SPX Cooling Technologies Refrigerator MHF702 User Manual

Marley MH Fluid Cooler  
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User Manual sea_05-116E  
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Contents  
This manual contains vital information for the proper installation  
and operation of your fluid cooler. Carefully read the manual before  
installation or operation of the fluid cooler and follow all instructions.  
Save this manual for future reference.  
Note  
Fluid Cooler Location ............................................................................. 5  
Fluid Cooler Shipment............................................................................ 6  
Receiving Fluid Cooler ........................................................................... 6  
Hoisting Fluid Cooler.............................................................................. 6  
Fluid Cooler Installation.......................................................................... 7  
Motor Wiring........................................................................................... 8  
Mechanical Equipment......................................................................... 11  
Fluid Cooler Start-Up ........................................................................... 13  
Fluid Cooler Operation ......................................................................... 15  
Wintertime Operation ........................................................................... 16  
Water Treatment ................................................................................... 20  
Fluid Cooler Cleaning........................................................................... 21  
Blowdown............................................................................................. 21  
Belt Adjustment.................................................................................... 22  
Sheave Alignment ................................................................................ 24  
Fluid Cooler Maintenance .................................................................... 25  
Seasonal Shutdown Instructions.......................................................... 28  
Prolonged Shutdown............................................................................ 29  
Troubleshooting.................................................................................... 32  
Additional Information .......................................................................... 34  
Troubleshooting.................................................................................... 29  
Maintenance Schedule......................................................................... 31  
The following defined terms are used throughout this manual to bring at-  
tention 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.  
Warning  
Indicatespresenceofahazardwhichwillorcancausepersonalinjury  
or property damage if ignored.  
Caution  
Indicatesspecialinstructionsoninstallation,operationormaintenance  
which are important but not related to personal injury hazards.  
Note  
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Preparation  
The Marley MH Fluid Cooler with CoolBoost™, purchased for this instal-  
lation represents the current state of the art in crossflow, induced draft  
fluid cooler design. Thermally and operationally, it is the most efficient  
fluid cooler of its class.  
These instructions—as well as those offered separately on motors, fans,  
Geareducer®, couplings, drive shafts, float valves, pumps, etc.—are in-  
tended to assure that the fluid cooler serves you properly for the maximum  
possible time. Since product warrantability may well depend upon your  
actions, please read these instructions thoroughly prior to operation.  
If you have questions about the operation and/or maintenance of this  
product, and you don’t find the answers in this manual, please contact  
your Marley sales representative. When writing for information, or when  
ordering parts, please mention product serial number shown on the name-  
plate located on the access door.  
Safety First  
The location and orientation of the fluid cooler can affect the safety of those  
responsible for installing, operating or maintaining the fluid cooler. However,  
since SPX Cooling Technologies does not determine the location or orienta-  
tionoftheuidcooler, wecannotberesponsibleforaddressingthosesafety  
issues that are affected by the fluid cooler’s location or orientation.  
WarNiNg  
Thefollowingsafetyissuesshouldbeconsideredbythoseresponsible  
for designing the tower installation.  
Warning  
• access to and from the fan deck  
• access to and from maintenance access doors  
• the possible need for ladders (either portable or permanent) to  
gain access to the fan deck or maintenance access doors  
• the possible need for handrails around the fan deck  
• the possible need for external access platforms  
• potential access problems due to obstructions surrounding the tower  
• lockout of mechanical equipment  
• the possible need for safety cages around ladders  
• theneedtoavoidexposingmaintenancepersonneltothepotentially  
unsafe environment inside the fluid cooler  
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Preparation  
Itisnotintendednorassumedthataccesstothefandeckonsingle-flow  
Note  
models—Models MHF702 thru MHF705—is needed or necessary.  
Those are only some of the safety issues that may arise in the design  
process.SPXstronglyrecommendsthatyouconsultasafetyengineer  
to be sure that all safety considerations have been addressed.  
Several options are available that may assist you in addressing some of  
these personnel safety concerns, including:  
• Louver face distribution basin access platform with ladder and handrail.  
• Louver face redistribution basin level access platform with ladder and  
handrail.  
• A handrail system around the perimeter of the fan deck with either one  
or two ladders for access to the deck. Double-flow models MHF706  
and MHF707 only.  
• Extended fan deck that provides additonal access around one end  
of the fan cylinder opposite the fan deck access ladder. Double-flow  
models MHF706 and MHF707 only.  
• Ladder extensions—used where the base of the tower is elevated.  
• Safety cages for ladders.  
• External lube lines.  
• Access door platform.  
• Motor located outside the tower. Double-flow models MHF706 and  
MHF707 with Geareducer drive only.  
• External motor access platform. Double-flow models MHF706 and  
MHF707 with Geareducer drive only.  
• Plenum walkway. Double-flow models MHF706 and MHF707 only.  
Standard on all other models.  
• Mechanical equipment access platform.  
Fluid Cooler Location  
Space available around the fluid cooler should be as generous as possible  
to promote ease of maintenance—and to permit freedom of airflow into  
and through the fluid cooler. If you have questions about the adequacy  
of the available space and the intended configuration of the fluid cooler,  
please contact your Marley sales representative for guidance.  
Prepare a stable, level support foundation for the fluid cooler, utilizing  
weight, wind load, and dimensional information appearing on appropri-  
ate Marley submittal drawings. Supports must be level to insure proper  
operation of the fluid cooler.  
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Installation  
The fluid cooler must be located at such distance and direction to  
avoid the possibility of contaminated fluid cooler discharge air be-  
ing drawn into building fresh air intake ducts. The purchaser should  
obtaintheservicesofaLicensedProfessionalEngineerorRegistered  
Architect to certify that the location of the fluid cooler is in compli-  
ance with applicable air pollution, fire and clean air codes.  
Warning  
Tower Shipment  
Unless otherwise specified, the MH Fluid Cooler ships by truck (on flat  
bed trailers), which lets you receive, hoist, and install the tower in one  
continuous operation. Single-cell single-flow fluid coolers ship on one  
truck. Double-flow and multicell fluid coolers, depending on their size,  
may require more than one truck.  
