Marley Aquatower User manual

Aquatower®cooling tower
INSTALLATION - OPERATION - MAINTENANCE
READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
user manual
uk_Z0504653_E ISSUED 8/2018

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 Installation.........................................................................................................5
Piping to Tower............................................................................................................5
Mechanical Equipment Installation .........................................................................6
Motor Electrical Connections...................................................................................9
Starting and Operating Instructions ....................................................................10
Freezing Weather Operation.................................................................................13
Maintenance Instructions .......................................................................................15
Blowdown..................................................................................................................16
Cooling Tower Inspection and Maintenance ..................................................... 17
Seasonal Shutdown Instructions .........................................................................18
Troubleshooting........................................................................................................20
Wiring Diagrams.......................................................................................................21
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.
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, 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 war-
rantability 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 equip-
ment may result in improper installation and/or operation of the cooling tower.
Any such deviation, change or modification shall be the responsibil-
ity 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 cooling
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.
Receiving Inspection
The motor and miscellaneous parts ship with the tower. Check motor name-
plate to be sure that power supply and motor have the same characteristics.
Inspect the entire shipment for any damage that may have occurred in transit.

4
installation
➠
Tower Location
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.
Locate so prevailing wind will blow into the louvered face, and direct fan
discharge away from building surfaces. Locate so there is free air flow to and
from the tower. Allow clearance on all sides for maintenance.
Indoor Installation
Use a duct from the tower air discharge to the outside. You may also want to
install an inlet air duct. Do not allow the total pressure loss through ducts to
exceed 25 Pa. To minimize pressure losses:
• Use 20% oversize ducts.
• Avoid sharp turns or abrupt changes in size.
• Keep duct length to a minimum.
• Screened or louvered openings should have a net free area at least 20%
greater than the tower discharge opening area.
Attach ducts to the tower using flexible connections, and support ducts
independently from the tower. Provide access openings for servicing the me-
chanical equipment if air discharge ducts are installed. If the duct discharges
into the prevailing wind, you may need to install a windbreak or an elbow to
serve as a deflector. Ducts installed on towers with year-round usage should
be water tight and insulated to prevent condensation.
Warning

5
installation
Tower Installation
Install tower in a level position on a stable foundation. Anchor tower to the
foundation through holes at base of tower, using four M10 diameter bolts (not
supplied). Remove strapping and brackets from the louver face on models
494—496 and reinstall the bolts to the cold water basin. Install the overflow
(fiberglass models only) as shown in Figure 1.
INSTALL DRAIN FITTING
WITH GASKET ON TOP
Cooling
Tower
with
Bottom
Outlet
Heat
Load
Indoor
Storage
Tank
Pump
Make-Up
Line
Inlet
Gravity Line
from Outlet
Overflow and
Drain to Sewer
Figure 2
Piping to Tower (Summer–Only Operation)
1. Use large enough piping to minimize friction loss.
2. Connect float valve to makeup water supply. Install the threaded valve
stem and float located in the loose parts package.
3. Install a valved blowdown line at some point in the system, preferably in
the hot water line near the top of the tower, so that water will flow through
the line whenever the pump is operating. (Blowdown is the continuous
removal of a small amount of water during operation to retard scale and
corrosion.)
Figure 1
➠

6
SUPPORT BRACKET
(WITH ADJUSTMENT SLOTS)
1/4" TAP SCREW
installation
Piping to Tower (Year–Round Operation)
1. If your tower must operate during freezing weather, it is recommended
that the tower be installed for gravity flow operation. See Figure 2.
2. Provide an indoor open type storage tank with a capacity that will contain
all water that will drain into the tank from the system during shutdown.
3. Connect tower outlet to storage tank. Bottom outlet option should be
used for gravity flow.
4. Install makeup water, bleed-off, overflow and drain lines on tank.
5. Insulate and heat water lines exposed to freezing temperatures.
Mechanical Equipment Installation
Aquatowers with factory-installed controls ship with the motor,
sheave, belt, and belt guard factory-installed. Remove shipping
stiffener plate and hardware at the adjustable end of the motor
support plate and proceed to Motor Electrical Connections.
Motor, Sheave, and V-Belt Installation
1. Check the motor nameplate to be sure its voltage, phase and frequency
ratings are the same as the power supply.
Note
Motor Frame Fastener
Size
56–143T–145T 5⁄16"
182T thru 215T 3⁄8"
Figure 3
➠
BELT GUARD FOR STEEL
AQUATOWER SHOWN

