Marley Aquatower Cooling Tower 3800 4800 User Manual
Contents
1. 66 Dia 338129 338129 118SE Bearing Housing 574194 574194 574194 574194 574194 574194 574194 48 Dia HDG C53626 C53626 C53626 54 Dia HDG C53627 C53627 66 Dia HDG C53628 C53628 Float Valve Fan Guard Motor sheave part number shown is for a standard motor frame application Because of the various motor frame options the Brass Body 3 4 NPT 155929 155929 155929 155929 155929 155929 155929 Brass Stem 088708 088708 088708 088708 088708 088708 088708 Plastic Float 720680 720680 720680 720680 Aquatower serial number is required to insure correct sheave replacement part 26 720680 720680 720680 Parts List 4800 Aquatower 60 Cycle Motor Use this table to identify the Aquatower motor Contact your local Marley sales representative for prices and availability to place your order or for help with identifying the correct motor Model Number Motor 60 Cycle hp 1 60 115 230 1800 rpm 56 Frame 454215 hp 1 60 115 230 1800 rpm 56 Frame 200113 200113 200113 200113 1 hp 3 60 200 1800 rpm 143T Frame C04703 C04703 C04703 C04703 1 hp 3 60 230 460 1800 rpm 143T Frame C04704 C04704 C04704 C04704 1 hp 3 60 575 1800 rpm 143T Frame C04705 C04705 C04705 C04705 2 hp 3 60 200 1800 rpm 145T Frame C04719 C04719 2 hp 3 60 230 460 1800 rpm145T Frame C047202. 4841 4842 A100 609347 A105 320333 A112 221820 221820 221820 A120 197632 Motor Sheave 089359 107045 094979 107805 094979 131193 107508 112698 Fan Sheave 135210 135210 135210 135210 154856 154856 154245 154245 24 Dia 436741 436741 436741 436741 36 Dia 437046 437046 42 Dia 437582 437582 1301SE Bearing Housing C72316 C72316 C72316 C72316 C72316 C72316 C72316 C72316 24 Dia HDG C53623 C53623 C53623 C53623 36 Dia HDG C53624 C53624 42 Dia HDG C53625 C53625 Float Valve Fan Guard Brass Body 3 4 NPT 155929 155929 155929 155929 155929 155929 155929 155929 Brass Stem 720755 720755 720755 720755 720755 720755 720755 720755 Plastic Float Model Number 2 A120 720680 216218 720680 216218 720680 720680 720680 720680 720680 720680 2 A128 216234 B140 617407 2 B144 216218 216218 216218 216556 216556 2 B150 617407 720672 Motor Sheave 182873 210633 215673 129544 424143 215913 226209 Fan Sheave 427179 427179 427179 427286 427286 427286 427286 48 Dia 439109 439109 439109 54 Dia 024869 024869
3. 720755 720755 720755 Plastic Float Model Number 2 A120 720680 216218 720680 216218 720680 216218 720680 720680 720680 720680 720680 B140 617407 2 B144 216556 216556 216556 Motor Sheave 571562 180398 211136 112169 217497 212100 215822 Fan Sheave 427179 427179 427179 427286 427286 427286 427286 48 Dia 439109 439109 439109 54 Dia 024869 024869 66 Dia 118SE Bearing Housing 574194 574194 574194 574194 574194 338129 574194 338129 574194 48 Dia HDG C53626 C53626 C53626 54 Dia HDG C53627 C53627 66 Dia HDG C53628 C53628 Float Valve Fan Guard Motor sheave part number shown is for a standard motor frame application Because of the various motor frame options the Brass Body 3 4 NPT 155929 155929 155929 155929 155929 155929 155929 Brass Stem 088708 088708 088708 088708 088708 088708 088708 Plastic Float 720680 720680 720680 720680 720680 720680 Aquatower serial number is required to insure correct sheave replacement part for your application 720680 25 Parts List 4800 Aquatower 50 Cycle Motor Application Model Number A75 4811 693531 4812 693531 4821 4822 4831 4832
4. Inlet Cooling Tower with Bottom Outlet Gravity Line from Outlet Indoor Storage Tank Overflow and Drain to Sewer A Note Motor Frame Fastener Size 56 143T 145T 182T thru 215T 254T 5 16 3 8 1 2 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 Connecttower outletto 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 supply 1 4 TAP SCREW SUPPORT BRACKET WITH ADJUSTMENT SLOTS Figure 4 SHEAVES MUST BE PARALLEL TO EACH OTHER AND IN THE SAME PLANE OF OPERATION Installation Ma
