Marley Aquatower Installation, Operation and Maintenance User
Contents
1. 2 Connect T2 T3 and L8 and insulate 3 Connect T4 T5 and L2 and insulate 4 Connect P1 and L1 and insulate 19 wiring diagrams Low Voltage 1 Connect P1 and L1 and insulate 2 Connect P2 T3 and T8 and insulate 3 Connect T2 4 T5 and L2 and insulate General Colors may be substituted for numbers as follows T1 Blue T5 Black T2 White T6 Red T3 Orange P1 No Color Assigned T4 Yellow P2 Brown To reverse rotation interchange leads T5 and T8 Three Phase Motors There are two basic ways of wiring a three phase motor Wye and Delta The following show the terminal connections that could be used in Marley motors Numbers could be stamped on insulation or cloth plastic or metal bands around each lead 1 Three Wire Single Voltage Motors Leads are not always numbered They could be numbered 1 2 3 or T1 T2 and T3 T1 T1 WYE DELTA T3 T2 T3 T2 2 Nine Wire Dual Voltage Motors Leads are numbered 1 2 3 4 5 6 7 8 and 9 or T1 T2 T3 T4 T5 T6 T7 T8 and T9 wiring diagrams NAMEPLATE T4 T5 T6 T4 T5 T6 o o O T7 WYE T7 T8 T9 T7 T8 T9 T6 2 Je T5 Tid toh a di i L Lo 1 1 LOW V HIGH V Tie Together T4 T5 T6 T4 T7 T5 T8 T6 T9 7 T4 T5 T6 T6 T9 T4 DELTA T6 T7 T 77 Te To Ti T2 T3 T3 T8 T5 T2 1 L2 L3 HIGH V Voltage L1 L2 Tie Together Low T12. 4 to 5 mg L ppm for six hours measurable with standard commercial water test kits If the cooling tower has been in operation and then shut down for a du ration of time and not drained perform one of the two previous biocidal treatment programs directly to the cooling water storage vessel cooling tower sump drain down tank etc without circulating stagnant water over the cooling tower fill or operating the cooling tower fan After biocidal pretreatment has been successfully completed cooling water may be circulated over the tower fill with the fan off When biocidal treatment has been maintained at a satisfactory level for at least six hours the fan may be turned on and the system returned to service Resume the standard water treatment program including biocidal treatment operation 9 Check fan for free rotation and check oil level in bearing housing as re quired see maintenance instructions Start motor and check direction of rotation Fan must rotate clockwise when viewed from the fan discharge side If the rotation is incorrect change any two of the three motor leads Fan cycling limits Considering the normal fan and motor sizes utilized on Aquatowers Note anticipate that approximately 4 to 5 starts per hour are allowable If your tower is equipped with a two speed motor you will enjoy greater op portunity fortemperature control When the watertemperature becomes too cold switching the fan to half speed will c
3. T7 T6 T2 T8 T4 T3 T5 T9 High T1 T2 T3 T4 T7 T5 T8 6 T9 3 Two Speed Single Winding Consequent Pole Variable Torque Motor Leads are marked 1 2 3 4 5 and 6 or T1 T2 T3 T4 5 or T6 T4 NAMEPLATE T4 TB T6 T2 T3 0 0 TN y B p T6 T4 T5 LY Lo 1 tu Tu L3 T5 T6 LOW SPEED HIGH SPEED Tie Together Insulate Separately T4 T5 T6 T1 T2 21 SPX COOLING TECHNOLOGIES INC 7401 W 129 STREET OVERLAND PARK KANSAS 66213 USA P 913 664 7400 F 913 664 7439 spxcooling spx com In the interest of technological progress all products are subject to design and or material change without notice ISSUED 05 2014 20504653 rev 1 1248 COPYRIGHT 2014 SPX Corporation Aquatower user manual
4. may require additional cleaning Inspect louvers drift eliminators and basin trash screens and remove any de bris or scale which may have accumulated Replace any damaged or worn out components The louvers drift eliminators and easily accessible fill surfaces should be flushed by use of a moderate pressure water nozzle being careful not to cause physical damage Use of high pressure water may damage the eliminator and louver material 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 15 Note A Caution A Warning 16 maintenance Blowdown A cooling tower cools water by continuously causing a portion of it to evapo rate Although the water lost by evaporation is replenished by the makeup system it exits the tower 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 high level In order to achieve water quality which is acceptable to the cooling tower as well as the remainder of your circulating water system the selected water treatment company must work from a relatively constant level of concentra tions This stabilization of contaminant concentrations is usually accomplished by blowdown which is the constant disc
