How it Works
Marley
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MD5009
User Manual
40 pgs827.54 Kb0

Marley MD, MD5006, MD5007, MD5009, MD5016 User Manual

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MD cooling tower
INSTALLATION - OPERATION - MAINTENANCE
user manual
Z0602117_F ISSUED 8/2018
READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT
Note
Note
contents
This manual contains vital information for the proper installation and operation of your cooling tower. Carefully read the manual before installation or operation of the tower and follow all instructions. Save this manual for future reference..
Overview ...................................................................................................................................... 3
Mechanical Equipment .......................................................................................................... 11
Cold Water Basin Access / Air Inlet Louver Removal .....................................................27
Access Door Operation......................................................................................................... 28
Drift Eliminator Removal and Replacement ...................................................................... 28
Distribution System Maintenance ....................................................................................... 30
Seasonal Shutdown Instructions ........................................................................................ 34
Maintenance Schedule ...........................................................................................................37
Troubleshooting ....................................................................................................................... 38
Warning
Caution
Note
2
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. Also, please observe all Caution and Warning labels on the tower.
Indicates presence of a hazard which can cause severe personal injury, death or substantial property damage if ignored.
Indicates presence of a hazard which will or can cause personal injury or property damage if ignored.
Indicates special instructions on installation, operation or mainte­nance which are important but not related to personal injury hazards.
overview
This User Manual as well as those offered separately on motors, fans, Geareducer, couplings, drive shafts, float valves, pumps, etc., are intended to assure that this cooling tower serves you properly for the maximum possible time. Since product warrantability may well depend upon your actions, please read this User Manual thoroughly prior to operation.
This User Manual provides information regarding general cooling tower in­stallation and operation. Any deviation from, change or modification to, the User Manual, the original design conditions or the original intended use of the equipment may result in improper installation and/or operation of the tower.
Any such deviation, change or modification shall be the responsibility of the party or parties making such deviation, change or modification. SPX Cooling Technologies, Inc. expressly disclaims all liability for any such deviation, change or modification. The equipment shall be warranted in accordance with the applicable SPX Cooling Technologies Certification of Limited Warranty.
If you have questions about the operation and/or maintenance of this cooling tower, and you don’t find the answers in this manual, please contact your Marley sales representative. When writing for information, or when ordering parts, please include the serial number shown on the cooling tower nameplate.
Warning
Safety First
The location and orientation of the cooling tower can affect the safety of those responsible for installing, operating or maintaining the tower. However, since SPX Cooling does not determine the location or orientation of the tower, we cannot be responsible for addressing those safety issues that are affected by the tower’s location or orientation.
The following safety issues should be considered by those respon­sible for designing the tower installation.
• Access to and from the collection basin
• Access to and from mechanical access door(s)
• The possible need for ladders (either portable or permanent) to gain access to the mechanical access door(s)
• The possible need for external mechanical access platforms
• Access issues due to obstructions surrounding the tower
• Lockout of mechanical equipment
• The possible need for safety cages around ladders
• The need to avoid exposing maintenance personnel to the poten­tially unsafe environment inside the tower.
3
overview
Those are only some of the safety issues that may arise in the design process. SPX strongly recommends that you consult a safety engi­neer to be sure that all safety considerations have been addressed.
Several options are available that may assist you in addressing some of these personnel safety concerns, including:
— mechanical access platform and ladder
— ladder extensions (used where the base of the tower is elevated)
— safety cages for ladders
— safety gate for ladders
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 representative for guidance.
Warning
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.
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
Unless otherwise specified, MD cooling towers ship by truck on trailer(s), which lets you receive, hoist, and install the tower in one continuous operation. Single-cell towers ship on one truck. Multicell towers, depending on their size, and towers with access options (i.e. factory assembled access platforms) may require more than one truck.
Responsibility for the condition of the tower upon its arrival belongs to the truck driver—as does the coordination of multiple shipments, if required. Each tower has recommended tie down instructions by which they should be se­cured to the flatbed. Drivers should follow these instructions when securing
the tower to the flat-bed.
4
OFFSET MAY BE REQUIRED FOR BALANCED LIFT
BOTH MODULES
Caution
receiving and hoisting
Receiving Tower
Prior to unloading the tower from the delivering carrier, inspect the shipment for evidence of damage in transit. If damage is apparent, note the freight bill accordingly. This will support your future recovery claim.
Find and remove the installation instruction drawings and bills of material located in a plastic container in the cold water basin. This information should be kept for future reference and maintenance purposes.
Hoisting Tower
All models consist of two modules per cell. Both modules have hoisting clips. Detailed hoisting drawing are included in the literature package.
MD upper and lower modules must be hoisted and set separately. Do not preassemble modules prior to hoisting.
Warning
A Hoisting-Installation label which has hoisting dimensional information is located on the side casing of the tower modules. Remove tower from the car­rier and hoist into place according to the instructions on the label.