5. ff v H TAK e b z b x L 9 E SS SX 7 we oe Figure 8 Reassembly Reassemble in reverse order Precautions The following precautions will simplify reassembly and will help to assure proper operation 1 Install the fill support tubes and hangers as one pack The fill pack contains two different types of sheets Alternate the two types to form a honeycomb pattern at louvers and eliminators 2 Make sure that sealing washers are installed as required and tighten screws or bolts to flatten washers 3 Make sure mechanical equipment is installed correctly and fan rotates freely 4 Reseal all locations that were sealed prior to disassembly Clean joints before assembly to assure water tight joints Wiring Diagrams Capacitor Start Single Phase Motors Reversible Double Voltage T1 L1 T2 O ce ts 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 4 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 I With Thermal Overload Fractional HP High Voltage 1 Insulate P2 2 Connect T2 T3 and L8 and insulate 3 Connect T4 T5 and L2 and insulate 4 Connect P1 and L1 and insulate me 19 20 W
6. C04720 2 hp 3 60 575 1800 rpm 145T Frame C04721 C04721 3 hp 3 60 200 1800 rpm 182T Frame C04736 3 hp 3 60 230 460 1800 rpm 182T Frame C04737 3 hp 3 60 575 1800 rpm 182T Frame C04738 Model Number Motor 60 Cycle 2 hp 3 60 200 1800 rpm 145T Frame C04719 2 hp 3 60 230 460 1800 rpm145T Frame C04720 2 hp 3 60 575 1800 rpm 145T Frame C04721 3 hp 3 60 200 1800 rpm 182T Frame C04736 3 hp 3 60 230 460 1800 rpm 182T Frame C04737 3 hp 3 60 575 1800 rpm 182T Frame C04738 5 hp 3 60 200 1800 rpm 184T Frame C11602 C11602 5 hp 3 60 230 460 1800 rpm 184T Frame C11604 C11604 5 hp 3 60 575 1800 rpm 184T Frame C11606 C11606 7 hp 3 60 200 1800 rpm 213T Frame C11618 C11618 7 hp 3 60 230 460 1800 rpm 213T Frame C11620 C11620 7 hp 3 60 575 1800 rpm 213T Frame C11622 C11622 7 hp 3 60 208 1800 900 rpm 215T Frame 235085 235085 7 hp 3 60 460 1800 900 rpm 215T Frame 652636 652636 7 hp 3 60 575 1800 900 rpm 215T Frame 235168 235168 10 hp 3 60 200 1800 rpm 215T Frame C04706 10 hp 3 60 230 460 1800 rpm 215T Frame C04708 10 hp 3 60 575 1800 rpm 215T Frame C04711 10 hp 3 60 200 1800 900 rpm 254T Frame 119594 10 hp 3 60 460 1800 900 rpm 254T Frame 198754 10 hp 3 60 575 1800 900 rpm 254T Frame 246371 Indicates standard motor for each model Other motors shown are supplied for particular electrical supply characteristics Check the moto
7. motor to service Prolonged Shutdown If shutdown period is longer than seasonal contact your Marley Sales Representative 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 Troubleshooting 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 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 Clean motor and check ventilation openings Allow am
8. 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 Fillthecirculating system with water The cold water basin should be filled with water until level is at the rim of the overflow 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 Startyour 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 from 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 floatvalve duringtower operation with heat load to maintain 4 water depth in the depressed section of the basin on Models 4810 through 4840 and Models 3810 through 3840 Maintain 5 1 2 water depth on Models 4850 through 4870 and Models 3850 and 3860 Hot water temperatures exceeding 125 F could
9. supports Remove fan sheet with fan cylinder intact Remove basin covers splash box and top girt aro y Remove makeup float valve Disassembly and Reassembly 6 Remove fill 7 Remove hot water distribution basin 8 Remove side casing sheets 9 Disassemble cold water collection basin and skids Reassembly Reassemble in reverse order Precautions The following precautions will simplify reassembly and will help to assure proper operation 1 Install the fill support tubes and hangers as one pack The fill pack contains two different types of sheets Alternate the two types to form a honeycomb pattern at louvers and eliminators 2 Make sure that sealing washers are installed as required and tighten Screws or bolts to flatten washers 3 Make sure mechanical equipment is installed correctly and fan rotates freely 4 Resealbasinsandallotherlocations that were sealed prior to disassembly Clean joints before assembly to assure water tight joints Series 3800 Aquatower See Figure 8 on page 18 Disassembly 1 o o uoo FWD Remove fan guard fan bearing housing bearing housing supports and motor supports Remove fan sheet Remove basin covers splash box and air seal Remove makeup float valve Remove fill Remove hot water distribution basin Remove side casing sheets Remove cold water collection basin Disassemble base skids 17 Disassembly and Reassembly iY
