Marley Primus P11 User manual

Manual 04-131
User Manual
®
Models P11 through P15

2
Contents
Tower Location ...................................................................................... 4
Tower Shipment ..................................................................................... 5
Receiving Tower .................................................................................... 5
Hoisting Tower ....................................................................................... 5
Tower Installation ................................................................................... 6
Field Installed Mechanical Equipment ................................................... 9
Vibration Switch Option ....................................................................... 16
Basin Heater Option ............................................................................ 16
Tower Start-Up..................................................................................... 18
Tower Operation .................................................................................. 21
Winter Operation .................................................................................. 23
Tower Cleaning, Water Treatment and Blowdown .............................. 26
Cleaning ............................................................................................... 27
Belt Replacement ................................................................................ 29
Belt Tensioning .................................................................................... 30
Sheave Alignment ................................................................................ 31
Schedule of Tower Maintenance ......................................................... 31
Seasonal Shutdown Instructions ......................................................... 33
Prolonged Shutdown ........................................................................... 34
Marley Services ................................................................................... 35
Maintenance Schedule ........................................................................ 36
Troubleshooting ................................................................................... 37
▲
▲▲Note
This manual contains vital information for the proper installation and
operation of your cooling tower. Carefully read the manual before
installation or operation of the tower and follow all instructions. Save
this manual for future reference.
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.
Indicates special instructions on installation, operation or
maintenance which are important but not related to personal injury
hazards.
▲
▲▲Warning
▲
▲▲Caution
▲
▲▲Note
The following defined terms are used throughout this manual to bri
attention to the presence of hazards of various risk levels, or to important
information concerning the life of the product.

3
Preparation
The Marley Primus cooling tower purchased for this installation represents
the current state of the art in crossflow, induced draft cooling tower design.
Thermally and operationally, it is the most efficient cooling tower of its
class.
These instructions—as well as those offered separately on motors, fans,
float valves, etc.—are intended to assure that the tower 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
tower, 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 tower serial number shown on the nameplate
located on the access door.
Safety First
The location and orientation of the cooling tower can affect the safety of
those responsible for installing, operating or maintaining the tower. However,
since Marley does not determine the location or orientation of the tower, we
cannot be responsible for addressing those safety issues that are affected
by the tower’s location or orientation.
The following safety issues should be considered by those responsible
for designing the tower installation.
• access to and from maintenance access doors
• the possible need for ladders (either portable or permanent) to
gain access to the distribution basin or maintenance access doors
• 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 tower.
It is not intended nor assumed that access to the fan deck is needed
or necessary.
▲
▲▲Warning
▲
▲▲Note

4
Preparation
Those are only some of the safety issues that may arise in the design
process. Marley strongly recommends that you consult a safety
engineer to be sure that all safety considerations have been addressed.
Tower Location
Space available around the tower should be as generous as possible to
promote ease of maintenance—and to permit freedom of airflow into and
through the tower. If you have questions about the adequacy of the
available space and the intended configuration of the tower, please
contact your Marley sales engineer for guidance.
Prepare a stable, level support foundation for the tower, utilizing weight,
wind load, and dimensional information appearing on appropriate Marley
literature. Supports must be level to insure proper operation of the tower.
The cooling tower must be located at such distance and direction to
avoid the possibility of contaminated tower 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 tower is in compliance with
applicable air pollution, fire, and clean air codes.
▲
▲▲Warning
▲
▲▲Note

5
Tower Shipment
Unless otherwise specified, Primus towers ship by truck (on flat bed
trailers), which lets you receive, hoist, and install the tower in one
continuous operation. Single-cell towers ship on one truck. Multicell
towers, depending on the quantity, may require more than one truck.
Responsibility for the condition of the tower upon its arrival belongs to the
trucker—as does the coordination of multiple shipments, if required.
Receiving Tower
Prior to unloading the tower from the delivering carrier, inspect the
shipment for evidence of damage in transit. If damage is apparent, note the
freight bill accordingly. This will be needed to support any future recovery
claim.
Find and remove the installation instructions and manuals (literature kit)
located in a plastic bag in the cold water basin. This information should be
kept for future reference and maintenance purposes.
Hoisting Tower
All models ship in a single module. A Hoisting-Installation label is located
on the side casing near the access door. Remove tower from the carrier
and hoist into place according to the instructions on the label.
Receiving and Hoisting