7
2. Make sure the fan is tightly secured to the bearing housing shaft and that
it rotates freely. Make sure the bearing housing is secured to its support.
3. Attach motor to motor base with four bolts, flat washers, lock washers
and nuts provided, see Figure 3. You may want to loosen the adjusting
bolts and raise the motor base so you can reach under the motor base
to tighten the motor hold-down bolts.
4. Apply a rust preventive coating to the motor shaft to prevent shaft corro-
sion and to ease sheave installation and removal.
5. Install motor sheave and align it with fan sheave. Motor support brackets
are slotted to assist in alignment. See Figure 3. A plumb line will be helpful
in aligning sheaves. See Figure 4.
6. Remove the fan guard and fan cylinder splice plate (steel tower only) at
the top of the fan cylinder. Install the belt over the fan by passing the belt
over the fan and rotating the fan blades past the belt. Install the belt onto
the sheaves.
Figure 4
installation
PLUMB LINE
SHEAVES MUST BE PARALLEL TO
EACH OTHER AND IN THE SAME
PLANE OF OPERATION FAN SHEAVE
MOTOR SHEAVE
➠

8
installation
Figure 5
7. Use the adjusting bolts on the motor support to adjust belt tension. A
correctly tensioned belt does not slip when the fan is running—and the
“tight” side is straight between sheaves. The “slack” side will have a slight
bow. If possible, use a commercially available tension measuring device.
Avoid over-tensioning. Too much tension reduces bearing and belt life.
Check the tension on new belts after 8 to 12 hours of operation.
8. Install the belt guard as shown in Figure 3 for a steel tower or Figure 5
for a fiberglass tower.
9. Install fan cylinder splice plate (steel tower) and fan guard.
10. Check bearing housing oil cup level. Fill to the proper level with SAE 30
(ISO 100) weight oil.
3/8" x 1 1/2" BOLT
3/8" WASHERS
USE 3/8" WASHERS TO
SHIM AS REQUIRED
3/8" NEOPRENE WELL-NUT
BELT GUARD FOR FIBERGLASS
AQUATOWER SHOWN

9
Motor Electrical Connections
If Aquatower is equipped with Marley Control System, refer to Con-
trol System Manual for wiring instructions.
Internal space heaters may be present, depending upon the motor manufac-
turer. For space heater operation and wiring refer to Marley “Fan Motor”
User Manual Z0239042.
Connect motor to power supply in accordance with the National Electric
Code and local requirements. Failure to wire the motor correctly will void its
warranty. Overload protection for motors must be part of the control system.
Figure 6 shows one possible control scheme. Other various wiring diagrams
appear on pages 19 through 22.
Note
installation
L1
L2
L3
MMM
STOP START
M
M
OL
2-WIRE CONTROL (IF USED)
NOTE: L3 IS USED ON 3-PHASE MOTOR ONLY.
MOTOR
Figure 6

