SPX Cooling Technologies MHF705, MHF702 User Manual

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SPX Cooling Technologies MHF705, MHF702 User Manual

/ Marley MH Fluid Cooler /

User Manual sea_05-116E

Note

Warning

Caution

Note

Contents

This manual contains vital information for the proper installation and operation of your fluid cooler. Carefully read the manual before installation or operation of the fluid cooler and follow all instructions. Save this manual for future reference.

Fluid Cooler Location..............................................................................

5

Fluid Cooler Shipment............................................................................

6

Receiving Fluid Cooler............................................................................

6

Hoisting Fluid Cooler..............................................................................

6

Fluid Cooler Installation..........................................................................

7

Motor Wiring...........................................................................................

8

Mechanical Equipment.........................................................................

11

Fluid Cooler Start-Up............................................................................

13

Fluid Cooler Operation..........................................................................

15

Wintertime Operation............................................................................

16

Water Treatment....................................................................................

20

Fluid Cooler Cleaning............................................................................

21

Blowdown.............................................................................................

21

Belt Adjustment.....................................................................................

22

Sheave Alignment.................................................................................

24

Fluid Cooler Maintenance.....................................................................

25

Seasonal Shutdown Instructions..........................................................

28

Prolonged Shutdown............................................................................

29

Troubleshooting....................................................................................

32

Additional Information...........................................................................

34

Troubleshooting....................................................................................

29

Maintenance Schedule.........................................................................

31

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 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.

Indicatesspecialinstructionsoninstallation,operationormaintenance which are important but not related to personal injury hazards.

3

Preparation

The Marley MH Fluid Cooler with CoolBoost™, purchased for this installation represents the current state of the art in crossflow, induced draft fluid cooler design. Thermally and operationally, it is the most efficient fluid cooler of its class.

These instructions—as well as those offered separately on motors, fans, Geareducer®, couplings, drive shafts, float valves, pumps, etc.—are intended to assure that the fluid cooler serves you properly for the maximum possible time. Since product warrantability may well depend upon your actions, please read these instructions thoroughly prior to operation.

If you have questions about the operation and/or maintenance of this product, 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 mention product serial number shown on the nameplate located on the access door.

Safety First

The location and orientation of the fluid cooler can affect the safety of those responsible for installing, operating or maintaining the fluid cooler. However, since SPX Cooling Technologies does not determine the location or orientation of the fluid cooler, we cannot be responsible for addressing those safety issues that are affected by the fluid cooler’s location or orientation.

 

Warning

 

The following safety issues should be considered by those responsible

Warning

for designing the tower installation.

 

access to and from the fan deck

access to and from maintenance access doors

the possible need for ladders (either portable or permanent) to gain access to the fan deck or maintenance access doors

the possible need for handrails around the fan deck

the possible need for external access platforms

potential access problems due to obstructions surrounding the tower

lockout of mechanical equipment

the possible need for safety cages around ladders

theneedtoavoidexposingmaintenancepersonneltothepotentially unsafe environment inside the fluid cooler

4

 

Preparation

 

Itisnotintendednorassumedthataccesstothefandeckonsingle-flow

Note

models—Models MHF702 thru MHF705—is needed or necessary.

 

 

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:

 

Louver face distribution basin access platform with ladder and handrail.

 

Louver face redistribution basin level access platform with ladder and

 

 

handrail.

 

• A handrail system around the perimeter of the fan deck with either one

 

 

or two ladders for access to the deck. Double-flow models MHF706

 

 

and MHF707 only.

 

Extended fan deck that provides additonal access around one end

 

 

of the fan cylinder opposite the fan deck access ladder. Double-flow

 

 

models MHF706 and MHF707 only.

 

Ladder extensions—used where the base of the tower is elevated.

 

Safety cages for ladders.

 

External lube lines.

 

Access door platform.

 

Motor located outside the tower. Double-flow models MHF706 and

 

 

MHF707 with Geareducer drive only.

 

External motor access platform. Double-flow models MHF706 and

 

 

MHF707 with Geareducer drive only.

 

Plenum walkway. Double-flow models MHF706 and MHF707 only.

 

 

Standard on all other models.

 

Mechanical equipment access platform.

Fluid Cooler Location

Space available around the fluid cooler should be as generous as possible to promote ease of maintenance—and to permit freedom of airflow into and through the fluid cooler. If you have questions about the adequacy of the available space and the intended configuration of the fluid cooler, please contact your Marley sales representative for guidance.

Prepare a stable, level support foundation for the fluid cooler, utilizing weight, wind load, and dimensional information appearing on appropriate Marley submittal drawings. Supports must be level to insure proper

operation of the fluid cooler.

5

Installation

The fluid cooler must be located at such distance and direction to Warning avoid the possibility of contaminated fluid cooler discharge air be-

ing 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 fluid cooler is in compliance with applicable air pollution, fire and clean air codes.

Tower Shipment

Unless otherwise specified, the MH Fluid Cooler ships by truck (on flat bed trailers), which lets you receive, hoist, and install the tower in one continuous operation. Single-cell single-flow fluid coolers ship on one truck. Double-flow and multicell fluid coolers, depending on their size, may require more than one truck.

Responsibility for the condition of the fluid cooler upon its arrival belongs to the trucker—as does the coordination of multiple shipments, if required.