Responsibilityfortheconditionoftheuidcooleruponitsarrivalbelongsto  
the trucker—as does the coordination of multiple shipments, if required.  
receiving Fluid Cooler  
Prior to unloading the fluid cooler from the delivering carrier, 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 instruction drawings and bills of mate-  
rial located in a plastic bag in the water collection basin. This information  
should be kept for future reference and maintenance purposes.  
Hoisting Fluid Cooler  
All MH Fluid Cooler models must use hoist clips and overhead lifting for  
handling assembled fluid cooler. Forklifting from base of fluid cooler  
is not permitted. The clips for the top modules are located at the fan  
deck level. The clips for the lower modules are located at the bottom of  
the modules at the water collection basin. A Hoisting-installation label  
which has hoisting dimensional information is located on the side casing  
near the tower centerline. Remove tower from the carrier and hoist into  
place according to the instructions on the label.  
MH Fluid Cooler upper and lower modules must be hoisted and set  
separately. Do not preassemble modules prior to hoisting.  
Caution  
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Installation  
Hoisting clips are provided for ease of unloading and positioning the  
fluid cooler. For overhead lifts or where additional safety is required,  
safety slings should also be placed under the fluid cooler modules.  
Under no circumstances should you combine the top and bottom  
modules of modular models and attempt to hoist them at the same  
time by utilizing the hoisting clips alone!  
Warning  
Fluid Cooler installation  
These installation instructions are intended to help you prepare be-  
fore your fluid cooler arrives. If discrepancies exist between these  
instructions and those shipped with the fluid cooler, the instructions  
shipped with the fluid cooler will govern.  
Note  
1. Prior to placement of the fluid cooler, confirm that the supporting  
platform is level, and that the anchor bolt holes are correctly located  
in accordance with Marley drawings.  
2. Place bottom module on your prepared supports, aligning anchor bolt  
holes with those in your supporting steel. Make sure that the orienta-  
tion agrees with your intended piping arrangement. Attach fluid cooler  
to supporting steel with 19mm diameter bolts and flat washers (by  
others). See support drawing for location and quantity. Position flat  
washers between the bolt head and the fluid cooler basin flange.  
3. Before setting top module in place on bottom module, clean any  
debris from the underside of the top module fill, skid and beams and  
from the top of the bottom module and remove shipping cover from  
bottom of top module—replace fasteners at side of module to pre-  
vent leaks. Place top module on the top peripheral bearing surface  
(factory-installed gasket) of bottom module, aligning mating holes as  
it is set in place. Attach top module to bottom module with fasteners  
provided according to drawings shipped with your fluid cooler.  
4. Connect the recirculation piping with rubber boot shipped with the  
bottom module piping according to drawings shipped with you fluid  
cooler.  
5. Attach makeup water supply piping to appropriately-sized float valve  
connection located in collection water basin side wall. Install the drain  
and overflow according to drawings shipped with your fluid cooler.  
If you wish to pipe overflow and drain water to a remote discharge  
point, make those connections at this time also.  
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Installation  
Fastenersandcomponentsprovidedbyothersthataretobeattached  
to the tower must be compatible with the cooling tower materials—  
i.e. fasteners in a stainless steel cold water basin must be stainless  
steel.  
Note  
6. Attach process fluid supply and return piping to the coil. Field piping  
connection is an NPT male connection at the coil. A welded connec-  
tion requires removing the threaded portion of the coil.  
For welded connections protect adjacent areas from excessive heat  
and sparks or damage may occur.  
Caution  
7. Wire motor(s) and recirculation pump(s) in accordance with wiring  
diagram.  
Formaintenance/safetypurposes, SPXCoolingTechnologiesrecom-  
mendsalockouttypedisconnectswitchforallmechanicalequipment.  
In addition to a disconnect switch, the motor should be wired to main  
powersupplythroughshortcircuitprotection, andamagneticstarter  
with overload protection.  
Warning  
Motor Wiring  
Wire motor leads as shown on the motor nameplate matching the supply  
voltage. Do not deviate from the motor nameplate wiring.  
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.  
8
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Installation  
• Do not start the motor more than six 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 six 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”  
Note  
per NEMA MG-1, part 31.  
• 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 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  
feet a DV/DT output filter is recommended to avoid damage to the  
motor. 31mº 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 con-  
stant torque modes may damage the gearbox.  
• Donotstartandstopthemotorusingthesafetyswitchatthemotor.  
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 en-  
ergy being used and provide better temperature control. In addition, it  
reduces the mechanical and electrical stress on the motor and mechanical  
9
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Installation  
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.  
MarleysuppliesVFDandVFDcontrolsspecificallydesignedforourcooling  
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.  
Warning  
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  
10  
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Installation  
Mechanical Equipment:  
The fluid cooler is designed to operate at full speed and half speed.  
Warranty is void if the tower is operated at speeds which cause  
damaging vibrations to the tower and associated equipment. When  
utilizing a variable frequency drive, the tower must be tested across  
the full range of speeds and checked against CTI guidelines for ex-  
cessive vibration. Speed ranges not meeting these guidelines must  
be locked out in the VFD.  
Warning  
Warning  
Always shut off electrical power to the tower fan motor prior to  
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. (Although the Geareducer was filled to the  
proper level at the factory, tipping during shipment and hoisting may  
have caused some loss of oil.) If oil is required, fill Geareducer to the  
proper level with approved lubricant. (See Geareducer User Manual )  
Check oil level at the Geareducer or dipstick (standpipe located on fan  
deck, if so equipped) to confirm that the proper level is indicated.  
2. On double-flow models—MHF706 and MHF707—install fan cylinder  
and two-piece fan guard according to the installation drawing shipped  
with the fluid cooler.  
Improperinstallationofthefancylinderandfanguardwilldestroythe  
structuralintegrityofthefanguard.Failureofthefanguardcouldallow  
operating or maintenance personnel to fall into the rotating fan.  
Warning  
3. Spin the fan(s) manually to assure that all fan blades properly clear  
the inside of the fan cylinder. If equipped, observe the action of the  
coupling (or drive shaft couplings) to be sure that the motor and  
Geareducer are properly aligned. If necessary, correct the alignment  
in accordance with the included manual.  
