERLOAD TRIP ALARM OPTIONAL RANGE ADJUSTMENT SCREW DIFFERENTIAL ADJUSTMENT SCREW SEE TABLE BELOW TEMPERATURE SWITCH SENSING BULB MOTOR LEAD CONNECTIONS MOTOR LEADS TO STARTER MOTOR LEADS TIED TOGETHER T1 amp T7 T2 amp T8 T3 amp T9 T4 T5 amp T6 T1 T2 T3 TO TERMINALS T1 T2 amp T3 AT STARTER 21
10. for Selector Switch Quan Part No A74930 C00683 C00682 B56497 B56498 B56499 B56500 B56501 A74936 A74940 A74944 A74945 A74952 A74953 A74955 A74956 35 36 Parts List 1 hp through 7 1 2 hp 208V Single Speed 1 hp through 10 hp 240V Single Speed 1 hp through 15 hp 480V Single Speed Description Quan Part No 1 Contact Kit 1 A74931 2 Solid State Overload Relay SQ D Number Type SFB20 FLA 1 5A 4 5A C00683 Type SSC20 FLA 3A 9A 00682 55020 FLA 6A 18A B56497 Type 55120 FLA 9A 27A B56498 Type 55220 FLA 15A 45A B56499 Type 55320 FLA 30A 90A B56500 Type S8420 FLA 45A 135A B56501 3 Magnet Coil Starter 1 A74936 4 Fuse Clips 250V and 0 30 Amps 1 A74940 600V and 0 30 Amps 1 A74941 250V and 31 60 Amps 1 A74941 5 Transformer 240 or 480 Volts 1 A74944 208 Volts 1 A74945 6 Terminal Blocks 6 A74952 7 Fuse Blocks 2 A74953 8 Selector Switch 1 A74955 9 Contact Blocks for Selector Switch 1 A74956 Parts List 10 hp 15 hp and 20 hp 208V Single Speed 15 hp and 20 hp 240V Single Speed 20 hp 25 hp and 30 hp 480V Single Speed Description 1 Contact Kit Quan 1 2 Solid State Overload Relay SQ D Number Type SFB20 Type SSC20 Type 55020 Type 55120 Type 55220 Type 55320 Type S8420 3 Magnet Coil Starter 4 Fuse Clips FLA 1 5A 4 5A FLA 3A 9A FLA 6A 18A FLA 9A 27A FLA 15A 45A FLA 30A 90A FLA 45A 135A 60
11. Hazard of electrical shock or burn Be sure to turn off power to panel before servicing If working on equipment out of sight of panel disconnect lockout using standard lock out procedure Safety The Marley control system uses UL listed components installed in accordance with the National Electrical Code The location of the cooling tower and field installation of the control system can affect the safety of those responsible for installing operating or maintaining the tower and controls However since SPX Cooling Technologies does not control the tower location or field instal lation we cannot be responsible for addressing safety issues that are affected by these items The following safety issues should be addressed by those responsible for installation maintenance or repair of the tower and controls Access to and from the control panel including the discon nect switch Proper grounding of electrical control circuits Sizing and protection of branch circuits feeding the control panel Qualification of persons who will install maintain and service the electrical equipment These are only some of the safety issues that may arise in the design and instal lation process SPX strongly recommends that you consult a safety engineer to be sure that all safety considerations have been addressed Other safety issues are addressed in literature supplied with your tower You should closely review the literature prior to ins
12. The fan will start at the selected speed Change the motor speed by changing the position of the High Low selector switch Verify the time delay is at least 30 seconds when switching from High to Low speed 15 16 Control System Operation 11 Check to be sure the fan rotation is correct at both speeds 12 Rotate the Hand Off Auto selector switch to the Off position to stop the fan Single Speed Automatic Operation 1 10 Check all mechanical equipment in the driven system to be sure it is free of obstructions and safe to operate Check all electrical equipment for proper connection to be sure it is in good operating condition Note a jumper or a normally closed de vice must be installed between points 5 and 7 1 and 3 on single phase control panel on the terminal block or the system will not operate Close and latch the control panel door Remove the cover from the temperature switch by removing the two screws in diagonally opposite corners of the cover Check the cut in and cut out settings on the temperature scale These have been factory preset at 85 F for the cut in temperature and 80 F for the cut out temperature Adjust the settings as required to suit your applica tion The minimum differential is 5 F Increasing the differential will reduce the frequency of cycling the fan motor off and on resulting in longer equipment life See Figure 1 Replace the cover on the temperat
