SPX Cooling Technologies Marley Aquatower User's Manual
Contents
1. The thermoformed 4mm thick PVC fill sheets withstand hot water temperatures as high as 52 C Fill sheets are immune to biological and corrosive decay and their flame spread rating is less than 25 per ASTM E 84 Galvanized structural tubes support and stabilize the fill They also hold the bottom of the fill sheets above the cold water basin floor to simplify basin cleaning Removable 25 x 25 mesh galvanized air inlet screens keep larger airborne trash out of the collection basin and fill area MX Fill E Cold Water Collection Basin The Aquatowers collection basin reduces operating weight simplifies basin cleaning and assures proper outflow Water flows from the elevated area under the fill into the basin s rear depressed section where side suction piping connects A bottom outlet is also available for gravity flow applications Standard equipment on each tower basin includes a screened suction connection a threaded overflow connection a threaded and plugged drain connection and a float operated make up valve Models 492A through 496B also include a bottom outlet conforming to flat flange specification A blank cover plate is provided to seal the outlet connection not used Construction And Components E Mechanical Equipment Belt driven propeller fans insure design airflow at minimum power Fans are supported by an oil lubricated tapered roller bearing assembly with remote oil reservoir For ease of maintena2. Marley Aquatower Cooling Tower SP COOLING TECHNOLOGIES The Aquatower Advantage Proven Performance CTI Certified Plus SPX stands by its responsibility for reliable thermal performance We designed it We rate it We guarantee it Induced Draft Design Save on fan power The fan will operate in a warm atmosphere even in winter so you ll never have to work on frozen mechanical equipment Crossflow Design Save on pump power because you only pay to move the water to the top of the tower Gravity does the rest The mechanical equipment and water distribution system are out where you can easily maintain them All Season Reliability Aquatowers perform as specified in the heat of summer They respond well to energy management techniques in the spring and fall and with appropriate fan controls they can operate virtually ice free in the dead of winter Plus they offer simple maintenance all year long Proven Corrosion Protection Thousands of users over more than 40 years confirm the value of heavy galvanizing And Marley s Z 600 is the most effective galvanizing used in the industry QUA Gy D PVC Film Fill with Integral Drift Eliminators and Louvers If you ve ever had to replace deteriorated eliminators or louvers you ll appreciate this advantage Now those components are molded right in the PVC fill sheets Integral honeycomb louvers keep the circulating water inside your tower and off your roof Sel
3. 45 gr wF 492A 22 1206 1543 2248 432 241 1219 203 1956 75 4 4 M note 3 492B 28 1206 1543 2248 432 241 1219 203 1956 1 5 4 4 M 493A 36 1816 1549 2248 432 241 1524 203 1956 1 5 4 4 M note 3 493B 42 1816 1549 2248 432 241 1524 203 1956 2 4 4 M 494A 51 1816 1972 2743 608 292 1829 3251 235 2403 1 5 6 6 MC 494B 57 1816 1972 2743 608 292 1829 3251 235 2403 2 2 6 6 MC 494C 68 1816 1972 2743 608 292 1929 3251 235 2403 3 7 6 6 MC 495A 80 2426 1975 2743 608 292 2134 3251 235 2403 3 7 6 6 MC 495B 91 2426 1975 2743 608 292 2134 3251 235 2403 5 5 6 6 MC 496A 111 3035 1984 2953 589 292 2743 3345 235 2610 3 7 e 6 MC 496B 126 3035 1984 2953 589 292 2743 3345 235 2610 5 5 6 6 MC Nominal tons are based upon 35 C HW 29 5 C CW 25 5 C WB and 68 m hr per ton The Marley UPDATE web based selection software provides Aquatower model recommendations based on specific design requirements Minimum clearance for adequate air supply Consult your Marley sales representative or your local distributor if this clearance is impractical for your job Vertical discharge hood is for applications in restrictive enclosures or other locations where horizontal discharge is not desirable CTI Certification does not apply when this option is selected Available only on models 494A and larger Ook O ON Motors are 400 volt 3 phase TEFC Motor belt and belt guard ship uninstalled Installation by others Outl
