user manual

Cube DT evaporative condenser

I N STA L L AT I O N - O P E R AT I O N - M A I N T E N A N C E

Z0921107_A ISSUED 8/2017 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT
 contents

This manual contains vital information for the proper installation and
Note operation of your evaporative condenser. Carefully read the manual
before installation or operation of the evaporative condenser and
follow all instructions. Save this manual for future reference.

Overview....................................................................................................................................... 3
Location......................................................................................................................................... 4
Shipment....................................................................................................................................... 4
Receiving...................................................................................................................................... 5
Hoisting......................................................................................................................................... 5
Installation..................................................................................................................................... 6
Motor Wiring................................................................................................................................ 8
Mechanical Equipment........................................................................................................... 10
Start-Up...................................................................................................................................... 12
Operation................................................................................................................................... 14
Dry Operation........................................................................................................................... 15
Freezing Weather Operation................................................................................................. 15
Water Treatment and Blowdown...........................................................................................17
Evaporative Condenser Cleaning........................................................................................ 18
Water Collection Basin Access/ Air Inlet Louver Removal............................................ 19
Access Door Operation......................................................................................................... 20
Belt Tensioning......................................................................................................................... 21
Sheave Alignment.................................................................................................................... 24
Fan Motor Access and Removal.......................................................................................... 25
Drift Eliminator Removal and Replacement........................................................................27
Distribution System Maintenance........................................................................................ 28
Routine Maintenance.............................................................................................................. 29
Seasonal Shutdown Instructions......................................................................................... 32
Maintenance Schedule............................................................................................................37
Troubleshooting........................................................................................................................ 38

The following defined terms are used throughout this manual to

bring attention to the presence of hazards of various risk levels, or
to important information concerning the life of the product. Also,
please observe all Caution and Warning labels on the tower.

Indicates presence of a hazard which can cause severe personal

Warning injury, death or substantial property damage if ignored.

Indicates presence of a hazard which will or can cause personal

Caution injury or property damage if ignored.

Indicates special instructions on installation, operation or mainte-

Note nance which are important but not related to personal injury hazards.

2
 overview

This User Manual as well as those offered separately on motors, fans,

Geareducer, couplings, drive shafts, float valves, pumps, etc., is intended to
assure that this evaporative condenser serves you properly for the maximum
possible time. Since product warrantability may well depend upon your actions,
please read this User Manual thoroughly prior to operation.
This User Manual provides information regarding general equipment installation
and operation. Any deviation from, change or modification to, the User Manual,
the original design conditions or the original in-tended use of the equipment
may result in improper installation and/or operation.
Any such deviation, change or modification shall be the responsibility of the
party or parties making such deviation, change or modification. SPX Cool-
ing Technologies, Inc. expressly disclaims all liability for any such deviation,
change or modification. The equipment shall be warranted in accordance with
the applicable SPX Cooling Technologies Certification of Limited Warranty.
If you have questions about the operation and/or maintenance of this evapora-
tive condenser, and you don’t find the answers in this manual, please contact
your sales representative. When writing for information, or when ordering
parts, please include the serial number shown on the equipment nameplate.

Safety First
The location and orientation of the evaporative condenser can affect the safety
of those responsible for installation, operation or maintenance. However, since
SPX Cooling Technologies does not determine the evaporative condenser
location or orientation, we cannot be responsible for addressing those safety
issues that are affected by evaporative condenser location or orientation.

The following safety issues should be considered by those

Warning responsible for designing the evaporative condenser installation.
• access to and from the collection basin
• access to and from mechanical access door(s)
• the possible need for ladders (either portable or permanent) to
gain access to the mechanical access doors(s)
• the possible need for safety cages around ladders
• the possible need for external mechanical access platforms
• access issues due to obstructions surrounding the evaporative
condenser
• lockout of mechanical equipment
• the need to avoid exposing maintenance personnel to the
potentially unsafe environment inside the evaporative condenser.

3
 overview

Those are only some of the safety issues that may arise in the design
process. SPX strongly recommends that you consult a safety engi-
neer 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:
— mechanical access platform and ladder
— ladder extensions (used where the base of the tower is elevated)
— safety cages for ladders
— safety gates for platforms

Location
Space available around the evaporative condenser should be as generous as
possible to promote ease of maintenance—and to permit freedom of airflow
into and through the evaporative condenser. If you have questions about the
adequacy of the available space or the intended configuration of the equip-
ment, please contact your Marley sales representative for guidance.

Prepare a stable, level support foundation for the evaporative condenser, utiliz-
ing weight, wind load, and dimensional information appearing on appropriate
Marley submittal drawings. Supports must be level to insure proper operation
of the evaporative condenser.

The evaporative condenser must be located at such distance and

Warning direction to avoid the possibility of contaminated 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 equipment is
in compliance with applicable air pollution, fire and clean air codes.

Shipment
Unless otherwise specified, evaporative condensers ship by truck (on trailer(s)),
which lets you receive, hoist, and install in one continuous operation. Smaller
single-cell evaporative condensers generally ship on one truck. Larger single-
cell evaporative condensers, multi-cell evaporative condensers, and evapora-
tive condensers with access options (i.e. factory assembled platforms) may
require more than one truck.
Responsibility for the condition of the evaporative condenser upon its arrival
belongs to the trucker—as does the coordination of multiple shipments, if
required.

4
 receiving and hoisting

Receiving
Prior to unloading the evaporative condenser from the delivering carrier, in-
spect 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 material located
in a plastic tub in the crate accompanying the evaporative condenser. This
information should be kept for future reference and maintenance purposes.

Hoisting
All DT evaporative condenser models must use hoist clips and overhead lifting
for handling assembled shipping modules. Fork lifting from base of evapo-
rative condenser modules is not permitted. Hoisting clips are located at
the bottom of the basin (bottom) module and at the bottom of the coil/fan
(top) module. On models where the upper fan module is shipped separately
from the coil module, hoisting clips are located at the fan deck level on the fan
(top) module and at the bottom of the coil (middle) module. Never use hoisting
clips located at the fan deck level if the fan and coil modules are combined.
A Hoisting-Installation label which has hoisting dimensional information is
located on the side casing of the equipment, and a hoisting drawing is located
in the installation instruction drawings accompanying the equipment. Remove
evaporative condenser from the trailer and hoist into place according to the
instructions.

Modules must be hoisted and set according to instructions. Do not

Warning preassemble modules prior to hoisting unless specifically allowed
in the hoisting drawing for that model size and configuration. Under
no circumstances should you use hoisting clips located at the fan
deck level if the fan and coil modules are combined.

Hoisting clips are provided for ease of unloading and positioning

the evaporative condenser. For overhead lifts or where additional
safety is required, safety slings should also be placed under the
evaporative condenser modules.

