Marley Quadraflow cooling tower User manual

Quadraow®cooling tower
INSTALLATION - OPERATION - MAINTENANCE
sea_Z0238885_D ISSUED 8/2018 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
user manual

2
contents
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.
Overview ........................................................................................................... 3
Tower Location ................................................................................................ 3
Tower Shipment............................................................................................... 4
Receiving Tower.............................................................................................. 4
Tower Assembly .............................................................................................. 4
Motor Wiring .................................................................................................... 4
Tower Startup .................................................................................................. 9
Freezing Weather Operation........................................................................ 10
Tower Maintenance......................................................................................... 13
Water Quality and Blowdown...................................................................... 13
Schedule of Tower Maintenance................................................................. 15
Seasonal Shutdown Instructions ................................................................ 18
Motor Relubrication Instructions ................................................................. 19
Prolonged Shutdown ..................................................................................... 19
Additional Services......................................................................................... 20
Additional Information .................................................................................... 21
Troubleshooting............................................................................................... 22
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.
Note
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 mainte-
nance which are important but not related to personal injury hazards.
Warning
Caution
Note

3
overview
This User Manual as well as those offered separately on motors, fans,
Geareducer, couplings, drive shafts, float valves, pumps, etc., are intended to
assure that this cooling tower serves you properly for the maximum possible
time. Since product warrantability may well depend upon your actions, please
read this User Manual thoroughly prior to operation.
This User Manual provides information regarding general cooling tower in-
stallation and operation. Any deviation from, change or modification to, the
User Manual, the original design conditions or the original intended use of the
equipment may result in improper installation and/or operation of the tower.
Any such deviation, change or modification shall be the responsibility of
the party or parties making such deviation, change or modification. SPX
Cooling Technologies, Inc. expressly disclaims all liability for any such deviation,
change or modification. The equipment shall be warranted in accordance with
the applicable SPX Cooling Technologies Certification of Limited Warranty.
If you have questions about the operation and/or maintenance of this cool-
ing 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 include the serial number shown on the cooling tower nameplate.
Tower Location
Space available around the tower should be as generous as possible to pro-
mote 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 submittal
drawings. 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 ob-
tain 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

4
installation
Tower Shipment
QuadraFlow towers ship by truck (on flat bed trailers) in an unassembled
condition. Single cell towers ship on one truck. Multicell towers, depending
on their size, 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 shipment. If damage is apparent, note the freight
bill accordingly. This will support your future recovery claim.
Tower Assembly
Your Marley sales representative is able to provide for the tower assembly by
SPX’s construction division or through a qualified subcontractor. Our subcon-
tractors provide safe, efficient assembly which complies with all requirements
for five-year warranty protection of your tower by SPX.
Motor Wiring
Wire motor leads as shown on the motor nameplate matching the supply
voltage. Do not deviate from the motor nameplate wiring.
Internal space heaters may be present, depending upon the motor manufac-
turer. For space heater operation and wiring refer to the Marley “Fan Motor”
User Manual Z0239042.
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
cools are common during tower commissioning when the tower is dry
and the ambient air temperature is cool.

5
➠
Do not start the motor more than four to five 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 four to five 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 name-
plate 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 opera-
tion. 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 30 me-
ters a DV/DT output filter is recommended to avoid damage to the
motor. 30 meters 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 constant
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 energy
being used and provide better temperature control. In addition, it reduces the
mechanical and electrical stress on the motor and mechanical equipment.
Note
Note
Note
installation

6
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.
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.
Mechanical Equipment:
Always make certain that mechanical equipment is inoperable
during periods of maintenance—or during any situation of possible
endangerment to personnel. If your electrical system contains a
disconnect switch, lock it out until the period of exposure to injury
is over.
1. Check the Geareducer oil level at the sight glass near the motor. If oil is
required, fill to the proper level.
2. Spin the fan manually to assure that all fan blades properly clear the inside
of the fan cylinder. Observe the action of the driveshaft couplings to be
sure that the motor and Geareducer are properly aligned. If necessary,
correct the alignment in accordance with the included driveshaft manual.
3. Momentarily energize (“bump”) the motor and observe rotation of the
fan. The fan should rotate in a counterclockwise direction when viewed
from below. If rotation is backwards, shut off the fan and reverse two of
the three primary leads supplying power to the motor.
Warning
Warning
installation
Warning