13. fan rotation if the cold water temperature is below the cut in set point Rotate the Hand Off Auto selector switch to the Off position to stop the fan 19 Warning Note 20 System Maintenance Hazard of electrical shock or burn Be sure to turn off power to panel before servicing If working on equipment out of sight of panel dis connect lock out using standard lock out procedure Contacts The contacts inside the electromagnetic contactor which connect the motor to the power source are the only components that experience wear in normal service requiring periodic replacement Two years is not considered unusual for the service life of silver alloy contacts All service work such as replacement of the contacts should be performed by a qualified electrician Contacts are replaced many times when this expense is not neces sary Contacts are not harmed by discoloration of the surface orslight pitting We do not recommend filing them as dressing only removes contact material which is wasteful Replacement is necessary only when the contact has worn thin Coils Coils have an indefinite service life under normal operating conditions Coils generally operate improperly or fail because of unacceptable voltage or from mechanical abuse Fuses and Thermal Overloads The fuses and overloads installed by Marley are the maximum size allowed by the National Electrical Code If a fuse blows repeatedly check the system for
14. hp 240V Two Speed 30 hp 40 hp and 50 hp 480V Two Speed Description Quan 1 Contact Kit 2 2 Solid State Overload Relay SQ D Number Type SFB20 FLA 1 5A 4 5A Type SSC20 FLA 3A 9A Type SS020 FLA 6A 18A Type 88120 FLA 9A 27A Type 55220 FLA 15A 45A Type 55320 FLA 30A 90A Type 55420 FLA 45A 135A 3 Magnet Coil Starter 2 4 Pneumatic Timing Relay 120 V 60 Hz 1 5 Magnet Coil Timing Relay 1 6 Snap Switch Timing Relay 1 7 Fuse Clips 250V 61 200 Amps 1 600V 61 200 Amps 1 8 Transformer 240 or 480 Volts 1 208 Volts 1 9 Terminal Blocks 9 10 Fuse Blocks 2 11 High Low Selector Switch 1 12 H O A Selector Switch 1 13 Contact Blocks For Selector Switch 2 Part No A74933 C00683 C00682 B56497 B56498 B56499 B56500 B56501 A74938 A74958 A74959 A74960 A74943 A74943 A74950 A74951 A74952 A74953 A74961 A74955 A74956 Parts List 30 hp and 40 hp 208V Two Speed 40 hp and 50 hp 240V Two Speed 60 hp 75 hp and 100 hp 480V Two Speed Description 1 Contact Kit Quan 2 2 Solid State Overload Relay SQ D Number 10 11 12 13 Type SFB20 Type SSC20 Type 55020 Type 55120 Type 55220 Type 55320 Type SS420 FLA 1 5A 4 5A FLA 3A 9A FLA 6A 18A FLA 9A 27A FLA 15A 45A FLA 30A 90A FLA 45A 135A Magnet Coil Starter Pneumatic Timing Relay 120V 60 Hz Magnet Coil Timing Relay Snap Switch Timing Relay Fuse Clips 250V 61 20
15. in the field The following information is provided as an overview of the field installation for the various options Please refer to the drawings supplied with the tower for more detailed instructions to complete the installation HAZARD OF ELECTRICAL SHOCK OR BURN BE SURE TO TURN OFF POWER to panel before servicing If working on equipment out of sight of panel disconnect lockout using standard lock out procedure AquaTower 1 Incoming power and ground lines must be run through the opening pro vided on the top of the control panel Conduit must be connected to the panel using a watertight or raintight fitting Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet 2 After completing the electrical connections to the panel provide power to the panel operate the system in the manual mode and verify proper direction of fan rotation on the tower If the direction of rotation is incorrect turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel 3 The temperature and differential set points have been preset at the fac tory Check the settings and adjust as necessary to suit your operating requirements Be sure to maintain adequate differential between the cut in and cut out settings or
16. 0 and 0 30 Amps 250V and 31 60 Amps 600V and 31 60 Amps Transformer 240 or 480 Volts 208 Volts Terminal Blocks Fuse Blocks H O A Selector Switch Contact Blocks for Selector Switch Part No A74932 C00683 C00682 B56497 B56498 B56499 B56500 B56501 A74937 A74941 A74941 A74942 A74946 A74947 A74952 A74953 A74955 A74956 37 38 Parts List 25 hp 208V Single Speed 25 hp and 30 hp 240V Single Speed 40 hp through 100 hp 480V Single Speed Item Description 1 Contact Kit Quan 1 2 Solid State Overload Relay SQ D Number Type SFB20 Type SSC20 55020 Type 55120 Type 55220 Type 55320 Type S8420 3 Magnet Coil Starter 4 Fuse Clips FLA 1 5A 4 5A FLA 3A 9A FLA 6A 18A FLA 9A 27A FLA 15A 45A FLA 30A 90A FLA 45A 135A 250V and 61 200 Amps 1 600V and 200 Amps 5 Transformer 240 or 480 Volts 208 Volts 6 Terminal Blocks 7 Fuse Blocks H O A Selector Switch Contact Blocks for Selector Switch Part No A74933 C00683 C00682 B56497 B56498 B56499 B56500 B56501 A74938 A74943 A74943 A74948 A74949 A74952 A74953 A74955 A74956 This page intentionally left blank 39 Parts Schematic Two Speed Ext d s ir L3 3 Y eo napa ga 40 Parts List 1 hp through 3 hp 208V Two Speed 1 hp through 3 hp 240V