Receiving Fluid Cooler

Prior to unloading the fluid cooler 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 bag in the water collection basin. This information should be kept for future reference and maintenance purposes.

Hoisting Fluid Cooler

All MH Fluid Cooler models must use hoist clips and overhead lifting for handling assembled fluid cooler. Forklifting from base of fluid cooler is not permitted. The clips for the top modules are located at the fan deck level. The clips for the lower modules are located at the bottom of the modules at the water collection basin. A Hoisting-Installation label which has hoisting dimensional information is located on the side casing near the tower centerline. Remove tower from the carrier and hoist into place according to the instructions on the label.

Caution

MH Fluid Cooler upper and lower modules must be hoisted and set

separately. Do not preassemble modules prior to hoisting.

 

6

Warning

Note

Installation

Hoisting clips are provided for ease of unloading and positioning the fluid cooler. For overhead lifts or where additional safety is required, safety slings should also be placed under the fluid cooler modules. 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!

Fluid Cooler Installation

These installation instructions are intended to help you prepare before your fluid cooler arrives. If discrepancies exist between these instructions and those shipped with the fluid cooler, the instructions shipped with the fluid cooler will govern.

1.Prior to placement of the fluid cooler, 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 fluid cooler to supporting steel with 19mm diameter bolts and flat washers (by others). See support drawing for location and quantity. Position flat washers between the bolt head and the fluid cooler basin flange.

3.Before setting top module in place on bottom module, clean any debris from the underside of the top module fill, skid and beams and from the top of the bottom module and remove shipping cover from bottom of top module—replace fasteners at side of module to prevent leaks. Place top module on the top peripheral bearing surface (factory-installed gasket) of bottom module, aligning mating holes as it is set in place. Attach top module to bottom module with fasteners provided according to drawings shipped with your fluid cooler.

4.Connect the recirculation piping with rubber boot shipped with the bottom module piping according to drawings shipped with you fluid cooler.

5.Attach makeup water supply piping to appropriately-sized float valve connection located in collection water basin side wall. Install the drain and overflow according to drawings shipped with your fluid cooler. If you wish to pipe overflow and drain water to a remote discharge point, make those connections at this time also.

7

Note

Caution

Warning

Installation

Fasteners and components provided by others that are to be attached to the tower must be compatible with the cooling tower materials— i.e. fasteners in a stainless steel cold water basin must be stainless steel.

6.Attach process fluid supply and return piping to the coil. Field piping connection is an NPT male connection at the coil. A welded connection requires removing the threaded portion of the coil.

For welded connections protect adjacent areas from excessive heat and sparks or damage may occur.

7.Wire motor(s) and recirculation pump(s) in accordance with wiring diagram.

For maintenance/safety purposes, SPX Cooling Technologies recommendsalockouttypedisconnectswitchforallmechanicalequipment.

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.

Motor Wiring

Wire motor leads as shown on the motor nameplate matching the supply voltage. Do not deviate from the motor nameplate wiring.

Either of following symbols may be shown on the motor nameplate – 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.

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.

8

Installation

Do not start the motor more than six 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 six times per hour (each low

 

 

speed start and each high speed start count as one start).

 

When using a VFD:

 

Before beginning, ensure that the motor is rated for “Inverter Duty”

Note

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 31m

 

 

feet a DV/DT output filter is recommended to avoid damage to the

 

 

motor. 31mº 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. Flux vector and constant torque modes may damage the gearbox.

• Donotstartandstopthemotorusingthesafetyswitchatthemotor.

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

9

Installation

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.

MarleysuppliesVFDandVFDcontrolsspecificallydesignedforourcooling 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

Warning 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 Warning cause the fan to operate in an unstable region which may result in

damage to the equipment and possible injury.

10

Warning

Warning

Warning

Installation

Mechanical Equipment:

The fluid cooler is designed to operate at full speed and half speed. Warranty is void if the tower is operated at speeds which cause damaging vibrations to the tower and associated equipment. When utilizing a variable frequency drive, the 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.

Always shut off electrical power to the tower 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.

1.If equipped, check oil level in accordance with the Geareducer User Manual for the Geareducer. (Although the Geareducer was filled to the proper level at the factory, tipping during shipment and hoisting may have caused some loss of oil.) If oil is required, fill Geareducer to the proper level with approved lubricant. (See Geareducer User Manual ) Check oil level at the Geareducer or dipstick (standpipe located on fan deck, if so equipped) to confirm that the proper level is indicated.

2.On double-flow models—MHF706 and MHF707—install fan cylinder and two-piece fan guard according to the installation drawing shipped with the fluid cooler.

Improper installation of the fan cylinder and fan guard will destroy the structuralintegrityofthefanguard.Failureofthefanguardcouldallow operating or maintenance personnel to fall into the rotating fan.

3.Spin the fan(s) manually to assure that all fan blades properly clear the inside of the fan cylinder. If equipped, observe the action of the coupling (or drive shaft couplings) to be sure that the motor and Geareducer are properly aligned. If necessary, correct the alignment in accordance with the included manual.

For belt drive equipped models observe the action of the sheaves and belts to be sure that the motor is properly aligned with the fan sheave. See Belt Tensioning and Sheave Alignment on pages 22 thru 24.

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