7
➠
If tower is equipped with a two-speed motor, check for proper rota-
tion at both speeds. Check also to see that starter is equipped with
a 20-second time delay which prevents direct switching from high
speed to low speed. This delay will allow the fan to slow down and
will prevent abnormal stress from being applied to the mechanical
equipment and the electrical circuit components.
4. Run the motor and observe the operation of the mechanical equipment. Opera-
tion should be stable, and there should be no evidence of oil leakage.
If the water supply system is not being operated—or if there is no
heat load on the system—motor amps read at this time may indicate
an apparent overload of as much as 10–20%. This is because of the
increased density of unheated air flowing through the fan. Deter-
mination of an accurate motor load should await the application
of the design heat load.
General:
The cold water temperature obtained from an operating cooling tower will
vary with the following influences:
1. Heat Load With the fan in full operation, if the heat load increases, the
cold water temperature will rise. If the heat load reduces, the cold water
temperature will reduce.
Note that the number of degrees (“range”) through which the tower cools
the water is established by the system heat load and the amount of water
being circulated, in accordance with the following formula:
The cooling tower establishes only the cold water temperature attainable
under any operating circumstance.
2. Air Wet-Bulb Temperature Cold water temperature will also vary with
the wet-bulb temperature of the air entering the louvered faces of the tower.
Reduced wet-bulb temperatures will result in colder water temperatures.
However, the cold water temperature will not vary to the same extent as
the wet-bulb. For example, an 11°C reduction in wet-bulb may result in
only an 8°C reduction in cold water temperature.
Caution
Note
Heat Load (kW)
Water Flow (m3/h) x 1.162
Range (°C) =
installation

8
3. Water Flow Rate Increasing the water flow rate (m3/h) will cause a
slight elevation in cold water temperature, while reducing the water flow
rate will cause the cold water temperature to lower slightly. However, at
a given heat load (see formula above), m3/h reductions also cause an
increase in the incoming hot water temperature. Use care to prevent the
hot water from exceeding 52°C, in order to prevent damage to the tower
components.
4. Airflow Rate Reducing airflow through the tower causes the cold water
temperature to rise. This is the approved method by which to control
leaving water temperature.
If your tower is equipped with a single-speed motor, the motor may be
shut off when the water temperature becomes too cold. This will cause
the water temperature to rise. When the water temperature then becomes
too warm for your process, the motor can be restarted.
Fan cycling limits:
Considering the normal fan and motor sizes utilized on Quadraflow
towers, anticipate that approximately 4 to 5 starts per hour are al-
lowable.
If your tower is equipped with a two-speed motor, greater opportunity
for temperature control is afforded you. When the water temperature
becomes too cold, switching the fan to half-speed will cause the cold
water temperature to rise—stabilizing at a temperature a few degrees
higher than before. With a further reduction in water temperature, the
fan may be cycled alternately from half-speed to off.
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).
If your tower consists of two or more cells, cycling of motors may be shared
between cells, increasing your steps of operation accordingly. For greater
insight on cold water temperature control, please read Marley Technical
Report #H-001-A , “Cooling Tower Energy and its Management”
available for download at spxcooling.com.
Note
Note
installation

9
operation
Tower Startup
Microorganisms including Legionella bacteria can exist in premise
plumbing including cooling towers. The development of an effective
water management plan (WMP) and implementation of maintenance
procedures are essential to prevent the presence, dissemination and
amplification of Legionella bacteria and other waterborne contami-
nants throughout premise plumbing. Before operating the cooling
tower, the water management plan and maintenance procedures
must be in place and regularly practiced.
Water System:
1. Consult a knowledgeable water treatment professional to clean and treat
your new cooling tower prior to startup. Cooling towers must be cleaned
and disinfected regularly in accordance with ASHRAE Standard 188 and
Guideline 12.
2. Do NOT attempt any service unless the fan motor is locked out.
3. Remove any and all accumulated debris from tower. Pay particular at-
tention to inside areas of cold water basin, entire hot water basin, and
hot water inlet. Make sure that cold water suction screens are clear and
installed in place.
4. Fill the water system to an approximate depth of 76mm in the elevated
section of the cold water basin. This is the recommended operating water
level. Adjust the float valve so that it is essentially closed at that level.
Continue filling the system until the water reaches a level approximately
3mm below the lip of the overflow.
5. Start your pump(s). Observe system operation. Since the water system
external to the tower will have been filled only to the level achieved in the
cold water basin, a certain amount of “pump-down” of the basin water level
will occur before water completes the circuit and begins to fall from the
fill. The amount of initial pump-down may be insufficient to cause the float
valve to open. However, you can check its operation by pressing down
on the operating lever to which the stem of the float valve is attached.
6. Continue pump operation for about 15 minutes, after which it is recom-
mended that the water system be drained, flushed, and refilled in order
to clean the system.
Warning