10. 155929 155929 155929 155929 155929 155929 155929 155929 155929 155929 Brass Stem 720755 720755 720755 720755 720755 720755 088708 088708 088708 088708 088708 Plastic Float 720680 720680 720680 720680 720680 720680 720680 720680 720680 720680 720680 Fan Guard Float Valve Motor sheave part number shown is for a standard motor frame application Because of the various motor frame options the Aquatower serial number is required to insure correct sheave replacement part for your application 22 Parts List 3800 Aquatower 50 Cycle Motor Application Model Number A75 3816 693531 3817 693531 3831 3832 3841 3842 3851 3852 3853 3861 3862 A112 221820 221820 221820 A120 197632 2 A120 216218 216218 2 A128 216234 B140 617407 2 B144 216556 Motor Sheave Fan Sheave 089359 135210 578187 135210 094979 154856 131193 154856 107508 154245 112698 154245 182873 427179 210633 427179 215673 427179 129544 424143 424143 424143 24 Dia 36 Dia 436741 436741 437046 437046 42 Dia 437582 437582 48 Dia 439109 439109 439109 54 Dia 024869 024869 1301SE Bearing Housing C72316 C72316 C72316 C72316 C72316 C72316 118
11. 2 hp 3 60 200 1800 rpm 145T Frame 2 hp 3 60 230 460 1800 rpm 145T Frame 2 hp 3 60 575 1800 rpm 145T Frame 3 hp 3 60 200 1800 rpm 182T Frame 3 hp 3 60 230 460 1800 rpm 182T Frame 3 hp 3 60 575 1800 rpm 182T Frame 5 hp 3 60 200 1800 rpm 184T Frame 5 hp 3 60 230 460 1800 rpm 184T Frame 5 hp 3 60 575 1800 rpm 184T Frame 7 2 hp 3 60 200 1800 rpm 213T Frame 7 e hp 3 60 230 460 1800 rpm 213T Frame 7 2 hp 3 60 575 1800 rpm 213T Frame 7 e hp 3 60 208 1800 900 rpm 215T Frame 7 hp 3 60 460 1800 900 rpm 215T Frame 7 hp 3 60 575 1800 900 rpm 215T Frame 454215 200113 200113 04703 04703 04704 04704 04705 04705 04719 04719 04719 04720 04720 04720 04721 04721 04721 125757 125757 125765 125765 04738 04738 11602 11602 11604 11604 11606 11606 11618 11620 11622 235085 652636 235168 Indicates standard motor for each model Other motors shown are available for particular electrical supply characteristics Check the motor nameplate information before you order Model Number 3816 3817 3831 3832 3841 3842 3851 3852 3853 3861 3862 Motor 50 Cycle V5 hp 1 50 115 230 1500 rpm 56 Frame 1 hp 3 50 220 380 1500 rpm 143T Frame 205492 221176 221176 2 hp 3 50 220 380 1500 rpm 182T Frame 2239
12. 74 223974 223974 3 hp 3 50 220 380 1500 rpm 182T Frame 5 hp 3 50 220 380 1500 rpm 213T Frame 7 hp 3 50 220 380 1500 rpm 215T Frame 230722 230722 233056 233056 235275 24 Parts List 4800 Aquatower 60 Cycle Motor Application Contact your local Marley sales representative for prices and availability to place your order or for help with identifying parts To find you local Marley sales representative call 913 664 7400 or check the internet at www marleycoolingtower com Model Number A75 4811 693531 4812 693531 4821 4822 4831 4832 4841 4842 A100 609347 A105 320333 A112 221820 221820 221820 221820 Motor Sheave Fan Sheave 082172 135210 094979 135210 082859 135210 106310 135210 082859 154856 112292 154856 095778 154245 107508 154245 24 Dia 36 Dia 436741 436741 436741 436741 437046 437046 42 Dia 437582 437582 T g S 3 c 9 2 gt i 1301SE Bearing Housing Dia HDG C72316 C53623 C72316 C53623 C72316 C53623 C72316 C53623 C72316 C72316 C72316 C72316 Dia HDG C53624 C53624 Dia HDG Brass Body 3 4 NPT 155929 155929 155929 155929 155929 155929 C53625 155929 C53625 155929 Brass Stem 720755 720755 720755 720755 720755