10
operation
Starting and Operating Instructions
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.
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. Clean all debris, such as leaves and dirt from the cooling tower fill and
basin.
4. Fill the circulating system with water. The cold water basin should be filled
with water until level is at the rim of the overflow.
The water conditions during the initial tower operation are crucial in pre-
venting premature corrosion of galvanized steel (white rust). For at least
the first eight weeks of operation, pH should be controlled between 6.5
and 8.0 with hardness and alkalinity levels between 100 and 300 mg/L
(expressed as CaCO3).
If tower is equipped with a standard side-suction connection, vent
any accumulated air from the top of the suction hood by removing
one or both tap screws provided at that location. Replace these tap
screws when venting is complete.
5. Start your pump(s). Observe system operation. Since the water system
external to the tower will have been filled only to the level in the cold water
basin, some “pump-down” of the basin water level will occur before water
completes the circuit and begins to fall from the fill. The initial pump-down
may not be enough to cause the float valve to open. However, you can
check its operation by pressing down on the operating lever. Adjust the
Warning
Note

11
float valve during tower operation with heat load to maintain 100mm water
depth in the depressed section of the basin on Models 490—493. Maintain
140mm water depth on Models 494—496.
Hot water temperatures exceeding 50°C could damage PVC fill.
6. Make sure blowdown line is discharging water.
7. Depth of water in hot water basin should be uniform. If the basin overflows,
reduce the flow rate. Do not pump more water than design capacity.
8. Continue pump operation for about 15 minutes, after which it is recom-
mended that the water system be drained, flushed, and refilled.
9. 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 du-
ration 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.
Note
operation
➠

12
operation
10. Check fan for free rotation and check oil level in bearing housing as required
(see maintenance instructions). Start motor and check direction of rotation.
Fan must rotate clockwise when viewed from the fan discharge side. If the
rotation is incorrect, change any two of the three motor leads.
Fan Cycling Limits:
Considering the normal fan and motor sizes utilized on Aquatowers,
anticipate that approximately 4 to 5 starts per hour are allowable.
If your tower is equipped with a two-speed motor, you will enjoy greater op-
portunity for temperaturecontrol. When thewater temperature becomestoo
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).
For greater insight on cold water temperature control, please read
“Cooling Tower Energy and its Management”, Technical Report
H-001, available on our website.
Note
Note

13
operation
Freezing Weather Operation
The Marley fill system used in the Aquatower 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.
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 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 minimum heat load, it should be safe for all operating conditions.
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 operation, the
louvers and lower periphery of the tower structure remain partly dry, see-
ing only random splashing from within the tower—plus normal atmospheric
moisture from the entering air. Such lightly wetted areas are most subject
to freezing.
Note
Caution
➠

14
operation
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 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 cycling limits
on page 11 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.
Warning

15
maintenance
Maintenance Instructions
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.
The top of the tower is not a working surface. Do not stand, sit or
walk on top of the tower. Use an appropriate ladder adjacent to
the tower whenever you perform any maintenance activity on the
tower’s upper surfaces.
This product is constructed of fiberglass or cold-formed sheet
metal. Use protective clothing, gloves and shoes as appropriate
for protection against edges of thin gage material.
Fan Motor:
Lubricate the motor according to the motor manufacturer’s supplied instruc-
tions. Sealed bearing motors do not require lubrication maintenance. Refer
to motor nameplate to determine if grease type and amount are specified.
Remove any oil, dust or scale deposits from the motor which can cause ex-
cessive insulation temperatures.
Refer to Marley “Fan Motor” User Manual Z0239042 for additional main-
tenance and lubrication information.
Fan Shaft Bearing Housing:
Check bearing housing oil cup level. Fill to the proper level with ISO 100
(SAE 30) weight oil.
Belt Tension:
Check belt tension every two to three weeks during peak operating season.
Makeup Float Valve:
Check float valve periodically for proper operation and proper water level.
Basin and Suction Screen:
Drain and clean cold water basin and suction screen periodically.
Blowdown:
Check the blowdown for continuous water discharge during operation.
Warning