5. top of the tower so that water will flow through the line whenever the pump is operating Blowdown is the continuous removal of a small amount of water during operation to retard scale and corrosion Inlet Cooling Tower with Bottom Outlet Gravity Line from Outlet Make Up Line Pump Overflow and Drain to Sewer Note Motor Frame Fastener Size 56 143T 145T She 182T thru 215T 9g Figure 3 installation Piping to Tower Year Round Operation 1 If your tower must operate during freezing weather it is recommended that the tower be installed for gravity flow operation See Figure 2 Provide an indoor open type storage tank with a capacity that will contain all water that will drain into the tank from the system during shutdown Connect tower outlet to storage tank Bottom outlet option should be used for gravity flow Install makeup water bleed off overflow and drain lines on tank Insulate and heat water lines exposed to freezing temperatures Mechanical Equipment Installation Aquatowers with factory installed controls ship with the motor sheave belt and belt guard factory installed Remove shipping stiffener plate and hardware at the adjustable end of the motor support plate and proceed to Motor Electrical Connections Motor Sheave and V Belt Installation 1 Check the motor nameplate to be sure its voltage phase and frequency ratings are the same as the power s
6. Clean motor and check ventilation openings Allow ample ventilation around motor Winding fault Check with Ohmmeter Bent motor shaft Straighten or replace shaft Insufficient grease Remove plugs and regrease bearings Too frequent starting Limit cumulative starting time to a total of 30 seconds each hour Deterioration of or foreign material in grease Flush bearings and relubricate Unusual fan drive vibration Bearings damaged Replace bearings Loose bolts and cap screws Tighten all bolts and cap screws on all mechanical equipment and supports Worn fan shaft bearings Replace bearings Bent shaft Replace shaft Misalignment Make sure fan and motor are straight and properly aligned Loose or stretched belt Check belt for proper tension Unbalanced motor Disconnect load Remove sheave tape key in keyway and operate motor If motor still vibrates rebalance motor wiring diagrams Capacitor Start Single Phase Motors Reversible Double Voltage T1 L1 T2 T3 T4 T8 i T5 L2 Without Thermal Overload Integral HP High Voltage 1 Connect T1 and L1 and insulate 2 Connect T2 T3 and T8 and insulate 3 Connect T4 T5 and L2 and insulate Low Voltage 1 Connect T2 T3 T8 and L1 and insulate 2 Connect T2 T4 T5 and L2 and insulate P1 L1 T5 L2 With Thermal Overload Fractional HP High Voltage 1 Insulate P2
7. SP Aquatower cooling tower INSTALLATION OPERATION MAINTENANCE 20504653 rev A ISSUED 05 2014 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT Marley A Warning A Caution Note contents This Manual contains vital information for the proper installation and operation of your cooling tower Carefully read the manual before installation or operation of the tower and follow all instructions Save this manual for future reference Tower Install lations E 3 PIPING to TOW 4 Mechanical Equipment Installation seen 5 Motor Electrical Connections ener 8 Starting and Operating Instructions sese 9 Fan Cycling LUMI scs itt tette t meten nem ecrit ntc 11 Wintertime Operation essent tnter tnter 12 Maintenance Instructions n irte tete tir i SERERE 14 ze m 16 Seasonal Shutdown Instructions siististi 17 Troubleshoot G uh 18 Wiring Diagrams c e tecti ena 19 Parts 22 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 whic
8. ause the cold water temperature to rise stabilizing at a temperature a few degrees higher than before With a further reduction in water temperature the fan may be cycled alternately from half speed to off Do not start the motor more than four to five times per hour each Note low speed start and each high speed start count as one start For greater insight on cold water temperature control please read Cooling Tower Energy and its Management Technical Report H 001 A available on our website 11 Note A Caution 12 operation Wintertime Operation The Marley fill system used in the Aquatower has air entrance louvers that are molded as an integral part of the fill This feature makes these towers very forgiving of cold weather operation even at the low temperature and reduced load conditions encountered in free cooling and other low temperature applica tions Nevertheless during operation in subfreezing weather the opportunity exists for ice to form in the colder regions of the tower Slushy transitory ice forms routinely in the colder regions of the fill of low temperature towers and is visible through the tower louvers Such ice normally has no adverse effect on tower operation but its appearance should be a signal to the operator to undertake ice control procedures Itis the operator s responsibility to prevent the formation of destruc tive hard ice on the cooling tower fill Certain guidelines should be f
