Marley HP7000 Fan
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User Manual 97-1342B
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Fan Hub Installation
The following instructions detail the process for installing a Marley
HP7000 fan on a Marley Geareducer® with a tapered fan (output)
shaft utilizing a bolted fan hub retention plate or a straight fan shaft
using a split taper bushing. Installation on other gear reduction
units may be different. Contact your Marley sales representative
for supplemental instructions if required.
If the fan installation is for a Marley 36, 38, 3600, or 4000 model
Geareducer, or uses a U1 split taper bushing on a straight (out-
put) shaft, refer to the applicable instructions below.
Note
1–Remove the retention plate and hardware from the top of the
Geareducer shaft. Thoroughly clean the fan shaft, fan shaft key,
and the fan hub center bore to remove any debris and/or protective
coatings. After cleaning, apply a coat of anti-seize compound to
the top 7″ (180mm) of the fan shaft.
2–Prior to hub installation, fully seat the key in the fan shaft keyway.
The key is a tight fit across the width and must never be altered.
3–Raise the fan hub above the fan shaft for installation. Slowly lower
the hub onto the shaft with the keyways properly aligned. Make
certain the key does not slide down during installation. Stake the
key in the keyway with a center punch if necessary.
The fan shaft key should be approximately centered in the engaged
portion of the hub when engaged on the shaft. Verify the center hub
is fully seated by visual inspection.
4–Install the retention plate and hardware. Torque bolts to 70 ft·lbƒ
(95 N·m).
36 and 38 Series Geareducers use a tapered fan shaft key.
Correct key installation is imperative for proper and safe op-
eration. The following instructions detail installation for these
applications.
36 and 38 Geareducer
1–Remove the retention plate and hardware from the top of the
Geareducer. Thoroughly clean the fan shaft, fan shaft key, and the
hub center bore to remove any debris and/or protective coatings.
After cleaning, apply a coat of anti-seize compound to the top 7″
(180mm) of the fan shaft.
2–Install the 36 and 38 Series Geareducer fan shaft key in the fan
shaft keyway as shown in Figure 2. The key is a tight fit across the
width and must never be altered.
➠
3
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Fan Hub Installation
1
/
2
"
1
1
/
2
"
1
GEAREDUCER
FAN SHAFT
5
/
8
"
MIN
3
/
8
"
1
TAPERED SIDE
OF KEY
Figure 2
36 and 38 Geareducer
3–Raisethehubassemblyabovethefanshaftforinstallation. Slowly
lower the assembly onto the shaft with the keyways aligned. Make
certain the key does not slide down during installation. Stake the
key in the keyway with a center punch if necessary.
After the hub assembly is installed the bottom end of the key must
extend through the bottom of the center hub, and the top end of
the key must extend 5/8″ (16mm) minimum above the top of the fan
shaft. Do not force the key down once these criteria are met.
4–Figure 3 illustrates proper retention plate and hardware installa-
tion. The retention plate is designed to allow clearance for the fan
shaft key, and when properly installed will not extend over or inter-
fere with the key in any way. Torque the retention bolts to 70 ft·lbƒ
(95 N·m) then turn up the locking strap corners to prevent the bolts
from loosening.
RETENTION
PLATE
FAN HUB
RETENTION
BOLTS
KEY
Figure 3
36 and 38 Geareducer
LOCKING
STRAPS
4
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Fan Hub Installation
The U1 split taper bushing provided with the fan installation kit
will be either a Type 1 or a Type 2 bushing. A Type 1 bushing will
use the fan shaft key provided with the Geareducer. A Type 2
bushing uses an integral key that is shared by the output shaft
and the fan hub keyways. To distinguish which type of bushing
is provided, refer to Figure 4.
U1 Split Taper Bushing
1–Remove the fan shaft key from the top of the Geareducer shaft
and discard if a Type 2 split taper bushing is being used. Thoroughly
clean the fan shaft and fan hub center bore to remove any debris
and/or protective coatings. After cleaning, apply a coat of anti-seize
compound from the end of the fan shaft down to the length of the
shaft keyway.
