User Manual - SPX Cooling Technologies
Contents
1. Material LLL S E Fans Manufacturer Diameter Blade Material Fixed Pitch L Adjustable Pitch Number of Blades Hub Material Hub Cover Material Blade Assembly Hardware Blade Tip Clearance min Vibration Level ax Fan Cylinder Height Mech Eqpt Support Mat Oil Fill amp Drain Lines Oil Level Sight Glass Vibration Limit Switches Other Components Motor Manufacturer Name Plate Data HP RPM F L Amps Frame Phase Cycle Volts S F Special Info Last Lubrication Date Grease Used Type Any Unusual Noise No Any Unusual Vibration No U O D Any Unusual Heat Build up No Yes Yes Yes U D O Action Required Action Required Action Required 17 4 Marley Cooling Technologies 7401 W 129 Street Overland Park KS 66213 800 462 75439 www marleyct com e email info marleyct spx com In the interest of technological progress all products are subject to design and or material change without notice 2004 Marley Cooling Technologies Inc Printed in USA2. Motor leads connected incorrectly Check motor connections against wiring diagram on motor Ball bearings Check lubrication Replace bade bearings Electrical unbalance Check voltages and currents of all three lines Correct if required Air gap not uniform Check and correct bracket fits or bearing Rotor unbalance Rebalance Cooling fan hitting guard Reinstall or replace fan Motor Runs Hot Wrong voltage or unbalanced voltage Check voltage and current of all three lines against nameplate values Overload Check fan blade pitch See Fan Service Manual Check for drag in fan drive train as from damaged bearings Wrong motor RPM Check nameplate against power supply Check RPM of motor and gear ratio Bearings overgreased Remove grease reliefs Run motor up to speed to purge excessive grease Rotor rubs stator bore If not poor machining replace worn bearing Wrong lubricant in bearings Change to proper lubricant See motor manufacturer s instruction 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 ample ventilation around motor Winding fault Check with Ohmmeter Bent motor shaft Straighten or replace shaft Insufficient grease Remove plugs and regrease bearings Deterioratio
3. Shipment of these parts are normally made within ten days after an order is received If emergency service is necessary contactthe local Marley sales office or representative for assistance To prevent prolonged shutdown periods in case of damage to the mechanical equipment it is suggested that the following parts be carried in the owner s stock 1 One fan assembly 2 One Geareducer assembly 3 One drive shaft assembly Be sure to furnish the tower serial number when ordering parts Seasonal Shutdown Instructions Tower Drain all tower piping During shutdown clean the tower and make any necessary repairs Apply protective coating as required to all metal parts Particular attention should be given to mechanical equipment supports drive shaft and drive shaft guards Mechanical Equipment Geareducer shutdown for 3 months or less 1 Eachmonth drain water condensate from the lowest point ofthe Geareducer andits oil system Check oil level and add oil if necessary Operate to recoat all interior surfaces with oil 2 Atstart up drain water condensate and check oil level Add oil if necessary Refer to Geareducer Service Manual for maintenance and lubrication instructions A Warning Geareducer shutdown for 3 months or more 1 Ifthe motors have space heaters operate mechanical equipment one hour each month 2 If the motors do not have space heaters operate mechanical equipment one hour each week 3 At star
4. Schedule ssss page 16 Inspection Checklist siiani anai aa page 17 A Note Before Start up CLEANING Remove any dirt and trash which has accumulated in the cold water basin Remove any sediment from the cold water collection basin sump and screens Use a water hose to flush cold water collection basins OPERATE WATER SYSTEM Start the circulating water pumps Increase the flow of circulating water gradually to match design water flow rate Circulate water over the cooling tower continuously for several days before starting the mechanical equipmentand placing the cooling tower into continuous operation When starting in cold weather follow procedures outlined in Cold Weather Operation INSPECTION It is imperative that all operating assemblies be inspected before they are placed in operation The following is a list of components to be checked before starting the tower 1 Check drive shaft alignment Realign if necessary See Marley Drive Shaft Service Manual 2 Check tightness of bolts in fan cylinder joints 3 Check tightness of the following bolted joints in the fan and drive assemblies a Fan hub clamp bolts See Marley Fan Service Manual for correct torque setting b Fan hub cover bolts c Geareducer and motor mounting bolts d Drive shaft coupling and guard bolts 4 Check Geareducer oil for sludge or water by draining off and testing a sample as outlined inthe Geareducer Servi
