Marley Nc fiberglass User manual

NC®berglass cooling tower

INSTALLATION - OPERATION - MAINTENANCE

uk_Z0702489_D ISSUED 8/2018 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

user manual

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.

Page

Tower Shipment............................................................................................... 3

Receiving Tower.............................................................................................. 3

Tower Location ................................................................................................ 4

Tower Assembly .............................................................................................. 4

Motor Wiring .................................................................................................... 5

Mechanical Equipment .................................................................................. 6

Tower Startup .................................................................................................. 8

Tower Maintenance......................................................................................... 14

Water Quality and Blowdown ...................................................................... 14

Schedule of Tower Maintenance................................................................. 16

Seasonal Shutdown Instructions ................................................................ 19

Prolonged Shutdown ..................................................................................... 19

Maintenance Schedule.................................................................................. 20

Additional Services......................................................................................... 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 maintenance

which are important but not related to personal injury hazards.

Warning

Caution

Note

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 instal-

lation 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.

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

SPX Cooling Technologies 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.

Tower Shipment

NC Fiberglass towers ship by truck unassembled. Responsibility for the

condition of the tower upon its arrival belongs to the shipper—as does the

coordination of multiple shipments, if required. Refer to the NC Fiberglass

Assembly Manual for instructions.

Receiving Tower

Prior to assembly, inspect the shipment for evidence of damage in transit. If

damage is apparent, note the freight bill accordingly. This will support your

future recovery claim.

Find and remove the installation instructions and bills of material. This informa-

tion should be kept for future reference and maintenance purposes.

installation

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

representative 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.

Tower Assembly

Your Marley sales engineer is able to provide for the tower assembly by Marley’s

construction division or through a qualified subcontractor. Our subcontrac-

tors provide safe, efficient assembly which complies with all requirements for

warranty protection of your tower by SPX Cooling Technologies. Refer to the

NC Fiberglass Assembly Manual for instructions.

Before assembly make sure that the tower orientation agrees with

your intended piping arrangement.

Except for horizontal components of top-mounted piping and as

prescribed on Marley drawings, do not support your pipe from the

tower or outlet connection—support it externally.

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.

Warning

Note

Caution

Warning

installation

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

cooler weather it is common for the motor to draw 6 to 10% higher than

nameplate amps. High amps are common during tower commissioning

when the tower is dry and the ambient air temperature is cool.

Do not start the motor more than four to five times per hour. Short cy-

cling 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 switch-

ing 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

IEC 60 034 and 60 079.

• 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. “Maximum current parameter” will reduce fan speed and limit amp

Note

➠

draw to nameplate amps during cold weather operation. 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 31m a

DV/DT output filter is recommended to avoid damage to the motor.

31m 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.

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 Cool-

ing 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.

Warning

installation

Mechanical Equipment

Always shutoffelectrical powerto thetowerfan motorpriorto performing

any maintenance on the tower. Any electrical switches should be locked

out and tagged out to prevent others from turning the power back on.

1. If equipped, check oil level in accordance with the Geareducer User Manual

for the Geareducer. If oil is required, fill Geareducer to the proper level with

approved lubricant.

2. Spin the fan manually to assure that all fan blades properly clear the inside

of the fan cylinder. Observe the action of the sheaves and belts to be sure

that the motor is properly aligned with the fan sheave. See Belt Tensioning

and Sheave Alignment on page 16 and 17. If equipped with Geareducer

drive observe the action of the coupling (or drive shaft couplings) to be sure

the motor and Geareducer are properly aligned. If necessary correct align-

ment (see Geareducer User 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.

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. If the fan is intended to be reversed for deicing

purposes, make sure that the starter is equipped with a two minute

time delay between changes of direction. These delays will prevent

abnormal stress from being applied to the mechanical equipment

and the electrical circuit components.

5. Run the motor and observe the operation of the mechanical equipment. Operation

should be stable.

6. If equipped with belt drive check the torque on the fan and motor sheave

after 10 to 60 hours of operation.

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.

Warning

Caution

Note

installation

operation

Tower Start-Up

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 local public

health services and recommendations.

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 properly installed.

4. For NC8401 thru NC8405 fill the water system to an approximate

depth of 178mm in the depressed section of the cold water basin. For

NC8407 thru NC8414 fill the water system to an approximate depth

of 203mm in the depressed 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 4mm 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.