9. between sheaves The slack side will have a slight bow If possible use a commercially available tension measuring device Avoid over tensioning Too much tension reduces bearing and belt life Check the tension on new belts after 8 to 12 hours of operation 8 Install the belt guard as shown in Figure 3 for a steel tower or Figure 5 for a fiberglass tower 9 Install fan cylinder splice plate steel tower and fan guard 10 Check bearing housing oil cup level Fill to the proper level with SAE 30 ISO 100 weight oil BELT GUARD FOR FIBERGLASS AQUATOWER SHOWN 3 8 x 1 1 2 BOLT 3 8 WASHERS USE 3 8 WASHERS SHIM AS REQUIRED Note Figure 6 installation Motor Electrical Connections If Aquatower is equipped with Marley Control System refer to Con trol System Manual for wiring instructions Connect motor to power supply in accordance with the National Electric Code and local requirements Failure to wire the motor correctly will void its warranty Overload protection for motors must be part of the control system Figure 6 shows one possible control scheme Other various wiring diagrams appear on pages 19 through 22 isset a 2 WIRE CONTROL IF USED i TART i OL STOP i E L2 M L3 M M M NOTE L3 IS USED ON 3 PHASE MOTOR ONLY A Warning Note operation Starting and Operating Instructions Among other sources outbreaks of Legionnaires Diseas
10. e have reportedly been traced to cooling towers Maintenance and water treatment procedures that prevent amplification and dissemination of Legionella and other airborne bacteria should be formulated and implemented BEFORE systems are operated and continued regularly thereafter to avoid the risk of sickness or death 1 Newinstallations should be cleaned and treated with biocides by a water treatment expert before startup 2 Clean all debris such as leaves and dirt from the cooling tower fill and basin 3 Fillthe circulating system with water The cold water basin should be filled with water until level is at the rim of the overflow The water conditions during the initial tower operation are crucial in pre venting 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 ppm expressed as If tower is equipped with a standard side suction connection vent any accumulated air from the top of the suction hood by removing one or both tap screws provided at that location Replace these tap screws when venting is complete 4 Start your pump s Observe system operation Since the water system external to the tower will have been filled only to the level in the cold water basin some pump down of the basin water level will occur before water completes the circuit and begins to fall fro
11. er must be bypassed without modulation 13 A Warning 14 Maintenance Instructions Always make certain that mechanical equipment is inoperable during periods of maintenance or during any situation of possible endangerment to personnel If your electrical system contains a disconnect switch lock it out until the period of exposure to injury is over The top of the tower is not a working surface Do not stand sit or walk on top of the tower Use an appropriate ladder adjacent to the tower whenever you perform any maintenance activity on the tower s upper surfaces This product is constructed of fiberglass or cold formed sheet metal Use protective clothing gloves and shoes as appropriate for protection against edges of thin gage material Motor Lubricate the motor according to the motor manufacturer s supplied instruc tions Remove any oil dust or scale deposits from the motor which can cause excessive insulation temperatures Refer to Electric Motors on Cooling Towers Manual 92 1475 for additional maintenance and lubrication information Fan Shaft Bearing Housing Check bearing housing oil cup level Fill to the proper level with SAE 30 ISO 100 weight oil Belt Tension Check belt tension every two to three weeks during peak operating season Makeup Float Valve Check float valve periodically for proper operation and proper water level Basin and Suction Screen Drain and clean c
12. es Use 20 oversize ducts Avoid sharp turns or abrupt changes in size Keep duct length to minimum Screened or louvered openings should have a net free area at least 20 greater than the tower discharge opening area Attach ducts to the tower using flexible connections and support ducts inde pendently from the tower Provide access openingsfor servicing the mechanical equipment if air discharge ducts are installed If the duct discharges into the prevailing wind you may need to install a windbreak or an elbow to serve as a deflector Ducts installed on towers with year round usage should be water tight and insulated to prevent condensation Figure 1 Figure 2 installation Tower Installation Install tower in a level position on a stable foundation Anchor tower to the foundation through holes at base of tower using four diameter bolts not supplied Remove strapping and brackets from the louver face on models 494 496 and reinstall the bolts to the cold water basin Install the overflow fiberglass models only as shown in Figure 1 INSTALL DRAIN FITTINGO WITH GASKET ON TOP Piping to Tower Summer Only Operation 1 Use large enough piping to minimize friction loss 2 Connect float valve to makeup water supply Install the threaded valve stem and float located in the loose parts package 3 Install a valved blowdown line at some point in the system preferably in the hot water line near the
