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cooling tower manualAbout About Us Contact Us Careers History Safety Emergency Service Green Building and LEED Green Building Water Calculator Water Resources Our Green Initiatives Water Conservation Recycled Material What Is A Cooling Tower. Videos Rep Locator Select Page Library: Manuals IMI 685B Vibration IOM User Manual Library, Manuals SGS Refrigeration Industrial Evaporator Parts Library, Manuals SGS Refrigeration Product Line Library, Manuals SGS industrial evaporators and evaporative condensers are designed and built to meet a broad range of industrial refrigeration applications with a clear focus on product quality and customer service. V Tech Adiabatic Fluid Cooler Layout Manual Engineering Data, Library Recold V Tech Adiabatic Fluid Cooler Layout Manual Library, Manuals Marley NC Steel Cooling Tower User Manual Library, Manuals Installation, operation and maintenance instructions - as well as those offered separately on motors, fans, float valves, etc. - are intended to assure that your NC tower serves you properly for the maximum possible time. Introducing SGS Industrial Evaporative Condenser Answering your need for a quality industrial evaporative condenser, count on the new SGS Industrial Evaporative Condenser to be precision engineered and carefully manufactured. With up to 50 greater cooling capacity, the tower cells serve five 1,850-ton chillers and offer higher energy savings, fewer components and lower maintenance costs. Marley FIT Selection Software Our new Marley FIT air delivery selection software takes into consideration the relationship among all cooling tower mechanical system components to recommend a complete system. Air flow is directly proportional to the thermal performance of your cooling tower. How To Install A Marley NC Cooling Tower Episode 11: Motor Outside Airstream On towers with a Motor Outside Airstream, or MOA option, the motor, motor support and driveshaft are installed and aligned on site.http://adanavidalikompresor.com/userfiles/drivers-manual-texas.xml
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How To Install A Marley NC Cooling Tower Episode 10: Ladder Assembly and Installation If your Marley NC Cooling Tower includes an optional ladder for accessing the fan deck, watch this video to ensure proper installation and configuration. How To Install A Marley NC Cooling Tower Episode 9: Guardrail for Air-Inlet Face Ladder If your Marley NC Cooling Tower includes an optional guardrail for a air-inlet (louver) face ladder, watch this video to ensure proper installation and configuration. How To Install A Marley NC Cooling Tower Episode 8: Guardrail for Cased Face Ladder If your Marley NC Cooling Tower includes an optional guardrail for a cased face ladder, watch this video to ensure proper installation and configuration. How To Install A Marley NC Cooling Tower Episode 3: Necessary Hardware In order to correctly assemble and install a Marley NC Cooling Tower, your team will need to be prepared with some basic tools, and you should also be aware of some basic equipment and procedures. How To Install A Marley NC Cooling Tower Episode 2: Installation Instructions and Drawings The Marley NC literature pack includes your installation instructions, bill of materials, and installation drawings for all NC cooling tower’s standard and optional components. How To Install A Marley NC Cooling Tower Episode 1: Site Prep, Tower Arrival and Unloading Follow these simple guidelines and the entire process for your NC Cooling Tower’s arrival and unloading will be smooth and efficient. Marley DT Fluid Cooler Take a look at the Marley DT Fluid Cooler, now with a new finned coil option for expanded dry capacity and thermal performance. Take a look at the difference in dimensions and capacity between Marley NC8407, the Marley NC8414 and the Marley NC8422 cooling towers. Crossflow Vs. Counterflow Cooling Towers Spencer Kaufman with SPX Cooling Technologies, Inc.http://chinajessie.com/seadata/data/uploads/img/160098612243.xmlDidcot B Power Station Repair Follow our Time Lapse video as SPX repairs Didcot B Power Station's cooling tower cells to their original design following an unfortunate fire that severely damaged more than three cells. Is My Cooling Tower Fill Dirty. Mitch Case discusses how to tell the difference cooling tower fill with normal scale build-up and clogged fill that needs maintenance. Cooling Tower Gear Drives Vs. Marley NCWD Cooling Tower Lift The NCWD is an innovative, patented factory assembled hybrid cooling tower designed specifically for plume reduction. Watch as this NCWD is lifted in London, England. Marley MBX EZ Pack Fill The MBX EZ Pack fill's contractor-friendly fill design makes installation fast and easy without requiring major tower modifications. Marley MD Everest Assembly Watch as the new Marley MD Everest modular cooling tower is assembled. Marley Cooling Tower Bearing Lubrication Jerome Jennings, Product Manager for SPX Cooling Technologies, Inc., explains the importance of properly maintaining Marley cooling tower bearings and provides some helpful tips for making bearing lubrication easy. Marley NS Spray System Overview Jerome Jennings, product manager for SPX Cooling Technologies Inc, discusses the advantages of the Marley NS Spray System for field erected cooling towers. Marley Geareducer Rebuild and Repair Whether you have questions on Marley Geareducer operation and maintenance, need components to perform a repair yourself, or want to send your unit back to us for the highest level of care, SPX has the solution. Marley ST Nozzle and Cup System Rob Negless, Sr. Engineer with SPX Cooling Technologies, discusses the benefits of the Marley ST Nozzle and Cup