10
operation
7. While operating the condensing 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 shut-
down. Utilize the services of the water treatment supplier. Maintain the
maximum recommended biocide residual (for the specific biocide) for
a sufficient period of time (residual and time will vary with the biocide)
to bring the system under good biological control
or
• Treat the system with sodium hypochlorite to a level of 4 to 5 mg/L
free chlorine residual at a pH of 7.0 to 7.6. The chlorine residual must
be held at 4 to 5 mg/L for six hours, measurable with standard com-
mercial water test kits.
If the cooling tower has been in operation and then shut down for a duration
of time and not drained, perform one of the two previous biocidal treatment
programs directly to the cooling water storage vessel (cooling tower sump,
drain down tank, etc.) without circulating stagnant water over the cooling
tower fill or operating the cooling tower fan.
After biocidal pretreatment has been successfully completed, cooling water
may be circulated over the tower fill with the fan off.
When biocidal treatment has been maintained at a satisfactory level for at
least six hours, the fan may be turned on and the system returned to service.
Resume the standard water treatment program, including biocidal treatment.
Freezing Weather Operation
The Marley fill system used in the Quadraflow has air entrance louvers that
are molded as an integral part of the fill. This feature makes these towers very
forgiving of cold weather operation, even at the low temperature and reduced
load conditions encountered in free cooling and other low temperature applica-
tions. Nevertheless, during operation in subfreezing weather the opportunity
exists for ice to form in the colder regions of the tower.
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 tower operation, but
its appearance should be a signal to the operator to undertake ice
control procedures.
Note

11
operation
It is the operator's responsibility to prevent the formation of destruc-
tive (hard) ice on the cooling tower fill. Certain guidelines should
be followed:
1. Do not allow the tower’s leaving water temperature to drop below a mini-
mum allowable level—say 2°C to 5°C. If such low temperature operation is
necessary or beneficial to your process, establish the minimum allowable
level as follows:
During the coldest days of the first winter of operation, observe whether
any ice is forming on the louver face, particularly near the bottom part of
the louver face. If hard ice is present on the louvers, you must increase
the allowable cold water temperature. If the coldest possible water is ben-
eficial to your process, ice of a mushy consistency can be tolerated—but
routine periodic observation is advisable.
If the minimum allowable cold water temperature is established at or
near minimum heat load, it should be safe for all operating conditions.
Having established the minimum allowable cold water temperature,
maintaining that temperature can be accomplished by fan manipulation,
as outlined in Item 4 on page 8. However, in towers of more than one
cell, where fans are manipulated sequentially, please realize that the water
temperature will be significantly lower in the cell or cells operating at the
highest fan speed than the net cold water temperature produced by the
entire tower would indicate. Wintertime operation of multicell towers at
low cold water temperature levels requires that the operator be especially
watchful.
2. As cold air enters the louvers, it causes the water flowing over the fill to
be drawn inward toward the center of the tower. Thus, under fan opera-
tion, the louvers and lower periphery of the tower structure remain partly
dry, seeing only random splashing from within the tower—plus normal
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. Reversal
of fan should only be done at half speed or less. Reverse operation of
Caution
Caution
➠