17. 0 Amps 600V 61 200 Amps Transformer 240 or 480 Volts 208 Volts Terminal Blocks Fuse Blocks High Low Selector Switch H O A Selector Switch Contact Blocks For Selector Switch Part No A74934 C00683 00682 56497 B56498 B56499 B56500 B56501 A74939 A74958 A74959 A74960 A74943 A74943 A74950 A74951 A74952 A74953 A74961 A74955 A74956 45 Fan Does Start Nuisance Tripping Contact Chatter Contact Welding Short Contact Life 46 Troubleshooting Guide Power disconnected Fuses blown Overloads tripped Vibration switch tripped or jumper wire missing Sustained overload Check for equipment grounds or shorts Check motor winding resistance fan pitch drive reduction ratios air flow restrictions on tower fans and tower loading Loose connections Excessive motor cycling Increase temperature differential until a maxi mum of five starts per hour is achieved on the fan motor Broken shading coil Low voltage Intermittent supply voltage Abnormal inrush of current Check for grounds shorts or excessive overload currents Insufficient tip pressure Replace contact springs Low voltage preventing magnet from sealing e Chattering contacts Filing or dressing Excessive cycling of fan motor Increase temperature differential on temperature switch Weak contact pressure Replace contact spring e Short circ
18. TOMERS REMOTE USE Elementary Diagram See Page 27 for Connection Diagram T11 T12 T13 T1 2 T3 This page intentionally left blank 31 Parts Schematic Single Speed Single Phase 32 Parts List 1 3 hp through 3 4 hp Single Speed 120V and 230V Single Phase Description Quan Part No 1 Contact Kit 1 A74930 2 Melting Alloy Overload Contact Unit with Alarm Circuit 1 A74935 3 Magnet Coil Starter 1 A74936 4 Fuse Clips for 250V and 0 30 Amps 1 A74940 5 Transformer Transformer not included on 120V systems 6 Terminal Blocks 6 A74952 7 Fuse Blocks not included on 120V systems 8 H O ASelector Switch 1 A74955 9 Contact Blocks for Selector Switch 1 A74956 33 Parts Schematic Single Speed Three Phase 34 Parts List 1 3 hp through 3 4 hp Single Speed 208V 230V and 460V Three Phase Description 1 Contact Kit 2 Solid State Overload Relay SQ D Number Type SFB20 Type SSC20 55020 Type 55120 Type 55220 Type 55320 Type 55420 3 Magnet Coil Starter FLA 1 5A 4 5A FLA 3A 9A FLA 6A 18A FLA 9A 27A FLA 15A 45A FLA 30A 90A FLA 45A 135A 4 Fuse Clips for 250V and 0 30 Amps 5 Transformer 240 or 480 Volts 208 Volts 6 Terminal Blocks 7 Fuse Blocks 8 H O A Selector Switch 9 Contact Blocks
19. Two Speed Single Winding Wiring Details TIME DELAY RELAY SET AT 30 ADJUSTING SEC OR MORE SCREW INCOMING POWER TERMINAL BLOCK z adr pnr 2 Lb NORMALLY CLOSED _ GREEN VIBRATION SWITCH RED lt OR JUMPER AT 6 TO 7 BED NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED RED HIGH SPEED RED OVERLOAD TRIP ALARM OPTIONAL NORMALLY OPEN CONTACTS FOR RED CUSTOMER SUPPLIED RED LOW SPEED OVERLOAD TRIP ALARM OPTIONAL RED TEMPERATURE DIAL TEMPERATURE SWITCH JUMPER BAR 22 TA o0 0 SENSING BULB IF MOTOR RUNS BACKWARDS SWITCH ANY TWO WIRES Note Terminal block numbers are shown out of order Actual terminals are numbered in sequential order PANEL BLACK TYP ALL MOTOR LEADS Two Speed Two Winding Wiring Details TIME DELAY RELAY SET AT 30 ADJUSTING SEC OR MORE SCREW INCOMING POWER TERMINAL BLOCK 5 EU L A i 1 2 3 NORMALLY CLOSED GREEN 5 dir dieque o BACKWARDS SWITCH VIBRATION SWITCH RED ANY TNO WIRES OR JUMPER RED AT 6 TO 7 NORMALLY OPEN NTACTS FOR 6 CONTACTS FO RED 7 Note Terminal block numbers are shown out CUSTOMER SUPPLIED RED 1 HIGH SPEED 5 order Actual terminals are numbered in OVERLOAD TRIP ae sequential order ALARM OPTIONAL 9 NORMALLY OPEN RED 16 CONTACTS FOR RED CUSTOMER SUPPLIED LOW SPEED RED OVERLOAD TRIP ALARM OPTIONAL PANEL BLACK TYP ALL MOTOR LEADS T
20. e 26 for Elementary Diagram 27 28 STANDARD TEMP CONTROLLER PENN STAT 77 RRS Y LOW HIGH Le SH B BULB SENSOR OPTIONAL TEMP CONTROLLER MARLEY SMART SYSTEM ORANGE ORANGE 16 r 9 BLUE BLUE 24 VAC SENSOR DRY WELL 14 AC Combination Starter 3 Phase Two Speed One Winding Li Bu 4 L2 4 aoa aoa 35 13 T6 ng j a6 a Elts ou 2 GTS o H1 PRI 6 5 1 X2 1 GND AUTO LOW LOL Tp 10 12 13 6 o zl _16 CONTROL HIGH HIGH ALARM ALARM d lt LOW AE ME ALARM 6 18 M I 120V FOR gt CUSTOMERS lt REMOTE USE Elementary Diagram See Page 25 for Connection Diagram OPEN TOGETHER TA T5 16 1 T2 T3 AC Combination Starter 3 Phase Two Speed Two Winding TIME DELAY RELAY 57 9 J 65 58 66 21 31 43 15 T T 14 22 A1 A2 32 44 3 4 2 34 IP1 FU3 441 TP2 54 1 x2 FU1 L 194 Tp 6 GND 11