For belt drive equipped models 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 pages 22 thru 24.  
11  
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Installation  
It is essential that the fan cylinder and fan guard be installed in ac-  
cordance with the drawings shipped with the tower. Do not force the  
fan cylinder out of round.  
Note  
4. Momentarily bump (energize) the motor(s) and observe rotation of the  
fan(s). 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 2 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.  
Caution  
5. Run the motor and observe the operation of the mechanical equip-  
ment. Operation should be stable, and, if equipped, there should be  
no evidence of oil leakage from the Geareducer.  
6. Ifequippedwithbeltdrivecheckthetorqueonthefanandmotorsheaveafter  
10 - 60 hrs. of operation. See Bushing Fastener Torque Values on page 25.  
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. Determi-  
nation of an accurate motor load should await the application of the  
design heat load.  
Note  
12  
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Operation  
Fluid Cooler Start-Up  
Amongothersources,outbreaksofLegionnairesDiseasehavereport-  
edlybeentracedtocoolingtowersanduidcoolers.Maintenanceand  
watertreatmentproceduresthatpreventamplificationanddissemina-  
tion of Legionella and other airborne bacteria should be formulated  
and implemented BEFORE systems are operated and continued  
regularly thereafter to avoid the risk of sickness or death.  
Warning  
Water System:  
1. New installations should be cleaned and treated with biocides by a  
water treatment expert before startup.  
2. Remove any and all accumulated debris from fluid cooler. Pay par-  
ticular attention to inside areas of collection water basin, distribution  
water basins, louvers and drift eliminators. Make sure that cold water  
suction screens are clear and properly installed.  
3. Fill the water system to an approximate depth of 8(203 mm) in the  
depressedareaofthecollectionwaterbasin. Thisistherecommended  
operating water level. Adjust the float valve so that it is 75% open at  
that level. Continue filling the system until the water reaches a level  
approximately 3 mm below the lip of the overflow.  
4. Start your pump(s) and check for proper rotation as indicated by  
the arrow on the pump cover, observe system operation. 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 in the up-  
per module. 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.  
Some trial and error adjustment of the float valve may be required to  
balance the makeup water with tower operation. Ideally, the float valve  
setting will be such that no water is wasted through the overflow at  
pump shutdown. However, the water level after pump start-up must  
be deep enough to assure positive pump suction.  
5. Open the valve on the tower bleed line and adjust bleed to the recom-  
mended rate. See Water Treatment section on page 20.  
6. Continue pump operation for about 15 minutes, after which it is rec-  
ommended that the water system be drained, flushed and refilled.  
13  
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Operation  
7. While operating the recirculating water pump(s) and prior to operat-  
ing 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 shutdown. 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  
commercial water test kits.  
If the fluid cooler 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 fluid cooler storage vessel  
(collection basin, 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.  
Whenbiocidaltreatmenthasbeenmaintainedatasatisfactorylevelfor  
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.  
14  
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Operation  
Fluid Cooler Operation  
general:  
The cold process fluid temperature obtained from an operating fluid cooler  
will vary with the following influences:  
1. Heat load: With the fan in full operation, if the heat load increases,  
the cold process fluid temperature will rise. If the heat load reduces,  
the cold process fluid temperature will reduce.  
Heat Load (kilowatts)  
Range – °C  
=
Liters/sec x 4.187  
Note that the number of degrees (“range”) through which the fluid  
cooler cools the process fluid is established by the system heat load  
andtheamountofuidbeingcirculated,inaccordancewiththefollow-  
ing formula—formula is only valid for 100% water as process fluid:  
The fluid cooler establishes only the cold process fluid temperature  
attainable under any operating circumstance.  
2. air wet-bulb temperature: Cold process fluid temperature will also  
vary with the wet-bulb temperature of the air entering the louvered  
faces of the fluid cooler. Reduced wet-bulb temperatures will result  
in colder process fluid temperatures. However, the cold process fluid  
temperature will not vary to the same extent as the wet-bulb. For ex-  
ample, a 11°C reduction in wet-bulb may result in only a 8°C reduction  
in cold process fluid temperature.  
3. Fluid flow rate: Increasing the process fluid flow rate (L/s) will cause  
a slight elevation in cold process fluid temperature, while reducing  
the fluid flow rate will cause the cold process fluid temperature to  
decrease slightly. However, at a given heat load (see formula above),  
process fluid flow reductions also cause an increase in the incoming  
hot process fluid temperature and thermal range.  
Under no circumstances should the recirculation water pump(s) be  
cycled to control process fluid temperature. It is recommenced that  
while process fluid is being circulated through the coil the fluid cooler  
recirculation water system always be in operation.  
Note  
15  
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Operation  
4. airowrate:Reducingairowthroughtheuidcoolercausesthecold  
process fluid temperature to rise. This is the recommended method  
by which to control leaving process fluid temperature.  
If your fluid cooler is equipped with a single-speed motor, the motor  
may be shut off when the process fluid temperature becomes too  
cold. This will cause the process fluid temperature to rise. When the  
fluid temperature then becomes too warm for your process, the motor  
can be restarted.  
When operating in this mode care must be taken not to exceed a total  
fan acceleration time of 30 seconds per hour.  
Caution  
Fan cycling limits: From a dead stop, determine the number of sec-  
onds it takes the fan to arrive at full speed. Divide this number into 30  
to determine the allowable number of starts per hour. Considering the  
normal fan and motor sizes utilized on MH Fluid Coolers, anticipate  
that approximately 4 to 5 starts per hour are allowable.  
If your fluid cooler is equipped with a two-speed motor(s), you will  
enjoy greater opportunity for process temperature control. When the  
process fluid temperature becomes too cold, switching the fan to  
half-speed will cause the cold process fluid temperature to rise—  
stabilizing at a temperature a few degrees higher than before. With a  
furtherreductioninuidtemperature,thefanmaybecycledalternately  
from half-speed to off—subject to the same constraint of 30 seconds  
of allowable acceleration time per hour as outlined above.  