5. screens several times during the first weeks of operation After this clean sump screens weekly When starting in cold weather follow procedures outlined in Cold Weather Operation STARTING FAN Start the fan After 30 minutes of operating time to permit Geareducer oil to come up to operating temperature check motor load with watt meter or take operating volt and ampere readings and calculate motor HP Refer to Marley Fan Service Manual for instructions Pitch fans to pull correct contract horsepower when circulating design water rate at design hot water temperature Operation Entering water temperature in excess of 125 F may result in fill deformation TOWER PERFORMANCE Keep the cooling tower clean and water distribution uniform to obtain continued maximum cooling capacity The capacity of a cooling tower to cool water to a given cold water temperature varies with the wet bulb temperature and the heat load applied to the cooling tower As the wet bulb temperature drops the cold water temperature also drops However the cold water temperature does not drop linearly with the wet bulb temperature A cooling tower will not control heat load The flow rate of water circulated through the cooling tower will determine the temperature range of cooling in conjunction with a given heatload The hot water and cold watertemperatures will increase with higher heat loads HOT WATER DISTRIBUTION SYSTEM WMaintain uniform water distribution a
6. Semi annually Inspect and Repair for Safe Use Yearly Inspect and Repair Before Each Use As Required 13 Inspection and Maintenance Schedule General Recommendations more frequent inspection and maintenance may be desirable Stairs Ladders Walkway Doors Handrails E oO v i P N S p o 2 g o ca o i oO vc a oO 9 v S 5 S o E x c E m 2 8 0 o re o G S g O o X 2 o LL d O0 x Oo gt D Z o O qc gt C o 53o gt P 52 LE 2 Ez 8 20 c c gt O E Se G 0 5 0 c gt g 9 E 0 000505 5 G g buszaqaourtrtroxrdtononoou Q 1 Inspect for clogging M IM W W Check for unusual noise or vibration Inspect keys keyways and set screws Make sure vents are open Lubricate grease Check oil seals Check operating oil level Check static oil level oO ON Oo oO P W Iv Check oil for water and sludge o Change oil Check fan blade tip clearance k N Check water level A Co Check for leakage Inspect general condition Tighten loose bolts Clean Repaint Rebalance Inspect repair for safe use Inspect and repair before each use 14 Inspection and Maintenance Notes 15 Inspection Checklist Date Inspected Owner Owner s Tower Desig
7. ce Manual Check Geareducer oil level at oil level mark on the side of the case Add oil as required The oil level placard must be adjusted so that its full mark is at the same elevation as the full mark on the side of the Geareducer case Check oil lines to be sure there are no leaks See Geareducer Service Manual for oil filling procedure and list of recommended lubricants 5 Rotate fan by hand to be sure of free rotation and ample tip clearance See Fan Service Manual 6 Check motor insulation with a Megger See Maintenance Section of Marley Electric Motors Service Manual 7 Lubricate the motor according to motor manufacturer s instructions continues A Note N Note N Caution 8 Test run each fan separately for a short time Check for excessive vibration or unusual noise If either is present see Troubleshooting Guide on pages 12 and 13 of this manual Fan must rotate clockwise when viewed from above Recheck Geareducer oil level 9 Check functioning of make up water supply 10 Make sure the blowdown will carry the proper amount of water Starting Procedure WATER SYSTEM Fill the cold water collection basin and circulating water system until the operating water level is reached See Operation Section below Prime and start the circulating water pumps Increase the flow of circulating water gradually to design water flow rate to avoid water hammer which could damage the distribution piping system Cleanthesump
8. class ALLE MU User Manual Cooling Technologies A Warning A Caution N Note A Note Contents 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 presence of a hazard which will or can cause personal injury or property damage if ignored Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards These instructions assist in obtaining efficient long life from Marley counterflow cooling towers Direct questions concerning cooling tower operation and maintenance to your Marley sales office or representative Always include your tower serial number when writing for information or ordering parts Look for this number on the sidewall casing Before Startpreis ufo erede page 3 Starting Procedure sesije iiu poteet Fed cese n xii xti e xa iaa page 4 Operation m page 4 Tower Maintenance sseeeeenneenn een page 6 Water Treatment eccrine eene nennen page 7 Seri uci ER page 9 Seasonal Shutdown Instructions sesssssssesss page 12 Tower Cleaning PEE page 13 Sii X page 15 Inspection and Maintenance