21. excessive cycling of the fan motor may occur and shorten equipment life Field Connection NC Tower Standard 1 Install temperature sensing element in its final position on the basin floor as near the basin outlet as possible Sealer is used to attach the bracket to the basin floor 2 Incoming power and ground lines must be run through the opening pro vided on the top of the control panel Conduit must be connected to the panel using a watertight or raintight fitting Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet 3 After completing the electrical connections to the panel provide power to the panel operate the system in the manual mode and verify proper direction of fan rotation on the tower If the direction of rotation is incorrect turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel 4 The temperature and differential set points have been preset at the fac tory Check the settings and adjust as necessary to suit your operating requirements Be sure to maintain adequate differential between the cut in and cut out settings or excessive cycling of the fan motor may occur and shorten equipment life NC Tower Motor Outside Option 1 Insert the power leads and ground wire for
22. ground lug in the motor conduit box Connectthe wiresforthe vibration switch if applicable tothe normally closed contacts of the switch Connect the ground lead inside the switch Install temperature sensing element in its final position on the basin floor as near the basin outlet as possible Sealer is used to attach the bracket to the basin floor Insert the bulb into the holder Fill the bushing where the capillary tube goes through the casing with sealer Incoming power and ground lines must be run through the opening pro vided on the top of the control panel Conduit must be connected to the panel using a watertight or raintight fitting Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet Field Connection 9 10 After completing the electrical connections to the panel provide power to the panel operate the system in the manual mode and verify proper direction of fan rotation on the tower If the direction of rotation is incorrect turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel Check the temperature and differential settings and adjust as necessary to suit your operating requirements Be sure to maintain adequate differential between the and cut out set
23. ing bulb be located near the basin exit in a vertical position 12 Check to be sure the fan rotation is correct You may need to operate the system manually to verify fan rotation if the cold water temperature is below the cut in set point 13 Rotate the Hand Off Auto selector switch to the Off position to stop the fan 17 Note Figure 2 18 Control System Operation Two Speed Automatic Operation 1 3 Check all mechanical equipment in the driven system to be sure it is free of obstructions and safe to operate Checkall electrical equipment for proper connection to be sure itis in good operating condition Note A jumper or a normally closed device must be installed between points 6 and 7 on the terminal block or the system will not operate Close and latch the control panel door 4 Remove the cover from the temperature switch by removing the two screws in diagonally opposite corners of the cover Check the temperature setting on the dial The temperature has been preset at 72 F at the factory The differential is fixed at 13 F and cannot be changed Adjust the temperature as required to suit your application The differential is built into the switch such that the cut out temperature will be the temperature you read on the dial See Figure 2 Sequence of Operation Basic System with Two Speed Motor OFF LOW ON HIGH i i 5 F 8 F OFF HIGH ON LOW 5
24. n 18 e c 18 Fuses and Thermal Overloads sse 18 Visual InSpectlons sciiicet i o rni rre ies ic rica tr eis 18 Single Speed Wiring Details 19 Two Speed Wiring Details ttti 20 AC Starter Wiring Schematic 22 Parts List Single Speed Motor nent 31 Wo oSpeed MOILQFL acier ttes tio te Wanna deans 39 Trouble Shooting imn treten 44 Warning Introduction The Marley Basic Control System purchased on this tower represents the most economical and reliable automatic control system available Since the System is factory tested and all components are operationally tested you can have confidence the system will perform as specified These instructions as well as those offered separately are intended to as sure that Field connections are completed properly and the control system serves you for the maximum possible time Since product warranty may depend on your actions please read these instructions thoroughly prior to operation If you have questions about the operation and or maintenance of this control system and you do not find the answers in this manual please contact your Marley sales representative When writing for information or when ordering parts please reference the Marley customer order number on the tag inside the door of the control panel