Warning

operation

6. Continue pump operation for about 15 minutes, after which it is rec-

ommended that the water system be drained, flushed, and refilled in

order to clean the system.

7. While operating the 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

• 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.

Tower Operation

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 attain-

able 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.

3. Water Flow Rate Increasing the water flow rate (m3/hr) 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/hr reductions also cause

an increase in the incoming hot water temperature. Use care to prevent

the hot water from exceeding 46°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.

operation

Range – °F =

Heat Load (Btu/hr)

GPM x 500

or — in SI units

Range – °C =Heat Load (kW)

Water Flow (m3/hr) x 1.162

operation

Fan Cycling Limits:

Considering the normal fan and motor sizes utilized on NC towers,

anticipate that approximately 4 to 5 starts per hour are allowable.

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 , “Cooling Tower Energy and its

Management” available from your Marley sales representative or you

can download a copy from Marley’s website at spxcooling.com.

Freezing Weather Operation

During operation in subfreezing weather, the opportunity exists for ice to form

in the colder regions of the tower. Your primary concern is to prevent the

formation of destructive ice on the cooling tower fill. Your understanding of

cold weather operation will be enhanced if you read Marley Technical Report

H-003 , “Operating Cooling Towers in Freezing Weather,” augmented by

the following guidelines. Available for download at spxcooling.com.

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.

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:

Note

➠

Do not allow the tower’s leaving water temperature to drop

below a minimum allowable level (2.5° to 5°C) established as

follows:

During the coldest days of the first season of operation, observe whether

any ice is forming on the louver face, particularly near the bottom of the

louver face. If hard ice is present on the louvers, an appropriate eleva-

tion in the allowable cold water temperature is mandatory. If the coldest

possible water is beneficial 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 maximum heat load, it should be safe for all operating conditions.

However, if established at reduced load, increased heat loads may

reintroduce the potential for icing.

Having established the minimum allowable cold water temperature,

maintaining that temperature can be accomplished by fan manipulation,

as outlined in Item 4 under Tower Operation on page 10. However,

in towers of more than one cell, the limiting temperature established

applies to the water temperature of the cell or cells operating at the

highest fan speed—not necessarily the net cold water temperature

produced by the entire tower.

2. As cold air enters the louvers, it causes the falling water to be drawn

inward toward the center of the tower. Thus, under fan operation,

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.

Although ice is unlikely to cause structural damage to the fill, it may

build up sufficiently to restrict the free flow of air through the louvers.

This will have the effect of reducing the tower’s thermal performance

efficiency. When excessive ice forms on the louvers, stop the fan for

a few minutes. With the fan off, the increase in the water temperature

and the action of the cascading water will reduce the ice buildup on

the louvers.

operation

Intermittent Freezing Weather 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.

Consult your Marley sales representative for more information.

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.

It is recommended that you discuss your freeze prevention options with your

local Marley sales representative.

Caution

operation

maintenance

Water Treatment and Blowdown

Maintaining Water Quality:

The materials used in an NC Fiberglass tower are selected to offer long,

corrosion-free service in a “normal” cooling tower environment, defined

as follows:

• Circulating water with a pH between 6.5 and 8; a chloride content

(as NaCl) below 500 mg/L; a sulfate content (SO4) below 250 mg/L;

total alkalinity below 500 mg/L; calcium hardness (as CaCO3) above

50 mg/L.

• 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).

Unless you purchased an NC Fiberglass tower with stainless steel

structure, the structure of your tower consists primarily of galvanized

steel, therefore your water treatment program must be compatible

with zinc. In working with your water treatment supplier, it is impor-

tant that you recognize the potential effects on zinc of the specific

treatment program you choose.

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.*

Note

maintenance

* Range = Difference between hot water temperature coming to tower and cold water

temperature leaving tower.

EXAMPLE: 159.1 m3/hr circulating rate, 10°C cooling range. To main-

tain 4 concentrations, the required blowdown is 0.458% or .00458 times

159.1 m3/hr, which is 0.7 m3/hr.

If tower is operated at 4 concentrations, circulating water will contain four

times as much dissolved solid as the makeup water, assuming none of the

solids form scale or are otherwise removed from the system.

When water treatment chemicals are added, they should not be in-

troduced into the circulating water system via the cold water basin

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 local public health services and recommendations.

Note

Warning

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maintenance

• 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.

• 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 represen-

tative. For help identifying the sales representative in your area, visit

spxcooling.com/replocator.