13. h 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 installation Receiving Inspection The motor and miscellaneous parts ship with the tower Check motor name plate to be sure that power supply and motor have the same characteristics Inspect the entire shipment for any damage that may have occurred in transit Tower Location The cooling tower must be located at such distance and direction to avoid the possibility of contaminated tower discharge air being drawn into building fresh air intake ducts The purchaser should ob tain the services of a Licensed Professional Engineer or Registered Architect to certify that the location of the tower is in compliance with applicable air pollution fire and clean air codes Locate so prevailing wind will blow into the louvered face and direct fan discharge away from building surfaces Locate so there is free air flow to and from the tower Allow clearance on all sides for maintenance Indoor Installation Use a duct from the tower air discharge to the outside You may also want to install an inlet air duct Do not allow the total pressure loss through ducts to exceed 0 10 inches H O To minimize pressure loss
14. harge of a portion of the circulating water to waste As a rule acceptable levels on which to base a treatment schedule are in the range of 2 4 concentrations The following table gives ap proximate blowdown rates percent of total water flow rate constantly wasted to achieve those concentrations at various cooling ranges Blowdown Rate Cooling Two Four Range F Concentrations Concentrations 6 0 7 0 17 8 1 1 0 30 11 1 5 0 43 Range is the difference between hot water temperature entering the tower and cold water temperature leaving the tower When water treatment chemicals are added they should not be in troduced into the circulating water system via the cold water basin ofthe cooling tower Water velocities are lowest at that point which results in inadequate mixing and may damage the cooling tower Intermittent Wintertime 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 available from Marley Unless some means of freeze prevention is incorporated into your system the tower basin and exposed pipework should be drained at the beginning of each wintertime shutdown period If tower basin is drained verify that all basin heaters have been shut off either by automatic cutoff or d
15. isconnect switch A Warning Note maintenance Seasonal Shutdown Instructions When the system is to be shut down for an extended period of time it is recommended that the entire system cooling tower system piping heat exchangers etc be drained Leave the basin drain open During shutdown clean the tower and make any necessary repairs Apply protective coating as required to all metal parts Pay particular attention to bearing housing supports Bearing Housing At shutdown check the oil level in the oil cup Atstart of new operating season operate until the oil is warm drain and refill Use SAE 30 ISO 100 weight oil Bearing housing must be refilled at the point where the oil line from the oil reservoir cup connects to the bearing housing Attach oil line and fill line and oil cup Fan guard will have to be removed to change oil Each month check the oil level at the oil cup Electric Motor Clean and lubricate motor at close of each operating season Refer to motor manufacturer s recommendations Do not start motor before determining that there will be no interfer ence with free rotation of the fan drive The motor should be run for three hours at least once a month to dry out wind ings and relubricate bearing surfaces Refer to Electric Motors on Cooling Towers Manual 92 1475 At start of new operating season make sure bearings are adequately lubri cated before returning motor to service Prolo
16. m the fill The initial pump down may not be enough to cause the float valve to open However you can check its operation by pressing down on the operating lever Adjust the float valve during tower operation with heat load to maintain 4 water depth in the depressed section of the basin on Models 490 493 Maintain 5 water depth on Models 494 496 4 Note 10 operation Hot water temperatures exceeding 125 F could damage PVC fill Make sure blowdown line is discharging water Depth of water in hot water basin should be uniform If the basin overflows reduce the flow rate Do not pump more water than design capacity Continue pump operation for about 15 minutes after which it is recom mended that the water system be drained flushed and refilled While operating the condensing water pump s and prior to operating the cooling tower 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 Treat the system with sodium hypochlorite to a level of 4 to 5 mg L ppm free chlorine residual at a pH of 7 0 to 7 6 The chlorine residual must be held at
