/ MH Fluid Cooler / User Manual 05-116F
Contents Note 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................................................................................................
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.
Preparation Note 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.
Installation Warning The fluid cooler must be located at such distance and direction to avoid the possibility of contaminated fluid cooler 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 fluid cooler is in compliance with applicable air pollution, fire and clean air codes.
Installation Warning 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.
Installation 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.
Installation Caution For welded connections protect adjacent areas from excessive heat and sparks or damage may occur. 7. Warning Wire motor(s) and recirculation pump(s) in accordance with wiring diagram. 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.
Installation 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). When using a VFD: Note 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.
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.
Installation Warning 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 action of the coupling (or drive shaft couplings) to be sure that the motor and Geareducer are properly aligned.
Operation Fluid Cooler Start-Up Warning Among other sources, outbreaks of Legionnaires’ Disease have reportedly been traced to cooling towers and fluid coolers. 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.
Operation Some trial and error adjustment of the float valve may be required to balance the makeup water with tower operation. Ideally, the float valve setting will be such that no water is wasted through the overflow at pump shutdown. However, the water level after pump start-up must be deep enough to assure positive pump suction. 5. Open the valve on the tower bleed line and adjust bleed to the recommended rate. See Water Treatment section on page 20. 6.
Operation Fluid Cooler Operation General: The cold process fluid temperature obtained from an operating fluid cooler will vary with the following influences: 1. Heat load: With the fan in full operation, if the heat load increases, the cold process fluid temperature will rise. If the heat load reduces, the cold process fluid temperature will reduce.
Operation Fan cycling limits: Note Considering the normal fan and motor sizes utilized on MH Fluid Coolers, anticipate that approximately 4 to 5 starts per hour are allowable. If your fluid cooler is equipped with a two-speed motor(s), you will enjoy greater opportunity for process temperature control.
Operation motor is operating or not. The purpose of the energized space heater is to prevent moisture inside the unit from corroding the internal components. Failure to wire and energize the space heater will void the warranty if the actuator fails due to internal corrosion. Automatic Electric Actuator must be stored in a dry environment until installed. If a unit is going to sit idle prior to startup, the actuator must be removed from the damper and stored appropriately.
Operation Wintertime Operation The Marley film-fill system used in the MH Fluid Cooler has air entrance louvers that are molded as an integral part of the fill. This feature makes these fluid coolers very forgiving of cold weather operation, even at the low temperature and reduced load conditions encountered in low temperature applications. Nevertheless, during operation in subfreezing weather the opportunity exists for ice to form in the colder regions of the fluid cooler.
Operation 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.
Operation Protection Against Coil Freezing: Ethylene and propylene glycol solutions are the best means to protect the coil from freezing. The following table provides the coil volume for each MH Fluid Cooler model. MHF706 and MHF707 coil volumes are for both coils added together.
Maintenance Caution Draining the coil is not acceptable as a normal method of freeze protection—draining promotes corrosion inside the coil tubes. Draining is acceptable in an emergency if the coil is not protected by an antifreeze solution. It is recommended that you discuss your freeze prevention options with your local Marley sales representative. Water Treatment and Blowdown Maintaining Water Quality: The steel used in MH Fluid Cooler's has been galvanized with a heavy zinc coating averaging 2.
Maintenance Note The structure and coil of your fluid cooler consists primarily of galvanized steel, therefore your water treatment program must be compatible with zinc. In working with your water treatment supplier, it is important that you recognize the potential effects on zinc of the specific treatment program you choose. Coil Louver Removal The coil inlet louvers are comprised of a series of PVC pack assemblies, oriented to push water back into the fluid cooler.
Maintenance Coil Eliminator Removal The coil eliminators are comprised of a series of PVC pack assemblies, oriented to strip water from the air prior to leaving the fluid cooler. They are packed tightly to ensure no water escapes. Caution Eliminator sheets can be very sharp and could cut skin if proper protection is not used. Always wear gloves and sleeves when handling eliminator packs.
Maintenance Fluid Cooler Cleaning: Warning Any evaporative-type fluid cooler 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.
Maintenance a treatment schedule will be in the range of 2-4 concentrations. The following table shows the minimum amount of blowdown (percent of flow) required to maintain different concentrations with various cooling ranges*: Cooling Range Number of Concentrations 1.5X 2.0X 2.5X 3.0X 4.0X 5.0X 6.0X 5° F (2.78° C) .78 .38 .25 .18 .11 .08 .06 10° F (5.56° C) 1.58 .78 .51 .38 .25 .18 .14 15° F (8.33° C) 2.38 1.18 .78 .58 .38 .28 .22 20° F (11.11° C) 3.18 1.58 1.05 .78 .
Maintenance Belt Tensioning See Figure 1 and Figure 2 for MH Fluid Cooler models MHF702 thru MHF705. Loosen specified hardware located at the top and bottom of the motor support assembly before adjusting the jacking screws. Do not remove the hardware—it is required to support the motor. Tighten the LOOSEN HARDWARE JACKING SCREWS MOTOR Figure 1 SINGLE MOTOR—TWO FANS hardware after adjustment. Ideal tension is the lowest tension at which the belt will not slip under peak load conditions.
Maintenance A Dodge® V-Belt Tension Tester is an alternate method for tensioning V-belts. Check with you local belt supplier. See Figure 3 for MH Fluid Cooler models MHF706 and MHF707.The belts are adjusted by turning the threaded rod. Before tightening or loosening the belt, the double nuts holding the motor support in place must be loosened.There are two jam nuts at the end of the rod next to the casing. Turn the nut closest to the end of the rod to tighten the belt. Turn the other nut to loosen the belt.