25. ners Factory Installation Overload units are selected based upon the full load current as read from the motor nameplate Fuses are selected based upon the motor voltage and full load current high speed current on two speed motors as listed in the National Electric Code The overload units are installed into the motor starter and the time delay fuses are installed into the fuse clips with the grooved end on the bottom A bar in the fuse clip requires the use of a time delay fuse which has a groove to fit over the bar The time delay relay on the two speed control panel is adjusted for a 30 second or more delay and the thermostats are preset as follows One Speed Cut in Temperature 85 F Cut out Temperature 80 F Two Speed 72 F The completed factory installation is tested by cycling the fan off and on both manually and automatically with the control panel switches and the thermostat respectively Warning Field Connection The factory installation by Marley has been performed in accordance with the National Electrical Code using UL Listed components All installation and wiring performed after leaving the factory must be performed in accordance with the latest revision of the National Electrical Code and any local codes to insure safe operation The Marley Basic Control System has been factory tested to the fullest extent possible Some equipment selections and options require the installation be completed
26. position center posi tion Control System Operation Be sure all personnel are clear of the rotating equipment Clear and remove any lock out tags on the disconnect switch remove any locks and turn the disconnect switch to the On position Rotate the Hand Off Auto selector switch to the Hand position Depress the start push button until you hear the contactor engage then release the button Check to be sure the fan rotation is correct Rotate the Hand Off Auto selector switch to the Off position to stop the fan Two Speed Manual Operation 1 Check all mechanical equipment in the driven system to be sure it is free of obstructions and safe to operate Check all electrical equipment for proper connections to be sure it is in good operating condition Note a jumper ora normally closed device must be installed between points 6 and 7 on the terminal block or the system will not operate Close and latch the control panel door Press both reset buttons on the outside door to reset all overloads to the operating condition Turn the Hand Off Auto selector switch to the Off position Be sure all personnel are clear of the rotating equipment Clear and remove any lock out tags on the disconnect switch remove any locks and turn the disconnect switch to the on position Select the desired speed on the High Low selector switch Rotate the Hand Off Auto selector switch to the Hand position
27. r two speed motors each speed is considered one start Excessive cycling of the motor may reduce the life of the motor starter motor and driven mechani cal equipment When operating in subfreezing weather the opportunity exists for ice to form in the colder regions of the cooling tower Your primary concern is to prevent the formation of destructive ice in the cool ing tower fill Care must be taken not to allow temperature control settings below 40 for automatic operation or unattended manual operation in subfreezing weather Yourunderstanding of cold weather operation will be enhanced if you read Marley Technical Report 003 Operating Cooling Towers in Freezing Weather and your cooling tower s Installation Operation and Maintenance Instruc tions manual Failure to comply with these instructions will result in damage to your tower Single Speed Manual Operation 1 Check all mechanical equipment to be sure it is free of obstructions and safe to operate 2 Check all electrical equipment for proper connections and to be sure it is in good operating condition A jumper or a normally closed device must be installed between points 5 and 7 1 and 3 on single phase control panel on the terminal block or the system will not operate 3 Close and latch the control panel door 4 Press the reset button on the outside door to reset all overloads to the operating condition 5 Turn the Hand Off Auto selector switch to the Off
