Marley Primus P11 User Manual Download Page 36 | Manualshive

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36

Maintenance Schedule

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Summary of Contents for Primus P11

Page 1: ...Manual 04 131 User Manual Models P11 through P15 ...

Page 2: ...r 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...

Page 3: ... on the nameplate located on the access door Safety First The location and orientation of the cooling tower can affect the safety of thoseresponsibleforinstalling operatingormaintainingthetower 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 Thefollo...

Page 4: ...f 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 disc...

Page 5: ...oading 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 maintena...

Page 6: ... 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 th...

Page 7: ...m 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 an...

Page 8: ...e 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 ...

Page 9: ... using 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 FieldInstalledMechanicalEquipment DirectDriveModels 1 Install brackets and motor plate to motor as...

Page 10: ...TAIL A 3 8 X 1 BOLT 3 PLACES FLAT WASHER MOTOR FLAT WASHER BRACKET LOCK WASHER NUT 2 Install motor assembly on tower cross beams as shown in Figure 2 and DetailA Leaveboltslooseenoughtoallowforfancenteringadjustment Figure 2 ...

Page 11: ...gure 2 Bushing is to be flush with the end of the motor shaft Tighten bushing bolts See page 31 for torque specifications BUSHING AND HARDWARE FAN MOTOR KEY DETAIL B 4 Adjust assembly so that fan is centered in fan opening Tighten bracket bolts See Detail A 5 Apply Loctite 242 to all fasteners except bushing hardware Do not apply to tensioning nut ...

Page 12: ...ngmodelsP13throughP15 tomotor shaft Leave sheave loose enough to allow for sheave adjustment later If present remove drain plugs from the bottom of the motor on the end opposite of shaft 1 2 X 6 ALLTHREAD BOLT MOTOR PLATE MOTOR SHEAVE MOTOR KEY MOTOR MOTOR BOLT SIZE VARIES 1 2 X 1 BOLT LOCK WASHER NUT BRACKET BRACKET JAM NUT ASSEMBLY DETAILS MODEL P12 ...

Page 13: ... that are not used The motor sheave will always have the correct number of grooves for your tower model The bottom surface of the motor and fan sheaves must be aligned with of each other and level within in 12 in order to not adversely affect belt and sheave life Alignment can be achieved by placing a straight edge across the top of the fan sheave making sure that it is level and measuring down to...

Page 14: ... be relocated to another set of holes Tighten the tensioning nut on the all thread bolt at the adjusting clip to tension belts Proper tension is achieved when a belt deflects about under a force of 5 to 7 pounds Tighten jam nut against the adjusting clip to lock adjustment Tighten bolts in tower cross beam 5 Apply Loctite 242 to all fasteners except bushing hardware Do not apply to tensioning nut ...

Page 15: ...15 Installation 3 8 X 1 BOLT 4 PLACES 1 2 X 6 ALLTHREAD BOLT FAN SHAFT LOCK WASHER NUT ADJUSTING CLIP JAM NUT TENSIONING NUT Figure 3A Model P13 P15 ...

Page 16: ... electrical code and localcodes Heaterpackagecomponentsconsistofanenclosure magnetic contactor circuit board transformer heater element and control probe Failure to follow the Basin Heater installation procedure may result in fire Control Box components Transformer steps down line voltage to 24 volts for control circuit Magnetic Contactor controls power to heater Contacts are rated for line voltag...

Page 17: ...element as shown in Figure 4 3 Attach heater support as shown in Figure 4 4 The basin heater control box is to be located and installed outside of the cooling tower Control probe cord length of 12 0 may restrict control box location Installation Figure 4 BULKHEAD FITTING WITH GASKET CONTROL PROBE 1 1 8 HOLE HEATER ELEMENT PROBE CORD TO CONTROL BOX ...

Page 18: ... of the tower This is the recommended 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 Normal water operating level is 5 for model P11 6 for models P12 and P13 and 7 for models P14 and P15 If tower is equipped with a standard suction connection vent accumulat...

Page 19: ...cesofthewatertreatmentsupplier 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 ppm free chlorine residual at a pH of 7 0 to 7 6 The chlorine residual must be held at 4 to 5 mg...

Page 20: ...e primary leads supplying power to the motor Iftowerisequippedwithatwo speedmotor checkforproperrotation 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 dire...

Page 21: ...t the number of degrees range through which the tower cools the water is established by the system heat load and the amount of water being circulated in accordance with the following formula Operation F e g n a R r h u t B d a o L t a e H 0 0 5 x M P G s t i n u I S n i r o C e g n a R s t t a w o l i k d a o L t a e H 7 8 1 4 x c e s s r e t i L Note Thecoolingtowerestablishesonlythecoldwatertemp...

Page 22: ...econds per hour Fan cycling limits From a dead stop determine the number of seconds 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 Primus towers anticipate that approximately 4 to 5 starts per hour are allowable If your tower is equipped with a two speed motor you will e...

Page 23: ...s leaving water temperature to drop below a minimum allowable level say 36 F to 40 F 2 C to 4 5 C If such low temperature operation is necessary or beneficial to your process establish the minimum allowable level as follows During the coldest days of the first winter of operation observe whether any ice is forming on the louver face particularly near the bottom part of the louver face If hard ice ...