4. End 305 x 330 x 914 7 85 6 1278 674 Collection Basin Floor 76 x 762x 813 11 18 6 43 6 689 490A 490B Front Panel 51x914x112 10 POS 43 8 61 8 727 Casing Panel 51x102x132 20 495B 61 5 116 5 829 Distribution Basin 203 x 406 x 813 8 116 7 173 3 912 Collection Basin End 356 x 406 x 122 11 oeste 2 Collection Basin Floor 76x914x112 jl 496A GROS 220 wer Front Panel 51x 122x173 24 496B B5J1 1112 8 1026 Casing Panel 51 x 660 x 1600 16 Tai aay 1211 Distribution Basin 203x406x112 11 Collection Basin End 356 x 406 x 183 17 Volumes shown are maximums for the flowrate ranges indicated Collection Basin Floor 76 x 914 x 1727 26 Actual volumes will usually be less Contact your local Marley sales ee Front Panel 51x 940x183 16 representative for more specific information Casing 51 x 660 x 1600 16 Distribution 203 x 406 x 173 17 i 3 BoHomigutedMaximumimi hr Collection Basin End 457 x 457 x 1829 22 Tower Outlet Diameter Collection Basin Floor 102 x 864 x 1727 26 Model 2 6 8 10 494A Front Panel 51x1117x 1829 19 492A 492B 27 51 51 na e Casing Panel 51 x 1016 x 1930 29 493A 493B 27 61 79 na Distribution Basin 203 x 711 x 1727 24 494a 494B 494C 32 70 79 142 Optional Discharge Side 51x1041x1956 17 495A 495B 32 70 79 193 Optional Discharge Floor 229 x 1143 x 1727 21 496A 496B 32 70 79 193 Collection Basin End 457 x 457 x 2438 29 Collection Basin Floor 102x864 x 2338 34 j 5 i Front Panel 51x1118x2438 26 Maximum m hr applies to both
5. easily remove any debris from the upper basin or nozzles while the tower is in operation Heavy mill galvanizing on all steel components prevents base metal corrosion You won t have to worry about paint chips clogging your strainers and nozzles because there is no paint to flake off Heavy galvanizing also protects much better than paint Above all the Aquatower is readily available You won t have to wait around or accept second best when you need a cooling tower We maintain an impressive stock of completed towers at our own plants A growing number of local distributors can draw from that stock Contact your local distributor or Marley representative They ll be glad to help you choose the proper model for your needs They can also help you with your layout and piping You ll enjoy single source responsibility and reliability because we design and manufacture virtually all major cooling tower components All Marley components are designed and selected to be a part of an integrated system For example the spray pattern from nozzles and the pressure drop through drift eliminators both affect a fill s heat transfer capacity So we include that impact in our thermal analysis Drift eliminators must be effective at the air velocities where fill is most efficient So we ve carefully designed both components to work together efficiently How many other cooling tower companies can offer you this assurance They may use Brand A
6. Assembly hardware is also galvanized Freeze Prevention When the ambient air temperature falls below O C the water in a cooling tower can freeze Marley Technical Report 1tH 003 Operating Cooling Towers in Freezing Weather describes how to prevent freezing during operation Ask your Marley sales representative for a copy or download from our website Water collects in the cold water basin during shutdowns and may freeze solid You can prevent freezing by adding heat to the water left in the tower Or you can drain the tower and all exposed piping at shutdown E Electric Basin Heaters Provide an electric immersion heater for each cell of the tower to prevent freezing of water in the collection basin during periods of shutdown The rod type heater is installed in the side of the cold water basin Each heater will include an integral thermostat set point nominally 4 C but adjustable to suit local operating requirements Any exposed piping that is still filled with water at shutdown including the makeup water line should be electrically traced and insulated by others E Indoor Tank Method In this type of system water flows from an indoor tank through the load system and back to the tower where it is cooled The cooled water flows by gravity from the tower to the tank located in a heated space At shutdown all exposed water drains into the tank where it is safe from freezing The table on page 9 lists ty