13. Aquatower User Manual OM 3800 4800B Marley Manual 92 1311G A Warning N Note A Note Contents Tower Installation 2 oce ome Hee HE D as 3 PIPING tO TOWO 2 de cte eee 4 Mechanical Equipment Installation 5 Motor Electrical Connections 8 Starting and Operating Instructions 9 Maintenance Instructions seeeenn en 11 BlOWGOWL cci t opt 12 Seasonal Shutdown Instructions ccceeceeeeeeeeeeeeeeeeeseeseeeeeeseeeeeeees 13 Troubleshooting 2 Eie tee der RR eso eed une hist 15 Disassembly and Reassembly 16 Wiring Diagrams Ace eth e Tete e ate edet e 19 Darts ISU c ttd LER e e ete vane etes 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 whichcan cause severe personal injury death or substantial property damage if ignored Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards This Manual contains vital information for the proper installation and operation of your cooling tower Carefully read th
14. SE Bearing Housing 574194 574194 574194 574194 574194 Fan Guard 24 Dia HDG 36 Dia HDG C53623 C53623 C53624 C53624 42 Dia HDG C53625 C53625 48 Dia HDG 54 Dia HDG C53626 C53626 C53626 C53627 C53627 Float Valve Brass Body 3 4 NPT 155929 155929 155929 155929 155929 155929 155929 155929 155929 155929 155929 Brass Stem 720755 720755 720755 720755 720755 720755 088708 088708 088708 088708 088708 Plastic Float 720680 720680 720680 720680 720680 720680 720680 720680 720680 720680 720680 Motor sheave part number shown is for a standard motor frame application Because of the various motor frame options the Aquatower serial number is required to insure correct sheave replacement part for your application 23 Parts List 3800 Aquatower 60 and 50 Cycle Motor Use this table to identify the Aquatower motor Contact your local Marley sales representative for prices and availability to place your order or for help with identifying the correct motor Model Number 3816 3817 3831 3832 3841 3842 3851 3852 3853 3861 3862 Motor 60 Cycle V5 hp 1 60 115 230 1800 rpm 56 Frame hp 1 60 115 230 1800 rpm 56 Frame 1 hp 3 60 200 1800 rpm 143T Frame 1 hp 3 60 230 460 1800 rpm 143T Frame 1 hp 3 60 575 1800 rpm 143T Frame
15. damage PVC fill 5 Make sure blowdown line is discharging water 6 Depthofwaterin hotwater basin should be uniform Ifthe basin overflows reduce the flow rate Do not pump more water than design capacity 4 A Note 10 Operation 7 Continue pump operation for about 15 minutes after which it is recommended 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 shutdown Utilize the services ofthe watertreatment 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 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 duration 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
16. e manual before installation or operation of the tower and follow all instructions Save this manual for future reference A Warning Installation Receiving Inspection The motor and miscellaneous parts ship with the tower Check motor nameplate 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 obtain 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 HO To minimize pressure losses e Use 20 oversize ducts Avoid sharp turns or abrupt changes in size e Keep duct length to a minimum Screened or louvered openings should have a net free area at least 20 greater than the tow
17. er discharge opening area Attach ducts to the tower using flexible connections and support ducts independently from the tower Provide access openings for 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 4 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 3 8 diameter bolts not supplied Remove strapping and brackets from the louver face on models 4850 4860 and 4870 and reinstall the bolts to the cold water basin Install the overflow 3800 models only as shown in Figure 1 INSTALL DRAIN FITTING WITH GASKET ON TOP Piping to Tower Summer Only Operation 1 Uselarge 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 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
