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Lenntech

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cooling tower parts reference guide


O E M PA R T S F O R M A R L E Y C O O L I N G TOW E R S A N D F L U I D C O O L E R S
Brands

Lenntech bv
Current Brands Legacy Brands

Marley Balcke
Recold Ceramic
Hamon Dry Cooling Custodis-Ecodyne
Davenport
Head Wrightson
Heenan Coolers
Pritchard
Zurn Balcke-Drr

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Contents

Water Distribution Drift Eliminators...............................................................................................32


Crossflow Nozzles......................................................................................5 Fans and Drives
Counterflow Nozzles..................................................................................7 Single Reduction Geareducer.................................................................34
Counterflow Distribution System...........................................................9 Double Reduction Geareducer...............................................................36
Legacy Nozzles............................................................................................10 Geareducer Oil.............................................................................................38
HC Crossflow Valves.................................................................................11 Geareducer Sound Levels........................................................................39
Make-Up Float Valves................................................................................12 Sprag Clutch Backstop.............................................................................40
Fiberglass Hot Water Basin.....................................................................13 Reflex RTM Fan Cylinder..........................................................................41
Counterflow Film Fill H3 Fan.............................................................................................................42
DF254 Fill......................................................................................................14 X7 Fan.............................................................................................................43
DF381 Fill......................................................................................................15 Ultra Quiet Fan.............................................................................................44
MVC20 Fill.....................................................................................................16 HP7i Fan.........................................................................................................45
MC120 Fill.....................................................................................................17 HP7000 Fan.................................................................................................46
FB20 Fill.........................................................................................................18 Series 400 Driveshaft................................................................................47
Cleanflow (AAFNCS) Fill.........................................................................19 Driveshaft Specis.........................................................................................48
MC75 Film Fill..............................................................................................20 Comp-DS Driveshaft..................................................................................49
MCR Film Fill.................................................................................................21 Close Coupling............................................................................................50
Crossflow Film Fill Cooling Tower Motors...............................................................................51
MX Fill..............................................................................................................22 Controls
MBX Fill...........................................................................................................23 Can-Do Fan Motor Control Panel.........................................................52
M106 Film Fill...............................................................................................24 Variable Speed Drive..................................................................................53
Crossflow Splash Fill Basin Heaters...............................................................................................54
Alpha Fill.........................................................................................................25 Multicell Motor Sequence.........................................................................55
Mesa Fill..........................................................................................................26 Water Level Control....................................................................................56
Ladder Fill.......................................................................................................27 M-5 Vibration Switch..................................................................................58
Omega Fill......................................................................................................28 Rental Cooling Towers.................................................................................59
Counterflow Splash Fill Aftermarket Services/Reconstruction.............................................60
Permagrid Fill.................................................................................................29 Cooling Tower Fundamentals.................................................................61
TrickleBloc Fill...............................................................................................30 Maintenance Schedule................................................................................62
GridLoc Splash-Fill Support.....................................................................31

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Parts Guide

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Water Distribution Nozzles

SpiralTarget Crossflow Nozzles

Snap-on
n Patented design Orifice
n The standard in crossflow nozzle
design
n Available in 3 lengths to
fit virtually every structural
configuration
n 13 orifice diameters available
for optimum performance
adjustments
n No moving parts
n Wide range of adjustments in
water flow rate

The Marley SpiralTarget nozzle is an The Spiral Target nozzle is available


injection molded polypropylene unit in three lengths. The 2.625" nozzle is
consisting of two partsthe main body used on wood, steel, and fiberglass Maintenance Know How
with integral target diffuser and a snap- cooling towers where basin support
on insert or orifice cap. structure does not obstruct the release
of water. The 4.875" nozzle is used on When cleaning basins
The orifice cap is available in 13 larger industrial wood and concrete avoid using a round dowel
diameters ranging from .362" through cooling towers and on applications to clean nozzles. In most
1.099". This amount of flexibility allows where clogging might be a concern. cases the daisy at the
for a wide range of adjustment in water The 6.875" nozzle is used on towers
flow rates and basin water levels.
end of the nozzle will be
where the release of the water has knocked off which will
to clear obstructions within the tower destroy the distribution
structure. performance of the nozzle.
In every application the target portion Best practice is to remove
of the nozzle should be located at the the nozzle for cleaning.
correct distance above the top of the
cooling tower fill to obtain maximum
water distribution over the fill area.