7. actory Water shall enter the basin through a removable wave suppressor splash box The basin shall be no less than 162mm deep to provide adequate freeboard against overflow and splash out Removable and replaceable polypropylene nozzles installed in the floor of the basin shall provide full coverage of the fill by gravity flow Nozzles must all have the same orifice size and be spaced symmetrically in both longitudinal and transverse directions Cold Water Basin and Accessories The cold water basin shall 11 be factory sealed For maximum installation flexibility basin accessories shall include both a side suction connection and a hole and bolt circle in the basin floor suitable for gravity flow Both connections shall include a debris screen and anti cavitation device A factory installed float operated mechanical makeup valve shall be included having a diameter inlet connection SP COOLING TECHNOLOGIES SPX COOLING TECHNOLOGIES UK LTD GREGORY S BANK WORCESTER WR3 8AB UNITED KINGDOM 44 0 1905 720 200 info uk spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2008 SPX Cooling Technologies uk_AQ 08
8. ect Your Aquatower on Our Website The Marley UPDATE web based selection software available at www spxcooling com provides Aquatower model recommendations based on your specific design requirements Simple Flexible Installation Just mount the motor belts and belt guard install the outlet connection that suits your needs both side suction and bottom outlet are provided complete with screens and adjust the float valve Attach air inlet screens on models 494A and larger and your Aquatower is ready for operation The Marley Difference Today s Aquatower may be the most space energy efficient cooling tower available Your needs have dictated constant technological improvement Thousands of Aquatower users enjoy the benefits of eight major redesigns and dozens of minor improvements in the past 40 years For example PVC film fill enables the Aquatower to reject more heat per unit size We also put the air inlet louvers and drift eliminators right on the fill sheets This new arrangement saves you fanpower by improving airflow through the tower The Aquatower is a maintenance delight You ll appreciate the way the Aquatower simplifies maintenance No hidden spray systems tiny nozzles or enclosed basins here You can easily replace and align V belts from outside the tower You won t have the chore and expense that goes with high power blower fan towers All primary components of the Aquatower are open to view You can
9. et sizes shown are side outlets All models except 490A and 490B have connections for both side and bottom outlet Install the desired connection and seal the unused opening with the cover plate provided Pump suction should use side outlet See page 9 for size and flow capacities of bottom outlets Overflow is a 2 F connecton located in side of collection basin Drain is a 2 F connection located in collection basin floor Makeup valve connection is 3 4 M located in tower side Support 4 L 4 L 7 25mm 4 F 44 25mm 25mm 44 F 4 25mm ANCHOR ANCHOR 6 ANCHOR ANCHOR 6 mH BOLT BOLT mH BOLT BOLT E d vara a E 9 T te n te n 99 99 o o z z lt lt TOWER COLLECTION BASIN wG He w c 16mm DIAMETER HOLES A 16mm DIAMETER HOLES x x 2 TOWER 9g COLLECTION BASIN 54 zo 1 lt 8 l z9 ys a 7 _ __ ____ z LH AIR INLET FACE LH AIR INLET FACE SUPPORTING STEEL PLAN SUPPORTING STEEL PLAN OPTION ONE OPTION TWO TOWER TOWER COLLECTION COLLECTION 51 MIN BEARING WIDTH BASIN J RE BASIN ii AT EACH ANCHOR BOLT j NORMAL normaL GAUGE GAUGE SUPPORT SUPPORT BY OTHERS BY OTHERS SECTION A VIEW B Dimensions Maxi Maximun Wind Load kg Tower Shipping Weight re Operating Load Model kg Operating at Anchor Max Vertical Max Horizontal L w F G H kg kg Reaction at Reaction at Anchor Ancho
