/ Marley Class F400 Cooling Tower / User Manual 93-1288A
Contents 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. 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.
Before Start-up Warning Among other sources, outbreaks of Legionnaires’ disease have reportedly been traced to cooling towers. Maintenance procedures that prevent amplification and dissemination of Legionella and other airborne bacteria should be formulated and implemented BEFORE systems are operated and continued reqularly thereafter to avoid the risk of sickness or death CLEANING–New installations should be cleaned and treated with biocides by a water treatment expert before startup.
The oil level placard must be adjusted so that its “full” mark is at the same elevation as the “full” mark on the side of the Geareducer case. Check oil lines to be sure there are no leaks. See Geareducer User Manual for oil filling procedure and list of recommended lubricants. 5–Rotate fan by hand to be sure of free rotation and ample tip clearance. See Fan User Manual. 6–Check motor insulation with a “Megger”. See Maintenance Section of Marley Electric Motor User Manual.
TOWER PERFORMANCE–Keep the cooling tower clean and water distribution uniform to obtain continued maximum cooling capacity. The capacity of a cooling tower to cool water to a given cold water temperature varies with the wet-bulb temperature and the heat load applied to the cooling tower. As the wet-bulb temperature drops, the cold water temperature also drops. However, the cold water temperature does not drop linearly with the wet-bulb temperature. A cooling tower will not control heat load.
cold weather operation will be enhanced if you read “Operating Cooling Towers in Freezing Weather” Marley Technical Report #H-003. Ice forming characteristics on any given cooling tower will vary, depending on velocity and direction of wind, circulating water rate, and heat load. Excessive ice formation may be controlled by regulating air and water flow through the tower by one or more of the following procedures: 1–Shut the fan down.
least tower maintenance. See Cooling Tower Inspection Check List in this manual. Keep a continuous lubrication and maintenance record for each cooling tower. HOT WATER DISTRIBUTION SYSTEM–Keep the circulating water and distribution system (piping and nozzles) clean and free of dirt, algae, and scale. Algae and scale may clog nozzles, eliminators, fill, and piping, and may collect on the equipment served thus reducing its performance.
Water Treatment BLOWDOWN–Blowdown, or bleed-off, is the continuous removal of a portion of the water from the circulating system. Blowdown is used to prevent the dissolved solids from concentrating to the point where they will form scale. The amount of blowdown required depends upon the cooling range (the difference between the hot and cold water temperatures) and the composition of the make-up water (water added to the system to compensate for losses by blowdown, evaporation and drift).
compounds which contain copper are not recommended. Chlorine and chlorine containing compounds are effective algaecides and slimicides. If used, chlorine should be added as intermittent (or shock) treatment only as frequently as needed to control the slime and algae. Chlorine and chlorine containing compounds should be added carefully since very high levels of chlorine may occur at or near the point of entry into the circulating water system.
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Spare Parts SPX Cooling Technologies manufactures and maintains a stock of replacement parts for all cooling tower mechanical equipment. Shipment of these parts are normally made within ten days after an order is received. If emergency service is necessary, contact the local Marley representative for assistance. To prevent prolonged shutdown periods in case of damage to the mechanical equipment, it is suggested that the following parts be carried in the owner’s stock: • One fan assembly.
Geareducer (shutdown for 3 months or more). 1. If the motors have space heaters, operate mechanical equipment one hour each month. 2. If the motors do not have space heaters, operate mechanical equipment one hour each week. 3. At startup, operate mechanical equipment one hour or until oil is warm, then shut the equipment down. Drain the oil and refill with new oil. Refer to Geareducer Manual for instruction on changing oil. Refer to Downtime Instruction Manual for downtime exceeding six months.
Troubleshooting Trouble Cause Remedy Motor Will Not Start Power not available at motor terminals 1. Check power at starter. Correct any bad connections between the control apparatus and the motor. 2. Check starter contacts and control circuit. Reset overloads, close contacts, reset tripped switches or replace failed control switches. 3. If power is not on all leads at starter make sure overload and short circuit devices are in proper condition.
Troubleshooting Trouble Cause Remedy Wrong Rotation (Motor) Geareducer Noise Wrong sequence of phases Geareducer bearings Change any two of the three motor leads. If new, see if noise disappears after one week of operation. Drain, flush and refill Geareducer. See Geareducer User Manual. If still noisy, replace. Correct tooth engagement. Replace badly worn gears. Replace gears with imperfect tooth spacing or form. Tighten all bolts and cap screws on all mechanical equipment and supports.
Structural Members Casing Fan Cylinder Stairs, Ladders, Walkway, Doors, Handrails Davits, Derricks, Hoists Inspection and Maintenance Schedule S Y S S S General Recommendations 2. Check for unusual noise or vibration D D D D 3. Inspect keys, keyways and set screws S S S S W Control Valves Suction Screen Float Valve Hot Water Distribution System M Cold Water Basin M W S 4. Make sure vents are open R 5. Lubricate (grease) S 6. Check oil seals M 7.
Inspection and Maintenance Notes 17
Inspection Checklist Date Inspected Inspected By Owner Location Owner’s Tower Designation Tower Manufacturer Model No. Process Served by Tower Operation: Continuous Design Conditions GPM HW °F CW Serial No.
Inspection Checklist Condition: 1—Good 2—Keep an eye on it 3—Needs immediate attention Mechanical Equipment 1 2 3 Comments Gear Drive Units Manufacturer Model Oil Level: Full Low, check again soon ❑ Oil Condition: Good ❑ Contains Water Oil Used—type Seals Back Lash Fan Shaft End Play Any Unusual Noises? ❑ Add Immediately ❑ No Contains Metal ❑ ❑ Yes ❑ Ratio Contains Sludge ❑ Action Required: ❑ Drive Shafts Manufacturer Material Fans Manu
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