system. Marley MH Fluid Cooler Ryan Miller, Regional Sales Manager for SPX Cooling Technologies, provides an overview of the Marley MH Fluid Cooler. Marley Mechanical Float System Mitch Case with SPX Cooling Technologies Discusses the Marley Mechanical Float System. Marley MD Tower Overview Mitch Case with SPX Cooling Technologies provides an overview of the features of the Marley MD Cooling Tower. Marley Cooling Tower Maintenance Mitch Case from SPX Cooling Technologies discusses mechanical service tips for your Marley cooling tower. Marley Cooling Tower Duty Motor Ryan Miller with SPX Cooling Technologies talks about Weg Duty Motors for Marley cooling towers. Marley HC Flow Control Valve Robert Swafford, Parts Manager for SPX Cooling Technologies, provides an overview of the operation of the Marley HC Flow Control Valve Marley H3 Fan Blade Pitch Adjustment Gary Stauffer from Marley demonstrates how to adjust the blade pitch on your Marley H3 fan blades. Ultra Quiet Fan Blade Pitch Adjustment Gary Stauffer from Marley demonstrates how to adjust the blade pitch on your Marley Ultra Quiet fan blades. Marley X7 Blade Pitch Adjustment Gary Stauffer from Marley demonstrates how to adjust the blade pitch on your Marley X7 fan blades. SPX Cooling Technologies, Inc. Carefully read the manual before installation or operation of the tower and follow all instructions. Save this manual for future reference. Page Tower Location. 3 Tower Shipment. 3 Receiving Tower. 4 Tower Assembly. 4 Motor Wiring. 4 Tower Start-Up. 9 Wintertime Operation. 10 Tower Maintenance. 13 Water Treatment and Blowdown. 13 Schedule of Tower Maintenance. 15 Seasonal Shutdown Instructions. 18 Motor Relubrication Instructions. 19 Prolonged Shutdown. 19 Additional Services. 20 Additional Information. 21 Troubleshooting. 22 Warning Indicates presence of a hazard which can cause severe personal injury, death or substantial property damage if ignored. Caution Indicates presence of a hazard which will or can cause personal injury or property damage if ignored. Note 2 Indicates special instructions on installation, operation or maintenance which are important but not related to personal injury hazards.The QuadraFlow represents a major step forward in lowmaintenance, long-life cooling towers. These instructions—as well as those offered separately on motors, fans, Geareducers, driveshafts, float valves, etc.—are intended to assure that the tower serves you properly for the maximum possible time. Since the QuadraFlow’s warrantability may well depend upon your actions, please read these instructions thoroughly prior to operation. When writing for information, or when ordering parts, please mention tower serial number shown on the tower’s nameplate. Tower Location Space available around the tower should be as generous as possible to promote ease of maintenance—and to permit freedom of airflow into and through the tower. If you have questions about the adequacy of the available space and the intended configuration of the tower, please contact your Marley sales engineer for guidance. Prepare a stable, level support foundation for the tower, utilizing weight, wind load, and dimensional information appearing on appropriate Marley submittal drawings. Supports must be level to insure proper operation of the tower. Warning 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. Tower Shipment QuadraFlow towers ship by truck (on flat bed trailers) unassembled. Single cell towers ship on one truck. Multicell towers, depending on their size, may require more than one truck. Responsibility for the condition of the tower upon its arrival belongs to the trucker—as does the coordination of multiple shipments, if required. 3 installation Receiving Tower Prior to unloading the tower from the delivering carrier, inspect the shipment for evidence of damage in shipment. If damage is apparent, note the freight bill accordingly. This will support your future recovery claim. Tower Assembly Your Marley sales representative is able to provide for the tower assembly by SPX’s construction division or through a qualified subcontractor. Our subcontractors provide safe, efficient assembly which complies with all requirements for five-year warranty protection of your tower by SPX. Motor Wiring Wire motor leads as shown on the motor nameplate matching the supply voltage. Do not deviate from the motor nameplate wiring. This setting allows the fan motor to operate during cooler weather. During cooler weather it is common for the motor to draw 6 to 10 higher than the nameplate amps. High amps are common during tower commissioning when the tower is dry and the ambient air temperature is cool. Do not start the motor more than four to five times per hour. Short cycling the tower will cause fuses, breakers or O.L.s to operate and will decrease motor life. Single winding motor requires a starter with a shorting contactor. Two-winding motor requires a starter with out a shorting contactor. All two-speed starters must have a 20 second time delay relay when switching from high speed to low speed.If the drive is being commanded to run and the load side is cycled ON and OFF with the safety switch this may damage the VFD. Using a VFD in cooling applications has advantages over traditional single or two speed motor control. A VFD can reduce the cost of electrical energy being used and provide better temperature control. In addition, it reduces the mechanical and electrical stress on the motor and mechanical equipment. Electrical savings can be large during periods of low ambient temperature when the cooling requirement can be satisfied at reduced speeds. To benefit from these advantages, it is important that the drive be installed correctly. Marley supplies VFD and VFD controls specifically designed for our cooling products. Most VFD problems can be avoided by purchasing the Marley drive system. If you are installing a VFD other than the Marley drive, please refer to that drives installation manual. ? 