For greater insight on process fluid temperature control, please read  
“Cooling Tower Energy and its Management”, Technical Report  
#H-001-A, available from your Marley sales representative.  
Wintertime Operation:  
The Marley film-fill system used in the MH Fluid Cooler has air entrance  
louvers that are molded as an integral part of the fill. This feature makes  
theseuidcoolersveryforgivingofcoldweatheroperation, evenatthelow  
temperature and reduced load conditions encountered in low temperature  
applications.Nevertheless,duringoperationinsubfreezingweathertheop-  
portunity exists for ice to form in the colder regions of the fluid cooler.  
16  
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Operation  
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 fluid cooler operation,  
but its appearance should be a signal to the operator to undertake  
ice control procedures.  
Note  
It is the operator's responsibility to prevent the formation of destruc-  
tive (hard) ice on the fluid cooler fill. Certain guidelines should be  
followed:  
1. Do not allow the fluid cooler's leaving process fluid temperature to  
drop below 7°C. If such low temperature operation is necessary or  
beneficial to your process, establish the minimum allowable level as  
follows:  
Duringthecoldestdaysoftherstwinterofoperation,observewhether  
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 minimum allowable cold process fluid temperature is estab-  
lished at or near minimum heat load, it should be safe for all operat-  
ing conditions.  
Caution  
Having established the minimum allowable cold water temperature,  
maintaining that temperature can be accomplished by fan manipula-  
tion, as outlined in Item 4 under Fluid Cooler Operation.  
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,thelouversandlowerperipheryofthetowerstructureremain  
partly dry, seeing only random splashing from within the tower—plus  
normalatmosphericmoisturefromtheenteringair. Suchlightlywetted  
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 op-  
erate the fan in reverse. This forces warm air out through the louvers,  
melting any accumulated ice—adequate heat load must be available.  
17  
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Operation  
Reversal may be at either full or half speed; however, reversal at half  
speed is recommended. 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. Monitor-  
ing is required to determine the time required to melt accumulated ice.  
Reverse operation of fans 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  
minutedelaybetweenreverseoperationandforwardoperationduring  
subfreezing weather to permit ice to dissipate from fan blades and  
fan cylinders. See Fan Drive Caution note on page 12 for fan speed  
change and reversing precautions.  
Warning  
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 and pump  
freeze protection systems available from Marley.  
Basin heaters systems will not prevent the coil from freezing.  
Warning  
Caution  
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  
Protection against Coil Freezing:  
Ethylene and propylene glycol solutions are the best means to protect the  
coil from freezing. The following table provides the coil volume for each  
MH Fluid Cooler model. MHF706 and MHF707 coil volumes are for both  
coils added together.  
18  
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Operation  
Coil Volume  
Coil Volume  
Model  
Model  
Liters  
Liters  
MHF702__061  
MHF702__081  
MHF702__101  
MHF702__121  
MHF702__062  
MHF702__082  
MHF702__102  
MHF702__122  
MHF703__061  
MHF703__081  
MHF703__101  
MHF703__121  
MHF703__062  
MHF703__082  
MHF703__102  
MHF703__122  
MHF704__061  
246  
322  
397  
473  
284  
379  
454  
568  
322  
435  
530  
644  
379  
492  
625  
757  
606  
MHF705__061  
MHF705__081  
MHF705__101  
MHF705__121  
MHF705__062  
MHF705__082  
MHF705__102  
MHF705__122  
MHF706__061  
MHF706__081  
MHF706__101  
MHF706__121  
MHF706__062  
MHF706__082  
MHF706__102  
MHF706__122  
MHF707__061  
890  
1192  
1476  
1760  
1079  
1438  
1779  
2139  
1476  
1893  
2309  
2744  
1798  
2309  
2839  
3350  
1703  
MHF704__081  
MHF704__101  
MHF704__121  
MHF704__062  
MHF704__082  
MHF704__102  
MHF704__122  
795  
984  
MHF707__081  
MHF707__101  
MHF707__121  
MHF707__062  
MHF707__082  
MHF707__102  
MHF707__122  
2196  
2688  
3180  
2158  
2801  
3426  
4054  
1173  
719  
946  
1192  
1420  
When the use of industrial antifreeze solutions is not possible, the system  
must be operated to meet both of the following conditions.  
1. Maintain sufficient flow rate through the coil.  
2. Maintain sufficient heat load on the process fluid. Fluid exiting the  
coil must be maintained at or above 7°C. Cycling of the recirculation  
pump should not be used to control process temperatures.  
Draining the coil is not acceptable as a normal method of freeze  
protection—draining promotes corrosion inside the coil tubes. Drain-  
ing is acceptable in an emergency if the coil is not protected by an  
antifreeze solution.  
Note  
It is recommended that you discuss your freeze prevention options with  
your local Marley sales representative.  
19  
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Maintenance  
Water Treatment and Blowdown  
Maintaining Water Quality:  
The steel used in MH Fluid Cooler's has been galvanized with a heavy  
zinc coating averaging .051mm in thickness. Other materials used (PVC  
fill, drift eliminators, and louvers, aluminum fans, cast iron Geareducer,  
etc.) are selected to offer maximum service life in a “normal” fluid cooler  
environment, defined as follows:  
Recirculating water with a pH between 6.5 and 8; a chloride content (as  
NaCl) below 500 ppm; a sulfate content (SO4) below 250 mg/L; total al-  
kalinity (as CaCO ) below 500 mg/L; calcium hardness (as CaCO ) above  
3
3
50 mg/L; no significant contamination with unusual chemicals or foreign  
substances; and adequate water treatment to minimize scaling.  
• Startup Conditions: The water conditions during initial fluid cooler op-  
eration are crucial in preventing 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 CaCO ).  
3
• 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 (H S).  
2
• Many proprietary chemicals exist for control of scale, corrosion, and  
biological growth and should be used prudently. Also, combinations  
of chemicals may cause reactions which reduce treatment effective-  
ness, and certain chemicals such as surfactants, biodispersants and  
antifoams may increase drift rate.  
