Instruction/ maintenance manual of the product 800 SPX Cooling Technologies
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2 Notice The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to im- portant information concerning the life of the product. Indicates presence of a hazar d which can cause severe personal injury , death or substantial property damage if ignor ed.
3 General ................................................................................................... 4 Before Start-up ....................................................................................... 5 Initial Starting Procedur e .....
4 General A cooling tower , like any heat exchanger , exchanges all heat imposed upon it from one fluid to another fluid. For a cooling tower , heat from the water is put into the air . The plant process replenishes the heat to the water , typically at another heat exchanger such as a condenser .
5 Befor e Start-up Safety T emporary safety barricades should be placed around any exposed openings in the operating (or nonoperating) tower , safety harnesses should be worn by personnel wher e appropriate, and other safety precautions should be taken in compliance with OSHA r egulations and standards.
6 Befor e Start-up See Geareducer Service Manual for oil filling procedur e and list of recommended lubricants. • Rotate fan by hand to be sure of fr ee rotation and ample tip clearance. See Marley Fan Service Manual . • Check motor insulation with a “Megger .
7 Initial Starting Pr ocedure 1— Fill the cold water basin and circulating water system to a level 1/2” (13 mm) below the overflow . 2— Bypass valve should be closed unless start-up is in cold weather . (See Routine Starting Procedur e on page 8.
8 Routine Starting Pr ocedure After periods of routine shutdown, the following restarting procedure should be followed: • Start the circulating water pump(s). Increase the flow of circulating water gradually to design water rate to avoid sur ges or water hammer which could damage the distribution piping.
9 Operation ➠ T ower Performance The following is intended to serve as a guideline for the operation of this counterflow mechanical draft cooling tower .
10 Operation When changing fan direction of rotation, allow a minimum of two minutes time delay before energizing the fan motor . Hot W ater Distribution System Hot water from the process flows thr ough an inlet to each cell, which sup- plies a distribution header and a system of branch arms and nozzles.
11 Fr eezing W eather Operation During periods of low ambient air temperatures, 35°F to 40°F (2°C to 4°C) or below , it is advisable to maintain the cold water temperature at or above 70°F (21°C) to retar d the formation of ice and to assist in its control.
12 Fr eezing W eather Operation • Under extended extreme cold conditions, it may be necessary to operate the fan in reverse. This forces warm air out through the air inlets, melt- ing any accumulated ice. Reversal may be at either full or half speed; however , full speed is r ecommended if adequate heat load is available.
13 T emperature Contr ol and Energy Management ➠ The wet-bulb temperature of the ambient air varies significantly on a daily basis, and considerably from season to season.
14 T emperature Contr ol and Energy Management number of seconds it takes your fan to get to full-speed (by obser - vation) and divide that number into 30 to obtain the recommended maximum number of starts per hour . T wo-speed motors cycling be- tween half and full speeds permit a commensurately greater number of control cycles.
15 Maintenance ➠ W ell maintained equipment gives the best operating results and the least maintenance cost. A regular inspection schedule is recommended to insure effective safe operation of the cooling tower . Use the Inspection and Maintenance Schedule on page 25 to obtain continuously good performance with least tower maintenance.
16 Maintenance sibility to institute a pr ogram of water treatment and maintenance that will minimize their impact. (See W ater T reatment on pages 18 and 19.) T ower Framework Inspect for cracks and spalling and repair if necessary . Keep bolts tight in the mechanical equipment supports.
17 Cleaning Any evaporative-type cooling tower must be thoroughly cleaned on a regular basis to minimize the growth of bacteria, including Legionella Pneumophilla, to avoid the risk of sickness or death. Service person- nel must wear proper personal pr otective equipment.
18 Blowdown Blowdown, or bleed-off is the continuous removal of a portion of the water from the cir culating system. It is used to prevent dissolved solids from concentrating to the point where they will form scale.
19 predict the corrosive tendencies of the tower water toward concrete. An explanation and method of calculating the Langelier index can be found in all books on water treatment. Maintaining a positive Langelier index provides excellent pr otection of concrete.
20 Seasonal Shutdown Instructions T ower Drain all tower piping. During shutdown, clean the tower and make any necessary repairs. Ap- ply protective coating as required to all metal parts. Particular attention should be given to mechanical equipment supports, drive shaft and drive shaft guards, Gear educers, and motors.
21 Spar e Parts and Accessories Spare Parts SPX Cooling T echnologies manufactures and maintains a stock of re- placement parts for all cooling tower mechanical equipment. Shipment of these parts is normally made within ten days after an or der is received.
22 T r oubleshooting Remedy 1. Check power at starter . Correct any bad connections be- tween the control apparatus and the motor . 2. Check starter contacts and control circuit. Reset overloads, close contacts, reset tripped switches, or r eplace failed control switches.
23 T r oubleshooting Remedy Cause T rouble Wr ong sequence of phases Geareducer bearings Gears Loose bolts and cap screws Unbalanced drive shaft or worn cou- plings Fan W orn Geareducer bearings Unbal.
24 The tower has been designed to provide a safe working environment while either operating or shut down. The ultimate r esponsibility for safety r ests with the Operator and Owner . When flow to the tower is shut of f or when portions of the tower requir e maintenance, temporary safety barricades may be required around openings.
25 Inspection and Maintenance Schedule Fan Motor Drive Shaft and Guards Geareducer Drift Eliminators Fill Cold W ater Basin Hot W ater System W ater Make-up System Suction Screen Control V alves or Ga.
26 Inspection Checklist Date Inspected Inspected By Owner Location Owner's Tower Designation Tower Manufacturer Model No. Serial No. Process Served by Tower Operation: Continuous ❏ Intermittent ❏ Seasonal ❏ Design Conditions GPM HW °F CW °F WB °F Cell No.
27 Inspection Checklist Condition: 1—Good 2—Keep an eye on it 3—Needs immediate attention Mechanical Equipment 1 2 3 Comments Speed Reducer Type Belt ❏ Gear ❏ Direct Drive ❏ Belt Drive Uni.
Manual 95-1356A / 7401 W 129 Street // Overland Park, KS USA 66213 // +1 913 664 7400 // spxcooling@ct.spx.com // www .spxcooling.com / In the interest of technological progress, all products are subject to design and/or material change without notice .
An important point after buying a device SPX Cooling Technologies 800 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought SPX Cooling Technologies 800 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data SPX Cooling Technologies 800 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, SPX Cooling Technologies 800 you will learn all the available features of the product, as well as information on its operation. The information that you get SPX Cooling Technologies 800 will certainly help you make a decision on the purchase.
If you already are a holder of SPX Cooling Technologies 800, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime SPX Cooling Technologies 800.
However, one of the most important roles played by the user manual is to help in solving problems with SPX Cooling Technologies 800. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device SPX Cooling Technologies 800 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