28. switch in the control panel 5 The temperature and differential set points have been preset at the factory Check the settings and adjust as necessary to suit your operating require ments Be careful to maintain adequate differential between the cut in and cut out settings or excessive cycling of the fan motor may occur and shorten equipment life NC Tower Modular 1 After the modules have been assembled run the conduit from the control panel to the motor and vibration switch 2 Place the power leads and ground wire for the motor through the conduit opening in the motor junction box Connect the conduit to the motor junc tion box The motor power leads have been marked to match the motor leads for easy reconnection in the field Make pigtail connections at the motor using hardware to fasten motor lug to the ring terminal on the power lead wire from the control panel Wrap the pigtail with insulation putty to smooth out the points and edges and wrap the pigtail completely with vinyl electrical tape Connect the ground lead to the ground lug inside the motor conduit box 3 If a vibration switch is installed feed the wires through the conduit open ing on the switch connect the conduit to the threaded switch opening connect the wires to the normally closed contacts of the vibration switch and connect the ground wire Slope conduit away from switch if possible to avoid condensation in the switch Field Connection 4 Support
29. talling maintaining or repairing your tower Factory Installation The control panel bolts directly to the tower with spacers or to a bracket at tached to the tower The thermostat is bolted to the tower casing adjacent to the cold water basin depressed section The capillary runs through a bushing in the tower casing and the bulb is installed vertically in a holder near the outlet for proper temperature measurement The holder is glued to the cold water basin floor with a layer of sealer applied to its bottom flange and the bushing through which the capillary passes is filled with sealer to protect the capillary A vibration limit switch is mounted near the Geareducer on larger towers and near the motor on belt driven towers Liquid tight flexible metal conduit connects all points which are to be wired motor control panel thermostat and vibration limit switch if required The conduit is installed with associated couplings connectors and fittings approved for this conduit and is also supported by conduit clamps as required by code After the completion of the conduit installation the wiring is pulled through the conduit to each component Pulling type fittings are used to provide access for pulling the wire and meeting the N E C requirement for maximum number of bends allowed in each conduit run All wire ends are tagged for identifica tion and connections at each end are made at terminal blocks or by terminal connectors with faste
30. the conduit at appropriate locations in accordance with the re quirements of the National Electrical Code 5 Install temperature sensing element in its final position on the basin floor as near the basin outlet as possible Sealer is used to attach the bracket to the basin floor 6 Incoming power and ground lines must be run through the opening pro vided on the top of the control panel Conduit must be connected to the panel using a watertight or raintight fitting Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet 7 After completing the electrical connections to the panel provide power mode and verify proper to the panel operate the system in the manua direction of fan rotation on the tower If the direction of rotation is incorrect turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel 8 The temperature and differential set points have been preset at the fac tory Check the settings and adjust as necessary to suit your operating requirements Be sure to maintain adequate differential between the cut in and cut out settings or excessive cycling of the fan motor may occur and shorten equipment life 11 12 Field Connection Field Installed Systems Single Speed Motor 1