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Water Distribution Nozzles

NX Crossflow Nozzle

n A truly clog-resistant crossflow


nozzle
n Nozzles are spaced on nominal
2'-0" centers
n 1.875" and 2.5" orifice diameters
available

The Marley NX nozzle is used only The NX nozzle is the ideal solution
on splash-fill crossflow towers where for overflowing basin problems due to
objects in the water supply create clogged nozzles in splash-fill, industrial
blockage in smaller nozzles. crossflow cooling towers.

NX nozzles are injection-molded,


high-impact black polypropylene. Each
nozzle is a single assembly with no
moving parts.

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Water Distribution Nozzles

NS7 Counterflow Nozzles

n Available in two sizes


n Easily removed for cleaning
n No moving parts
n Wide range of adjustments in
water flow rate

The Marley NS7 counterflow nozzle


is an injection molded polypropylene
unit consisting of two partsthe main
assembly with integral turbulator
and an EDPM rubber grommet. NS7
nozzles are designed to economically
NS7 Nozzle with Turbulator installed provide desired thermal performance
at low spray heights typical of factory
assembled cooling towers

NS7 nozzles are produced in two sizes.


The NS7-150 has a nominal insert OD
of 112" and the NS7-200 has a nominal
insert OD of 2". Recommended spray
height above the fill is between 7" and NS7 EDPM Grommet
15". NS7 grommets are made from
EDPM rubber with a durometer rating
between 45 and 50.

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Water Distribution Nozzles

NS5 and NS6 Counterflow Nozzles

n Patented design
n Easy to installno tools required
to install into adaptor pipes
n Clog resistant
n No moving parts
n Self draining

Marley NS5A Nozzle


Cooling Tower Know How

Q Why are there


two styles of
counterflow NS nozzles?

A Typically t he N S5
is used in most
locations. The NS6 will
handle higher GPMs and
is used in areas where
obstructions limit the use
of NS5 nozzles. Marley NS6 Nozzle

The orifice sizes (1"-3.5") of Marley Full cone distribution pattern assures
NS nozzles are large enough that uniform water distribution for all film
many competitive nozzles will actually fills. Minimal spray overlap is required,
fit inside a Marley nozzle. Marley providing uniform water distribution
counterflow nozzles have no internal even near spray boundaries. Marley NS
parts or narrow passageways. The counterflow nozzles develop uniform
attached diffusion ring will not retain water distribution over a wide range of
even fibrous debris. operating water pressures.

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Water Distribution Nozzles

Counterflow Distribution Assembly

n Self Draining
n Economical Installation
n Economical Operation
n Easy disassembly and
Reassembly
n Larger pipe spacing
n Easily adapts to a variety of
nozzle spacings

Spray Arm Extender Adapter

Assembly of the entire system The nozzle outlet is always the lowest
requires only a few simple hand tools. elevation in the distribution system. This
All connections are positiveyet the arrangement is self draining when the
design allows repeated disassembly supply water is shut off. There are no
and reassembly. special valves to open or close.

Nozzles are installed in pairseach The nozzle assembly is attached to


supply pipe serving multiple pairs of the header/lateral using a unique
nozzles. Multiple nozzle pairs per supply design EPDM grommet that is inserted
EPDM Grommet pipe mean larger pipe spacing and, into the pipethe entire assembly is
therefore, lower installed cost than attached with stainless steel strapping.
most other systems. The adaptor allows
nozzle spacing on 3'-0" centers.

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Water Distribution Legacy Nozzles

Legacy Product Nozzles

Cooling Tower Know How

In most cases it makes


sense to replace older
design nozzles with
modern current designs.