Maintenance Motor Sheave diameter Used V-Belt minimum New V-Belt maximum 3.4" - 4.2" 85cm - 105cm 4.9 lb 2.2 kg 7.2 lb 3.3 kg 4.4" - 5.6" 106cm - 140cm 7.1 lb 3.2 kg 10.5 lb 4.8 kg 5.8" - 8.6" 141cm - 220 cm 8.5 lb 3.9 kg 12.6 lb 5.7 kg Sheave Alignment 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.
Maintenance Fluid Cooler Maintenance Some maintenance procedures may require maintenance personnel to enter the fluid cooler. Each cased face of the fluid cooler has a door for access to the interior of the tower. The optional fan deck ladder—models MHF706 and MHF707—is designed and intended solely for personnel to gain access to the fan deck. The fan deck ladder should not be used to enter or exit the access doors located on the cased face of the tower unless the optional access door platform is provided.
Maintenance Monthly (Weekly at start up): Observe, touch, and listen to the fluid cooler. 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 fluid cooler until the problem can be located and corrected. Observe operation of the motor, coupling (or drive shaft), Geareducer, if equipped and fan.
Maintenance Semi-Annually: If equipped, check the belt tension and condition. If equipped with dampers, lubricate jack shaft bearings and tiebar linkage with silicone lubricant. If dampers are equipped with pneumatic or electric actuators, the manufacturer's recommended maintenance procedures should be observed. If dampers are exposed to heavy dust-laden air, occasional flushing of the bearings with water is recommended. Clean and disinfect cooling tower with biocides.
Maintenance Motor Relubrication Instructions Motor located outside plenum option. Double-flow models MHF706 and MHF707 only. Open and lock out disconnect switch to make certain motor cannot be started. 1. Remove guard as shown in Figure 4. Opposite end motor bearing is accessible from outside the tower. 2. Remove grease fill and relief plugs at both shaft extension end and opposite end bearings and remove hardened grease, using clean wire.
Maintenance Caution Draining the coil is not recommended—draining promotes corrosion inside the coil tubes. See protecting coil in Freezing weather on page 18. During shutdown, clean the fluid cooler (see Warning, page 21) and make any necessary repairs. Eliminators and louvers are easily removed to gain access to the coil. Pay particular attention to mechanical equipment supports and sheaves or coupling (or drive shafts).
Maintenance At start of new operating season, make sure bearings are adequately lubricated before returning motor to service. Long-Term Storage Procedures Instructions for protection of non-operating equipment for more than 3 months. After installation of the Fluid Cooler and completion of the pre-startup instructions, the operational availability of equipment will last for a maximum period of three months. Ensure that the tower and coil are completely drained of all water and process fluid.
Maintenance Recirculation pumps: All pumps and pump motors should be taken down and stored indoors (pumps and motors may be stored fully assembled). Then, every month, turn pump impeller shaft to evenly distribute lubricant to the bearing parts. Belts: Properly stored belts will retain their properties unchanged for several years. Under unfavorable storage conditions and with improper handling, deterioration of their physical properties will result.
Maintenance Cleaning Cleaning of dirty belts can be carried out with a mixture of glycerin and spirit in a ratio of 1:10. Caution Benzene, benzol, turpentine and similar substances may not be used. Furthermore, sharpedged objects, wire brushes, emery paper etc., may not be used, as they will cause mechanical damage to the belts. Ball / roller bearings: Every month, turn the fan shaft and rotate by hand to distribute grease evenly over the bearing parts.
Maintenance Replacement parts: A complete stock of parts and components is maintained at one or more of the various Marley plants. In cases of emergency, they can normally be shipped within 24 hours—by air freight if necessary. However, you would obviously benefit from anticipating your need in advance, thus avoiding the cost of special handling. Be sure to mention your fluid cooler serial number (from the fluid cooler nameplate) when ordering parts.
Maintenance Schedule Maintenance Service Monthly Semi-annually Seasonal Startup or Annually x x Mechanical–motor, fan and drive mechanism x x Makeup valve (if equipped) x x Inspect for unusual noise or vibration x x Air inlet x x PVC drift eliminators x x Distribution basin, nozzles and collection basin x x Fan and pump motor exterior x Inspect General Condition and Operation Observe Operation of: Inspect and Clean: x x Coil surface Check: Collection water basin level x x Blo
Troubleshooting Trouble Cause Remedy Check power at starter. Correct any bad connections between the control apparatus and the motor. Power not available at motor terminals Check starter contacts and control circuit. Reset overloads, close contacts, reset tripped switches or replace failed control switches.
Troubleshooting Trouble Geareducer noise. (If equipped). Unusual fan drive vibration Cause Remedy Geareducer bearings If new, see if noise disappears after one week of operation. Drain flush, and refill Geareducer oil. See Geareducer User Manual. If still noisy, replace. Gears Correct tooth engagement. Replace badly worn gears. Replace gears with broken or damaged teeth. Loose bolts and cap screws Tighten all bolts and cap screws on all mechanical equipment and supports.
Additional Information Increased load requirements: MH Fluid Coolers are designed so that cells of either equal or unequal capacity can be added in the future. This allows you to compensate for the load increases that normally occur with the replacement or addition of production equipment—and still retain continuity with respect to your fluid cooler system. Fluid cooler rebuilding: SPX routinely rebuilds and upgrades fluid coolers and cooling towers of all materials and manufacture.
7401 WEST 129 STREET | OVERLAND PARK, KANSAS 66213 UNITED STATES | 913 664 7400 | spxcooling@spx.com | spxcooling.com In the interest of technological progress, all products are subject to design and/or material change without notice. ©2010 SPX Cooling Technologies, Inc.