17. 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 cylinders 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 cycling limits on page 11 of this manual 4 With no heat load on the circulating water icing cannot be controlled effectively by air control during freezing weather Towers must not be operated with reduced water rate and or no heat load during freezing weather If the circulating water system cannot be shut down water returning from the process should be made to bypass the tower If a bypass is used all wat
18. nged Shutdown If shutdown period is longer than seasonal contact your Marley Sales Rep resentative for additional information Whenever you order parts or correspond with us about your tower please include the tower serial number located on the tower s name plate 17 troubleshooting 18 Trouble Cause Remedy Unusual motor noise Motor running single phase Stop motor and attempt 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 voltage and currents of all three lines Correct if required Rotor unbalance Rebalance Motor runs hot Motor overload wrong voltage or unbalanced voltage Check voltage and current of all three lines against nameplate values Check nameplate RPM of motor and sheave ratio against parts list Wrong fan RPM Check nameplate RPM of motor and sheave ratio against parts list Measure RPM Bearings overgreased Remove grease 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 start if single phased Check wiring controls and motor Poor ventilation
19. old water basin and suction screen periodically Blowdown Check the blowdown for continuous water discharge during operation Warning maintenance Cooling Tower Cleaning Any evaporative type cooling tower 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 water cooling tow 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 See Starting and Operating Instructions on page 9 A visual inspection should take place at least once a week during the operating season Inspect for bacterial growth and general operation conditions Bacte rial growth should be reported to your water treatment expert for immediate attention At a minimum cooling towers should be cleaned and disinfected with biocides twice a year Systems with biofouling or positive cultures of legionella
20. ollowed 1 Do not allow the tower s leaving water temperature to drop below a mini mum allowable level say 36 F to 40 F 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 coldest possible water is beneficial to your process ice of a mushy consistency can be tolerated but routine periodic observation is advisable If the minimum allowable cold water temperature is established at or near minimum heat load it should be safe for all operating conditions 2 As cold air enters the louvers it causes the water flowing over the fill to be drawn inward toward the center of the tower Thus under fan operation the louvers and lower periphery of the tower structure remain partly dry seeing only random splashing from within the tower plus normal atmospheric moisture from the entering air Such lightly wetted areas are most subject to freezing A Warning 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
21. upply BELT GUARD FOR STEEL AQUATOWER SHOWN 1 4 TAP SCREW Cer SUPPORT BRACKET WITH ADJUSTMENT SLOTS Figure 4 SHEAVES MUST BE PARALLEL EACH OTHER AND IN THE SAMEO PLANE OF OPERATION installation Make sure the fan is tightly secured to the bearing housing shaft and that it rotates freely Make sure the bearing housing is secured to its support Attach motor to motor base with four bolts flat washers lock washers and nuts provided see Figure 3 You may want to loosen the adjusting bolts and raise the motor base so you can reach under the motor base to tighten the motor hold down bolts MOTOR SHEAVE PLUMB LINE WT FAN SHEAVE Y Apply a rust preventive coating to the motor shaft to prevent shaft corro sion and to ease sheave installation and removal Install motor sheave and align it with fan sheave Motor support brackets are slotted to assist in alignment See Figure 3 A plumb line will be helpful in aligning sheaves See Figure 4 Remove the fan guard and fan cylinder splice plate steel tower only at the top of the fan cylinder Install the belt over the fan by passing the belt over the fan and rotating the fan blades past the belt Install the belt onto the sheaves Figure 5 installation 7 Use the adjusting bolts on the motor support to adjust belt tension A correctly tensioned belt does not slip when the fan is running and the tight side is straight
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