12
operation
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.
Operating the fan in reverse at half speed for prolonged periods
during subfreezing weather can cause severe damage to fans and
fan cylinders. Ice can accumulate inside fan cylinders at fan blade
plane of rotation and fan blade tips will eventually strike this ring of
ice, damaging the fan blades or cylinder. Ice can also accumulate
on fan blades and be thrown off, damaging fan cylinder or blades.
Allow a minimum of 10 minute delay between reverse operation
and forward operation during subfreezing weather to permit ice to
dissipate from fan blades and fan cylinders. See Fan Drive Caution
Note in the Mechanical Equipment Installation section of this manual.
4. With no heat load on the circulating water, icing cannot be controlled
effectively by air control during freezing weather. Towers must not be
operated with reduced water rate and/or no heat load during
freezing weather. If the circulating water system cannot be shut down,
water returning from the process should be made to bypass the tower.
If a bypass is used, all water must be bypassed without modulation. If
the water bypass is directly into the tower's cold water basin, its design
must be approved by SPX Cooling Technologies.
Intermittent Wintertime Operation:
If periods of shutdown (nights, weekends, etc.) occur during freezing weather,
measures must be taken to prevent the water in the cold water basin —and
all exposed pipework—from freezing. Several methods are used to combat
this, including automatic basin heater systems available from Marley. It is
recommended that you discuss your freeze prevention options with your local
Marley sales representative.
Unless some means of freeze prevention is incorporated into your
system, the tower basin and exposed pipework should be drained
at the beginning of each wintertime shutdown period.
If tower basin is drained, verify that all basin heaters have been shut
off either by automatic cutoff or disconnect switch.
Warning
Caution
Warning

13
➠
maintenance
Water Quality and Blowdown
Maintaining Water Quality:
The materials used in the QuadraFlow tower are selected to offer long, corro-
sion-free service in a “normal” cooling tower environment, defined as follows:
• Circulating water with a pH between 6 and 8; a chloride content (as NaCl)
below 750 mg/L; a sulfate content (SO4) below 1200 mg/L; a maximum
inlet water temperature not to exceed 52°C; no significant contamina-
tion with unusual chemicals or foreign substances; and adequate water
treatment to minimize scaling.
• Chlorine (if used) shall be added intermittently, with a free residual not to
exceed 1 mg/L – maintained for short periods. Excessive chlorine levels
may deteriorate sealants and other materials of construction.
• An atmosphere surrounding the tower no worse than “moderate indus-
trial,” where rainfall and fog are no more than slightly acid, and they do
not contain significant chlorides or hydrogen sulfide (H2S).
Blowdown:
A cooling tower cools water by continuously causing a portion of it to evaporate.
Although the water lost by evaporation is replenished by the makeup system, it
exits the tower as pure water—leaving behind its burden of dissolved solids to
concentrate in the remaining water. Given no means of control, this increasing
concentration of contaminants can reach a very high level.
In order to achieve water quality which is acceptable to the cooling tower (as
well as the remainder of your circulating water system), the selected water
treatment company must work from a relatively constant level of concentra-
tions. This stabilization of contaminant concentrations is usually accomplished
by blowdown, which is the constant discharge of a portion of the circulating
water to waste. As a rule, acceptable levels on which to base a treatment
schedule will be in the range of 2-4 concentrations. The following table gives
approximate rates of blowdown (percent of total water flow rate constantly
wasted) to achieve those concentrations at various cooling ranges.*
*Range = Difference between hot water temperature entering the tower and cold water tempera-
ture leaving the tower.
Blowdown Rate
Cooling Two Four
Range (°C) Concentrations Concentrations
6 0.7% 0.17%
8 1.1% 0.30%
11 1.5% 0.43%

14
maintenance
When water treatment chemicals are added, they should not be
introduced into the circulating water system via the cold water ba-
sin of the cooling tower. Water velocities are lowest at that point,
which results in inadequate mixing.
Cooling Tower Inspection and Maintenance
Microorganisms including Legionella bacteria can exist in premise
plumbing including cooling towers. The development of an effective
water management plan (WMP) and implementation of maintenance
procedures are essential to prevent the presence, dissemination and
amplification of Legionella bacteria and other waterborne contami-
nants throughout premise plumbing. Before operating the cooling
tower, the water management plan and maintenance procedures
must be in place and regularly practiced.
In addition, the following steps are recommended:
Do NOT attempt any service unless the fan motor is locked out.
• Consult a knowledgeable water treatment professional to clean and treat
your cooling tower. See Tower Startup section of this manual.
• Cooling towers must be cleaned and disinfected regularly in accordance
with ASHRAE Standard 188 and Guideline 12.
• Workers performing decontamination procedures must wear personal
protective equipment (PPE) as directed by their facility safety officer.
• Cooling towers must be visually inspected regularly to assess signs of
bacterial growth, appearance of debris and scale on drift eliminators
and general operating conditions. Refer to ASHRAE Standard 188 and
Guideline 12 for specific frequency recommendations.
• Replace worn or damaged components.
To minimize the presence of waterborne microorganisms, including Legionella,
follow the water management plan for your facility, perform regularly scheduled
cooling tower inspections and maintenance, and enlist the services of water
treatment professionals.
For additional technical support, contact your Marley sales representative.
References:
ashrae.org. Search “ASHRAE Standard 188” and “ASHRAE Guideline 12.”
cdc.gov. Search “Water Management Program.”
Note
Warning