The structure and coil of your fluid cooler consists primarily of  
galvanized steel, therefore your water treatment program must be  
compatible with zinc. In working with your water treatment supplier,  
it is important that you recognize the potential effects on zinc of the  
specific treatment program you choose.  
Note  
20  
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Maintenance  
Fluid Cooler Cleaning:  
Any evaporative-type fluid cooler must be thoroughly cleaned on a  
regular basis to minimize the growth of bacteria, including Legionella  
Pneumophila, toavoidtheriskofsicknessordeath. Servicepersonnel  
must wear proper personal protective equipment during decontami-  
nation. Do NOT attempt any service unless the fan motor is locked  
out.  
Warning  
Operators of evaporative cooling equipment, such as closed circuit cool-  
ing towers, should follow maintenance programs which will reduce to an  
absoluteminimumtheopportunityforbacteriologicalcontamination.Public  
Health Service officials have recommended that “good housekeeping”  
procedures be followed, such as: regular inspections for concentrations  
of dirt, scale, and algae; periodic flushing and cleaning; and the following  
of a complete water treatment program including biocidal treatment.  
The visual inspection should take place at least once a week during the  
operating season. The periodic flushing and cleaning should be done  
before and after each cooling season, but in any event at least twice a  
year. The louvers, drift eliminators, easily accessible fill surfaces and the  
coil should be flushed by use of a moderate-pressure water nozzle, being  
careful not to cause physical damage. A reliable water treatment program  
should be installed and maintained. Filtration devices may be employed  
to reduce the suspended solids concentrations, thus increasing the ef-  
fectiveness of the water treatment program. See Fluid Cooler Startup  
instructions on page 13.  
Blowdown:  
A fluid cooler 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 fluid cooler, the  
selected water treatment company must work from a relatively constant  
level of concentrations. 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 con-  
centrations. The following table shows the minimum amount of blowdown  
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Maintenance  
(percent of flow) required to maintain different concentrations with various  
cooling ranges*:  
Number of Concentrations  
Cooling Range  
1.5X  
2.0X  
2.5X  
3.0X  
.18  
.38  
.58  
.78  
.98  
4.0X  
.11  
.25  
.38  
.51  
.64  
5.0X  
.08  
.18  
.28  
.38  
.48  
6.0X  
.06  
.14  
.22  
.30  
.38  
3°C  
6°C  
.7  
.38  
.25  
1.5  
2.3  
3.1  
3.9  
.78  
.51  
8°C  
1.18  
1.58  
1.98  
.78  
11°C  
14°C  
1.05  
1.32  
Multipliers are based on drift of 0.02% of the circulating water rate.  
*
Range = Difference between hot water temperature and cold water temperature.  
EXaMPLE: 44.2 L/s circulating rate, 10°C cooling range. To maintain 4  
concentrations, the required blowdown is 0.467% or .00467 times 44.2  
L/s, which is 0.2 L/s.  
If fluid cooler 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 water collection  
basin of the cooling tower. Water velocities are lowest at that point,  
which results in inadequate mixing. An ideal location would be the  
redistribution basin above the coil.  
Note  
Belt Tensioning  
See Figure 1 and Figure 2 for MH Fluid Cooler models MHF702 thru  
MHF705. Loosen specified hardware located at the top and bottom of  
the motor support assembly before adjusting the jacking screws. Do not  
remove the hardware—it is required to support the motor. Tighten the  
hardware after adjustment. Ideal tension is the lowest tension at which  
the belt will not slip under peak load conditions. Check tension frequently  
during the first 24-48 hours of run-in operation. Overtensioning shortens  
beltandbearinglife.Keepbeltsfreefromforeignmaterialwhichmaycause  
slipping. Never apply belt dressing as this will damage the belt and cause  
early failure. A Dodge® V-Belt Tension Tester is an alternate method for  
tensioning V-belts. Check with you local belt supplier.  
22  
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Maintenance  
LOOSEN HARDWARE  
JACKING  
SCREWS  
MOTOR  
SINGLE MOTOR—TWO FANS  
Figure 1  
See Figure 3 for MH Fluid Cooler models MHF706 and MHF707.The belts  
areadjustedbyturningthethreadedrod.Beforetighteningorlooseningthe  
belt, thedoublenutsholdingthemotorsupportinplacemust beloosened.  
There are two jam nuts at the end of the rod next to the casing. Turn the  
nut closest to the end of the rod to tighten the belt. Turn the other nut to  
loosen the belt. After achieving proper tension tighten the double nuts  
located on the fan side of the motor support against the motor support  
to maintain belt tension, then retighten the motor support nuts. Ideal ten-  
JACKING  
SCREWS  
MOTOR  
Figure 2  
SINGLE MOTOR—SINGLE FAN  
23  
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Maintenance  
sion is the lowest tension at which the belt will not slip under peak load  
conditions. Check tension frequently during the first 24-48 hours of run-in  
operation. Overtensioning shortens belt and bearing life. Keep belts free  
from foreign material which may cause slipping. Never apply belt dress-  
ing as this will damage the belt and cause early failure. A Dodge® V-Belt  
Tension Tester is an alternate method for tensioning V-belts. Check with  
you local belt supplier.  
FAN SHAFT  
SHEAVE  
SHEAVE  
Figure 3  
STRAIGHT EDGE  
Sheave alignment  
• The motor sheave is to be positioned as close as possible to the motor  
in order to minimize stress on the motor bushings.  
• The motor and fan sheaves may have grooves that are not used. The  
bottom surface of the motor and fan sheaves must be aligned within  
3mm of each other and level within 12° (3mm in 305mm) in order to  
not adversely affect belt and sheave life.  
• Alignment can be achieved by placing a straight edge across the  
sheaves making sure that it is level and measuring down to the bot-  
tom surface of both sheaves at four points.  
• The belt is to be located in the grooves closest to the motor center-  
line.  