9. e Various proprietary materials containing chromates phosphates or other compounds are available for corrosion control When water treatment chemicals are required the services of reliable water treating companies should be obtained Slime a gelatinous organic growth and algae a green moss may grow in the cooling tower or heat exchangers Their presence can interfere with cooling efficiencies Proprietary compounds are available from water treating companies for the control of slime and or algae however compounds which A Warning contain copper are not recommended Chlorine and chlorine containing compounds are effective algaecides and slimicides If used chlorine should be added as intermittent or shock treatment only as frequently as needed to control the slime and algae Chlorine and chlorine containing compounds should be added carefully since very high levels of chlorine may occur at or near the point of entry into the circulating water system FOAMING Heavy foaming sometimes occurs when a new tower is put into operation This type of foaming generally subsides after a relatively short period of operation Persistent foaming can be caused by the concentrations of certain combinations of dissolved solids or by contamination of the circulating water with foam causing compounds This type of foaming can sometimes be minimized by increasingthe blowdown butin some cases foam depressant chemicals must be added to the system Foam depres
10. from center of fan as safety devices permit All blades must be pitched the same See Fan Service Manual Clean off deposit build up on blades Worn Geareducer bearings Check fan and pinion shaft endplay Replace bearings as necessary Unbalanced motor Disconnect load and operate motor If motor still vibrates rebalance rotor Bent Geareducer shaft Check fan and pinion shaft with dial indicator Replace if necessary Fan Noise Loose fan hub cover Tighten hub cover fasteners Blade rubbing inside of fan cylinder Adjust cylinder to provide blade tip clearance Loose bolts in blade clamps Check and tighten if necessary SAFETY FIRST The tower has been designed to provide a safe working environment while either operating or shut down The ultimate responsibility for safety rests with the Operator and Owner When flow to the tower is shut off or when portions of the tower require maintenance temporary safety barricades may be required around openings and other safety precautions such as safety harnesses should be utilized where appropriate for compliance with OSHA regulations and standards and good safety practices Routine periodic maintenance must be performed on all personnel access and Ladders Stairways material handling accessories in accordance walkways Handrails Covers y with the following schedule Decks and Access Doors Davits Derricks and Hoists Inspect for General Condition Semi annually
11. intermediate platform provides means for inspection of the plenum area above the eliminators Removal of an access hatch at the plenum level allows access to the spray chamber for inspection and maintenance of the nozzles and top of fill Provide surface protection before walking on the fill DRIFT ELIMINATORS Eliminators should be kept clean Do not walk or step on the eliminators without planking and safety harness COLD WATER COLLECTION BASIN supplied by others Inspectcollection basin occasionally for leaks and repair if necessary Keep cold water outlets clean and free of debris Makeup and circulating water controls must operate freely and maintain the desired water quantity in the system DRIVE SHAFT Check drive shaft alignment and condition of couplings every six months See the Drive Shaft Service Manual for correcting misalignment balancing or replacing parts ELECTRIC MOTOR Lubricate and maintain each electric motor in accordance with the manufacturer s instructions If repair work is necessary contact the nearest representative of the motor manufacturer See Warranty Section of Marley Electric Motors Service Manual FAN Inspect fan blade surfaces every six months For detailed maintenance information refer to Marley Fan Service Manual GEAREDUCER Make weekly and monthly oil checks Inspect internal parts during seasonal oil change Refer to the Geareducer Service Manual for detailed maintenance instructions PAINTING Pe
12. n of or foreign material in grease Flush bearings and relubricate Bearings damaged Replace bearings Incorrect fan blade pitch See Fan Service Manual for blade pitching instructions Motor Does Not Come Up Voltage too low at motor terminals To Speed because of line drop Check transformer and setting of taps Use higher voltage on transformer terminals or reduce loads Increase wire size or reduce inertia Broken rotor bars 12 Look for cracks near the rings A new rotor may be required Have motor service man check motor Troubleshooting Trouble Cause Remedy Wrong Rotation Motor Wrong sequence of phases Change any two of the three motor leads Geareducer Noise Geareducer bearings If new see if noise disappears after one week of operation Drain flush and refill Geareducer See Geareducer Service Manual If still noisy replace Gears Correct tooth engagement Replace badly worn gears Replace gears with imperfect tooth spacing or form Unusual Fan Drive Loose bolts and cap screws Tighten all bolts and cap screws on all mechanical equipment Vibration and supports Unbalanced drive shaft or worn couplings Make sure motor and Geareducer shafts are in proper alignment and match marks properly matched Repair or replace worn couplings Rebalance drive shaft by adding or removing weights from balancing cap screws See Drive Shaft Service Manual Fan Make certain all blades are as far