Page 24: ...t may be necessary to operate the fan in reverse This forces warm air out through the louvers melting any accumulated ice adequate heat load must be available Reversal may be at either full or half speed however Marley recommends reversal at half speed 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 nee...

Page 25: ...ntertime Operation If periods of shutdown nights weekends etc occur during freezing weather measures must be taken to prevent the water in the cold water basin and all exposed pipework from freezing Several methods are used to combat this including automatic basin heater systems available from Marley Unless some means of freeze prevention is incorporated into your system the tower basin and expose...

Page 26: ... 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 ppm expressed as CaCO3 Many systems can be successfully treated with the MarleyOzone System This removes the requirement for other chemical feed systems andprovidessignificantwatersavings Forcompleteinformation contact your local Marl...

Page 27: ...ae periodic flushing and cleaning and the following of a complete water treatment program including biocidal treatment See Tower Startup instructions on page 18 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 elimin...

Page 28: ... cooling range To maintain 4 concentrations the required blowdown is 0 458 or 00458 times 700 GPM 44 2 L s which is 3 2 GPM 0 2 L s If tower is operated at 4 concentrations circulating water will contain four times as much dissolved solid as the makeup water assuming none of the solids form scale or are otherwise removed from the system When water treatment chemicals are added they should not be i...

Page 29: ...ey are removed Replace as required 1 Loosen but do not remove bolts attaching the motor bracket to top of the support beam 2 Remove tension on belt by loosening the tension nut 3 Cut through belts and remove 4 Loosen but do not remove bolts from top bearing Be sure all threads on nuts are fully engaged Warning Note MOTOR 1 2 5 Remove bolts from bottom bearing Pull bearing away from support and sli...

Page 30: ...t at the motor support 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 belt and bearing life Keep belts free from foreign material which may cause slip Never apply belt dressing as this will damage the belt and cause early failure A Dodge V Belt Tension T...

Page 31: ...eaves at four points The belts are to be located in the lowest set of grooves Warning g n i h s u B e z i S r e n e t s a F e u q r o T b l t f ƒ m N H S 0 2 6 8 S D S 0 2 6 8 D S 0 2 6 8 K S 8 1 3 1 8 1 F S 6 1 2 2 0 3 Torque Values Schedule of Tower Maintenance Some maintenance procedures may require maintenance personnel to enter the tower One cased face of the tower has a door for access to th...

Page 32: ...ve touch and listen to the tower Become accustomed to its normal appearance sound and level of vibration Abnormal aspects relating to the rotating equipment should be considered reason to shut down the tower until the problem can be located and corrected Observe operation of the motor sheaves belt and fan Become familiar with the normal operating temperature of the motor as well as the sight and s...

Page 33: ...ire additional cleaning Refer to Cooling Tower Cleaning section on page 24 Consult your water treatment expert as to prudent biological evaluation testing If basin silt level is significant drain the basin and clean it out Refer to Cooling Tower Cleaning section on page 26 Inspect the tower thoroughly making maximum use of instructions given in the separate service manuals Check structural bolted ...

Page 34: ...haft bearings Lubricate fan shaft bearings at close of each operating season 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 Donotstartmotorbeforedeterminingthattherewillbenointerference with free rotation of the fan drive The motor should be operated for three hours at least ...

Page 35: ...ts With the exception of the motor drive system and float valve every standard component of your tower is designed and manufactured by Marley We do this because commercially available componentshavenotprovedcapableofwithstandingtheharshenvironment of a cooling tower nor do they contribute their share to the thermal capability and operating characteristics intended Allpartsandcomponentsareavailable...

Page 36: ... M n a F x x k c e h C l e v e L n i s a B r e t a W d l o C x x s l a e S e v l a V t a o l F p u e k a M x d e r i u q e r s a t s u j d a n w o d w o l B x x r o f m e t s y S e v i r D l a c i n a h c e M k c e h C n o i t i d n o c d n a n o i s n e T t l e B x x e u q r o T r e n e t s a F g n i h s u B e v a e h S x x s h t n o m 2 y r e v e n o i t a c i r b u L g n i r a e B t f a h S n a...

Page 37: ... u r o e g a t l o v g n o r W e t a l p e m a n t s n i a g a s e n i l e e r h t l l a f o t n e r r u c d n a e g a t l o v k c e h C s e u l a v d a o l r e v O r o f k c e h C l a u n a M n a F e e S h c t i p e d a l b n a f k c e h C s g n i r a e b d e g a m a d m o r f s a n i a r t e v i r d n a f n i g a r d M P R r o t o m g n o r W r o t o m f o M P R k c e h C y l p p u s r e w o p t...

Page 38: ...o l f i e e s o t k c e h C r e w o t f o n o i t a l u c r i c e r g n i s u a c e r a s e r u t c u r t s g n i d n u o r r u s e v i t a t n e s e r p e r y e l r a M h t i w y d e m e r s s u c s i D r i a e g r a h c s i d w o l o o t s a w p m e t b l u b t e w n g i s e D y e l r a M h t i w y d e m e r s s u c s i D e z i s r e w o t e s a e r c n i o t e v a h y a M e v i t a t n e s e r ...

Page 39: ...39 ...

Page 40: ...k KS USA 66213 800 462 7539 info marleyct spx com www marleyct com In the interest of technological progress all products are subject to design an or material change without notice 2004 Marley Cooling Technologies Inc Printed in USA ...

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