18. f thin gage material Motor Lubricate the motoraccording tothe motor manufacturer s supplied instructions 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 cold water basin and suction screen periodically Blowdown Check the blowdown for continuous water discharge during operation 11 A Warning 12 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 equipment during decontamination Do NOT attempt any service unless the fan motor is locked out Operators of evaporative cooling equipment such as water cooling towers should follow maintenance programs which will reduce to an absolute minimum the opportunity for bacteriological contamination Public Health Service official
19. ing and may damage the cooling tower 13 A Warning A Note 14 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 Atstartof 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 andoil 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 interference with free rotation of the fan drive The motor should be run for three hours at least once a month to dry out windings and relubricate bearing surfaces Referto Electric Motors on Cooling Towers Manual 92 1475 At start of new operating season make sure bearings are adequately lubricated before returning
20. iring Diagrams Low Voltage 1 Connect P1 and L1 and insulate 2 Connect P2 T3 and T8 and insulate 3 Connect T2 T4 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 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 Voltage NAMEPLATE T4 T5 T6 T4 Tie Together Low T4 T5 T6 High L1 LOW V L3 T8 T7 T1 L2 L3 T2 T4 T7 T5 T8 6 T9 NAMEPLATE T4 T5 T8 T9 T2 T3 a 1 12 HIGH V T6 T6 T9 T3 L3 Tie Together T1 T7 T6 T2 T8 T4 T3 T5 T9 T1 T2 T3 T4 T7 T5 T8 T6 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 T5 o
21. it to evaporate 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 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 are in the range of 2 4 concentrations The following table gives approximate 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 10 0 7 0 17 15 1 1 0 30 20 1 5 0 43 Range is the difference between hot water temperature entering the tower and cold water temperature leaving the tower When water treatmentchemicals are added they should notbe introduced into the circulating water system via the cold water basin of the cooling tower Water velocities are lowest at that point which results in inadequate mix
22. ke 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 WI FAN SHEAVE Apply a rust preventive coating to the motor shaft to prevent shaft corrosion and to ease sheave installation and removal Install motor sheave and align it with fan sheave Motor support brackets are slotted to assistin alignment See Figure 3 A plumbline will be helpful in aligning sheaves See Figure 4 Model 4861 and 3861 fan sheave has two grooves but uses only one belt and a single groove motor sheave Remove the fan guard and fan cylinder splice plate Series 4800 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 between sheaves The slack side will have a slight bow If possible use a commercially available tension measuring device Avoid over tensioni
23. ng 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 for a Series 4800 or Figure 5 for a Series 3800 Aquatower 9 Install fan cylinder splice plate Series 4800 only and fan guard 10 Check bearing housing oil cup level Fill to the proper level with SAE 30 ISO 100 weight oil 3 8 x 1 1 2 BOLT 3 8 WASHERS USE 3 8 WASHERS TO SHIM AS REQUIRED N Note Figure 6 Installation Motor Electrical Connections If Aquatower is equipped with Marley Control System refer to Control 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 Pap StS SSS ier Sis SSeS A SS SSeS SSS ey 2 WIRE CONTROL IF USED i START i OL STOP L1 TEE L2 13 M M NOTE L3 IS USED ON 3 PHASE MOTOR ONLY A Warning A Note A Note Operation Starting and Operating Instructions Among other sources outbreaks of Legionnaires Disease have reportedly been traced to cooling towers Maintenance and water treatment procedures that prevent amplification and dissemination of Legionella and