13. nation Inspected By Location Tower Manufacturer Process Served by Tower Design Conditions GPM HW Model No Operation Continuous Q F CW Number of Fan Cells Serial No Intermittent L Seasonal U F Condition 1 Good 2 Keep an eye on it 3 Needs immediate attention Structure Casing Material 1 2 3 Comments Structural Material Fan Deck Material Stairway Material Ladder Material Handrails Material Interior Walkway Material Cold Water Basin Material Water Distribution System Distribution System Header Material Manifold Material Branch Arms Nozzles Orifice diameter inches Heat Transfer System Fill Inlet Face of Fill Eliminators Use this space to list specific items needing attention 16 Inspection Checklist Condition 1 Good 2 Keep an eye on it 3 Needs immediate attention 1 z s comments Mechanical Equipment Gear Drive Units Manufacturer Oil Level Full LJ Add Immediately Oil Condition Good L Contains Water LL Oil Used type Model Ratio Low check again soon Contains Metal L Contains Sludge L Seals Back Lash Fan Shaft End Play Any Unusual Noises No LL Yes Drive Shafts E Action Required Manufacturer
14. nit is operated intermittently during winter weather it is necessary that the water be drained from the tower piping to insure protection against freezing and possible rupture Tower Maintenance The FM400 Cooling Tower is a highly specialized design incorporating features which limit damage in the event of a fire These features which are necessary for FM approval include the plastic caps and perimeter tarp onthefan deck These two items are designed to burn away quickly in a fire and as a result are not as durable as typical cooling tower components Periodic replacement of these two components is likely necessary to maintain thermal performance of the cooling tower Well maintained equipment gives the best operating results and the least maintenance cost Marley recommends setting up a regular inspection schedule to insure effective safe operation of the cooling tower Use the schedule on page 14 to obtain continuously good performance with the least tower maintenance See Cooling Tower Inspection Check List in this manual Keep a continuous lubrication and maintenance record for each cooling tower A Warning HOT WATER DISTRIBUTION SYSTEM Keep the circulating water and distribution system piping and nozzles clean and free of dirt algae and scale Algae and scale may clog nozzles eliminators fill and piping and may collect on the equipment served thus reducing its performance An access hatch in the fan deck with ladder to an
15. our understanding of cold weather operation will be enhanced if you read Operating Cooling Towers in Freezing Weather Marley Technical Report H 003 Ice forming characteristics on any given cooling tower will vary depending on velocity and direction of wind circulating water rate and heat load Excessive ice formation may be controlled by regulating air and water flow through the tower by one or more of the following procedures continues N Caution A Note 1 Shut the fan down This reduces the cooling air rate to a minimum and increasesthe quantity of warm water atthe airinletto a maximum However normal fan off operation causes reverse air flow by aspiration and may cause water blowout and therefore must be done with caution and monitoring For automatic operation a timer switch can be provided to shut the fan down for a few minutes each hour 2 When a cooling tower has two speed motors operate the fans at half speed forward This reduces the cooling air rate heat transfer and increases the quantity of warm water at the air inlet 3 With no heat load on the circulating water icing cannot be controlled Towers must not be operated with reduced water rate and or no heat load during freezing weather If a bypass directly into the cold water basin is used all water must be bypassed Reverse operation of fans is not recommended See Fan Drive for fan speed change precautions INTERMITTENT OPERATION When the u
16. riodically clean and if necessary recoat all metal parts subject to corrosion Water Treatment BLOWDOWN Blowdown or bleed off is the continuous removal of a portion of the water from the circulating system Blowdown is used to prevent the dissolved solids from concentrating to the point where they will form scale The amount of blowdown required depends upon the cooling range the difference between the hot and cold water temperatures and the composition of the make up water water added to the system to compensate for losses by blowdown evaporation and drift The following table shows the amount of blowdown required to maintain different concentrations with various cooling ranges BLOWDOWN OF CIRCULATING RATE COOLING RANGE F EXAMPLE 7000 GPM circulating rate 15 cooling range To maintain 4 concentrations the required blowdown is 38 or 0038 times 7000 GPM which is 26 6 GPM Iftower is operated at 4 concentrations circulating water will contain four times as much dissolved solid as the make up water providing none of the solids form scale or are otherwise removed from the system CHEMICAL TREATMENT In some cases chemical treatment ofthe circulating water is not required if adequate blowdown is maintained In most cases however chemical treatment is required to prevent scale formation and corrosion Sulfuric acid or one of the polyphosphates is most generally used to control calcium carbonate scal