10. m provides Aquatower model recommendations based on customer s specific design requirements Construction And Components Water Distribution System Warm water flows through external piping not included with the tower into a splash box chamber at the top of the Aquatower A splash box prevents the incoming water from spilling out of the basin and helps provide uniform water distribution Water then flows by gravity from the basin through nozzles to the fill 4 eerie Eliminator air seal removed showing distribution area above fill Hot water distribution basin covers are provided as standard equipment to keep the distribution basin free from airborne debris and to reduce the likelihood of biological growth All Aquatowers use Marley Spiral Target nozzles These inert polypropylene nozzles are evenly spaced thoughout the distribution basin to assure uniform water distribution over all portions of the fill Their large openings resist clogging Nozzles are easy to remove and replace if you ever want to change the design water flow rate Spiral target distribution nozzle E Fill Louvers Drift Eliminators Fill sheets include integral louvers and drift eliminators designed to minimize resistance to airflow This patented arrangement prevents water from escaping the fill sheets assuring proper heat transfer throughout wide variations in airflow Users find this fill operates ice free even in extremely cold weather
11. nce all drive components are accessible from outside the tower Fan and fan guard Guard is easily removed for access to fan and drive belts Fan drive motors are TEFC designed specifically for cooling tower use Kilowatts and electrical characteristics appear in the table on page 4 Other types of motors are available A Caution The cooling tower must be located at such distance and direction to avoid the possibility of contaminated tower discharge air being drawn into building fresh air intake ducts The purchaser should obtain the services of a Licensed Professional Engineer or Registered Architect to certify that the location of the tower is in compliance with applicable air pollution fire and clean air codes Fan drive motor showing adjustable base and belt guard B Hoisting and Handling Hoisting instructions on each tower explains how to use a spreader bar and slings beneath the cold water basin floor to hoist the Aquatower The tower s design also allows easy handling with a forklift E Safety Standard Aquatower safety features include fan guards and belt guards Fan guards consist of welded heavy gauge steel wire hoops and spokes hot dip galvanized after fabrication The galvanized steel belt guard encloses both belts and pulleys Guards are easily removed for servicing E Construction and Finish Aquatowers offer the corrosion protection of Z 600 galvanized providing long term protection for the steel
12. nd larger It provides vertical discharge of the air leaving the tower Hoods are galvanized steel They ship separately for installation by others A large ac cess door provides entry to the fan and mechanical equipment For use in restrictive enclosures or other site situations where horizontal discharge is not desirable CTI Certification does not apply when this option is selected 10 Factory installed control center in IP55 IEC enclosure mounted on tower casing Complete with thermostat con troller for single or two speed motors to maintain chosen cold water temperature Specifications Base Furnish and install an induced draft crossflow factory assembled steel cooling tower of 1 cell s as shown on plans Tower shall be similar and equal in all respects to Marley Series 4900 Aquatower Model Tower must be warranted by the manufacturer for one year from date of shipment Performance Tower shall cool m hrofwaterfrom C to C ata design entering air wet bulb temperature of ____ C and its thermal rating shall be certified by the Cooling Technology Institute Construction Structural components of the tower including the cold water basin framework mechanical equipment supports casing hot water basin and fan cylinder shall be fabricated of heavy gauge steel protected against corrosion by Z 600 galvanizing per BS EN 10327 2004 All components subjected to factory welding shall be hot dip galvani