5
 installation

Installation
These installation instructions are intended to help you prepare
Note before your evaporative condenser arrives. If discrepancies exist
between these instructions and those shipped with the evaporative
condenser, the instructions shipped with the evaporative condenser
will govern

1. Prior to placement of the evaporative condenser, confirm that the support-

ing platform is level, and that the anchor bolt holes are correctly located
in accordance with Marley drawings. If your installation uses vibration
isolators to dampen vibration, they must be mounted below the support-
ing steel. See support drawings for further information.
2. Place basin (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 to supporting
steel with bolts and flat washers (by others) — see support drawing for
size, location and quantity. Position flat washers between the bolt head
and the evaporative condenser basin flange.
3. Before setting coil module (middle module on 3-piece shipments, top
module on 2-piece shipments) in place on the basin module, clean any
debris from the underside of the coil module and the top of the basin
module. Apply sealing gasket tape to the top of the basin module per the
installation instructions shipped with the evaporative condenser. Make
sure that the orientation of the modules agrees with your intended piping
arrangement. Pay close attention to face designations on sales orientation
drawings e.g. Face A, Face B, etc. Place coil module on the top peripheral
bearing surface of basin module, aligning mating holes with drift pins as it
is set in place. Use care when setting the modules as lifting and resetting
will compromise the sealing gasket between the two sections, possibly
resulting in a leaking joint. If the modules must be reset, it may be neces-
sary to remove the sealing gasket tape and replace. Attach the modules
together with fasteners provided according to drawings shipped with your
evaporative condenser.

Sealing details must be followed correctly or leaks may occur that

Note will not be covered under warranty.

6
 installation

4. Connect the recirculation piping with rubber coupling shipped with the
bottom module piping according to drawings shipped with the evaporative
condenser.
If evaporative condenser fan and coil sections are combined for
Note shipment, skip step 5.

5. If the evaporative condenser was shipped with the fan and coil in separate
modules, it is necessary to now set the fan module. Before setting fan
module in place on the coil module, clean any debris from the underside
of the fan module and the top of the coil module. Apply sealing gasket
tape to the top of the basin module per the installation instructions shipped
with the evaporative condenser. Pay close attention to module orientation
and face designations on sales orientation drawings. Place coil module on
the top peripheral bearing surface of basin module, aligning mating holes
with drift pins as it is set in place. Use care when setting the modules as
lifting and resetting will compromise the sealing gasket between the two
sections, possibly resulting in a leaking joint. Attach the modules together
with fasteners provided according to drawings shipped with your evapora-
tive condenser.
6. Attach makeup water supply piping to appropriately-sized float valve con-
nection located in collection water basin side wall. Install the drain and
overflow according to drawings shipped with your evaporative condenser.
If you wish to pipe overflow and drain water to a remote discharge point,
make those connections at this time also.

Fasteners and components provided by others that are to be at-

Note tached to the evaporative condenser must be compatible with the
evaporative condenser materials—i.e. fasteners in a stainless steel
cold water basin must be stainless steel.

7. Attach the refrigerant supply and return piping to the condenser coil con-
nections. Coils are charged with nitrogen to approximately 20 psig at the
factory. Upon installation, coil connections require cutting and beveling.
Protect adjacent areas from excessive heat and sparks or damage may
occur. It is recommended that weld areas be protected against corrosion.
Cold galvanizing is suggested for weld areas on galvanized coils, applied
according to the manufacturer’s instructions.

7
 installation

Except for the horizontal components of piping, do not support your

Caution piping from the evaporative condenser inlet / outlet connections —
support it externally.
Protect adjacent areas from excessive heat and sparks during weld-
ing or damage may occur.

8. Wire fan motor(s) and recirculation pump motor(s) in accordance with

wiring diagrams.

For maintenance/safety purposes, SPX recommends a lockout

Warning type disconnect switch for all mechanical equipment. In addition to
a disconnect switch, the motor(s) should be wired to main power
supply through short circuit protection, and a magnetic starter(s)
with overload protection.

Motor Wiring

Wire motor leads as shown on the motor nameplate matching the supply
voltage. Do not deviate from the motor nameplate wiring.
Internal space heaters may be present, depending upon the motor manufac-
turer. For space heater operation and wiring refer to the Marley “Fan Motor”
User Manual Z0239042.
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 evaporative
condenser commissioning when the evaporative condenser is dry and
the ambient air temperature is cool.

Do not start the motor more than four to five times per hour. Short
Note cycling the motor(s) will cause fuses, breakers or O.L.s to operate
and will decrease motor life.

8
 installation

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 four to five times per hour (each
Note 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 name-
plate 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 opera-
tion. 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 100 feet
a DV/DT output filter is recommended to avoid damage to the motor.
100 feet distance is based on our field experience, the VFD manufac-
ture may state different distances and distance does vary depending
on the VFD manufacture.
• Program the VFD for variable torque output.
• Do not start and stop the motor using the safety switch at the motor.
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 energy
being used and provide better temperature control. In addition, it reduces the
mechanical and electrical stress on the motor and mechanical 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.

9
 installation

Marley supplies VFD and VFD controls specifically designed for our cool-
ing 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 instal-
lation manual.

Improper use of a VFD may cause damage to equipment or personal

Warning 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 Cool-
ing Technologies does not assume responsibility for any technical
support or damages for problems associate with non-Marley brand
VFD systems.
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.
The evaporative condenser is designed to operate at full speed and
half speed. Warranty is void if the evaporative condenser is oper-
ated at speeds which cause damaging vibrations to the evaporative
condenser and associated equipment. When utilizing a variable
frequency drive, the evaporative condenser must be tested across
the full range of speeds and checked against CTI guidelines for
excessive vibration. Speed ranges not meeting these guidelines
must be locked out in the VFD.

Mechanical Equipment:
Always shut off electrical power to the evaporative condenser fan
Warning motor prior to performing any maintenance on the tower. Any electri-
cal switches should be locked out and tagged out to prevent others
from turning the power back on.

1. If equipped, check Geareducer oil level. Although the Geareducer was

filled to the proper level at the factory, tipping during shipment and hoist-
ing may have caused some loss of oil. If oil is required, fill Geareducer to
the proper level with approved lubricant. See Geareducer User Manual.

10
 installation

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. 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
21and 24.

The following steps require operation of the fan motor while the ac-
Warning cess door is open. See Access Door Operation on page 20. DO NOT
view the fan operation from near or inside the access door location.
Fan rotation should be viewed from grade.

The access door should NOT be opened while the fan is operating.
Caution The fan rotation causes a negative pressure inside the evaporative
condenser and will abruptly pull the door open should access be at-
tempted. Only open the access door when the fan is off and locked out.