Schedule of Tower Maintenance:

Included with this instruction packet are separate User Manuals on each major

operating component of the tower, and it is recommended that you read them

thoroughly. Where discrepancies may exist, the separate User Manuals will

take precedence.

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.

Warning

Belt Tensioning:

The belts are adjusted by tensioning bolts which adjust the motor base. Check

tension frequently during the first 24-48 hours of run-in operation. To properly

adjust the belt tension, position the fan motor so that moderate pressure on

the belt midway between the sheaves will produce a 13mm deflection. Over-

tensioning 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 or similar device is

an alternate method for tensioning V-belts. Check with you local belt supplier.

Sheave Alignment:

• The motor sheave is to be positioned as close as possible to the motor

in order to minimize torque on the motor bushings.

• The motor and fan sheaves may have grooves that are not used. The bot-

tom surface of the motor and fan sheaves must be aligned within 3mm of

each other and level within ½° (3mm in 300mm) in order to not adversely

affect belt and sheave life.

• Alignment can be achieved by placing a straight edge across the top of

the sheaves making sure that it is level and measuring down to the bottom

surface of both sheaves at four points.

• The belts are to be located in the inboard set of grooves closest to the

bearing.

maintenance

➠

SHEAVE

STRAIGHT EDGE

SHEAVE

THREADED ROD

FAN SHAFT

maintenance

Weekly Visually inspect the cooling tower to assess general operating condi-

tions and for signs of microbial growth and appearance of debris, scale and

corrosion. Consult a knowledgeable water treatment professional to maintain

cooling tower hygiene.

Observe, touch, and listen to the tower. 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 tower until

the problem can be located and corrected. Observe operation of the motor, fan

shaft bearing 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.

Monthly (Inspect louvers, drift eliminators and basin trash screens and

remove any debris or scale which may have accumulated. Replace any dam-

aged 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.

Every 3 months Lubricate fan shaft bearings. While rotating equipment by

hand, grease the bearings with lithium based grease until a bead forms

around the seals. Mobil SHC 460 grease is recommended.

Semi-Annually If equipped, check the belt tension and condition.

If equipped, check Geareducer oil level. Shut down the unit and allow 5 min-

utes for the oil level to stabilize. Add oil if required.

If equipped, Geareducer models used on NC Fiberglass cooling

towers are designed for 5-year oil change intervals. To maintain five-

year change intervals, use only oil designed specifically for these

Geareducers. If, after five years, turbine-type mineral oil is used, the

oil must be changed semiannually. Refer to the Geareducer Manual

for oil recommendations and further instructions.

Annually Lubricate motor according to the manufacturer’s instructions. Fan

motors with sealed bearings do not require lubrication maintenance.

Check to see that all bolts are tight in the fan and mechanical equipment region,

including the fan guard. Refer to component User Manuals for torque values.

Inspect the tower thoroughly, making maximum use of instructions given in the

Note

maintenance

separate service manuals. Check structural bolted connections and tighten as

required. Make preventive maintenance repairs as necessary.

Every 5 Years: If equipped, change Geareducer oil. Refer to the Geareducer

User Manual for instructions.

Seasonal Shutdown Instructions

When the system is to be shut down for an extended period of time, it is recom-

mended 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.

Fan Check fan assembly bolting and tighten as required. Use torque settings

prescribed on the fan nameplate. Refer to fan user 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 lubricated

before returning motor to service. Does not apply to motors with sealed bearings.

Prolonged Shutdown:

If shutdown period is longer than seasonal, contact your Marley sales repre-

sentative for additional information.

Caution

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 (if equipped):

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 x

Check driveshaft or coupling alignment x

Check for loose driveshaft or coupling fasteners x

Check driveshaft or coupling bushings or flex element for unusual wear x x

Lube lines (if equipped):

Check for oil leaks in hoses or fittings x R x

Belt drive (if equipped):

Fan shaft bearing lubrication (every 3 mo.) every 3 months every 3 months

Check and tighten support fasteners x

Check shaft, sheave and belt alignment x

Check belt tension and condition x x

Check sheave bushing fastener torque x

Fan:

Check and tighten blade and hub fasteners x

Check fan blade pitch and tip clearance x

Inspect and touch up fan hub 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

Inspect and touch up all metal surfaces x

Structure, Bearing Housing, Sheaves, Coupling Flange:

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.

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