SPX Cooling Technologies MH Fluid Cooler User Manual

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Marley MH Fluid Cooler

User Manual 05-116D

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

Warning

Caution

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

The following deﬁned terms are used throughout this manual to bring at-

tention 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.

Note

Indicates special instructions on installation, operation or maintenance

which are important but not related to personal injury hazards.

Preparation

The Marley MH Fluid Cooler with CoolBoost™, purchased for this instal-

lation 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 in-

tended 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 name-

plate 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 orienta-

tion 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

WARNING

The following safety issues should be considered by those responsible

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

• the need to avoid exposing maintenance personnel to the potentially

unsafe environment inside the ﬂuid cooler

Note

Preparation

It is not intended nor assumed that access to the fan deck on single-ﬂow

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 appropri-

ate Marley submittal drawings. Supports must be level to insure proper

operation of the ﬂuid cooler.

➠

Warning

Installation

The ﬂuid cooler must be located at such distance and direction to

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 compli-

ance with applicable air pollution, ﬁre and clean air codes.

Fluid Cooler 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 mate-

rial 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.

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 be-

fore 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 3⁄4" 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 (fac-

tory-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.

➠

Note

Caution

Warning

Installation

Fasteners and components provided by others that are to be at-

tached 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 connec-

tion 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 recom-

mends 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.

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, 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.

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.

Note

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”

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. Flux vector and con-

stant torque modes may damage the gearbox.

• 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.

Using a VFD in cooling applications has advantages over traditional single

or two speed motor control. A VFD can reduce the cost of electrical en-

ergy being used and provide better temperature control. In addition, it

reduces the mechanical and electrical stress on the motor and mechanical

➠

Warning

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.

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 Cooling Technologies

does not assume responsibility for any technical support or damages

for problems associate with non-Marley brand VFD systems.

Warning

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.

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 ex-

cessive 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.

Warning

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

structural integrity of the fan guard. Failure of the fan guard could allow

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 ac-

tion of the coupling (or drive shaft couplings) to be sure that the

motor and Geareducer are properly aligned. If necessary, cor-

rect 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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