2–Remove the U1 split taper bushing from its packaging. Discard
and replace the 5/8-11NC black steel cap screws provided within
thebushingpackagingwiththe5/8-11NCstainlesssteelcapscrews
provided with the fan installation kit. Thoroughly clean the bushing
center bore and outside taper (barrel) surface to remove any protec-
tivecoating. Aftercleaning, applyathincoatofanti-seizecompound
to the outer taper surface of the bushing.
3–Aligning the outside taper (barrel) bushing key with the keyway
of the hub bore, loosely start the Type 1 or Type 2 bushing into the
bore of the hub. The three (3) threaded holes in the hub must be
aligned with the non-threaded holes in the bushing flange—Note,
the two (2) threaded holes in the bushing flange are used only
for disassembly. Apply anti-seize compound to the threads of the
5/8-11NC stainless steel cap screws. Insert the cap screws through
the non-threaded holes in the bushing flange and thread them by
hand into the hub two or three turns only.
4–If a Type 1 split taper bushing is being used, prior to installing the
bushing-hub assembly onto the fan shaft, fully seat the key in the
fan shaft keyway. The key is a tight fit across the width and must
never be altered.
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5
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Fan Hub Installation
5–Position the bushing-hub assembly over the Geareducer fan
shaft. Carefully align the bushing bore keyway with the previously
installed shaft key—or if using a Type 2 split taper bushing, align
the shared hub/bushing key with the fan shaft keyway. Lower the
assembly onto the shaft. The assembly must slide onto the output
shaft enough to ensure the shaft key runs the entire length of the
bushing bore. It may be necessary to slightly wedge open the split
taper bushing for easier engagement of the fan shaft into the bush-
ing bore. This can be accomplished by driving a wedge into the
bushing flange split.
6–Using a torque wrench, tighten the stainless steel cap screws
sequentially until each is tightened to 140 ft·lbƒ (190 N·m). When
the cap screw torque is at or near 140 ft·lbƒ (190 N·m), make at
least two more sequential rounds to assure all cap screws are to
the required torque value.
Type 1 U1 Split Taper Bushing
Type 2 U1 Split Taper Bushing
Figure 4
6
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Fan Blade Installation
MarleyHP7000fanbladesaremanufacturedtoequalmomentweight
and blade clamps to equal static weight. The blades and clamps
can be installed in any position without affecting fan balance.
At the end of the blade shank on a nameplate is inscribed a let-
ter code (i.e. “A” or “B” etc.). When installing or replacing blades
use only blades with the same letter code.
Note
1–Lubricate the 3/4″ bolt and 3/4″ hex-nut threads with thread lu-
bricant. Set the hardware aside.
2–Remove one set of blade clamps from the hub assembly. Blade
clampsareinstalledonthehubassemblyatthefactorywithspacers
for shipping purposes. Remove and discard the spacers. Position
the blade clamps around the shank of a blade with the machined-
face end of the blade clamp against the blade safety shoulder. See
Figure 4. Large nylon cable ties can be used to hold blade clamps
on the blade during installation providing easier assembly.
3–Insert the blade with blade clamps around the shank and with the
concave blade side (TOP) on the discharge side between the hub
assembly plates as shown in Figure 5 and Figure 6. Vertically align
the four bolt holes in the clamps and plates. Install four lubricated
3/4″ bolts, eight 3/4″ flat washers, (four 3/4″ lock washers if hard-
ware material is monel), and four 3/4″ hex nuts, engaging the nuts
only three to four threads as shown in Figure 5. Do not tighten the
hardware until all the blades have been installed. The blade must
be free to rotate in the clamp for pitch adjustment.
4–Repeat until all blades, clamps, and hardware have been installed
in the hub assembly.
LOCKING HEX NUT OR
HEX NUT AND LOCK WASHER
BLADE CLAMP
FLAT WASHER
HUB PLATE
HUB PLATE
FLAT WASHER
Figure 5
MACHINE BOLT
FAN BLADE
7
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Adjusting Fan Blade Pitch
The trial pitch is the calculated setting for design conditions
(water rate , heat load, air density, and brake horsepower). The trial
pitch is provided (see page 2).
1–Select a position on the fan circumference and rotate each blade
to this common location when setting or checking blade pitch. Sup-
port the blade tip to maintain a common rotation plane while setting
the fan pitch. The pitch is set within 2″ (51mm) of the blade tip by
placing a bevel protractor on top of a parallel sided straight edge
that extends across blade width as shown in Figure 6.
