Marley Fluid Cooler Fan and Pump Control Panel System User
Contents
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6. The temperature probe is furnished with 22 feet of lead length Longer lead lengths up to 99 feet are available Do not add wiring to the probe lead The solid state control card is located inside the CoolBoost control panel A power contactor inside the control panel is used to energize the heating element Sensor Probe with 22 foot lead Basin Heater Card The temperature card and basin heater element maintains water temperature in the basin between 40 F and 45 F The temperature probe includes a low water cut off circuit If the water level falls below the temperature probe the basin heater contactor will not energize 11 12 Options Solid State Water Level Control and Alarm Circuit The number of probes depends on the number of optional circuits being furnished Each water level event requires one card The card includes an on board relay with 1 form C dry contact Contacts are wired to a user Stilling Chamber Water Level Probes Water Level Card terminal strip for connection to remote devices such as makeup solenoids and alarms Water make up control Form 1 1 contact wired to 120 VAC fused circuit for customer use to power a remote solenoid High water alarm N O contact wired to user terminal block Low water alarm N O contact wired to user terminal block High water cutoff N C contact wired to user terminal block Low
7. and the fluid being cooled has reached he temperature required to run the fan motors Then using a voltage meter check for 120VAC being present between terminals 16 and 6 Then check or 120VAC between terminals 9 and 6 If voltage exists between 16 and 6 and not between 9 and 6 call for assistance to replace the PI controller Pump Motor When the pump switch is turned to the ON position the circulating pump motor will not run Pump motor OL Over Load tripped Verify the OLs sized correctly dial setting Reset motor OL To reset OLs sufficient time must elapse to cool the bi metal OL 5 Tripped circuit breaker for pump motor supply voltage Reset the circuit breaker The pump alarm light has energized Make appropriate adjustments to insure basin water level meets requirements Once basin water has reached its required level press the alarm reset located on the front of the control panel pump alarm light has energized Make appropriate adjustments to insure basin water temperature meets requirements Once basin water has reached its required temperature press the alarm reset located on the front of the control panel Integrated Basin Heater Control Option Basin heater control is not turning on Heater element s in the cold water basin are not heating the water Water temperature is above 45 F The water temperature must drop to 45 F before the basin heater circ
8. controller User terminal points for vibration switch shut down circuit Fan Operation Program the temperature controller with the required set point value 85 F is the factory default and may be field adjusted On the Love Controls series 16B controller press UP or DOWN arrow button to adjust the set point temperature The display will revert to the normal screen within 30 seconds HAND position With the selector switch in HAND the fan motor will ener gize and will run at a constant full speed The HAND position may be used to bump the motor to check fan rotation or manual motor operation OFF position Fan motor will be de energized AUTO position In AUTO position the temperature controller controls the ON and OFF cycling of the fan motor The temperature controller compares the error difference between the discharge fluid measurement by the RTD and the set point value making the decision to turn the fan motor on or off Operation Temperature Controller Information Solid State Temperature Control for one and two speed control panels Temperature Controller Love Control cat 16B 33 controller RTD Marley 037528 RTD 3 wire PT100 Love solid state temperature controller using an RTD to measure cold water discharge temperature providing ON OFF starter control The Love 16B 33 temperature controller furnished in this control panel has been preprogrammed as follows Marley CoolBoost Programming Parameters Si
9. water cutoff N C contact wired to user terminal block Pump Heat Trace If circulation pump is has the heat trace option connect the heat trace tape back to the CoolBoost control panel Options Damper Local Control Circuit 120VAC DAMPER MOTOR OPEN O CLOSED FAN CONTACTOR AUXILLARY CONTACTS CUSTOMER CONNECTION This circuit is furnished when a damper control option is ordered and the damper circuit is controlled from the CoolBoost panel in coordination with the fan starter The panel is furnished with a 120 VAC circuit for powering the damper actua tor motor Three wires and a ground are required between the control panel and the damper motor 120 VAC power for the actuator motor on the damper is brought out to user terminal points inside the panel Operation The damper will open when the fan motor is energized and will close when the fan motor is off H O A selector switch operation HAND position Damper opens OFF position Damper closes AUTOMATIC position Damper is closed when fan is off 13 2 jeordAL 29024 YUM 49 03 usog Assy Josuas 27 109 2 absoyosiq TOYLN
10. Marley CoolBoost Fan and Pump Control Panel System User Manual 09 1368 gt Marley Introduction NEMA fiberglass outdoor enclosure with the following features Hinged and lockable outer door Swing out dead front inner door Corrosion resistant enclosure Operators mounted on inner door Electrical Components External disconnect handle with padlocking provisions to meet lockout tag out safety requirements Main circuit breaker with thermal and magnetic overload protection Solid state temperature controller with two line display showing set point and coil fluid temperature RTD with dry well Fan and pump starter Pilot lights Status contacts Wiring diagram laminated and mounted on inside door Built to 01508 and CUL508 safety requirements Options Single Point Power Connection Integrated basin heater controls Integrated water level controls Integrated damper power circuit VFD feeder breaker if fan is controlled with remote VFD Factory installed and wired on selected products A Warning Warning Introduction These instructions are intended to assure that field connections are completed properly and the control system operates for the maximum time possible Since product warranty may depend on your actions please read these instructions thoroughly prior to operation If you have questions about the opera
