Marley Primus P11 User manual

Manual 04-131

User Manual

Models P11 through P15

Contents

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

Tower Shipment ..................................................................................... 5

Receiving Tower .................................................................................... 5

Hoisting Tower ....................................................................................... 5

Tower Installation ................................................................................... 6

Field Installed Mechanical Equipment ................................................... 9

Vibration Switch Option ....................................................................... 16

Basin Heater Option ............................................................................ 16

Tower Start-Up..................................................................................... 18

Tower Operation .................................................................................. 21

Winter Operation .................................................................................. 23

Tower Cleaning, Water Treatment and Blowdown .............................. 26

Cleaning ............................................................................................... 27

Belt Replacement ................................................................................ 29

Belt Tensioning .................................................................................... 30

Sheave Alignment ................................................................................ 31

Schedule of Tower Maintenance ......................................................... 31

Seasonal Shutdown Instructions ......................................................... 33

Prolonged Shutdown ........................................................................... 34

Marley Services ................................................................................... 35

Maintenance Schedule ........................................................................ 36

Troubleshooting ................................................................................... 37

▲

▲▲Note

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.

Indicates presence of a hazard which can cause severe personal

injury, death or substantial property damage if ignored.

Indicates presence of a hazard which will or can cause personal

injury or property damage if ignored.

Indicates special instructions on installation, operation or

maintenance which are important but not related to personal injury

hazards.

▲

▲▲Warning

▲

▲▲Caution

▲

▲▲Note

The following defined terms are used throughout this manual to bri

attention to the presence of hazards of various risk levels, or to important

information concerning the life of the product.

Preparation

The Marley Primus cooling tower purchased for this installation represents

the current state of the art in crossflow, induced draft cooling tower design.

Thermally and operationally, it is the most efficient cooling tower of its

class.

These instructions—as well as those offered separately on motors, fans,

float valves, etc.—are intended to assure that the tower 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

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 mention tower serial number shown on the nameplate

located on the access door.

Safety First

The location and orientation of the cooling tower can affect the safety of

those responsible for installing, operating or maintaining the tower. However,

since Marley does not determine the location or orientation of the tower, we

cannot be responsible for addressing those safety issues that are affected

by the tower’s location or orientation.

The following safety issues should be considered by those responsible

for designing the tower installation.

• access to and from maintenance access doors

• the possible need for ladders (either portable or permanent) to

gain access to the distribution basin or maintenance access doors

• potential access problems due to obstructions surrounding the

tower

• lockout of mechanical equipment

• the possible need for safety cages around ladders

• the need to avoid exposing maintenance personnel to the potentially

unsafe environment inside the tower.

It is not intended nor assumed that access to the fan deck is needed

or necessary.

▲

▲▲Warning

▲

▲▲Note

Preparation

Those are only some of the safety issues that may arise in the design

process. Marley strongly recommends that you consult a safety

engineer to be sure that all safety considerations have been addressed.

Tower Location

Space available around the tower should be as generous as possible to

promote ease of maintenance—and to permit freedom of airflow into and

through the tower. If you have questions about the adequacy of the

available space and the intended configuration of the tower, please

contact your Marley sales engineer for guidance.

Prepare a stable,

level

support foundation for the tower, utilizing weight,

wind load, and dimensional information appearing on appropriate Marley

literature.

Supports must be level to insure proper operation of the tower.

The cooling tower must be located at such distance and direction to

avoid the possibility of contaminated tower discharge air being

drawn into building fresh air intake ducts. The purchaser should

obtain the services of a Licensed Professional Engineer or Registered

Architect to certify that the location of the tower is in compliance with

applicable air pollution, fire, and clean air codes.

▲

▲▲Warning

▲

▲▲Note

Tower Shipment

Unless otherwise specified, Primus towers ship by truck (on flat bed

trailers), which lets you receive, hoist, and install the tower in one

continuous operation. Single-cell towers ship on one truck. Multicell

towers, depending on the quantity, may require more than one truck.

Responsibility for the condition of the tower upon its arrival belongs to the

trucker—as does the coordination of multiple shipments, if required.

Receiving Tower

Prior to unloading the tower from the delivering carrier, inspect the

shipment for evidence of damage in transit. If damage is apparent, note the

freight bill accordingly. This will be needed to support any future recovery

claim.

Find and remove the installation instructions and manuals (literature kit)

located in a plastic bag in the cold water basin. This information should be

kept for future reference and maintenance purposes.

Hoisting Tower

All models ship in a single module. A

Hoisting-Installation

label is located

on the side casing near the access door. Remove tower from the carrier

and hoist into place according to the instructions on the label.