3. 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 evaporative condenser is equipped with a two-speed motor, check

Caution for proper rotation 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.

4. Run the motor and observe the operation of the mechanical equipment.
Operation should be stable, and, if equipped, there should be no evidence of oil
leakage from the Geareducer.
5. If equipped with belt drive, check belt tension and torque on the fan and
motor sheave after 10 ‑ 60 hours of operation. See Bushing Fastener
Torque Values on page 25.

11
 installation

If the water supply system is not being operated—or if there is no

Note 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. Deter-
mination of an accurate motor load should await the application of
the design heat load.

Start-Up
Among other sources, outbreaks of Legionnaires’ Disease have re-
Warning portedly been traced to evaporative heat rejection equipment. Main-
tenance and water treatment procedures that prevent amplification
and dissemination 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.

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 evaporative condenser. Pay
particular attention to inside areas of collection water basin, distribution
water system, louvers and drift eliminators. Make sure that recirculating
water suction screens are clear and properly installed.
3. Fill the water system to the recommended operating water level. Shown
on the outlet piping drawing accompanying the evaporative condenser,
the recommended operating water level is typically a depth of 7” - 8" in
the depressed area of the collection water basin. Adjust the float valve
so that it is 75% open at that level. Continue filling the system until the
water reaches a level approximately 1⁄8" below the lip of the overflow.
4. Start your pump(s) and check for proper rotation as indicated by the ar-
row 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 coil(s). 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.

12
installation

Some trial and error adjustment of the float valve may be required to bal-
ance the makeup water with evaporative condenser 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 evaporative condenser bleed line and adjust bleed
to the recommended rate. See Water Treatment section on page 17.
6. Continue pump operation for about 15 minutes, after which it is recom-
mended that the water system be drained, flushed and refilled.
7. While operating the recirculating water pump(s) and prior to operating the
evaporative condenser fan(s), execute one of the two alternative biocidal
treatment programs described in the following:
• Resume treatment with the biocide which had been used prior to shut-
down. 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 com-
mercial water test kits.
If the evaporative condenser 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 recirculating water storage
vessel (collection basin, drain down tank, etc.) without circulating stagnant
water over the coil(s) or operating the fan(s).
After biocidal pretreatment has been successfully completed, cooling
water may be circulated over the coil(s) with the fan off.
When biocidal treatment has been maintained at a satisfactory level for
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.

13
 operation

Operation
General:
The refrigerant condensing temperature obtained from an operating evapora-
tive condenser will vary with the following influences:
1. Heat load: With the fan in full operation, if the heat load increases, the
condensing temperature will rise. If the heat load reduces, the condensing
temperature will reduce.
The evaporative condenser establishes only the condensing temperature
attainable under any operating circumstance.
2. Air wet-bulb temperature: Condensing temperature will also vary with
the wet-bulb temperature of the air entering the condenser. Reduced wet-
bulb temperatures will result in lower condensing temperatures. However,
the condensing temperature will not vary linearly with the wet-bulb. For
example, a 20°F reduction in wet-bulb may result in only a 15°F reduction
in condensing temperature.
3. Air flow rate: Reducing air flow through the condenser causes the con-
densing temperature to rise. This is the recommended method by which
to control condensing temperature.
If your condenser is equipped with a single-speed motor, the motor may
be shut off when the condensing temperature becomes too low. This
will cause the condensing temperature to rise. When the condensing
temperature then becomes too warm for your process, the motor can be
restarted.

Fan cycling limits:

Considering the normal fan and motor sizes utilized on DT evapo-

Note rative condensers, anticipate that approximately 4 to 5 starts per
hour are allowable.

If your evaporative condenser is equipped with a two-speed motor(s), you will

have an 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 further reduction in fluid temperature,
the fan may be cycled alternately from half-speed to off.

14
 operation

Do not start the motor(s) more than four to five times per hour (each
Caution low speed start and each high speed start count as one start).

For greater insight on cold water temperature control, please read

“Cooling Tower Energy and its Management”, Technical Report
H-001, available at spxcooling.

Pump cycling limits: Cycling the recirculating water pump(s) to control

process fluid temperature is not typically recommended. If the recirculating
water pumps(s) are cycled as part of normal system operation, care must be
exercised — frequent wet/dry cycles may lead to premature scaling of the coil
surface. Motor cycling limits apply.

Dry Operation:

Also refer to the Freezing Weather Operation and Protection Against

Note Coil Freezing sections.

DT evaporative condenser models may be operated dry without recirculating

water during colder weather as heat load and ambient conditions permit. Dry
operation is the best way to minimize the potential for ice buildup in freezing
weather operation.
If dry operation is intended and the recirculating water is at risk of freezing, the
recirculating pump should be turned off, and the water in the collection basin,
pump and make-up supply piping should be drained. Care must be exercised
when cycling the recirculating water pump(s) — frequent wet/dry cycles may
lead to premature scaling of the coil surface.

Freezing Weather Operation:

During operation in subfreezing weather, the opportunity exists for ice to
form in the colder regions of the tower. Your primary concern is to prevent
the formation of destructive ice on the cooling tower air inlet louvers. Your
understanding of cold weather operation will be enhanced if you read Marley
Technical Report H-003 “Cooling Towers and Freezing Weather” avail-
able at spxcooling.com.

15
 operation

It is the operator's responsibility to prevent the formation of de-

Note structive (hard) ice on the evaporative condenser air inlet louvers.
Certain guidelines should be followed:

1. As cold air enters the louvers, it causes the water flowing over the coil(s)
to be drawn inward toward the center of the condenser. Thus, under fan
operation, the louvers and lower periphery of the condenser structure remain
partly dry, seeing only random splashing from within the condenser—plus
normal atmospheric moisture from the entering air. Such lightly wetted
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.
2. Under extended extreme cold conditions, it 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
of fan should only be done at half speed or less. 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. Monitoring is required to determine the time required to melt
accumulated ice.

Operating the fan in reverse at half speed for prolonged periods

Warning 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 minute delay between reverse operation
and forward operation during subfreezing weather to permit ice to
dissipate from fan blades and fan cylinders. See Fan Drive Caution
note on page 10 for fan speed change and reversing precautions.

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 Marley automatic basin heater systems and pump freeze protection
systems.

16
 operation

Unless some means of freeze prevention is incorporated into your

Caution system, the evaporative condenser basin and exposed pipework
should be drained at the beginning of each freezing weather shut-
down period.