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Maintenance  
Torque  
Bushing  
Fastener Size  
N·m  
¹⁄₄ - 20  
¹⁄₄ - 20  
¹⁄₄ - 20  
⁵⁄₁₆ - 18  
³⁄₈ - 16  
¹⁄₂ - 13  
⁹⁄₁₆ - 12  
SH  
SDS  
SD  
SK  
SF  
E
8
8
8
18  
30  
48  
58  
Bushing Fastener  
Torque Values  
F
Fluid Cooler Maintenance  
Some maintenance procedures may require maintenance personnel to  
enter the fluid cooler. Each cased face of the fluid cooler has a door for  
access to the interior of the tower.  
The optional fan deck ladder—models MHF706 and MHF707— is de-  
signed and intended solely for personnel to gain access to the fan deck.  
The fan deck ladder should not be used to enter or exit the access doors  
located on the cased face of the tower unless the optional access door  
platform is provided.  
The purchaser or owner is responsible for providing a safe method  
for entering or exiting the access door. Use of the fan deck ladder to  
enter or exit the access doors may result in a fall.  
Warning  
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 main-  
tenance:  
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  
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Maintenance  
Weekly: Inspect for bacterial growth and general operation conditions.  
Bacterial growth should be reported to your water treatment expert for  
immediate attention.  
Monthly (Weekly at start up): Observe, touch, and listen to the fluid  
cooler. 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 fluid cooler until the problem can  
be located and corrected. Observe operation of the motor, coupling (or  
drive shaft), Geareducer, if equipped and fan. Become familiar with the  
normal operating temperature of the motor(s), as well as the sight and  
sound of all components as a whole.  
If equipped, check for Geareducer oil leaks. Check the Geareducer as well  
as any optional oil lines to external oil dipstick/sight glass.  
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.  
Clean the Thermal Equalizer™ trays above the coil removing any accu-  
mulated debris or scale.  
Observe operation of the float valve. Depress the operating lever to make  
sure that the valve is operating freely. Inspect the suction screen for plug-  
ging. Remove any debris that may have accumulated.  
Check for any buildup of silt on the floor of the collection basin. Mentally  
make note of the amount, if any, so future inspections will enable you to  
determine the rate at which it is forming.  
Every 3 months: If equipped, lubricate fan shaft bearings. While rotating  
equipment by hand, grease the bearings until a bead forms around the  
seals—a maximum charge of 0.30 ounces (MHF702-MHF704) and 1.4  
ounces (MHF706-MHF707) is recommended. 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  
minutes for the oil level to stabilize. Add oil if required.  
If equipped with dampers, lubricate jack shaft bearings and tiebar linkage  
with silicone lubricant. If dampers are equipped with pneumatic or electric  
actuators, the manufacturer's recommended maintenance procedures  
should be observed. If dampers are exposed to heavy dust-laden air, oc-  
casional flushing of the bearings with water is recommended.  
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Maintenance  
Clean and disinfect cooling tower with biocides. Systems with biofouling,  
high general bacterial counts, or positive cultures of legionella may require  
additional cleaning. Refer to “Fluid Cooler Cleaning” section—page 21.  
Consult your water treatment expert as to prudent biological evaluation  
testing.  
Note  
Geareducer models used on MH Fluid Coolers 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 semiannu-  
ally. Refer to the Geareducer User Manual for oil recommendations  
and further instructions.  
annually: Relubricate motor(s) according to the manufacturer’s instruc-  
tions. See instructions on the next page for towers with the motor located  
outside the plenum option.  
Check to see that all bolts are tight in the fan and mechanical equipment  
region, including the fan cylinder and fan guard. Refer to Component User  
Manuals for torque values.  
Inspect the fluid cooler thoroughly, making maximum use of instructions  
given in the separate user manuals. Check structural bolted connections  
and tighten as required. Make preventive maintenance repairs as neces-  
sary.  
Every5Years:Ifequipped,changeGeareduceroil.RefertotheGeareducer  
User Manual for instructions.  
Motor relubrication instructions  
Motor located outside plenum option. Double-flow models MHF706 and  
MHF707 only.  
Open and lock out disconnect switch to make certain motor cannot  
be started.  
1. Remove guard as shown in Figure 4. Opposite end motor bearing is  
accessible from outside the tower.  
2. Remove grease fill and relief plugs at both shaft extension end and  
opposite end bearings and remove hardened grease, using clean  
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Maintenance  
Steel Side Casing  
Motor  
Grease Fill Plug  
Attachment Screw  
Guard  
Grease Relief Plug  
Figure 4  
wire.  
3. Insertgreasettingsingreasellopeningsandaddgreaseuntilgrease  
is forced out through relief openings.  
4. Replace fill plugs and operate mechanical equipment 30 minutes to  
one hour to purge excess grease at grease relief opening.  
5. Reinstall grease relief plugs and reinstall guard.  
6. Resume normal fluid cooler operation.  
Seasonal Shutdown instructions  
When the system is to be shut down for an extended period of time, it is  
recommended that the recirculation water system be drained. Leave the  
basin drains open.  
Caution  
Draining the coil is not recommended—draining promotes corro-  
sion inside the coil tubes. See protecting coil in Freezing weather  
on page 18.  
During shutdown, clean the fluid cooler (see Warning, page 21) and make  
any necessary repairs. Eliminators and louvers are easily removed to gain  
access to the coil. Pay particular attention to mechanical equipment sup-  
ports and sheaves or coupling (or drive shafts).  
Following each year’s shutdown and cleaning, inspect the fluid cooler’s  
metal surfaces for evidence of the need to apply a protective coating. Do  
not misinterpret grime as a need to have the tower painted. If relatively  
28  
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Maintenance  
bright metal can be exposed by cleaning, consider that the galvanizing  
has remained effective. Unless there is evidence of a generalized failure  
of the galvanizing, localized touch-up should be all that is required.  
Note  
To the extent that the galvanizing (zinc coating) still exists, paint will  
not adhere to it readily. Contact the manufacturer of the coating you  
intend to use for instructions.  
Fluidcoolerframework:Checkstructuralboltedconnectionsandtighten  
as required.  
Fans: Check fan assembly bolting and tighten as required. Use torque  
values prescribed in the Fan User Manual.  
Fans shaft bearings: If equipped, lubricate fan shaft bearings at close of  
each operating season—see page 26.  