13. nozzles with Brand B fill and Brand C drift eliminators When they all come together the whole may be less than the sum of the parts Our total system approach assures that all the parts work together to provide you the greatest total performance And because we design specifically for cooling towers all our components will provide many years of service with minimal maintenance Every Aquatower cooling tower carries a full one year warranty The Aquatower you buy from us will work on your job or we ll make it right Your warranty includes thermal performance and every component of the tower The SPX Cooling Technologies warranty is your assurance of performance for a full year The Aquatower has inspired many imitators Only SPX Cooling Technologies can offer you the original Schematic D W TOWER INLET A MOTOR VERTICAL DER DISCHARGE OPTION NOTE 3 A P4 N N zd a IN Z a DOWN gf C pU WR Z S a 4 USE FOR UZ STATIC LIFT gr m we E Z 2 zar o pd lu d S 10 et TOWER COLLECTION B BASIN TOWER OUTLET BOTTOM OUTLET Dimensions Being Tower Nominal Tons Motor Connection Model note1 kW Outlet L w H A B C note 2 D E S Inlet note 6 490A 8 902 1292 1610 402 175 610 1318 25 gr 25F note 3 note 6 490B 10 902 1292 1610 402 175 610 1318
14. pical drain down capacities for all Aquatower models Although we do not produce tanks many of our representatives offer tanks supplied by reputable manufacturers The amount of water needed to successfully operate the system depends on the tower size flow and the volume of water contained in the piping system to and from the tower You must select a tank large enough to contain those combined volumes plus a level sufficient to maintain a flooded suction on your pump Control makeup water according to the level where the tank stabilizes during operation You should always use a bottom outlet for this type of piping system The following table lists the flow capacities for bottom outlets Basin Heater Selection Foe 12 C Ambient 25 C Ambient Model Tank Heater mao Tank Heater Campenni Heater Heater 490A 2 kW 3 kW 2 kW 3 kW 490B 2 kW 3 kW 2 kW 3 kW 492A 2 kW 3 kW 2 kW 3 kW 492B 2 kW 3 kW 2 kW 3 kW 493A 2 kW 3 kW 3 kW 3 kW 493B 2 kW 3 kW 3 kW 3 kW 494A 2 kW 3 kW 4 kW 3 kW 494B 2 kW 3 kW 4 kW 3 kW 494C 2 kW 3 kW 4 kW 3 kW 495A 3 kW 3 kW 6 kw 4 5 kw 495B 3 kW 3 kW 6 kw 4 5 kw 496A 3 kW 4 5 kw 6 kw 6 kW 496B 3 kW 4 5 kw 6 kw 6 kW 1 Required kw is the amount of heat needed to maintain 4 5 C basin water temperature at the indicated ambient air temperature 2 Tank heaters shown are 220 volts single phase 3 Component heaters shown are 400 volts three phase Op
15. pump and gravity flow piping sys 495A tems The outlet piping on gravity flow systems must have sufficient 495B Casi 51 x 10161x 1930 29 vertical drop to overcome all other head losses in the system Distribution Basin 208 x 711 x 2337 32 Bottom outlet is not available on Models 490A and 490B Gm Bacar Site 51x 1041x1956 17 Optional Discharge Floor 229 x 1143 x 1600 19 Collection Basin End 457 x 457 x 3048 36 Collection Basin Floor 102 x 864 x 2946 43 Front Panel 51 x 1168 x 3048 33 496A Note For economical transportation Aquatowers are normally 496B edna emd BOIS eley Sm j Distribution Basin 203 x 711 x 2946 40 packaged unassembled when shipped from the UK by sea or air i Optional Discharge Side 51x 1143 x 1956 17 freight Optional Discharge Floor 229 x 1143 x 1956 25 Options Option Field Assembly Description Option Stainless Steel Construction Where unique space restrictions or rigging conditions demand Aquatowers can be shipped ready for field assembly by others Complete step by step assembly instructions are provided Description All Aquatower models are available with stainless steel structure Or you can choose a galvanized tower with a stainless steel cold water collection basin Your Marley sales representative can help you choose the amount of corrosion resistance necessary for your installation Control System Vertical Discharge Hood This option is available on Models 494A a