If evaporative condenser basin is drained, verify that all basin heaters

Note have been shut off either by automatic cutoff or disconnect switch

Water Treatment and Blowdown

Maintaining Water Quality:
The steel used in DT evaporative condensers has been galvanized with a
heavy zinc coating averaging 2.0 mils in thickness. Other materials used (PVC
drift eliminators and louvers, aluminum fans, cast iron Geareducer, etc.) are
selected to offer maximum service life in a “normal” evaporative condenser
environment, defined as follows:
Circulating water with a pH between 6.5 and 8; a chloride content (as NaCl)
below 500 mg/L; a sulfate content (SO4) below 250 mg/L; total alkalinity (as
CaCO3) below 500 mg/L; calcium hardness (as CaCO3) above 50 mg/L;
a maximum inlet water temperature not to exceed 125°F; no significant con-
tamination with unusual chemicals or foreign substances; and adequate water
treatment to minimize scaling.
• Startup Conditions: The water conditions during the initial tower operation
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 CaCO3).
• 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 industrial”,
where rainfall and fog are no more than slightly acid, and they do not contain
significant chlorides or hydrogen sulfide (H2S).
• Many proprietary chemicals exist for control of scale, corrosion, and biologi-
cal growth and should be used prudently. Also, combinations of chemicals
may cause reactions which reduce treatment effectiveness, and certain
chemicals such as surfactants, biodispersants and antifoams may increase
drift rate.

17
 operation

The structure and coil of your evaporative condenser consists pri-

Note marily 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.

Blowdown:
Evaporative heat exchange equipment functions by continuously causing a por-
tion of the water circulated over the heat transfer media to evaporate. Although
the water lost by evaporation is replenished by the makeup system, it exits the
evaporative condenser 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 condenser, the
selected water treatment company must work from a relatively constant level
of concentrations. This stabilization of contaminant concentrations is usu-
ally accomplished by blowdown, which is the 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 concentrations. If the condenser
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-
Note troduced into the circulating water system via the cold water basin
of the evaporative condenser. Water velocities are lowest at that
point, which results in inadequate mixing.

Evaporative Condenser Cleaning:

Any evaporative-type condenser must be thoroughly cleaned on a
Warning regular basis to minimize the growth of bacteria, including Legio-
nella Pneumophila, to avoid the risk of sickness or death. Service
personnel must wear proper personal protective equipment during
decontamination. Do NOT attempt any service unless the fan motor
is locked out.

18
operation

Operators of evaporative cooling equipment, such as closed circuit evapo-

rative condensers, should follow maintenance programs which will reduce
to an absolute minimum the opportunity for bacteriological contamination.
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 oper-
ating 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, and coil(s) 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 effectiveness of the water treatment program. See Startup instructions
on page 12.

Water Collection Basin Access / Air Inlet Louver Removal

Some maintenance procedures require access to components located in the
water collection basin. These maintenance procedures can be performed
from the perimeter of the evaporative condenser without entering the basin.
To access the basin, one of the air inlet louver frames must be removed. To
remove, loosen the thumbscrews indicated in the image below and push the
louver retaining bracket up and to the left to move out of the way of the lou-
ver frame. Tip the top of the frame out from the evaporative condenser, then
remove. Louver frames are not always the same size, if more than one louver
frame is removed, the original location should be noted.

19
 maintenance

Collection basin floor has uneven surfaces and has the potential to
Caution be slippery. Care should be taken if entering the basin.
Louver edges can be very sharp and could cut skin if proper protec-
tion is not used. Always wear gloves and sleeves when handling
louver packs.

Access Door Operation

Always shut off electrical power to the evaporative condenser fan
Warning motor prior to performing any inspections that may involve physical
contact with the mechanical or electrical equipment in or on the
evaporative condenser. Lock out and tag out any electrical switches
to prevent others from turning the power back on. Service person-
nel must wear proper personal protective clothing and equipment.

To allow access to the mechanical system, eliminators, water distribution

system and coil surface, an access door is provided toward the top of the
evaporative condenser. To open, follow the following steps:
1. Remove any lock that is securing the door shut.
2. 
Loosen and remove the locking knob at the center of the access
door panel.
3. Slide the panel with the handle sideways as far as it will travel.
4. Push the panel toward the inside of the tower. The panel will hinge to the
side.

20
 maintenance

Belt Tensioning
Always shut off electrical power to the tower fan motor prior to
Warning 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.

On 8.5’ wide models, the fan motor and belt adjustment mechanism is located
outside the evaporative condenser. Remove the motor protection hood by
loosening the two thumbscrews on top and hinge the hood up and out of the
way. Also, remove the motor sheave safety bracket and set aside. See the
following images.
SAFETY
BRACKET

On 10' and 12' wide models, the motor is located inside the evaporative
condenser plenum. Open the access door (see Access Door Operation) and
hinge out of the way.

Any bolts loosened or removed functioning as mechanical or struc-

Caution tural hardware should be re-placed with the torques specified below.
Anti-seize compound is recommended for stainless steel hardware.

Fastener Torque Values

Machine Bolt Galvanized Stainless
Size ft·lbƒ N·m ft·lbƒ N·m
8mm 8 10 15 20
10mm 15 20 30 40
12mm 25 35 50 65
16mm 65 85 120 160
20mm 125 170 230 315

21
 maintenance

Belt tension on all mod-

els is adjusted by turning
a large threaded rod(s)
that drives the motor
mounting plate away
from (or toward) the fan
centerline. To turn the
rod(s), the rod retention
bracket(s) must first be
moved. On the models
with motors located
externally, loosen the thumbscrew holding this bracket in place and rotate
the bracket away from the assembly. On models with the motor located in
the plenum, rod retention brackets are held in place with fasteners. Loosen
fastener and slide bracket away from the adjusting rod. Turn the rod(s) clock-
wise to drive the motor away from the
fan (tighten belts) or counterclockwise
to drive the motor toward the fan (loosen
the belts). On models with more than
one rod, alternate turns on the rods to
prevent binding. There is no need to
loosen any other hardware to adjust the
belt tension. After belt tension is adjusted
to a satisfactory position, install the rod
retention bracket with the thumbscrew
and replace any safety hoods.
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. Over-tensioning shortens
belt and bearing life. Keep belts free from foreign material which may cause
slipping. Never apply belt dressing as this will damage the belt and cause
early failure. Specific tools are made to measure the tension of a V-belt drive
system. A Dodge® V-Belt Tension Tester, Browning® Belt Tension Checker or
equivalent an alternative should be used for tensioning V-belts. Check with
your local belt supplier.

22
maintenance

Belt tension is measured by applying a force perpendicular to the belt at the

center point between motor and fan sheaves. The belt should deflect 1⁄64" of
the entire span, (measured sheave centerline to sheave centerline) when the
pressure shown in the table below is applied. Because belt tension is a func-
tion of the motor sheave diameter, it is necessary to inspect the motor sheave
to determine the diameter. If diameter markings are unreadable, measure the
sheave diameter at the bottom of the sheave grooves.