Hoisting clips are provided for ease of unloading and positioning tower. For overhead lifts or where additional safety is required, safety slings should also be placed under the tower. Under no circumstances should you combine the top and bottom modules of modular models and attempt to hoist them at the same time by utilizing the hoisting clips alone!
OFFSET MAY BE REQUIRED FOR BALANCED LIFT
CENTER OF TOWER
WIDTH
LIFTING SLING
CENTER OF TOWER
LIFTING SLING
WIDTH
70° MAX
5
Note
installation
Tower Installation
These installation instructions are intended to help you prepare before your tower arrives. If discrepancies exist between these instructions and those shipped with the tower, the instructions shipped with the tower will govern.
1. Prior to placement of the tower, confirm that the supporting platform is level, and that the anchor bolt holes are correctly located in accordance with Marley drawings.
2. Place bottom module on your prepared supports, aligning anchor bolt holes with those in your supporting steel. Make sure that the orientation agrees with your intended piping arrangement. Attach tower to supporting steel with four 5⁄8" diameter bolts and flat washers (by others). Position flat washers between the bolt head and the tower bottom flange.
3. Before setting top module in place on bottom module, clean any debris from the top of the bottom module. Ensure that the fill surface is free from debris and all fill packs are level. Recommended tie-down instructions are provided to the truck driver upon tower pickup. If damage occurs to the tower due to tie-down procedures other than those recommended in the drawing, it should be noted upon arrival. Remove the protective paper off the sealing gasket tape before setting the top module and ensure there is coverage around the entire perimeter. Place the top module on the bottom module, aligning mating holes as it is set in place. Make sure that the ori­entation of the top module agrees with your intended piping arrangement. Sections are 180° reversible with respect to each other. Pay close attention to face designations on sales orientation drawings e.g. Face A, Face B, etc. Use drift pins to align bolt holes during the assembly of the top and bottom modules as the top is lowered into place. Use care when setting the modules as lifting and resetting the top module will compromise the sealing gasket between the two sections, possibly resulting in a leaking joint. If the top module must be reset, it may be necessary to remove the sealing gasket tape and replace.
Note
6
Gasket details must be followed correctly or leaks may occur that will not be covered under warranty.
4. Attach top module to bottom module with fasteners provided—according to “MD Field Installation Manual”.
Note
Note
installation
If tower purchased is one fan cell only, ignore steps 4 through 8.
5. If collection basins are to be equalized by the use of Marley standard
flumes, unbolt the coverplate from the basin of the cell just installed. The coverplate is located in the collection basin depressed section end.
6. Unbolt temporary coverplate from the basin of the second cell and set
the bottom module of the second cell in place. Align anchor bolt holes and flume openings in basin sides.
7. Install flume according to “MD Field Installation Manual”.
It is important that the cells be firmly anchored before the flume is attached to the 2nd cell.
8. Repeat steps 2 through 4 for the second top section.
9. Repeat steps 5 through 8 for any remaining cells.
10. Attach your cold water supply piping to the cold water basin outlet con-
nection in accordance with drawing instructions. Use gaskets where recommended.
Caution
Caution
Do not support your pipe from the tower or outlet connection—sup­port it externally.
Normally, one of the following three outlet arrangements is provided:
Side or End suction connection: This is a factory-installed, galvanized
pipe nipple, extending horizontally from the side or end of the cold water basin. It is both beveled for welding—and grooved for a mechanical cou­pling. If a weld connection is used, it is recommended that the weld area be protected against corrosion. Cold galvanizing is suggested, applied according to the manufacturer’s instructions.
Protect adjacent areas from excessive heat and sparks during weld­ing or damage could occur.
Bottom outlet connection: This is a factory-installed, circular opening
in the cold water basin floor of one or more cells. An appropriately sized circular opening has been drilled to 125# ANSI B16.1 flat-face flange specifications. A full faced gasket and appropriately sized bolts (by others) must be used for proper outlet function.
7
Note
installation
Side outlet sump connection: For shipping purposes, sumps are at-
tached upside down in the basin to prevent damage. Sumps are to be installed in the square opening in the floor of the cold water basin of one or more cells—sealed against leakage, and attached by machine bolts, according to the installation drawing included. An appropriately sized circular opening in the vertical face of the sump has been drilled to 125# ANSI B16.1 flat-face flange specifications. A full faced gasket and ap­propriately sized bolts (by others) must be used for proper distribution.
11. Attach makeup water supply piping to appropriately sized float valve con­nection located in cold water basin. Tower drain and overflow connections are located on the side of the collection basin. If you wish to pipe overflow and drain water to a remote discharge point, make those connections also.
12. Attach your warm water return piping to the inlet connection.
Fasteners and components provided by others that are to be attached to the tower must be compatible with the cooling tower materials—e.g. fasteners in a stainless steel cold water basin must be stainless steel.
Caution
Caution
Except for the horizontal components of piping, do not support your pipe from the tower inlet connection—support it externally.