16. r 490A 490B 902 1019 851 915 52 198 343 84 82 52 492A 492B 1206 1260 1156 1067 97 337 633 158 161 95 493A 493B 1816 1206 1765 1067 97 445 905 226 238 129 494A 49B 1816 1680 1765 1524 78 634 1337 334 252 161 495A 495B 2426 1680 2375 1524 78 797 1294 437 338 213 496A 496B 3035 1680 2985 1524 78 951 2155 539 497 290 Models with Vertical Discharge Hood Option 494A 494C 1816 1680 1765 1524 78 816 1519 380 316 284 495A 495B 2426 1680 2375 1524 78 968 1920 480 338 234 496A 496B 3035 1680 2985 1524 78 1178 2382 596 497 290 1 Use this bulletin for preliminary layouts only Obtain current draw ings from your Marley sales representative or your local distribu tor Use this data for preliminary layouts only 2 Purchaser to provide tower supports complete with holes and bolts Obtain current drawing from your Marley sales for anchorage All supports must be framed flush and level at top representative Maximum deflection to be 1 360th of span not to exceed 13mm 3 Maximum weight occurs with basin full to overflow level at shutdown The Marley UPDATE web based selection software Actual operating weight varies with flowrate and piping scheme 4 Wind loads are based on 1 4 kPa and are additive to operating loads Reactions due to wind loads exceed those resulting from Seismic loads based on the 1997 UBC code Zone 4 and an Impor tance Factor of 1 00 per Section 1634 Towers Not on a Building available at spxcooling co
17. tions or special heater selections may add several weeks to delivery 4 Heaters do not operate continuously Heaters cycle on and off automatically as basin water temperature dictates 5 Contact your Marley sales representative for selections appropriate for other ambient conditions than those shown here Field Assembly B Field Assembly Drain Down Capacity Tower Model Range of Tower Design m hr jx ii ae j If you choose to assemble your Aquatower at the job site 34 59 106 i your Aquatower will be shipped unassembled with complete ARDA 6 2 11 6 114 assembly instructions 490B 11 8 19 3 125 i 19 5 34 7 136 The following table shows the sizes and weights of the At o na tes largest Aquatower components for each model You can 492A er 208 use this information to plan your rigging and transportation 492B 21 843 227 needs 34 5 47 9 246 75 188 291 Unassembled tower shipment may add 3 to 5 weeks to AREY 19 32 7 318 normal lead times Your Marley sales representative will be gese 32 9 54 356 glad to help you plan for your unique needs 54 2 74 5 382 13 6 32 507 Component Sizes and Weights 494A 32 3 51 5 549 494B Tower Model Component Size mm Weight kg 494C 51 7 85 4 613 Collection Basin
18. zed after fabrication per BS EN 150 1461 1999 Cold galvanizing is not acceptable Motor Motor s shall be KW Totally Enclosed specially insulated for cooling tower duty Speed and electrical characteristics shall be 1500 or 1500 750 RPM single winding phase hertz volts The motor must be located out of the saturated discharge air stream Mechanical Equipment Fan s shall be adjustable pitch propeller type Fan shall be driven through V belt s with a minimum service factor of 1 5 based on full motor kW and protected with a belt guard The fan and fan pulley shall be supported by oil lubricated tapered roller bearings in a cast iron housing with externally accessible remote oil reservoir for easy maintenance Fill Louvers and Drift Eliminator Fill shall be film type thermoformed PVC with louvers and drift eliminator formed as part of each fill sheet Fill shall be suspended from hot dip galvanized structural tubing supported from the upper tower structure and shall be elevated above the floor of the cold water basin to facilitate cleaning Air inlet faces of the tower shall be free of water splash out Guaranteed drift losses shall not exceed 0 005 of the design flow rate Hot Water Distribution System An open basin above the fill bank shall receive hot water piped to each cell of the tower The basins shall be equipped with removable covers to keep out debris This basin shall be installed and sealed at the f
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