New belts (operating less than 8 hours) should be tensioned to the maximum
value. Tension after this period should use no less than the minimum value. If
the belt span was measured in inches, then use the pounds of force values.
If the belt span was measured in centimeters, then use the kilograms of force
values. If specific tensioning instructions are provided with your tensioning
tool, those instructions should be used instead.

Motor Sheave Used V-Belt New V-Belt

diameter minimum maximum
3.4" - 4.2" 4.9 lb 7.2 lb
85cm - 105cm 2.2 kg 3.3 kg
4.4" - 5.6" 7.1 lb 10.5 lb
106cm - 140cm 3.2 kg 4.8 kg
5.8" - 8.6" 8.5 lb 12.6 l
141cm - 220 cm 3.9 kg 5.7 kg

23
 maintenance

Sheave Alignment
Always shut off electrical power to the tower fan motor prior to
Warning 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.

• The motor sheave is to be positioned as close as possible to the motor

in order to minimize torque on the motor bushings.
• The motor and fan sheaves may have grooves that are not used. The bot-
tom surface of the motor and fan sheaves must be aligned within 1⁄8" of
each other and level within 1⁄2° (1⁄8" 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 sheaves making sure that it is level and measuring down to the bottom
surface of both sheaves at four points. See photo.

• The number of grooves on the motor and fan sheaves may not match
each other, or the number of grooves on the belt. Always install the belts
on the highest grooves on the fan sheave. Doing so will reduce the force
on the fan shaft bearings, thus increasing their life.

24
 maintenance

Torque
Bushing Fastener Bushing Fastener Size
ft· lbƒ N· m
Torque Values ¹⁄₄ - 20
SH 6 8
SDS ¹⁄₄ - 20 6 8
SD ¹⁄₄ - 20 6 8
SK ⁵⁄₁₆ - 18 13 18
SF ³⁄₈ - 16 22 30
E ¹⁄₂ - 13 35 48
F ⁹⁄₁₆ - 12 65 88

Fan Motor Access and Removal

Always shut off electrical power to the tower fan motor prior to
Warning 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.

The DT fan motors are located inside or outside the evaporative condenser,
depending on the model. On 8.5' wide models, the fan motor is located out-
side the evaporative condenser. The motor is fully accessed by removing the
motor protection hood. Remove motor protection hood and the drive belt by
following the instructions in the
Belt Tensioning section.
8.5' wide DT models’ fan mo-
tors are oriented with the shaft
up. The motor may be hoisted
by threading an eye bolt into
the motor shaft and lifting with
a hoist. To remove the motor
fastener hardware, lift on the
motor slightly with the hoist
to remove the weight from the
fasteners, then loosen and
remove motor fasteners.
On 10' and 12' wide models, the fan motor is located inside the plenum of the
evaporative condenser. The motor can be accessed through the mechanical
access panel. See the Access Door Operation section for instruction on
opening the access panel. Remove the drive belt by following the instructions
in the Belt Tensioning section.

25
 maintenance

Motor inside plenum models are equipped with either a hinged or sliding
motor plate. For hinged motor plate models, loosen the motor mount system
retaining bolts shown in the image. It is not necessary to loosen any hard-
ware other than what is indicated. Hinge the motor mounting system 90° out
through the access panel. Attach a hoist to the motor with straps or chains.
Lift on the motor slightly with the hoist to remove the weight from the motor
fasteners, then loosen and remove motor fasteners.

HINGE MOTOR MOUNT

HARDWARE RETAINING BOLTS
JACKING SCREW

ACCESS PANEL
OPENING

INSIDE VIEW

Hoisting attachment locations vary by motor - choose strap or chain

Caution attachment locations carefully to provide a balanced lift.

For sliding motor plate models, the motor may be hoisted out through the fan
cylinder opening. Turn the adjustment rod(s) counterclockwise to slide the
motor toward the interior of the evaporative condenser. Remove the portion
of the fan guard nearest the motor location. It may be necessary to de-pitch
or remove one or more fan blades -consult the fan manual accompanying
the evaporative condenser. Attach a hoist to the motor with straps or chains.
Lift on the motor slightly with the hoist to remove the weight from the motor
fasteners, then loosen and remove motor fasteners.
If the motor is removed from the mounting plate, it should be reinstalled at the
torques specified—do not lubricate the bolts.

26
 maintenance

Motor Mounting Bolt Torque

Machine Bolt Galvanized Stainless
Size ft·lbƒ N·m ft·lbƒ N·m
10mm 15 20 30 40
12mm 25 35 50 65
16mm 65 85 120 160
20mm 125 170 230 315

Drift Eliminator Removal and Replacement

The drift eliminators may be removed for cleaning, replacement or access to
the distribution system. The eliminators are held in place by a press fit, so
there is no need to remove any fasteners. However, eliminators are formed so
that they nest with each other and form a monolithic barrier. Individual packs
of eliminator are formed into two-foot wide sections that span from the casing
wall to the centerline of the evaporative condenser, just under the mechanical
torque tube.

Eliminator edges can be very sharp and can cut skin if proper pro-
Caution tection is not used. Always wear gloves and sleeves when handling
eliminator packs.

To remove the eliminator, stand inside the access panel and lift with two
hands on an eliminator section, this will indicate where one section stops and
another starts. Lift the eliminators at that intersection, removing two packs at

27
 maintenance

one time (see image). Once the first two packs are removed, the remaining
packs should be easily removed. Pay close attention to the orientation and
placement, they are not symmetrical. Each pack should be replaced at the
location which it was removed. Repeat this process for the second half of the
evaporative condenser..

Proper eliminator pack replacement is essential to evaporative

Note condenser operation. Incorrect installation may result in excessive
drift rates and fan inefficiency! To ensure packs are reinstalled in
the correct orientation, it is recommended that one pack is left in its
original location inside the evaporative condenser as a reminder of
pack orientation. Place packs in the evaporative condenser in the
order they were removed. Packs should nest tightly with each other,
leaving a level surface with no gaps. The last two packs should be
installed at the same time. Place the final two packs according to
the image on page 27, and push down to complete.

