Marley Quadraflow cooling tower

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Summary

overview

Tower Location

Guidance on selecting an appropriate site for the cooling tower, considering airflow and maintenance access.

installation

Tower Shipment

Details on how QuadraFlow cooling towers are transported and the responsibility for their condition upon arrival.

Receiving Tower

Instructions for inspecting the tower shipment for damage upon delivery to support future claims.

Tower Assembly

Information on professional assembly services provided by Marley sales representatives or qualified subcontractors.

Motor Wiring

Guidelines for correctly wiring the motor, referencing nameplate details and specific symbols.

When using a starter

Specific instructions and precautions for using standard motor starters, including single and two-speed types.

When using a VFD

Detailed instructions and precautions for installing and operating motors with Variable Frequency Drives (VFDs).

Mechanical Equipment

Procedures for ensuring mechanical equipment is safe and correctly aligned before operation or maintenance.

General

Factors influencing cold water temperature, including heat load, water flow rate, and air wet-bulb temperature.

Fan cycling limits

Guidelines on acceptable fan start/stop frequency per hour for single-speed and two-speed motors.

operation

Tower Startup

Steps for safely starting the cooling tower, including water system preparation and initial operation.

Water System

Detailed instructions for filling, cleaning, and treating the cooling tower water system before operation.

Freezing Weather Operation

Guidance on operating the cooling tower in subfreezing conditions and managing potential ice formation.

Intermittent Wintertime Operation

Measures to prevent freezing during periods of shutdown in cold weather, including draining and basin heaters.

maintenance

Water Quality and Blowdown

Maintaining optimal water quality parameters and understanding blowdown rates for cooling tower efficiency.

Cooling Tower Inspection and Maintenance

Essential procedures for inspecting and maintaining cooling towers to prevent microbial growth and ensure proper function.

Schedule of Tower Maintenance

Recommended routine maintenance schedule including weekly, monthly, and semi-annual tasks for cooling towers.

Seasonal Shutdown Instructions

Procedures for properly shutting down the cooling tower system for extended periods or at the end of an operating season.

Motor Lubrication Instructions

Step-by-step guide for lubricating the motor, including safety precautions and applicable models.

Fiberglass Components

Instructions for inspecting and refinishing fiberglass parts, including recommended coating systems.

Prolonged Shutdown

Guidance for situations where the cooling tower shutdown period exceeds the normal seasonal duration.

Additional Services

Replacement Parts

Information on the availability and ordering of replacement parts designed and manufactured by SPX Cooling Technologies.

Periodic Maintenance

Details on contracting Marley for scheduled maintenance visits and expert inspections.

Increased Load Requirements

Information on adding cells to QuadraFlow towers to compensate for future load increases.

Tower Renewal

Recommendation to consider rebuilding or upgrading existing cooling towers before ordering a new replacement.

troubleshooting

Motor will not start

Common causes and remedies for a motor failing to start, including power, connections, and winding issues.

Unusual motor noise

Diagnosing and resolving common causes of unusual noise from the motor, such as bearings or electrical unbalance.

Motor runs hot

Troubleshooting steps for motors that overheat, covering lubrication, ventilation, and phase issues.

Motor does not come up to speed

Identifying causes for motors not reaching the correct operating speed, such as low voltage or phase issues.

Wrong motor rotation

How to correct incorrect motor rotation direction, typically by switching motor leads.

Geareducer noise

Troubleshooting common causes of noise from the Geareducer, including bearings, gears, and oil issues.

Unusual fan drive vibration

Diagnosing and resolving vibration issues in the fan drive system, including alignment and balancing.

Fan noise

Identifying causes of fan noise, such as blade rubbing or improper pitch, and their remedies.

Scale or foreign substance in circulating water system

Addressing issues caused by scale or foreign particles in the water system, requiring water treatment specialist.

Cold-water temperature too warm

Troubleshooting steps when the cold water temperature is higher than expected, relating to process load or airflow.

Excessive drift exiting tower

Identifying and resolving causes of excessive drift, such as faulty drift eliminators or debris.

This document is the user manual for the Marley Quadraflow® cooling tower, specifically identified by the document number sea_Z0238885_D, issued 8/2018. It provides comprehensive information for the installation, operation, and maintenance of the cooling tower, emphasizing the importance of reading and understanding the manual prior to use to ensure proper function and to maintain product warranty.

Function Description

The Marley Quadraflow® cooling tower is designed to cool water by continuously causing a portion of it to evaporate. This process helps manage heat loads in various systems, ensuring that the cold water temperature remains within desired operational parameters. The tower is designed for long, corrosion-free service in a "normal" cooling tower environment, which is defined by specific water quality parameters and atmospheric conditions. It can be integrated into systems where precise temperature control is crucial, offering advantages over traditional motor control methods when equipped with a Variable Frequency Drive (VFD).