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12. allation Circulating Pump Circuits The circulating pump circuit utilizes two safety circuits to protect the pump a low water shut off and freezing water shut off These circuits are furnished as standard on every fluid cooler A dedicated stilling chamber with one reference probe and one level probe is furnished in the cold water basin serving as water level feedback for the low water safety circuit An optional second stilling chamber may be furnished with additional level probes but services a different purpose such as water make up and alarm Connect the two low water probes located in the basin stilling chamber to user terminal points in the CoolBoost control panel Marley probes are furnished with 20 0 leads which may be lengthened by splicing 18 gauge control wiring Refer to the wiring diagram in the CoolBoost control panel for connection points Stilling Chamber Water Level Probes Water Level Card Note Installation For the freeze safety circuit run two 18 gauge control wires from the thermostat located on the fluid cooler side casing to user terminal points in the CoolBoost control panel The thermostat has two sets of terminal points Use either the left or right two points oriented in a vertical column Adjust the temperature range so the red arrow on the left points to 35 F as shown below The thermostat provided with this system requires adjustment Remove the inne
13. by manual control only using a two position selector switch located on the door A removable run enable jumper is provided so customer may take control of cycling the pump See the control panel wiring diagram Cycling the pump on and off for temperature control could cause scaling on the coils and is not recommended OFF ON Selector Switch OFF position pump motor is off ON position pump motor will run constantly unless a safety circuit is activated If the water temperature in the cold water basin drops to 35 F a N O contact from the remote thermostat will close and latch in a relay which in turn shuts off the circulating pump This is a safety circuit to prevent pumping freezing water To reset this circuit press the reset button on the door The circuit can be only reset once the cold water basin temperature rises above 45 F If the basin water drops to a dangerously low level the water level card contact will close and also energize the latch in relay shutting the circulating pump off This is a safety circuit preventing the pump from running dry To reset this circuit press the reset button on the door The circuit can only be reset if the water in the basin has risen to an acceptable operating level Note Options Integrated Basin Heater Control Circuit This circuit monitors the water temperature in the cold water basin via a probe type sensor mounted through the side wall of the cold water basin
14. ngle speed motor programming Primary menu SV 85Push enter for 3 sec CnPt Pt enter push index tPun F enter push index tP h 300 enter push index tP L enter push index CtrL onoF enter push index S HC Cool enter push index ALA1 6 enter push index ALA2 7 enter push index ALA3 11 enter push index SALA oF F enter push index CosH oFF Ignore everything below CosH Push enter twice Cts 5 0 enter push index tPoF 0 0 enter push index Push enter Push index Operation r S rUn enter push index SP 0 enter push index AL1H 110 enter push index AL2L 43 enter push index AL8H 13 enter push index AL8L 8 enter push index LoC LoC2 Push enter These settings yield the following operation Single speed motor programming Low speed ON at 90 F Setpt 1 Output A Low speed OFF at 85 F Setpt 1 Output A Alarm ON above 110 F and below 43 AL1 Note Out put 2 is programmed but not used for 151 motor Two speed motor programming Low speed ON at 90 F Setpt 1 Output A High speed ON at 99 F 2 Output High speed OFF at 93 F Setpt 2 Output B Low speed OFF at 85 F Setpt 1 Output A Alarm ON above 110 F and below 43 AL1 Setpoint 2 is a deviation of Setpoint 1 so the actual ON and OFF Note points will change when Setpoint 1 is changed Caution 10 Operation Pump Operation Standard operation of the pump is
15. osition Blown fuse s Check primary and secondary fuses for the control supply voltage located on top of the control power transformer Check incoming Line Voltage fuses replace fuses as necessary Fan Motor Power Light is ON but the fan motor s will not operate in the HAND position Vibration switch external safeties or run permission contacts are inhibiting closure of the fan motor contactor open circuit between terminals 5 and 7 Reset vibration limit switch and or verify customer start inhibit does not exist e g Building automation Emergency Stop Fan motor OL Over Load tripped Verify the OLs sized correctly heater size or dial setting Reset motor OL To reset OLs sufficient time must elapse to cool the bi metal OL heaters Fan Motor Power Light is ON but the fan motor s will not operate in the AUTO position only Set point temperature programmed into the temperature controller is higher then the actual temperature of the fluid in the coil therefore there is no call for cooling Lower the set point value in the controller Temperature controller indicates an alarm Amber Program controller to an appropriate alarm setting Then press reset button located on the front door of the control panel Temperature controller is not functioning properly First verify the controller is not in a fault condition that the setpoint of the controller is accurately programmed