5 installation Warning Warning Improper use of a VFD may cause damage to equipment or personal injury. Failure to correctly install the VFD drive will automatically void all warranties associated with the motor and any equipment that is either electrically or mechanically (directly) attached to the VFD drive system. The length of this warranty avoidance will be contingent on properly installing the VFD system and repairing any damage that may have occurred during its operation. SPX Cooling Technologies does not assume responsibility for any technical support or damages for problems associate with non-Marley brand VFD systems. Changing the operational fan speed from the factory settings could cause the fan to operate in an unstable region which may result in damage to the equipment and possible injury. Mechanical Equipment Warning 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. 1. Check the Geareducer oil level at the sight glass near the motor. If oil is required, fill to the proper level. 2. Spin the fan manually to assure that all fan blades properly clear the inside of the fan cylinder. Observe the action of the driveshaft couplings to be sure that the motor and Geareducer are properly aligned. If necessary, correct the alignment in accordance with the included driveshaft manual. 3. Momentarily energize (“bump”) the motor and observe rotation of the fan. The fan should rotate in a counterclockwise direction when viewed from below. If rotation is backwards, shut off the fan and reverse two of the three primary leads supplying power to the motor. Caution 6 If tower is equipped with a two-speed motor, check for proper rotation at both speeds. Check also to see that starter is equipped with a 20-second time delay which prevents direct switching from high speed to low speed. This delay will allow the fan to slow down and will prevent abnormal stress from being applied to the mechanical equipment and the electrical circuit components.Operation should be stable, and there should be no evidence of oil leakage. This is because of the increased density of unheated air flowing through the fan. Determination of an accurate motor load should await the application of the design heat?load. General The cold water temperature obtained from an operating cooling tower will vary with the following influences: 1. Heat Load: With the fan in full operation, if the heat load increases, the cold water temperature will rise. If the heat load reduces, the cold water temperature will reduce. Reduced wet-bulb temperatures will result in colder water temperatures. However, the cold water temperature will not vary to the same extent as the wet-bulb. However, at a given heat load (see formula above), GPM reductions also cause an increase in the incoming hot water temperature. This is the approved method by which to control leaving water temperature. If your tower is equipped with a single-speed motor, the motor may be shut off when the water temperature becomes too cold. This will cause the water temperature to rise. When the water temperature then becomes too warm for your process, the motor can be restarted. Fan cycling limits: Note Considering the normal fan and motor sizes utilized on MCW towers, anticipate that approximately 4 to 5 starts per hour are allowable. If your tower is equipped with a two-speed motor, greater opportunity for temperature control is afforded you. When the water temperature becomes too cold, switching the fan to half-speed will cause 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. Note Do not start the motor more than four to five times per hour (each low speed start and each high speed start count as one start). If your tower consists of two or more cells, cycling of motors may be shared between cells, increasing your steps of operation accordingly. 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. Water System 1. New installations should be cleaned and treated with biocides by a water treatment expert before startup. 2. Remove any and all accumulated debris from tower. Pay particular attention to inside areas of cold water basin, entire hot water basin, and hot water inlet. This is the recommended operating water level. Adjust the float valve so that it is essentially closed at that level. Since the water system external to the tower will have been filled only to the level achieved in the cold water basin, a certain amount of “pump-down” of the basin water level will occur before water completes the circuit and begins to fall from the fill. The amount of initial pump-down may be insufficient to cause the float valve to open. Utilize the services of the water treatment supplier. 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 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. Wintertime Operation: The Marley fill system used in the Quadraflow 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 applications. Nevertheless, during operation in subfreezing weather the opportunity exists for ice to form in the colder regions of the tower. Note 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. It is the operator's responsibility to prevent the formation of destructive (hard) ice on the cooling tower fill. 