Electric motors: Clean and lubricate motor at close of each operating  
season (refer to motor manufacturer’s recommendations.) Check motor  
anchor bolts and tighten as required. See Page 28 for fluid coolers with  
motor located outside the plenum option.  
Caution  
Do not start motor before determining that there will be no interfer-  
ence with free rotation of the fan drive.  
The motor(s) should be operated for three hours at least once a month.  
This serves to dry out windings and re-lubricate bearing surfaces (refer  
to the Marley “Electric Motor User Manual” Manual 92-1475 available  
at spxcooling.com.  
At start of new operating season, make sure bearings are adequately  
lubricated before returning motor to service.  
Prolonged Shutdown  
If shutdown period is longer than seasonal, contact your Marley sales  
29  
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Maintenance  
representative for additional information.  
SPX Cooling Technologies Services  
Our interest in your MH Fluid Cooler does not end with the sale. Having  
conceived, designed, and manufactured the most reliable and longest-  
lasting fluid cooler 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: as-  
sure the maximum possible service life under your operating conditions;  
tailor the operating characteristics to your specific needs—and maintain  
consistently optimum thermal performance capability. They are available  
by contacting your Marley sales representative.  
replacement parts: A complete stock of parts and components is main-  
tained 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 ad-  
vance, thus avoiding the cost of special handling.  
Be sure to mention your fluid cooler serial number (from the fluid cooler  
nameplate) when ordering parts.  
Periodic maintenance: You may wish to contract with SPX Cooling for  
regularly scheduled visits—for the purpose of inspecting and reporting  
your fluid cooler’s condition—to make recommendations intended to  
prevent emergencies— and to perform maintenance considered outside  
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Maintenance Schedule  
Maintenance Service  
Monthly  
Semi-annually  
Seasonal Startup or annually  
Inspect General Condition and Operation  
Observe Operation of:  
x
x
Mechanical–motor, fan and drive mechanism  
Makeup valve (if equipped)  
x
x
x
x
x
x
Inspect for unusual noise or vibration  
inspect and Clean:  
Air inlet  
x
x
x
x
x
x
x
x
PVC drift eliminators  
Distribution basin, nozzles and collection basin  
Fan and pump motor exterior  
Coil surface  
x
Check:  
Collection water basin level  
x
x
x
x
Blowdown–adjust as required  
geareducer Drive (if equipped):  
Check for loose fasteners including oil drain plug  
Check oil level, check for / repair oil leaks  
Change oil  
x
x
x
R
x
Make sure vent is open  
x
x
x
x
Check driveshaft or coupling alignment  
Check for loose driveshaft or coupling fasteners  
Check driveshaft or coupling bushings or flex element for unusual wear  
Lube lines (if equipped):  
x
Check for oil leaks in hoses or fittings  
Belt drive (if equipped):  
x
R
x
Fan shaft bearing lubrication (every 3 mo.)  
Check and tighten support fasteners  
Check shaft, sheave and belt alignment  
Check belt tension and condition  
Check sheave bushing fastener torque  
Fan:  
every 3 months  
every 3 months  
x
x
x
x
x
Check and tighten blade and hub fasteners  
Check fan blade pitch and tip clearance  
Check fan cylinder for loose fasteners  
Motor:  
x
x
x
Lubricate (grease as required)  
Check mounting bolts for tightness  
Operate at least  
R
x
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  
Inspect/clean buildup of contaminant from sensor  
Structure:  
x
x
x
x
Inspect/tighten all fasteners  
x
x
Inspect and touch up all metal surfaces  
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.  
31  
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Troubleshooting  
Trouble  
Cause  
remedy  
Check power at starter. Correct any bad connections between the  
control apparatus and the motor.  
Check starter contacts and control circuit. Reset overloads, close  
contacts, reset tripped switches or replace failed control switches.  
Power not available at motor terminals  
If power is not on all leads at starter, make sure overload and short  
circuit devices are in proper condition  
Wrong connections  
Low voltage  
Check motor and control connections against wiring diagrams.  
Motor will not start  
Check nameplate voltage against power supply. Check voltage at  
motor terminals.  
Open circuit in motor winding  
Motor or fan drive stuck  
Rotor defective  
Check stator windings for open circuits.  
Disconnect motor from load and check motor and fan drive for cause  
of problem.  
Look for broken bars or rings.  
Check motor and attempt to start it. Motor will not start if single-  
phased. Check wiring, controls and motor.  
Motor running single-phase  
Motor leads connected incorrectly  
Bad bearings  
Check motor connections against wiring diagram on motor.  
Check lubrication. Replace bad bearings.  
Check voltages and currents of all three lines. Correct if required.  
Check and correct bracket fits or bearing.  
Rebalance  
Unusual motor noise  
Electrical unbalance  
Air gap not uniform  
Rotor unbalance  
Cooling fan hitting end belt guard  
Wrong voltage or unbalanced voltage  
Reinstall or replace fan.  
Check voltage and current of all three lines against nameplate values.  
Check fan blade pitch. See Fan User Manual. Check for drag in fan  
drivetrain as from damaged bearings.  
Overload  
Check nameplate against power supply. Check RPM of motor and drive  
ratio.  
Wrong motor RPM  
Remove bearing reliefs. Run motor up to speed to purge excessive  
grease.  
Bearing overgreased  
Wrong lubricant in bearings  
One phase open  
Change to proper lubricant. See motor manufacturer's instructions.  
Stop motor and attempt to start it. Motor will not stat if single-phased.  
Check wiring, controls and motor.  
Motor runs hot  
Clean motor and check ventilation openings. Allow ample ventilation  
around motor.  
Poor ventilation  
Winding fault  
Check with ohmmeter.  
Bent motor shaft  
Insufficient grease  
Straighten or replace shaft.  
Remove plugs and regrease bearings.  
Limit cumulative accelerations time to a total of 30 seconds/hour. Set  
on/off or speed change set points farther apart. Consider installing a  
Marley VFD drive for fine temperature control.  
Too frequent starting or speed changes  
Deterioration of grease or foreign material in grease Flush bearings and relubricate.  