24. 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 Resumethe standard water treatment program including biocidal treatment Check fan for free rotation and check oil level in bearing housing as required 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 Do notallow the total motor acceleration time to exceed 30 seconds per hour A Warning Maintenance 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 productis constructed using cold formed sheet metal Use protective clothing gloves and shoes as appropriate for protection against edges o
25. ple 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 15 16 Figure 7 Disassembly and Reassembly Never disassemble the Aquatower further than necessary When disassembling remember how each partfits in place and attaches to its mating parts Reattach fasteners as you reinstall each section Be careful not to mar galvanized coating Some sections of the tower are sealed with polyurethane sealer Apply Sika Flex or equivalent sealer when reassembling these areas Series 4800 Aquatower Disassembly Remove top sheet Remove fan guard fan bearing housing and bearing housing
26. r nameplate before you order 27 Parts List 4800 Aquatower 50 Cycle Motor Use this table to identify the Aquatower motor Contact your local Marley sales representative for prices and availability to place your order or for help with identifying the correct motor Model Number 4812 4821 Motor 50 Cycle hp 1 50 115 230 1500 rpm 56 Frame 205492 1 hp 3 50 220 380 1500 rpm 143T Frame 221176 221176 221176 221176 2 hp 3 50 220 380 1500 rpm 182T Frame 223974 223974 3 hp 3 50 220 380 1500 rpm 182T Frame 230722 Model Number 4852 4853 Motor 50 Cycle 2 hp 3 50 220 380 1500 rpm 182T Fram 223974 3 hp 3 50 220 380 1500 rpm 182T Frame 230722 5 hp 3 50 220 380 1500 rpm 213T Frame 233056 233056 7 hp 3 50 220 380 1500 rpm 215T Frame 235275 235275 10 hp 3 50 220 380 1500 rpm 254T Frame 238238 0 Marley Cooling Tower AUnited Dominion Company The Marley Cooling Tower Company 7401 W 129 Street Overland Park KS 66213 913 664 7400 email info marleyct com www marleyct com In the interest of technological progress all products are subject to design and or material change without notice 2001 Marley Cooling Tower Printed in USA
27. r T6 T5 T4 T6 T4 o T1 T5 o T2 L1 L2 LOW SPEED Tie Together L3 NAMEPLATE T6 T2 T3 o 0 0 O T3 T6 T4 T5 Li 12 1 HIGH SPEED Insulate Separately T4 T5 T6 T1 T2 T3 21 Parts List 3800 Aquatower 60 Cycle Motor Application Contact your local Marley sales representative for prices and availability to place your order or for help with identifying parts To find you local Marley sales representative call 913 664 7400 or check the internet at www marleycoolingtower com Model Number 3816 3817 3831 3832 3841 3842 3851 3852 3853 3861 3862 A75 693531 693531 A112 221820 221820 221820 221820 2 A120 216218 216218 216218 B140 617407 2 B144 216556 Motor Sheave 082172 559179 082859 112292 095778 107508 571562 180398 211136 112169 217497 Fan Sheave 135210 135210 154856 154856 154245 154245 427179 427179 427179 427286 427286 24 Dia 436741 436741 36 Dia 437046 437046 42 Dia 437582 437582 48 Dia 439109 439109 439109 54 Dia 024869 024869 1301SE Bearing Housing C72316 C72316 C72316 C72316 C72316 C72316 118SE Bearing Housing 574194 574194 574194 574194 574194 24 Dia HDG C53623 C53623 36 Dia HDG C53624 C53624 42 Dia HDG C53625 C53625 48 Dia HDG C53626 C53626 C53626 54 Dia HDG C53627 C53627 Brass Body 3 4 NPT 155929
28. s 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 Avisual inspection should take place at least once a week during the operating season Inspect for bacterial growth and general operation conditions Bacterial 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 may require additional cleaning 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 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 A Note Maintenance Blowdown A cooling tower cools water by continuously causing a portion of
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