16. ped Verify the OLs sized correctly dial setting Reset motor OL To reset OLs sufficient time must elapse to cool the bi metal OL heaters Pump motor ALARM LIGHTS Pump motor OL Over Load tripped Verify the OLs sized correctly dial setting Reset motor OL To reset OLs sufficient time must elapse to cool the bi metal OL heaters Over Load tripping is caused by excessive motor current Frequentand continued tripping indicates possible motor and or mechanical operation problems Troubleshooting procedures must be performed on these associated components to determine the cause of the over current condition The alarm setting on the temperature controller has been factory preset at 40 F A 5 differential exists between the when alarm is activated and when a reset is accepted For example if the programmed alarm temperature is reached the fluid temperature would need to rise an additional 5 in order to reset the controller if set at 40 it must rise above 45 SPX 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 2011 SPX Printed in USA Manual 09 1368
17. r most brass fitting located on the thermostat enclosure to gain access to the adjusting screw Adjust cut out set point temperature to 45 F This automatically sets the cut in point at 35 F Thermostat Installed on Casing Thermostat and Probe Use this Adjustment Screw N O Contact Set at 35 F Thermostat Probe Installation Thermostat Operation Main circuit breaker Operating handle for the main breaker is located behind the outer door which is pad lockable for lock out tag out Rotating the handle to the OFF position turns power off to the panel Rotating the handle to the ON position provides power to the control panel If servicing the panel hot door open and main breaker in energized position be sure to align the keyed slot on back of the operating handle with the key on the main breaker shaft before closing the door Power light A pilot light indicates the main disconnect is and the control panel is powered Fan circuit Full voltage across the line starter Bi metal type motor overload protection H O A selector switch control Solid state type temperature controller Dual display on the Pi temperature controller shows process fluid PV and set point SP temperatures Set point temperature is adjustable from the controller s keypad by pressing the up and down arrows on the keypad RTD with dry well used to sense temperature for the temperature
18. 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 cooling product You should closely review the literature prior to installing maintaining or repairing your cooling product Installation The control panel may be mounted indoors or outdoors Inside the control panel are steel mounting feet which may be bolted into the enclosure mounting holes and extend beyond the outside dimensions of the enclosure Locate all incoming and outgoing terminations in the bottom of the enclosure to avoid water entering the control panel Install the Marley RTD in the discharge piping coming from the coil dis charge Not Do not install the RTD in the fluid cooler coil piping ote Locate the RTD close to the fluid cooler to avoid building in a delayed reaction time The dry well is furnished with a 2 NPT stainless steel fitting Insertion length is 272 or less into the pipe depending on pipe fitting Locate the dry well in the side or bottom of the pipe to assure the tip of the dry well is covered with fluid at all times Run control wiring from the RTD to terminal points located in the control panel Belden 8770 wire is recommended RTD SENSOR FLUID RETURN LINE 1 2 NPT COUPLING THERMOWELL SENSOR WIRING RTD Temperature Controller located in CoolBoost panel Belden 8770 3 wire plus Shield Inst
19. tion and or maintenance of this control system and you do not find the answers in this manual please contact your Marley sales representative Hazard of electrical shock or burn Be sure to turn off power to the panel before servicing If working on equipment out of site of panel disconnect lockout using standard lockout procedure Safety First The Marley control system uses UL listed components installed in accordance with the National Electric Code The location of the cooling product 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 fluid cooler location or field installation we cannot be responsible for addressing safety issues that are affected by these items The following safetyissues 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 customer supplied main disconnect branch circuit protection 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 installation process SPX Cooling Technologies strongly recommends
20. uit will energize the heater contactor Once the contactor is energized the heater s will remain on until the temperature is above 50 F The fan motor is running The heater contactor circuit is designed not to energize the heater elements while the fan motor is running Blown fuse s If the fan motor is running and the basin cold water temperature is below 45 F Check the voltage supply fuses to the heating elements replace fuses as necessary Heater Control circuit card or heater elements not functioning correctly If the fan motor is running and the basin cold water temperature is below 45 F Call for troubleshooting assistance in determining if replacement of heater control card or heater element is necessary Integrated Damper Control Option Damper switch will not manually open or close the damper Blown fuse If by switching the OPEN OFF AUTO selector between OPEN and OFF does not change the position of the damper Check fuse which supplies the damper control circuit replace blown fuse Integrated Damper Control Option Damper will open and close manually but will not open in AUTO Fan motor is not running To check AUTO operation of the damper control the fan motor must be running When fan is running dampers should open When fan is off dampers should close Check for correct wiring at the damper logic contacts Fan motor ALARM LIGHTS Fan motor OL Over Load trip
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