16
maintenance
Blowdown Rate
Cooling Two Four
Range (°C) Concentrations Concentrations
3 0.7% 0.17%
4 1.1% 0.30%
6 1.5% 0.43%
Blowdown
A cooling tower cools water by continuously causing a portion of it to evapo-
rate. 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 are in the range of 2–4 concentrations. The following table gives
approximate blowdown rates (percent of total water flow rate constantly
wasted) to achieve those concentrations at various cooling ranges*:
* Range is the difference between hot water temperature entering the tower and
cold water temperature leaving the tower.
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 and may damage the cooling tower.
Note

17
maintenance
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 new cooling tower prior to startup. See Tower Startup section of
this manual.
• Cooling towers must be cleaned and disinfected regularly in accordance
with local public health services and recommendations.
• 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.
Warning

18
maintenance
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,
including automatic basin heater systems available from Marley.
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.
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 Inspection
and Maintenance section of this manual before attempting repairs. Apply
protective coating as required to all metal parts. Pay particular attention to
bearing housing supports.
Fan Shaft Bearing Housing:
• At shutdown, check the oil level in the oil cup.
• At start of new operating season, operate until the oil is warm—drain and
refill. Use ISO 100 (SAE 30) weight oil.
• Bearing housing must be refilled at the point where the oil line from the
oil reservoir cup connects to the bearing housing. Attach oil line and fill
line and oil cup. Fan guard will have to be removed to change oil. Each
month check the oil level at the oil cup.
Caution
Warning

19
maintenance
Fan Motor:
Clean and lubricate motor (if required) at close of each operating season.
Refer to motor manufacturer’s recommendations.
Do not start motor before determining that there will be no interfer-
ence with free rotation of the fan drive.
The motor should be run for three hours at least once a month to dry out
windings and lubricate bearing surfaces. Refer to Marley “Fan Motor” User
Manual Z0239042.
At start of new operating season, make sure bearings are adequately lubri-
cated 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 Rep-
resentative for additional information.
Whenever you order parts, or correspond with us about your tower,
please include the tower serial number, located on the tower's
name plate.
Warning
Note

20
troubleshooting
Trouble Cause Remedy
Unusual motor noise Motor running single-phase Stop motor and attempt to start it. Motor will not start if single-
phased. Check wiring, controls and motor.
Motor leads connected incorrectly Check motor connections against wiring diagram on motor.
Bad bearings Check lubrication. Replace bad bearings.
Electrical unbalance Check voltage and currents of all three lines. Correct if required.
Rotor unbalance Rebalance.
Motor runs hot Motor overload, wrong voltage or
unbalanced voltage
Check voltage and current of all three lines against nameplate values.
Check nameplate RPM of motor and sheave ratio against parts list.
Wrong fan RPM Check nameplate RPM of motor and sheave ratio against parts list.
Measure RPM.
Bearings overgreased Remove grease reliefs. Run motor up to speed to purge excessive
grease. Does not apply to motors with sealed bearings.
Wrong lubricant in bearings Change to proper lubricant. See motor manufacturer’s instructions.
One phase open Stop motor and attempt to start it. Motor will not start if single-
phased. Check wiring, controls and motor.
Poor ventilation Clean motor and check ventilation openings. Allow ample ventilation
around motor.
Winding fault Check with Ohmmeter.
Bent motor shaft Straighten or replace shaft.
Insufficient grease Remove plugs and regrease bearings. Does not apply to motors with
sealed bearings.
Too frequent starting Limit cumulative starting time to a total of 30 seconds each hour.
Deterioration of or foreign material in
grease
Flush bearings and relubricate.
Unusual fan drive vibration Fan shaft bearings damaged Replace bearings.
Loose bolts and cap screws Tighten all bolts and cap screws on all mechanical equipment and sup-
ports.
Worn fan shaft bearings Replace bearings.
Bent shaft Replace shaft.
Misalignment Make sure fan and motor are straight and properly aligned.
Loose or stretched belt Check belt for proper tension.
Unbalanced motor Disconnect load. Remove sheave, tape key in keyway and operate
motor. If motor still vibrates, rebalance motor.