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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............................................................................. 6 Receiving Fluid Cooler......................
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 Note 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.
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.
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.
Installation Mechanical Equipment: Warning Warning 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.
Installation Note It is essential that the fan cylinder and fan guard be installed in accordance with the drawings shipped with the tower. Do not force the fan cylinder out of round. 4. Momentarily bump (energize) the motor(s) and observe rotation of the fan(s). If rotation is backwards, shut off the fan and reverse two of the three primary leads supplying power to the motor. Caution If tower is equipped with a two-speed motor, check for proper rotation at both speeds.
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 7. While operating the recirculating water pump(s) and prior to operating the cooling tower fan, execute one of the two alternative biocidal treatment programs described in the following: • Resume treatment with the biocide which had been used prior to shutdown. Utilize the services of the water treatment supplier.
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, the heat load increases, Heat Loadif (Btu/hr) Range – °F = the cold process fluid temperature will rise. If the heat load reduces, GPM x 500 the cold process fluid temperature will reduce. or — in SI units Range – °C = Heat Load (kilowatts) Liters/sec x 4.
Operation 4. Air flow rate: Reducing air flow through the fluid cooler causes the cold process fluid temperature to rise. This is the recommended method by which to control leaving process fluid temperature. If your fluid cooler is equipped with a single-speed motor, the motor may be shut off when the process fluid temperature becomes too cold. This will cause the process fluid temperature to rise. When the fluid temperature then becomes too warm for your process, the motor can be restarted.
Operation Note Slushy, transitory ice forms routinely in the colder regions of the fill of low temperature towers, and is visible through the tower louvers. Such ice normally has no adverse effect on fluid cooler operation, but its appearance should be a signal to the operator to undertake ice control procedures. It is the operator's responsibility to prevent the formation of destructive (hard) ice on the fluid cooler fill. Certain guidelines should be followed: 1.
Operation Reversal may be at either full or half speed; however, reversal at half speed is recommended. Reverse operation of the fan should be used sparingly and should only be used to control ice, not to prevent it. Reverse fan operation should not need to exceed 1 or 2 minutes. Monitoring is required to determine the time required to melt accumulated ice. Warning Reverse operation of fans for prolonged periods during subfreezing weather can cause severe damage to fans and fan cylinders.
Operation Model Coil Volume Liters Model Coil Volume Liters MHF702__061 246 MHF705__061 890 MHF702__081 322 MHF705__081 1192 MHF702__101 397 MHF705__101 1476 MHF702__121 473 MHF705__121 1760 MHF702__062 284 MHF705__062 1079 MHF702__082 379 MHF705__082 1438 MHF702__102 454 MHF705__102 1779 MHF702__122 568 MHF705__122 2139 MHF703__061 322 MHF706__061 1476 MHF703__081 435 MHF706__081 1893 MHF703__101 530 MHF706__101 2309 MHF703__121 644 MHF706__121 2744 MHF70
Maintenance Water Treatment and Blowdown Maintaining Water Quality: The steel used in MH Fluid Cooler's has been galvanized with a heavy zinc coating averaging .051mm in thickness. Other materials used (PVC fill, drift eliminators, and louvers, aluminum fans, cast iron Geareducer, etc.) are selected to offer maximum service life in a “normal” fluid cooler environment, defined as follows: Recirculating water with a pH between 6.
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 (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 3°C .7 .38 .25 .18 .11 .08 .06 6°C 1.5 .78 .51 .38 .25 .18 .14 8°C 2.3 1.18 .78 .58 .38 .28 .22 11°C 3.1 1.58 1.05 .78 .51 .38 .30 14°C 3.9 1.98 1.32 .98 .64 .48 .38 Multipliers are based on drift of 0.02% of the circulating water rate.
Maintenance ,//3%. (!2$7!2% *!#+).' 3#2%73 -/4/2 Figure 1 SINGLE MOTOR—TWO FANS 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 sion is the lowest tension at which the belt will not slip under peak load conditions. Check tension frequently during the first 24-48 hours of run-in operation. Overtensioning shortens belt and bearing life. Keep belts free from foreign material which may cause slipping. Never apply belt dressing as this will damage the belt and cause early failure. A Dodge® V-Belt Tension Tester is an alternate method for tensioning V-belts. Check with you local belt supplier.
Maintenance Bushing Fastener Torque Values Bushing Fastener Size SH SDS SD SK SF E F 56M - 20 56M - 20 56M - 20 6QE - 18 6 - 1 6 56O - 13 6QE - 12 Torque N·m 8 8 8 18 30 48 58 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.
Maintenance Weekly: Inspect for bacterial growth and general operation conditions. Bacterial growth should be reported to your water treatment expert for immediate attention. 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.
Maintenance Clean and disinfect cooling tower with biocides. Systems with biofouling, high general bacterial counts, or positive cultures of legionella may require additional cleaning. Refer to “Fluid Cooler Cleaning” section—page 21. Consult your water treatment expert as to prudent biological evaluation testing. Note Geareducer models used on MH Fluid Coolers are designed for 5-year oil change intervals. To maintain five-year change intervals, use only oil designed specifically for these Geareducers.
Maintenance Steel Side Casing Motor Grease Fill Plug Attachment Screw Guard Grease Relief Plug Figure 4 wire. 3. Insert grease fittings in grease fill openings and add grease until grease is forced out through relief openings. 4. Replace fill plugs and operate mechanical equipment 30 minutes to one hour to purge excess grease at grease relief opening. 5. Reinstall grease relief plugs and reinstall guard. 6. Resume normal fluid cooler operation.
Maintenance bright metal can be exposed by cleaning, consider that the galvanizing has remained effective. Unless there is evidence of a generalized failure of the galvanizing, localized touch-up should be all that is required. Note To the extent that the galvanizing (zinc coating) still exists, paint will not adhere to it readily. Contact the manufacturer of the coating you intend to use for instructions. Fluid cooler framework: Check structural bolted connections and tighten as required.
Maintenance representative for additional information. SPX Cooling Technologies Services Our interest in your MH Fluid Cooler does not end with the sale. Having conceived, designed, and manufactured the most reliable and longestlasting fluid cooler of its class, we want to make sure that you gain the maximum possible benefit from its purchase.
Maintenance Schedule Maintenance Service Inspect General Condition and Operation 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 Observe Operation of: Inspect and Clean: x Coil surface x Check: Collection water basin level x x B
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 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. Unbalanced drive shaft or worn couplings.
Additional Information the norm. This service is not intended to replace the important function performed by your maintenance staff. Their attention assures the fluid coolers’s routine operating performance, and is invaluable. However, we recognize that the unusual manner in which a fluid cooler performs its function—as well as the unique forces which act upon it—may be considerations which occasionally require the services of an expert technician.
Cooling Technologies Balcke | Hamon Dry Cooling | Marley / Unit 505, Block B, Phileo Damansara 2 // No. 15 Jalan 16/11, Off Jalan Damansara // 46350 Petaling Jaya, Malaysia // +60 3 7665 1018 // spxcooling.com / In the interest of technological progress, all products are subject to design and/or material change without notice. ©2007 SPX Cooling Technologies, Inc.