Distribution System Maintenance

To keep your DT evaporative condenser operating at peak performance, it may
be necessary to clear the spray system of debris or sediment. To access the
spray system, remove the drift eliminators as explained in the previous section.
Observe the spray system with full flow on the unit. Each nozzle should pro-
duce a rectangular pattern spray which over-laps the adjacent nozzle patterns.
If a nozzle appears clogged or is not producing a proper pattern, remove the
nozzle and clean all surfaces. To remove the nozzle unscrew it from the adap-
tor. Inspect the nozzle for cleanliness or broken pieces. If the nozzle appears
broken or damaged, consult your Marley representative for replacement parts.
Insert the nozzles by screwing it back into the adaptor.
It may also be necessary to remove an entire branch arm from the spray sys-
tem. Each arm is held in place with a retention strap bolted to the branch arm
supports. Remove the bolts attaching the strap to the support and pull sharply
on the branch arm to disengage from the header box. It may be necessary to
rotate the branch arm while pulling out from the header box.
When branch arms are removed, access to the interior of the spray header
box is available to clean and remove any debris or sediment. A drain nozzle
at the centerline of the header box is intended to drain water from the system
at shutdown, as well as be removed to wash out the header box if necessary.
Be sure to replace this nozzle if removed.

28
 maintenance
Reinstall the branch arms to the header, engaging them far enough to align
the bolts of the tie down strap to the spray system supports. It may be neces-
sary to wet the rubber grommet and pipe to facilitate assembly. Ensure that
all nozzles are aligned to the bottom of the branch arm.

Routine Maintenance
Some procedures may require maintenance personnel to enter the evapora-
tive condenser. Each cell has an access door for entry into the evaporative
condenser. An optional mechanical access platform is designed and intended
solely for personnel to gain access to the motor and access door. Upon en-
tering the evaporative condenser, the eliminators and coil may be used as a
walking surface for inspection and typical maintenance. For those instances
of frequent or prolonged servicing, it is necessary to protect the surface with
plywood or planking. The fan deck and fan guard are not designed as walking
or working surfaces. There are no routine maintenance procedures that require
access to top of the evaporative condenser.

The purchaser or owner is responsible for providing a safe method

Warning for entering or exiting the access door.

Included with the instruction packet are separate User Manuals on each major
operating component of the evaporative condenser, 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 maintenance:

Always shut off electrical power to the tower fan motor prior to
Warning 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.

Weekly: Inspect for bacterial growth and general operation conditions. Bacte-
rial growth should be reported to your water treatment expert for immediate
attention.
Monthly (Weekly at start up): Observe, touch, and listen to the evaporative
condenser. Become accustomed to its normal appearance, sound, and level

29
 maintenance
of vibration. Abnormal aspects relating to the rotating equipment should be
considered reason to shut down the evaporative condenser until the problem
can be located and corrected. Observe operation of the motor, coupling (or
drive shaft) and Geareducer (if equipped), belt and sheaves (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 Geareducer oil level. Shut down the unit and allow 5 min-
utes for the oil level to stabilize. Add oil if required. 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.
Observe operation of the float valve. Depress the operating lever to make
sure that the valve is operating freely. Inspect the suction screen for plugging.
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.
View the water pattern as it exits the coil section. Consistent coverage in-
dicates that all nozzles are flowing properly. If there are dry spot in the coil
or inconsistent coverage, this may be evidence of a clogged nozzle. Inspect
nozzles for blockage.
Every 3 months: If equipped, lubri-
cate fan shaft bearings. Each cell is
equipped with extended lube lines
protruding through the casing adja-
cent to the access door. While rotat-
ing equipment by hand, grease the
bearings until a bead forms around
the seals—a maximum charge of 0.75
ounces is recommended. Chevron
SRI-2 grease (or equivalent lithium-
based grease) is recommended.
Semi-Annually: If equipped, check
the belt tension and condition. Adjust tension as necessary.
Clean and disinfect evaporative condenser with biocides. Systems with bio-
fouling, high general bacterial counts, or positive cultures of legionella may

30
 maintenance

require additional cleaning. Refer to Evaporative condenser Cleaning sec-

tion—page 18. Consult your water treatment expert as to prudent biological
evaluation testing.

Geareducer models used on DT evaporative condensers are de-

Note signed 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 semiannually. Refer to the “Geareducer User Manual” for
oil recommendations and further instructions.

Annually: Inspect the evaporative condenser 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 necessary.
Lubricate motor(s) according to the manufacturer’s instructions. See instruc-
tions following for evaporative condensers with geareducer drive and motor
located outside the plenum. Fan motors with sealed bearings do not require
lubrication maintenance.
If the motor has sealed bearings, additional lubrication is not re-
Note quired. Refer to the motor nameplate to determine if grease type
and amount are specified.

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.
Every 5 Years: If equipped, change Geareducer oil. Refer to the Geareducer
User Manual for instructions.

Motor Lubrication Instructions

Geareducer drive with motor located outside plenum. Not required for motors
with sealed bearings

Open and lock out disconnect switch to make certain motor cannot
Warning be started.
1. Remove guard as shown. Opposite end motor bearing is accessible from
outside the evaporative condenser.

31
 maintenance
MOTOR STEEL SIDE CASING
GREASE FILL PLUG

ATTACHMENT SCREW

GUARD

GREASE RELIEF PLUG

2. Remove grease fill and relief plugs at both shaft extension end and op-
posite end bearings and remove hardened grease, using clean wire.
3. Insert grease fittings in grease fill openings and add grease until grease
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 evaporative condenser operation.

Seasonal Shutdown Instructions

When the system is to be shut down for an extended period of time, it is rec-
ommended that the recirculating water system be drained. Leave the basin
drains open.
During shutdown, clean the evaporative condenser (see Caution, page 18)
and make any necessary repairs. Eliminators and louvers can be removed
to gain access to the coil. Pay particular attention to mechanical equipment
supports and sheaves or coupling (or drive shafts).
Following each year’s shutdown and cleaning, inspect the evaporative con-
denser’s metal surfaces for evidence of the need to apply a protective coat-
ing. Do not misinterpret grime as a need to have the evaporative condenser
painted. If relatively bright metal can be exposed by cleaning, consider that
the galvanizing has remained effective. Unless there is evidence of a general-
ized failure of the galvanizing, localized touch-up should be all that is required.

To the extent that the galvanizing (zinc coating) still exists, paint
Note will not adhere to it readily. Contact the manufacturer of the coating
you intend to use for instructions.

32
 maintenance

Evaporative condenser framework: Check structural bolted connections

and tighten 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 33.
Fan motors: Clean and lubricate motor (if required) at close of each operating
season (refer to motor manufacturer's recommendations.) Does not apply to
motors with sealed bearings. Check motor anchor bolts and tighten as re-
quired. See Page 35 for evaporative condensers with motor located outside
the plenum option.

Do not start motor before determining that there will be no interfer-

Caution ence with free rotation of the fan drive.