2–Pull the blade outward so the safety shoulder is in contact
with the blade clamp, then set the pitch. See Figure 5. Blades
should be within 1/4° of the desired pitch angle. After the de-
sired setting is obtained, progressively tighten the 3/4″ hex nuts to
120 ft·lbƒ (163 N·m) torque. Recheck the pitch angle. If required,
loosen the hex nuts and reset the pitch as necessary until the proper
pitch angle is obtained with the 3/4″ hex nuts at 120 ft·lbƒ (163 N·m)
torque.
3–Repeat step 2 for all blades.
4–Check the vertical blade-tip track variation. The allowable verti-
cal variation from a reference plane is 1″ (25mm). If a blade’s tip
track is out of tolerance, loosen the 3/4″ hardware and change the
blade tip support location higher or lower as required to adjust the
tip track. Recheck blade pitch angle.
BLADE
TIP
STRAIGHT
EDGE
BEVEL
PROTRACTOR
PITCH ANGLE
Figure 6
2"
8
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Hub Cover Installation
Install the hub cover as shown in Figure 1 and Figure 7. Tighten all
hex nuts to 15 ft·lbƒ (20 N·m) torque.
145
300
142
144
146
142
143
102
142
141
Figure 7
Fan Maintenance
Preventative maintenance will prolong useful life and assure contin-
ued trouble-free operation. After the first week and subsequently
at six month intervals:
• Torque all hardware to specifications referenced in this manual.
• Visually inspect the fan for airborne debris damage, contact with
fan cylinder segments, and corrosive attack. Correct any situations
determined detrimental to fan operation.
• Remove any accumulated scale or dirt.
• Clear blade drain holes.
9
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Service
Proper identification of your fan is necessary to insure you receive
correct replacement parts. The Marley cooling tower serial number
can be used to determine the fan and any components installed and
maintained as original equipment on a Marley cooling tower. The
fan diameter and moment weight class from the blade nameplate
(see Figure 8) is required to identify blades for replacement. The
fan hub assembly identification number (see Figure 1) is required to
identify a replacement hub assembly or repair components. Please
providetheMarleysalesofficeorsalesrepresentativethenecessary
information when ordering replacement fans or components.
Blades can be replaced without rebalancing the entire fan.
If rebalancing is desired, contact the Marley sales office or repre-
sentative in your area.
HP7000 Fan
BLADE SIZE
MOMENT WEIGHT CLASS
SERIAL NUMBER
For Additional Information Refer to HP7000 Manual
SPX Cooling Technologies
Overland Park, KS USA
913 664 7400
Figure 8–Blade Nameplate
10
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Motor Load
The corrected horsepower should be close to but not exceed the
contract horsepower specified by Marley. Determine corrected
horsepower using the following equation.
VOLTSA × AMPSA × DENSITYD
× HPN
HPC
=
VOLTSN × AMPSN × DENSITYA
HPC
=
=
=
=
Corrected Horsepower VOLTSN
=
=
=
=
Nameplate Volts
VOLTSA
AMPSA
DENSITYA
Actual Volts
AMPSN
HPN
Nameplate Amperage
Nameplate Horsepower
Design Air Density
Actual Amperage
Actual Air Density
DENSITYD
Actual volts and amperage must be obtained with the fan running
and the specified rate of water flowing over the tower after the motor
andGeareducerhavereachedoperatingtemperature(approximately
30 minutes of operation).
Measurements taken on motors operating with Variable Fre-
quency Drive controls may read up to 15% high from errors in
measuringtheapproximatedsinewave.Instrumentscapableof
measuring a squared off wave form accurately should be used
for measuring power in this situation.
Note
Do not exceed 30 sec/hour total motor starting time as motor
may overheat.
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7401 WEST 129 STREET OVERLAND PARK, KANSAS 66213 UNITED STATES 913 664 7400 [email protected] spxcooling.com
In the interest of technological progress, all products are subject to design and/or material change without notice.
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©2008 SPX Cooling Technologies, Inc. Printed in USA
Manual 97-1342B
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