6
▲
▲▲Caution
Tower Installation
These installation instructions are intended to help you prepare
before your tower arrives. If discrepancies exist between these
instructions and those shipped with the tower, the instructions
shipped with the tower will govern.
1. Prior to placement of the tower, confirm that the supporting platform is
level, and that the anchor bolt holes are correctly located in accordance
with Marley literature.
2. Place tower 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 tower to supporting
steel with bolts and flat washers (by others). Position flat washers
between the bolt head and the tower basin flange. P11 tower use ³⁄₈"
bolts, all other models use ¹⁄₂" bolts.
3. Attach your cold water supply piping to the cold water basin outlet
connection.
Do not support your pipe from the tower or outlet connection—
support it externally.
Normally, one of the following outlet arrangements is provided:
Cased face suction connection: Models P11 and P12 have a
polyethylene female NPT coupling attached to the side of the cold
water basin. It is extremely important not to overtighten the connection
to avoid damaging the coupling. The larger models have a galvanized
pipe nipple extending horizontally from the side of the cold water basin.
It is both beveled for welding—and grooved for a mechanical coupling.
If a weld connection is used, it is recommended that the weld area be
protected against corrosion. Cold galvanizing is suggested, applied
according to the manufacturer’s instructions. Install 2" plugs in outlets
that are not used.
Bottom outlet connection option: This is a factory-installed, circular
opening in the cold water basin floor. An appropriately-sized circular
opening has been drilled to 125# ASME B16.1 flat-face flange
connection specifications. Model P13 with 10" outlet and models P14
and P15 with 12" outlets have a galvanized pipe connection. It is both
beveled for welding—and grooved for a mechanical coupling. See
▲
▲▲Note
Installation
➠

7
PLUG
P11-P12
GASKET
COVER PLATE
P13-P14-P15
TRASH SCREEN
Figure 1A and 1B. The bottom outlet arrangement is also used for
equalizer connections between basins.
The typical attachment of customer piping for bottom outlet or equalizer
with flange connection using gasket (supplied by Marley) is shown in
Figure1. Sealing washers (by others) required at bolt connections
inside basin. The tower is not designed to support additional piping
loads. Do not support piping from the tower.
Installation
Figure 1 Install plug in side-outlet location for models P11 and P12. Remove
side-outlet connection assembly on larger models and install cover
plate using sealer as shown in Figure 1.
4. The welded galvanized pipe assembly utilized on some models P14
and P15 ships within the tower basin. Unbolt as shown in Figure 1A
and reinstall as shown in Figure 1B. Apply sealer as shown and reuse
existing hardware as well as additonal hardware shipped with tower.
If a weld connection is used, it is recommended that the weld area be
protected against corrosion. Cold galvanizing is suggested, applied
according to the manufacturer’s instructions. ➠

8
UNBOLT AND
REINSTALL
Installation
Figure 1A
COVER PLATE
TRASH SCREEN
Figure 1B
5. Attach makeup water supply piping to the float valve connection.
Install the float ball and stem. If you wish to pipe overflow and drain
water to a remote discharge point, make those connections at this
time.
6. Install your warm water piping at the inlet location on the tower.
Do not support your pipe from the tower or inlet connection—support
it externally.
▲
▲▲Caution

9
Installation
▲
▲▲Warning
3
/ 8 " X 1
1
/ 2 " BOLT
FLAT WASHER
LOCK WASHER
LOCK WASHER
NUT
NUT
MOTOR
MOTOR PLATE
BRACKET
BRACKET
3
/ 8 " X 1" BOLT
ASSEMBLY DETAILS
7. Wire motor in accordance with wiring diagram on motor nameplate.
Check motor connections and power supply voltage versus motor
nameplate voltage.
8. Install fan guard using ³⁄₈" tap screws provided.
For maintenance/safety purposes, Marley 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.
Field Installed Mechanical Equipment—Direct Drive Models
1. Install brackets and motor plate to motor as shown in Assembly
Details. If present, remove drain plugs from the bottom of the motor on
the end opposite of shaft.

10
A
B
Installation
DETAIL A
3
/ 8 " X 1" BOLT
3 PLACES
FLAT WASHER
MOTOR
FLAT WASHE
R
BRACKET
LOCK WASHER
NUT
2. Install motor assembly on tower cross beams as shown in Figure 2 and
Detail A. Leave bolts loose enough to allow for fan centering adjustment.
➠
Figure 2