The motor should be operated for three hours at least once a month. This
serves to dry out windings and lubricate bearing surfaces. Refer to Marley
“Fan Motor” User Manual Z0239042 for additional information.
At start of new operating season, make sure bearings are adequately lubricated
before returning motor to service. Does not apply to motors with sealed bearings.

Long Term Storage Procedures

Instructions for protection of non-operating equipment for more than 3 months.
After installation of the DT evaporative condenser and completion of the
pre-startup instructions, the operational availability of equipment will last for
a maximum period of three months. Ensure that the condenser is completely
drained of all water and the drain is open. Coils should remain charged with
nitrogen until put in service.
After this initial period of 3 months, until the unit is employed into continuous
operation, the fan shaft should be turned by hand for a few minutes every
month after: Inject a small amount of grease into ball /roller bearings of fan shaft
and drive components as per the manufacturer’s recommendation attached.
General Protective Requirements for Evaporative condensers: The fan
opening at the top of the evaporative condenser should be covered with a
tarp. This will protect the mechanical components from rain as well as keep
out dirt, trash, leaves, etc.
All coils on every evaporative condenser model are protected from the environ-
ment by the structure of the evaporative condenser as well as the PVC air inlet

33
 maintenance

louvers. No external protection of the coil is required for long-term storage.

Internal Protection of Coil: All of the coil inlet and outlet connections should
be sealed off and the coils should be charged with nitrogen gas to prevent
corrosion. Condenser coils from the factory are charged with nitrogen to
approximately 20 psig. No external protection of the coil is required for long-
term storage.
Machinery Components:
Electric motors: All drive motors should be taken down and stored indoors.
Then, every month, turn motor shafts to evenly distribute lubricant to the
bearing parts.
Recirculation pumps: All pumps and pump motors should be taken down
and stored indoors (pumps and motors may be stored fully assembled). Then,
every month, turn pump impeller shaft to evenly dis-tribute lubricant to the
bearing parts.
Belts: Properly stored belts will retain their properties unchanged for several
years. Under unfavorable storage conditions and with improper handling,
deterioration of their physical properties will result. These changes can be
caused by, for example, oxidation, ozone, extreme temperatures, light, damp
or sol-vents. It should be ensured that belts are stored stress free, which is to
say without tension, pressure or other causes of deformation, as strain causes
permanent deformation and failure due to fatigue, as well as cracking. If, for
reasons of space, they are stored suspended, the diameter of the bar from which
they are suspended must be equal to at least 10 times the height of the belt
The belts may not be stored for longer than 3 month in an open, uncontrolled
environment. The storage area must be dry and dust-free. Belts may not be
kept together with chemicals, solvents, fuels, lubricants, acids, etc.
Belts should be shielded from Radiators and their pipes. The distance between
radiators and stored equipment must be at least 10 feet.
Belts should be protected from light, particularly from direct sunlight and
strong artificial light with high ultraviolet content (formation of ozone), such as
for example fluorescent tubes installed in open fixtures. Ideally, room lighting
should be normal incandescent bulbs.
To counteract the damaging effect of ozone, the storage areas may not contain
any form of ozone generating equipment, such as for example fluorescent light
sources, mercury vapor lamps or electrical high voltage devices. Combus-
tion gases and vapors, which may lead to ozone formation due to chemical
processes, must be avoided or removed.

34
 maintenance

Damp storage areas are quite unsuitable. It should be ensured that no con-
densation occurs. The relative humidity should be below 65 %.
Cleaning of dirty belts can be carried out with a mixture of glycerin and spirit
in a ratio of 1:10.

Benzene, benzol, turpentine and similar substances may not be

Caution used. Furthermore, sharp objects, wire brushes, emery paper etc.,
may not be used, as they will cause mechanical damage to the belts.

Bearings: Every month, turn the fan shaft and rotate by hand to distribute
grease evenly over the bearing parts. Then, every three months, inject grease
to prevent any blocking of the lubrication lines possibly due to grease hard-
ening. Whenever the fan shaft has been turned, it is a must to secure them
at a standstill.
Fans: See Fan User Manual for instructions.

SPX Cooling Technologies Services

Our interest in your DT evaporative condenser does not end with the sale.
Having designed and manufactured one of the most reliable and longest-lasting
evaporative condensers in 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: assure
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 Mar-ley sales representative.
Replacement parts: A complete stock of parts and components is maintained
at one or more of the various manufacturing 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 advance,
thus avoiding the cost of special handling.
Be sure to mention your evaporative condenser serial number (from the
evaporative condenser 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
evaporative condenser’s condition—to make recommendations intended to pre-
vent emergencies— and to perform maintenance considered outside the norm.

35
 additional information

This service is not intended to replace the important function performed by

your maintenance staff. Their attention assures the evaporative condenser’s
routine operating performance, and is invaluable. However, we recognize that
the unusual manner in which a evaporative condenser performs its function—
as well as the unique forces which act upon it—may be considerations which
occasionally require the services of an expert technician.
Increased load requirements: DT evaporative condensers 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 evaporative condenser system.
Evaporative condenser rebuilding: SPX routinely rebuilds and upgrades
evaporative condensers, evaporative condensers 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 evaporative condenser.
Each DT evaporative condenser includes a document package containing
general orientation drawings, assembly instructions and evaporative condenser
component manuals. These documents contain important information
relating to safe installation and operation of the evaporative condenser.
Field installation is required for motors and motor supports on motor outside
plenum models and piping inlets and outlets. Some optional accessories,
such as access platforms, 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,
con-tact your local sales representative before proceeding.
In addition to these specific documents, numerous technical reports are pub-
lished by SPX including more detailed information on a variety of evaporative
heat rejection equipment operation and service topics. Your Marley sales
representative will be happy to give you copies of these reports at no charge
or you can download copies from our website at spxcooling.com.
For complete parts and service assistance, contact the Marley sales repre-
sentative in your area. If you need help locating your representative, please
phone 913 664 7400 or check the internet at spxcooling.com.