Normally, one of the following two inlet arrangements is provided:
Bevel and groove distribution connection: This is a factory-installed,
galvanized pipe nipple, extending horizontally from the side of the tower. It is both beveled for welding—and grooved for a mechanical coupling. If a weld connection is used, it is recommended that the weld area be protected against corrosion. Cold galvanizing is suggested, applied ac­cording to the manufacturer’s instructions.
Protect adjacent areas from excessive heat and sparks during welding or damage could occur.
Flanged distribution connection: The spray system is fitted with a flat-
face flange connection that conforms to 125# ANSI B16.1 specifications. A full faced gasket and appropriately sized bolts (by others) must be used for proper distribution function.
8
Warning
installation
Motor Wiring
For maintenance/safety purposes, SPX recommends a lockout type disconnect switch for all mechanical equipment. In addition to a disconnect switch, the motor should be wired to main power supply through short circuit protection, and a magnetic starter with overload protection.
Wire motor leads as shown on the motor nameplate matching the supply voltage. Do not deviate from the motor nameplate wiring.
Internal space heaters may be present, depending upon the motor manufac­turer. For space heater operation and wiring refer to the Marley “Fan Motor” User Manual” User Manual Z0239042.
Either of following symbols may be shown on the motor nameplate –
Δ, Δ Δ
, Y, or YY. These symbols represent how the motor is constructed on the inside and in no way have anything to do with a Delta or Wye electrical distribution system serving the motor.
Note
Note
When using a starter:
• Set motor overload protection to 110% of motor nameplate amps. 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 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(s) 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.
When using a two-speed starter:
• Motor rotation must be the same at slow speed and high speed.
• 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.
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).
9
Note
installation
When using a VFD:
Before beginning, ensure that the motor is rated for “Inverter Duty” per NEMA MG-1, part 31.
• Set the VFD solid state overload protection to 119% of motor nameplate amps and set “maximum current parameter” in the VFD to motor nameplate amps. “Maximum current parameter” will reduce fan speed and limit amp draw to nameplate amps during cold weather operation. If furnished with a mechanical O.L. set this at 110% over motor nameplate amps.
• Motor rotation must be the same in both VFD mode and By-pass mode.
• If cable distance between the VFD and motor is greater than 100 feet a DV/DT output filter is recommended to avoid damage to the motor. 100 feet distance is based on our field experience, the VFD manufacture may state different distances and distance does vary depending on the VFD manufacture.
• Program the VFD for variable torque output.
• Do not start and stop the motor using the safety switch at the motor. 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.
Warning
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. If you have purchased a Marley VFD and/or controls package, please follow the instructions in the User Manual for that system. 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.
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 Cool-
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Warning
installation
ing 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. Warranty is void if the cooling tower is operated at speeds which cause damaging vibrations to the cooling tower and associated equipment. When utilizing a variable frequency drive, the cooling tower must be tested across the full range of speeds and checked against CTI guidelines for excessive vibration. Speed ranges not meeting these guidelines must be locked out in the VFD.
Mechanical Equipment:
Always shut off electrical power to the fan motor prior to perform­ing any maintenance on the tower. Any electrical switches should be locked out and tagged out to prevent others from turning the power back on.
Warning
Caution
1. Spin the fan manually to assure that all fan blades properly clear the inside of the fan cylinder. Observe the action of the sheaves and belts to be sure that the motor is properly aligned with the fan sheave. If necessary, cor­rect the alignment in accordance with the Belt Tensioning and Sheave Alignment section on pages 21 and 24.
The following steps require operation of the fan motor while the access door is open. DO NOT view the fan operation from near or inside the access door location. Fan rotation should be viewed from tower grade.
The access door should NOT be opened while the fan is operating. The fan rotation causes a negative pressure inside the cooling tower and will abruptly pull the door open should access be attempted. Only open the cooling tower access door when the fan is off and locked out.
2. Momentarily bump (energize) 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.
11
Caution
Note
installation
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. If the fan is intended to be reversed for deicing purposes, make sure that the starter is equipped with a 2 minute time delay between changes of direction. These delays will prevent abnormal stress from being applied to the mechanical equipment and the electrical circuit components.
3. Run the motor and observe the operation of the mechanical equipment. Operation should be stable.
4. Check belt tension and torque on the fan and motor sheave after 10 to 60 hours of operation. See Torque Values on page 25.
If the water supply system is not being operated—or if there is no heat load on the system—motor amps read at this time may indicate an apparent overload of as much as 10–20%. 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.
Warning
Tower Startup
Microorganisms including Legionella bacteria can exist in premise plumbing including cooling towers. The development of an effective water management plan (WM P) and implementation of maintenance procedures are essential to prevent the presence, dissemination and amplification of Legionella bacteria and other waterborne contami­nants throughout premise plumbing. Before operating the cooling tower, the water management plan and maintenance procedures must be in place and regularly practiced.
Water System:
1. Consult a knowledgeable water treatment professional to clean and treat your new cooling tower prior to startup. Cooling towers must be cleaned and disinfected regularly in accordance with ASHRAE Standard 188 and Guideline 12.
2. Do NOT attempt any service unless the fan motor is locked out.
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