15
maintenance
Schedule of Tower Maintenance:
Included with this instruction packet are separate Service Manuals on each
major operating component of the tower, and it is recommended that you
read them thoroughly. Where discrepancies may exist, the separate Service
Manuals will take precedence.
Do not use the top horizontal surface of the tower as a working
platform. The tower is designed so that all maintenance can be
performed from the exterior and interior of the tower. Do not use
the upper basin covers as a walking surface or working platform.
Remove basin covers and use portable ladders whenever performing
service on the hot water basin. Use of ladder should be in accord
with manufacturer’s recommendations
The following is recommended as a minimum routine of scheduled maintenance:
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. Lock out
and tag out any electrical switches to prevent others from turning
the power back on. Service personnel must wear proper personal
protective clothing and equipment.
Weekly Visually inspect the cooling tower to assess general operating
conditions and for signs of microbial growth and appearance of debris,
scale and corrosion. Refer to ASHRAE Standard 188 and Guideline 12
for specific frequency recommendations. Consult a knowledgeable water
treatment professional to maintain cooling tower hygiene.
Monthly (Weekly at Start-up) Observe, touch, and listen to the tower. Be-
come 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 tower until the problem can be located and corrected.
Observe operation of the motor, driveshaft, Geareducer and fan. Become
familiar with the normal operating temperature of the motor, as well as the
sight and sound of all components as a whole.
Check Geareducer oil level. Shut down the unit and allow 5 minutes for the
oil level to stabilize. Add oil if required. Check system for leaks if the amount
of oil required appears unusual. (If oil is added at the external fill port, allow
adequate time for the level to stabilize before reading final level.)
Warning
Warning
➠

16
maintenance
Inspect louvers, drift eliminators and basin trash screens and remove any
debris or scale which may have accumulated. Replace any damaged or worn
out components. Use of high-pressure water may damage the eliminator and
louver material.
Observe operation of the float valve. Depress the operating lever to make
sure that the valve is operating freely. Inspect the suction screen for plugging.
Remove any debris that may have accumulated.
Check for any buildup of silt on the floor of the cold water basin. Mentally
note the amount, if any, so future inspections will enable you to determine
the rate at which it is forming.
Semi-Annually Relubricate motor according to the manufacturer’s instruc-
tions. See instructions on page 19.
Check to see that all bolts are tight in the fan and mechanical equipment region,
including the fan guard. Use torque settings prescribed on the fan nameplate.
To maintain five-year change intervals, use only oil designed specifi-
cally for these Geareducers. If, after five years, turbine-type mineral oil
is used, the oil must be changed semiannually. Refer to Geareducer
User Manual for oil recommendations and further instructions.
Annually: Inspect the tower thoroughly, making maximum use of instructions
given in the separate user manuals. Lubricate motor according to the manu-
facturer’s instructions. Refer to the Motor Lubrication Instructions on page
19. Fan motors with sealed bearings do not require lubrication maintenance.
If the motor has sealed bearings, additional lubrication is not re-
quired. Refer to the motor nameplate to determine if grease type
and amount are specified.
Check structural bolted connections and tighten as required. Make preventive
maintenance repairs as necessary.
Every 5 Years Change Geareducer oil. Refer to Geareducer User Manual
for instructions.
Note
Note

17
maintenance schedule
Maintenance Service Monthly Semi-annually Seasonal Startup or Annually
Inspect General Condition and Operation x x
Observe Operation of:
Mechanical–motor, fan and drive mechanism x x
Makeup valve (if equipped) x x
Inspect for unusual noise or vibration x x
Inspect and Clean:
Air inlet x x
PVC drift eliminators x x
Distribution basin, nozzles and collection basin x x
Fan motor exterior x x
Check:
Collection water basin level x x
Blowdown–adjust as required x x
Geareducer Drive
Check for loose fasteners including oil drain plug x
Check for / repair oil leaks x x
Check oil level x x
Change oil R
Make sure vent is open x
Check driveshaft alignment x
Check for loose driveshaft or coupling fasteners x
Check driveshaft flex element for unusual wear x x
Lube lines:
Check for oil leaks in hoses or fittings x x
Fan:
Check and tighten blade and hub fasteners x
Check fan blade pitch and tip clearance x
Check fan cylinder for loose fasteners x
Motor:
Lubricate (as required) R
Check mounting bolts for tightness x
Operate at least 3 hours a month 3 hours a month 3 hours a month
Basin Heater (if equipped):
Check for proper operation of temp/low water level sensor x
Inspect/clean buildup of contaminant from sensor x x
Structure:
Inspect/tighten all fasteners x x
Inspect and touch up all metal surfaces x
R— Refer to Component User Manual
Note: It is recommended at least weekly, that the general operation and condition be observed. Pay attention to
any changes in sound or vibration that may signify a need for closer inspection.