Bearings damaged  
Replace bearings.  
Check transformer and setting of taps. Use higher voltage on  
transformer terminals or reduce loads. Increase wire size or reduce  
inertia.  
Voltage too low at motor terminals because of line  
drop  
Motor does not come up to  
speed  
Look for cracks near the rings. A new rotor may be required. Have  
motor service person check motor.  
Broken rotor bars  
Wrong motor rotation  
Wrong sequence of phases  
Switch any two of the three motor leads.  
32  
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Troubleshooting  
Trouble  
Cause  
remedy  
If new, see if noise disappears after one week of operation. Drain flush,  
and refill Geareducer oil. See Geareducer User Manual. If still noisy,  
replace.  
Geareducer bearings  
Geareducer noise. (If  
equipped).  
Correct tooth engagement. Replace badly worn gears. Replace gears  
with broken or damaged teeth.  
Gears  
Tighten all bolts and cap screws on all mechanical equipment and  
supports.  
Loose bolts and cap screws  
Make sure motor and Geareducer shafts are in proper alignment and  
"match marks" properly matched. Repair or replace worn couplings.  
Rebalance drive shaft by adding or removing weights from balancing  
cap screws. See Driveshaft User Manual  
Unbalanced drive shaft or worn couplings. (If  
equipped)  
Make certain all blades are as far from center of fan as safety devices  
permit. All blades must be pitched the same. See Fan User Manual.  
Clean off deposit build-up on blades  
Unusual fan drive vibration  
Fan  
Worn Geareducer bearings. (If equipped)  
Worn fan shaft bearings. (Belt drive).  
Check fan and pinion shaft endplay. Replace bearings as necessary.  
Check fan shaft endplay. Replace bearings as necessary.  
Disconnect load and operate motor. If motor still vibrates, rebalance  
rotor.  
Unbalanced motor  
Bent Geareducer shaft. (If equipped).  
Blade rubbing inside of fan cylinder  
Loose bolts in blade clamps  
Fan shaft bearing. (Belt drive).  
Insufficient blowdown  
Check fan and pinion shaft with dial indicator. Replace if necessary.  
Adjust cylinder to provide blade tip clearance  
Check and tighten if necessary.  
Fan noise  
Grease bearings.  
See "Water Treatment" section of this manual.  
Scale or foreign substance in  
circulating water system  
Consult competent water treating specialist. See "Water Treatment"  
section of this manual  
Water treatment deficiency  
Check to see if local heat sources are affecting fluid cooler. See if  
surrounding structures are causing recirculation of tower discharge air.  
Discuss remedy with Marley representative.  
Entering wet bulb temperature is above design  
Design wet bulb temperature was too low.  
May have to increase fluid cooler size. Discuss remedy with Marley  
representative  
Cold water temperature too  
warm.  
May have to increase fluid cooler size. Discuss remedy with Marley  
representative  
Actual process load greater than design  
Overpumping  
Reduce water flow rate over fluid cooler to design conditions.  
See "Tower Operation."  
Check motor current and voltage to be sure of correct contract  
horsepower. Repitch fan blades if necessary. Clean louvers, fill and  
eliminators. Check to see if nearby structures or enclosing walls are  
obstructing normal airflow to fluid cooler. Discuss remedy with Marley  
representative.  
Fluid cooler starved for air  
Reduce water flow rate over fluid cooler to design conditions. Be sure  
distribution water basin nozzles are in place and not plugged.  
Distribution basins overflowing  
Faulty drift elimination  
Excessive drift exiting fluid  
cooler  
Check to see that integral fill. Louvers and eliminators are clean, free of  
debris and installed correctly. If drift eliminators are separate from fill,  
make sure they are correctly installed and in place. Clean if necessary.  
Replace damaged or worn out components  
33  
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Additional Information  
the norm.  
Thisserviceisnotintendedtoreplacetheimportantfunctionperformedby  
your maintenance staff. Their attention assures the fluid coolers’s routine  
operating performance, and is invaluable. However, we recognize that the  
unusual manner in which a fluid cooler performs its function—as well as  
the unique forces which act upon it—may be considerations which oc-  
casionally require the services of an expert technician.  
increased load requirements: MH Fluid Coolers are designed so that  
cells of either equal or unequal capacity can be added in the future. This  
allows you to compensate for the load increases that normally occur with  
the replacement or addition of production equipment—and still retain  
continuity with respect to your fluid cooler system.  
Fluidcoolerrebuilding:SPXroutinelyrebuildsandupgradesuidcoolers  
and cooling towers of all materials and manufacture. If your product ever  
reaches the limit of its service life, we recommend that you investigate the  
cost of rebuilding before you routinely order a new replacement tower.  
Each MH Fluid Cooler includes a document package containing general  
orientation drawings, and tower component manuals. These documents  
contain important information relating to safe installation and operation  
of the fluid cooler. Field installation is required for fan guards (double flow  
models), pipinginletsandpipingoutlets. Someoptionalaccessories, such  
as handrails, ladders and safety cages may also require field installation.  
A separate installation drawing or manual for each purchased option is  
included in the document package along with bills of material. If you have  
purchased an option and can’t find the appropriate installation drawing,  
contact your local Marley sales representative before proceeding.  
In addition to these specific documents, numerous technical reports are  
published by SPX including more detailed information on a variety of cool-  
ing tower and fluid cooler operation and service topics. Your Marley sales  
representativewillbehappytogiveyoucopiesofthesereportsatnocharge  
or you can download copies from our website at spxcooling.com.  
For complete parts and service assistance, contact the Marley sales  
representative in your area. If you need help locating your representative,  
please check the internet at spxcooling.com.  
34  
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SPX COOLING TECHNOLOGIES MALAYSIA Sdn Bhd  
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UNIT 505, BLOCK B, PHILEO DAMANSARA 2 NO. 15 JALAN 16/11, OFF JALAN DAMANSARA 46350 PETALING JAYA, MALASIA 60 3 7665 1018 spxcooling.com  
In the interest of technological progress, all products are subject to design and/or material change without notice.  
©2008 SPX Cooling Technologies  
sea_M05-116E  
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