Receiving and Hoisting

▲

▲▲Caution

Tower Installation

These installation instructions are intended to help you prepare

before your tower arrives. If discrepancies exist between these

instructions and those shipped with the tower, the instructions

shipped with the tower will govern.

1. Prior to placement of the tower, confirm that the supporting platform is

level, and that the anchor bolt holes are correctly located in accordance

with Marley literature.

2. Place tower on your prepared supports, aligning anchor bolt holes with

those in your supporting steel. Make sure that the orientation agrees

with your intended piping arrangement. Attach tower to supporting

steel with bolts and flat washers (by others). Position flat washers

between the bolt head and the tower basin flange. P11 tower use ³⁄₈"

bolts, all other models use ¹⁄₂" bolts.

3. Attach your cold water supply piping to the cold water basin outlet

connection.

Do not support your pipe from the tower or outlet connection—

support it externally.

Normally, one of the following outlet arrangements is provided:

Cased face suction connection: Models P11 and P12 have a

polyethylene female NPT coupling attached to the side of the cold

water basin. It is extremely important not to overtighten the connection

to avoid damaging the coupling. The larger models have a galvanized

pipe nipple extending horizontally from the side of the cold water basin.

It is both beveled for welding—and grooved for a mechanical coupling.

If a weld connection is used, it is recommended that the weld area be

protected against corrosion. Cold galvanizing is suggested, applied

according to the manufacturer’s instructions. Install 2" plugs in outlets

that are not used.

Bottom outlet connection option: This is a factory-installed, circular

opening in the cold water basin floor. An appropriately-sized circular

opening has been drilled to 125# ASME B16.1 flat-face flange

connection specifications. Model P13 with 10" outlet and models P14

and P15 with 12" outlets have a galvanized pipe connection. It is both

beveled for welding—and grooved for a mechanical coupling. See

▲

▲▲Note

Installation

➠

PLUG

P11-P12

GASKET

COVER PLATE

P13-P14-P15

TRASH SCREEN

Figure 1A and 1B. The bottom outlet arrangement is also used for

equalizer connections between basins.

The typical attachment of customer piping for bottom outlet or equalizer

with flange connection using gasket (supplied by Marley) is shown in

Figure1. Sealing washers (by others) required at bolt connections

inside basin. The tower is not designed to support additional piping

loads. Do not support piping from the tower.

Installation

Figure 1 Install plug in side-outlet location for models P11 and P12. Remove

side-outlet connection assembly on larger models and install cover

plate using sealer as shown in Figure 1.

4. The welded galvanized pipe assembly utilized on some models P14

and P15 ships within the tower basin. Unbolt as shown in Figure 1A

and reinstall as shown in Figure 1B. Apply sealer as shown and reuse

existing hardware as well as additonal hardware shipped with tower.

If a weld connection is used, it is recommended that the weld area be

protected against corrosion. Cold galvanizing is suggested, applied

according to the manufacturer’s instructions. ➠

UNBOLT AND

REINSTALL

Installation

Figure 1A

COVER PLATE

TRASH SCREEN

Figure 1B

5. Attach makeup water supply piping to the float valve connection.

Install the float ball and stem. If you wish to pipe overflow and drain

water to a remote discharge point, make those connections at this

time.

6. Install your warm water piping at the inlet location on the tower.

Do not support your pipe from the tower or inlet connection—support

it externally.

▲

▲▲Caution

Installation

▲

▲▲Warning

" BOLT

FLAT WASHER

LOCK WASHER

NUT

MOTOR

MOTOR PLATE

BRACKET

1" BOLT

ASSEMBLY DETAILS

7. Wire motor in accordance with wiring diagram on motor nameplate.

Check motor connections and power supply voltage versus motor

nameplate voltage.

8. Install fan guard using ³⁄₈" tap screws provided.

For maintenance/safety purposes, Marley recommends a lockout

type disconnect switch for all mechanical equipment.

In addition to a disconnect switch, the motor should be wired to main

power supply through short circuit protection, and a magnetic starter

with overload protection.

Field Installed Mechanical Equipment—Direct Drive Models

1. Install brackets and motor plate to motor as shown in Assembly

Details. If present, remove drain plugs from the bottom of the motor on

the end opposite of shaft.

Installation

DETAIL A

1" BOLT

3 PLACES

FLAT WASHER

MOTOR

FLAT WASHE

BRACKET

LOCK WASHER

NUT

2. Install motor assembly on tower cross beams as shown in Figure 2 and

Detail A. Leave bolts loose enough to allow for fan centering adjustment.

➠

Figure 2

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