Important Technical Specifications

While specific numerical technical specifications like exact dimensions, weight, or power ratings are not explicitly detailed in this general overview, the manual highlights several critical operational parameters and requirements:

Motor Overload Protection: When using a starter, motor overload protection should be set to 110% of motor nameplate amps.
VFD Settings: If using a VFD, the solid-state overload protection should be set to 119% of motor nameplate amps, and the "maximum current parameter" in the VFD should be set to motor nameplate amps. If a mechanical overload is present, it should be set at 110% over motor nameplate amps.
VFD Cable Distance: If the cable distance between the VFD and motor exceeds 30 meters, a DV/DT output filter is recommended to prevent motor damage.
VFD Output Mode: The VFD should be programmed for variable torque output; flux vector and constant torque modes may damage the gearbox.
Water Quality: Circulating water pH should be between 6 and 8, chloride content (as NaCl) below 750 mg/L, sulfate content (SO₄) below 1200 mg/L. Maximum inlet water temperature should not exceed 52°C.
Chlorine Levels: If chlorine is used, it should be added intermittently, with a free residual not to exceed 1 mg/L for short periods.
Blowdown Rates: The manual provides a table for approximate blowdown rates (percent of total water flow rate constantly wasted) to achieve 2-4 concentrations at various cooling ranges (e.g., 0.7% for 6°C range at two concentrations, 0.17% for 6°C range at four concentrations).
Cold Water Temperature: A minimum allowable leaving water temperature of 2°C to 5°C is suggested to prevent destructive ice formation.
Fan Cycling Limits: Approximately 4 to 5 starts per hour are allowable for normal fan and motor sizes. For two-speed motors, a 20-second time delay relay is required when switching from high speed to low speed.

Usage Features

The Quadraflow® cooling tower offers several features for flexible and efficient operation:

Temperature Control: The cold water temperature is influenced by heat load, water flow rate, and air wet-bulb temperature. Reducing airflow is the approved method to control leaving water temperature. For single-speed motors, the motor can be shut off to raise water temperature. Two-speed motors offer greater control by allowing operation at half-speed.
VFD Integration: The use of a VFD can reduce electrical energy costs and provide better temperature control, as well as reduce mechanical and electrical stress on the motor and equipment.
Freezing Weather Operation: The integrated air entrance louvers in the Marley fill system make these towers forgiving in cold weather. Procedures for ice control include maintaining a minimum allowable leaving water temperature, stopping the fan to reduce ice buildup on louvers, and operating the fan in reverse (at half speed or less for short durations) to melt accumulated ice.
Multicell Towers: For towers with multiple cells, cycling of motors can be shared between cells, increasing operational steps for temperature control.
Expandability: Quadraflow® towers are designed such that cells of equal or unequal capacity can be added in the future, allowing for compensation for increased load requirements.

Maintenance Features

The manual outlines a comprehensive maintenance schedule and important considerations for the longevity and safe operation of the cooling tower:

Scheduled Maintenance: A minimum routine of scheduled maintenance is provided, including weekly visual inspections, monthly (or weekly at start-up) observation of mechanical equipment, semi-annual motor relubrication, and annual thorough inspections. Geareducer oil should be changed every 5 years, or semi-annually if turbine-type mineral oil is used after the initial five-year period.
Water Management Plan (WMP): Essential for preventing the presence, dissemination, and amplification of Legionella bacteria and other waterborne contaminants. This includes regular cleaning and disinfection in accordance with ASHRAE Standard 188 and Guideline 12.
Safety Precautions: Emphasizes locking out electrical power to the fan motor before any inspections or maintenance involving physical contact with mechanical or electrical equipment. Personnel must wear proper personal protective clothing and equipment.
Component-Specific Manuals: Separate Service Manuals for major operating components (motors, fans, Geareducer, couplings, drive shafts, float valves, pumps) are included and take precedence where discrepancies exist.
Parts Availability: SPX Cooling Technologies manufactures most components (except the motor) and maintains a complete stock of parts for quick shipment, including emergency 24-hour air freight.
Periodic Maintenance Contracts: Marley offers contracts for regularly scheduled visits to inspect, report on tower condition, recommend preventive measures, and perform specialized maintenance.
Seasonal Shutdown: Recommendations for draining the system, inspecting mechanical equipment, and lubricating motors (if not sealed bearings) are provided for extended shutdown periods. For prolonged shutdowns beyond seasonal, contact a Marley sales engineer.
Fiberglass Component Care: Instructions for checking and repairing exposed glass fibers on fiberglass parts, including surface preparation and coating recommendations.
Troubleshooting Guide: A detailed table is provided to diagnose common issues such as motor not starting, unusual motor noise, motor running hot, fan noise, water quality problems, cold water temperature issues, and excessive drift, along with their respective remedies.