36
maintenance schedule
Maintenance Service Monthly Semi-annually Seasonal Startup or Annually

Inspect General Condition and Operation x x

Observe Operation of:

Mechanical–motor, fan and drive mechanism x x

Makeup valve (if equipped) x x

Inspect for unusual noise or vibration x x

Inspect and Clean:

Air inlet x x

PVC drift eliminators x x

Nozzles x x

Collection Basin x x

Fan and pump motor exterior x x

Coil surface x

Check:

Collection water basin level x x

Blowdown–adjust as required x x

Geareducer Drive (if equipped):

Check for loose fasteners including oil drain plug x

Check oil level, check for / repair oil leaks x x

Change oil R

Make sure vent is open x x

Check driveshaft or coupling alignment x

Check for loose driveshaft or coupling fasteners x

Check driveshaft or coupling bushings or flex element for unusual wear x x

Lube lines (if equipped):

Check for oil leaks in hoses or fittings x R x

Belt drive (if equipped):

Fan shaft bearing lubrication (every 3 mo.) every 3 months every 3 months

Check and tighten support fasteners x

Check shaft, sheave and belt alignment x

Check belt tension and condition x x

Check sheave bushing fastener torque x

Fan:

Check and tighten blade and hub fasteners x

Check fan blade pitch and tip clearance x

Check fan cylinder for loose fasteners x

Motor:

Lubricate (as required) R

Check mounting bolts for tightness x

Operate at least 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 x

Inspect/clean buildup of contaminant from sensor x x

Structure:

Inspect/tighten all fasteners x x

Inspect and touch up all metal surfaces x

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.
37
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,
Power not available at motor terminals
reset tripped switches or replace failed control switches.
If power is not on all leads at starter, make sure overload and short circuit
devices are in proper condition

Motor will not start Wrong connections Check motor and control connections against wiring diagrams.
Check nameplate voltage against power supply. Check voltage at motor
Low voltage
terminals.
Open circuit in motor winding Check stator windings for open circuits.
Disconnect motor from load and check motor and fan drive for cause of
Motor or fan drive stuck
problem.
Rotor defective Look for broken bars or rings.
Check motor and attempt to start it. Motor will not start if single-phased.
Motor running single-phase
Check wiring, controls and motor.
Motor leads connected incorrectly Check motor connections against wiring diagram on motor.
Bad bearings Check lubrication. Replace bad bearings.
Unusual motor noise
Electrical unbalance Check voltages and currents of all three lines. Correct if required.
Air gap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance
Cooling fan hitting end belt guard Reinstall or replace fan.
Wrong voltage or unbalanced voltage Check voltage and current of all three lines against nameplate values.
Check fan blade pitch. See “Fan User Manual.” Check for drag in fan
Overload
drivetrain as from damaged bearings.
Check nameplate against power supply. Check RPM of motor and drive
Wrong motor RPM
ratio.
Remove bearing reliefs. Run motor up to speed to purge excessive
Bearing overgreased
grease. Does not apply to motors with sealed bearings.
Wrong lubricant in bearings Change to proper lubricant. See motor manufacturer's instructions.
Stop motor and attempt to start it. Motor will not stat if single-phased.
One phase open
Check wiring, controls and motor.
Clean motor and check ventilation openings. Allow ample ventilation
Motor runs hot Poor ventilation
around motor.
Winding fault Check with ohmmeter.
Bent motor shaft Straighten or replace shaft.
Remove plugs and regrease bearings. Does not apply to motors with
Insufficient grease
sealed bearings.
Limit cumulative accelerations time to a total of 30 seconds/hour. Set on/
Too frequent starting or speed changes off or speed change set points farther apart. Consider installing a Marley
VFD drive for fine temperature control.
Flush bearings and relubricate. Does not apply to motors with sealed
Deterioration of grease or foreign material in grease
bearings.
Bearings damaged Replace bearings.

38
troubleshooting

Trouble Cause Remedy

Voltage too low at motor terminals because of line Check transformer and setting of taps. Use higher voltage on transformer
Motor does not come up to drop terminals or reduce loads. Increase wire size or reduce inertia.
speed Look for cracks near the rings. A new rotor may be required. Have motor
Broken rotor bars
service person check motor.
Wrong motor rotation Wrong sequence of phases Switch any two of the three motor leads.
If new, see if noise disappears after one week of operation. Drain flush,
Geareducer bearings and refill Geareducer oil. See “Geareducer User Manual.” If still noisy,
Geareducer noise. (If replace.
equipped).
Correct tooth engagement. Replace badly worn gears. Replace gears with
Gears
broken or damaged teeth.
Tighten all bolts and cap screws on all mechanical equipment and
Loose bolts and cap screws
supports.
Make sure motor and Geareducer shafts are in proper alignment and
Unbalanced drive shaft or worn couplings. (If "match marks" properly matched. Repair or replace worn couplings.
equipped) Rebalance drive shaft by adding or removing weights from balancing cap
screws. See “Driveshaft User Manual.”

Unusual fan drive vibration Make certain all blades are as far from center of fan as safety devices
Fan permit. All blades must be pitched the same. See “Fan User Manual.”
Clean off deposit build-up on blades
Worn Geareducer bearings. (If equipped) Check fan and pinion shaft endplay. Replace bearings as necessary.
Worn fan shaft bearings. (Belt drive). Check fan shaft endplay. Replace bearings as necessary.
Unbalanced motor Disconnect load and operate motor. If motor still vibrates, rebalance rotor.
Bent Geareducer shaft. (If equipped). Check fan and pinion shaft with dial indicator. Replace if necessary.
Blade rubbing inside of fan cylinder Adjust cylinder to provide blade tip clearance
Fan noise Loose bolts in blade clamps Check and tighten if necessary.
Fan shaft bearing. (Belt drive). Grease bearings.
Insufficient blowdown See "Water Treatment" section of this manual.
Scale or foreign substance in
circulating water system Consult competent water treating specialist. See "Water Treatment"
Water treatment deficiency
section of this manual
Check to see if local heat sources are affecting evaporative condenser.
Entering wet bulb temperature is above design See if surrounding structures are causing recirculation of evaporative
condenser discharge air. Discuss remedy with Marley representative.
May have to increase evaporative condenser size. Discuss remedy with
Design wet bulb temperature was too low.
Condensing temperature too Marley representative
warm. May have to increase evaporative condenser size. Discuss remedy with
Actual process load greater than design
See “Evaporative Condenser Marley representative
Operation.” Overpumping Reduce water flow rate over evaporative condenser to design conditions.
Check motor current and voltage to be sure of correct contract
horsepower. Repitch fan blades if necessary. Clean eliminators. Check to
Evaporative condenser starved for air
see if nearby structures or enclosing walls are obstructing normal airflow
to evaporative condenser. Discuss remedy with Marley representative.
Spray system malfunction Inspect spray system for proper operation. Correct as necessary.
Excessive drift exiting
evaporative condenser Check to see that the eliminators are clean, free of debris and installed
Faulty drift elimination
correctly. Clean if necessary. Replace damaged or worn out components.

39
 Cube DT evaporative condenser
U S E R M A N UA L

SPX COOLING TECHNOLOGIES, INC.

7401 WEST 129 STREET Z0921107_A | ISSUED 8/2017
OVERLAND PARK, KS 66213 USA COPYRIGHT © 2017 SPX CORPORATION
913 664 7400 | [email protected] In the interest of technological progress, all products are subject to design

spxcooling.com and/or material change without notice.