17. sants are available from a number of chemical companies MAINTENANCE OF FILL PERFORMANCE Owner must keep water clean by treatment screening or filtering to avoid the possibility of fill clogging and loss of thermal performance Potential Causes of Fill Clogging Suspended materials Trash etc Scale Can be sulfates silicates carbonates or oxides Scaling effects can be accentuated by suspended muds Algae and or Slime Can control with chlorine or non oxidizing biocides Possible Sources of Scale Calcium Sulfate From make up and sulfates produced by sulfuric acid for pH adjustment Calcium sulfate should be kept below 1000 ppm expressed as CaCO Calcium Carbonate Generally will not form scale in the cooling tower if carbonate scaling does not occur in the condenser Exceptions If make up water contains surplus free carbon dioxide scaling may be inhibited in the condenser but may occur in the tower fill because of CO stripping continues 10 Silicates and Oxides Silica scale is virtually impossible to remove Silica scale is unlikely if SiO is held below 150 ppm Oxides such as iron oxide can coat all parts of the system if soluble iron is present in concentrations above 0 5 ppm Iron oxides do not usually develop into thick scales but can accentuate the development of other scales Spare Parts Marley manufactures and maintains a stock of replacement parts for all cooling tower mechanical equipment
18. t the nozzles uniform spray cone The amount of water circulated should approximate the contract requirements and the nozzle pressure should be kept constant Lower pressures may indicate excessive losses in the piping system and or insufficient pump capacity greater pressures might indicate clogged nozzles and or overpumping If a greatly reduced water flow rate is desired it may be advisable to change nozzle sizes to obtain the desired pressure and maintain proper water distribution A Marley engineer can advise minimum and maximum flow rates for even distribution COLD WATER COLLECTION BASIN A suitable depth must be maintained to keep the pumps from pulling air into the line The amount of make up water required to keep the water in the collection basin at the required depth depends upon the evaporation loss and blowdown FAN DRIVE When using two speed motors allow a time delay of 20 seconds minimum after de energizing the high speed winding and before energizing the low speed winding Tremendous stresses are placed on driven machinery and motors unless the motors are allowed to slow to low speed RPM or less before the low speed winding is energized COLD WEATHER OPERATION During periods of low temperature operation 35 F to 40 F or below ice will form on the relatively dry parts of the cooling tower that are in contact with the incoming air Primarily this includes the air inlet and adjacent structural framing Y
19. take place at least once a week during the operating season Periodic flushing and cleaning should be done at least twice a year Nozzles should be checked for clogging Drifteliminators and easily accessible fill surfaces should be cleaned by use of a moderate pressure water nozzle being careful not to cause physical damage A reliable water treatment program should be installed and maintained 11 Troubleshooting Trouble Cause Remedy Motor Will Not Start Power not available at motor terminals 1 Check power at starter Correct any bad connections between the control apparatus and the motor 2 Check starter contacts and control circuit Reset overloads close contacts reset tripped switches or replace failed control switches 3 If power is not on all leads at starter make sure overload and short circuit devices are in proper condition Wrong connections Check motor and control connections against wiring diagrams Low voltage Check nameplate voltage against power supply Check voltage at motor terminals Open circuit in motor winding Check stator windings for open circuits Motor or fan drive stuck Disconnect motor from load and check motor and Geareducer for cause of problem Rotor defective Look for broken bars or rings 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
20. tup operate mechanical equipment one hour or until oil is warm then shut the equipment down Drain the oil and refill with new oil Referto Geareducer Manualfor instruction on changing oil Referto Downtime Instruction Manual for downtime exceeding six months Electric Motors 1 Donotstart motor without determining thatthere will be no interference with free rotation of the fan drive 2 Refer to Marley Cooling Tower Motor Operation and Maintenance instructions 3 If shutdown periodis longerthan seasonal contact your Marley sales office or representative for additional information Cooling Tower Cleaning Any evaporative type cooling tower must be thoroughly cleaned on a regular basis to minimize the growth of bacteria including Legionella Pneumophilla to avoid the risk of sickness or death Service personnel must wear proper personal protective equipment 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 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 Visual inspection should
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