18
maintenance
Seasonal Shutdown Instructions
When the system is to be shut down for an extended period of time, it is
recommended that the entire system—cooling tower, system piping, heat
exchangers, etc.—be drained. Leave the basin drain open.
During shutdown, follow recommendations in the Cooling Tower Inspec-
tion and Maintenance section of this manual before attempting repairs.
Pay particular attention to mechanical equipment supports and driveshafts.
Tower Framework Check structural bolted connections and tighten as
required.
Driveshaft Check driveshaft alignment, tightness of cap screws and set screws,
and condition of all components. Refer to driveshaft service manual.
Fan: Check fan assembly bolting and tighten as required. Use torque settings
prescribed on the fan nameplate. Refer to fan service manual.
Fan Motor Clean and lubricate motor (if required) at close of each operating
season (refer to motor manufacturer’s recommendations.) Does not apply to
motors with sealed bearings. Check motor anchor bolts and tighten as required.
Do not start motor before determining that there will be no interfer-
ence with free rotation of the fan drive.
The motor should be operated for three hours at least once a month. This
serves to dry out windings and lubricate bearing surfaces. Refer to Marley
“Fan Motor” User Manual Z0239042 for additional information.
At start of new operating season, make sure bearings are adequately lu-
bricated before returning motor to service. Does not apply to motors with
sealed bearings.
Warning

19
maintenance
Warning
Drive Shaft Air Seals
Motor
Motor Lubrication Instructions:
Open and lock out disconnect switch to make certain motor can-
not be started.
1. Remove interior driveshaft air seals as shown above. Opposite end motor
bearing is accessible by removing motor cover (24000 models do not
have a motor cover) on the exterior of the tower.
2. Lubricate motor according to the manufacturer’s instructions. Does not
apply to motors with sealed bearings.
Fiberglass Components Check all fiberglass parts for exposed glass fibers.
If found, the affected surfaces should be roughened up and solvent wiped.
Surfaces must be clean and dry and free of oil, grease or other contaminants
before applying new coating. The best coating system requires using a two-
part polyamide epoxy primer to promote adhesion and a two-part acrylic
polyurethane enamel for the topcoat. Contact your Marley sales representative
if additional information is required.
Prolonged Shutdown:
If shutdown period is longer than seasonal, contact your Marley sales engineer
for additional information.

20
maintenance
Additional Services
SPX’s interest in your Marley QuadraFlow cooling tower does not end with
the sale. Having conceived, designed, and manufactured the most reliable
and longest lasting cooling tower of its class, we want to make sure that you
gain the maximum possible benefit from its purchase.
Therefore, the following services are available which are intended to assure
the maximum possible service life under your operating conditions, tailor the
operating characteristics to your specific needs, and maintain consistent op-
timum thermal performance capability. They are available by contacting your
Marley sales representative.
Replacement Parts:
With the exception of the motor, every component of your tower is designed
and manufactured by SPX Cooling Technologies. We do this because com-
mercially available components have not proved capable of withstanding the
harsh environment of a cooling tower— nor do they contribute their share to
the thermal capability and operating characteristics intended.
A complete stock of all 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 tower serial number (from the tower nameplate) when
ordering parts. Refer to assembly manual for part identification.
Periodic Maintenance:
You may wish to contract with Marley for regularly scheduled visits—for the
purpose of inspecting and reporting your tower’s condition—to make recom-
mendations intended to prevent emergencies—and to perform maintenance
considered outside the norm.
This service is not intended to replace the important function performed by
your maintenance staff. Their attention assures the tower’s routine operating
performance, and is invaluable. However, Marley recognizes that the unusual
manner in which a cooling tower 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.