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. Caution If the minimum allowable cold water temperature is established at or near minimum heat load, it should be safe for all operating conditions. Having established the minimum allowable cold water temperature, maintaining that temperature can be accomplished by fan manipulation, as outlined in Item 4 on page 8. However, in towers of more than one cell, where fans are manipulated sequentially, please realize that the water temperature will be significantly lower in the cell or cells operating at the highest fan speed than the net cold water temperature produced by the entire tower would indicate. Wintertime operation of multicell towers at low cold water temperature levels requires that the operator be especially watchful. 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. 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 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, ? 11 operation 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. Warning 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 Drive Caution Note in the Mechanical Equipment Installation section of this manual. 4. With no heat load on the circulating water, icing cannot be controlled effectively by air control 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 water must be bypassed without modulation. If the water bypass is directly into the tower's cold water basin, its design must be approved by SPX Cooling Technologies. 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. It is recommended that you discuss your freeze prevention options with your local Marley sales representative. Warning Warning 12 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 disconnect switch. Cooling Tower Cleaning Warning 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. US Public Health Service publications 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 Tower start-up instructions on page 9. ? 13 maintenance The visual inspection should take place at least once a week during the operating season. The periodic flushing and cleaning should be done before and after each cooling season, but in any event at least twice a year. 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. 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. Blowdown A cooling tower cools water by continuously causing a portion of 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 will be in the range of 2-4 concentrations. Note 14 When water treatment chemicals are added, they should not be 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 mixing.Where discrepancies may exist, the separate Service Manuals will take precedence. Warning Do not use the top horizontal surface of the tower as a working platform. The tower is designed so that all maintenance can be performed from the exterior and interior of the tower. Do not use the upper basin covers as a walking surface or working platform. Remove basin covers and use portable ladders whenever performing service on the hot water basin. Use of ladder should be in accord with manufacturer’s recommendations The following is recommended as a minimum routine of scheduled maintenance: Warning Always shut off electrical power to the tower fan motor prior to performing any inspections that may involve physical contact with the mechanical or electrical equipment in or on the tower. Lock out and tag out any electrical switches to prevent others from turning the power back on. Service personnel must wear proper personal protective clothing and equipment. Weekly: Inspect for bacterial growth and general operation conditions. Bacterial growth should be reported to your water treatment expert for immediate attention. Monthly (Weekly at Start-up): Observe, touch, and listen to the tower. Become accustomed to its normal appearance, sound, and level of vibration. Abnormal aspects relating to the rotating equipment should be considered reason to shut down the tower until the problem can be located and corrected. Observe operation of the motor, driveshaft, Geareducer and fan. Become familiar with the normal operating temperature of the motor, as well as the sight and sound of all components as a whole. Check Geareducer oil level. Shut down the unit and allow 5 minutes for the oil level to stabilize. Add oil if required. Check system for leaks if the amount of oil required appears unusual. (If oil is added at the external fill port, allow adequate time for the level to stabilize before reading final level.) ? 15 maintenance 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. Use of high-pressure water may damage the eliminator and louver material. Observe operation of the float valve. Depress the operating lever to make sure that the valve is operating freely. Inspect the suction screen for plugging. Remove any debris that may have accumulated. Check for any buildup of silt on the floor of the cold water basin. Mentally note the amount, if any, so future inspections will enable you to determine the rate at which it is forming. Semi-Annually: Relubricate motor according to the manufacturer’s instructions. See instructions on page 19. Check to see that all bolts are tight in the fan and mechanical equipment region, including the fan guard. Use torque settings prescribed on the fan?nameplate. Clean and disinfect cooling tower with biocides. Systems with biofouling, high general bacterial counts, or positive cultures of legionella may require additional cleaning. Refer to “Cooling Tower Cleaning” section on page 13. Consult your water treatment expert as to prudent biological evaluation testing. Note To maintain five-year change intervals, use only oil designed specifically for these Geareducers. If, after five years, turbine-type mineral oil is used, the oil must be changed semiannually. Refer to Geareducer User Manual for oil recommendations and further instructions. Annually: Inspect the tower thoroughly, making maximum use of instructions given in the separate service manuals. Check structural bolted connections and tighten as required.