31. the motor through the conduit opening in the motor junction box Connect the conduit to the motor junction box The motor power leads have been marked to match the motor leads for easy reconnection in the field Make pigtail connections at the motor using hardware to fasten motor lug to the ring terminal on the power lead wire from the control panel Wrap the pigtail with insulation putty to smooth out the points and edges wrap the pigtail completely with vinyl electrical tape Connect the ground lead to the ground lug inside the motor conduit box 2 Install temperature sensing element in its final position on the basin floor as near the basin outlet as possible Sealer is used to attach the bracket to the basin floor Field Connection 3 Incoming power and ground lines mustbe run through the opening provided on the top of the control panel Conduit is connected to the panel using a watertight or raintight fitting Power connections are made at the top of the fusible disconnect located in the upper right hand side of the control panel The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet 4 After completing the electrical connections to the panel operate the sys tem the manual mode and verify proper direction of fan rotation on the tower If the direction of rotation is incorrect turn off power supplying the panel and change any two power leads at the fusible disconnect
32. tings or excessive cycling of the fan motor may occur and shorten equipment life Field Installed Systems Two Speed Motor 1 The installation is the same as for the single speed except direction of rotation must be checked on both speeds If motor runs forward on one speed and backwards on the other reverse any two wires at the motor starter connections for the speed that runs backwards The temperature switch on two speed systems has a differential that is preset by the manufacturer The temperature setting is all that needs to be checked on this system Remember the differential is all above the tem perature setting on the two stage switch Refer to Figure 2 on page 16 Set the pneumatic time delay relay for 30 seconds minimum time delay when switching from high to low speed The time delay is adjusted by turning the air bleed screw on the top front side of the relay 13 14 Control System Operation The Basic Control System allows the operation of the cooling tower in either the manual or automatic mode Automatic operation starts stops and or changes speed of the cooling tower fan motor based on cold water temperature Cold water temperature obtained from an operating cooling tower will vary with the heat load air wet bulb temperature water flow rate and air flow rate When operating in the automatic mode care must be taken not to exceed five starts per hour on the fan motor Fo
33. uits Loose connections Cooked Coil Troubleshooting Guitle Sustained overload Overvoltage or undervoltage condition Mechanical damage resulting in shorted turns Dirt or rust on pole faces increasing air gap Loose connections in control circuit Intermittent supply voltage causing chattering Transient voltage spikes 47 SP COOLING TECHNOLOGIES 7401 WEST 129 STREET OVERLAND PARK KANSAS 66213 UNITED STATES 913 664 7400 spxcooling spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2010 SPX Cooling Technologies Inc Printed in USA Manual 92 1320E
34. ure switch Be sure the gasket is tight against the case to prevent water from entering the switch Press the reset button on the outside door of the control panel to reset all overloads to the operating condition Turn the Hand Off Auto selector switch to the off position Be sure all personnel are clear of the rotating equipment Clear and remove any lock out tags on the disconnect switch remove any locks and turn the disconnect switch to the on position Figure 1 Control System Operation Sequence of Operation Basic System with Single Speed Motor TEMPERATURE SWITCH CUT IN SET POINT MOTOR ON ADJUSTABLE DIFFERENTIAL 5 F MINIMUM FALLING TEMPERATURE RISING TEMPERATURE MOTOR OFF TEMPERATURE SWITCH CUT OUT SET POINT PENN BASO Model A72AE 1 Thermostat Turning the cut in adjustment screw located above the cut in scale changes the cut in set point Turning the cut out adjustment screw located above the cut out scale changes the cut out set point Cut out set point cannot be set above cut in set point 11 Rotate the Hand Off Auto selector switch to the Auto position The fan will now start and stop automatically based on cold water temperature The water is colder on the louver face than on the eliminator face of the fillin the cooling tower The actual cold water temperature will be between these two extremes For best accuracy we rec ommend the temperature measur
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