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Water Distribution Valves

HC Crossflow Valves

The HC Valve has inspired many


imitatorsonly Marley can offer
you the original:
n Cast iron body
n Cast iron operating bar
n Cast iron locking bar
n Stainless steel stem
n Neoprene joint gasket and set for
floating valve disc
n Economical compared to a
separate valve and elbow
Standard HC Valve

Capacity GPM
Valve Size
@ 5 FPS @10 FPS
6" Diameter 425 850
8" Diameter 750 1500
10" Diameter 1200 2400
12" Diameter 1750 3500
14" Diameter 2350 4700

Flanged HC Valve 16" Diameter 3000 6000


18" Diameter 4000 8000
20" Diameter 5000 10000

HC valve body proportions and the The valve closure disc has a machined The greatly simplified design ensures
arrangement of internal parts provide lip which closes on a heavy neoprene long trouble-free operation with no
a low discharge velocity and confine gasket, avoiding maintenance of costly repairs or maintenance.
splash, resulting in low pressure drop. expensive metal seats. In a shut-off
position, the stem and yoke are external
to the water, eliminating the necessity
of valve stem packing.

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Water Distribution Valves

Water Make-Up Float Valves

n Heavy duty red brass body


construction
n Buna rubber seal disc assures
positive shut-off
n Free flow outlet
n Fully adjustable
n Available from 3/8" through 2"
diameters
n Floats available in polypropylene
or copper

Designed specifically for cooling tower


duty, Marley make-up water float valves
provide long life with little maintenance.
Typically, valves are available in
complete kits which include valve, float
arm and float in kits to fit a specific
application.

When installed some trial and error


adjustment of the float valve may be
required to balance the makeup water
with tower operation. Ideally, the float Maintenance Know How
valve setting will be such that no water
is wasted through the overflow at
pump shutdown. However, the water Maintain inlet water
level after pump start-up must be pressure at or below 50
deep enough to assure positive pump psig to ensure long valve
suction. seal life.

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Water Distribution FRP Basin

DuraLast FRP Hot Water Basin

Marley DuraLast FRP Basins offer


many advantages compared to
wood basins:
n Corrosion resistant
n Extremely stable
n Fire resistant
n Easy installationideal
replacement for wood basins
n High strength
n Light Weight
n No preservative treatment
chemicals
n Fasteners hidden by successive
interlocking panels

Your hot water basin can be a rugged,


light weight basin of Marley DuraLast
fiberglass composite material.

Pultruded fiberglass composite is an


ideal material for the wet, corrosive
cooling tower environment. Its strong
and lightweight. Yet, it will not corrode
from chemical exposure or moisture,
and it resists deterioration from
sunlight.

Our experience with composites


dates back to the early 1950s. Now,
the pultrusion process produces a
product with definite, predictable
and measurable performance.
Extensive laboratory, university and
field testing for long-term effects of
deflection, bending, shear, buckling and
temperature has enabled us to simulate
and evaluate DuraLasts performance.

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Fill Film Fill

DF254 Counterflow Film Fill

n High-performance low-clog
design
n Bottom supported
n Requires minimum number of
supports
n Log configuration

Marley DF254 is a film fill system Texturing creates thermal capability


Cooling Tower Know How
designed to significantly reduce the risk improvement with little effect on fouling.
of biological fouling without sacrificing DF254 offers low pressure drop in an

Q
high-performance heat transfer. aerodynamic, durable design.
What is the
DF254 is a bottom supported low-clog DF254 is easily adapted to any towers difference
log fill configuration. Open, angular configuration. To accommodate for between DF254 and
cross-corrugations allow debris and various fill heights and/or desired DF381?
biological growth foulant to pass, while duties, DF254 may be installed

A
providing maximum surface area and in multiple layers. DF254 fill is DF254 is a higher
turbulence to develop efficient heat thermoformed from .020 thick, UV performing low-
transfer. inhibited, chemically-resistant PVC clog fill. DF381 should
(polyvinyl chloride). The material is
be used where there is a
extruded and manufactured to rigid
greater risk of clogging or
specifications before forming, at one of
fouling.
Marleys plastics facility.

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Fill Film Fill

DF381 Counterflow Film Fill

n High-performance low-clog
design
n Bottom supported
n Requires minimum number of
supports
n Log configuration

Marley DF381 is a film fill system DF381 is easily adapted to any towers
Cooling Tower Know How
designed to significantly reduce the risk configuration. To accommodate for
of biological fouling without sacrificing various fill heights and/or desired
high-performance heat transfer. duties, DF381 may be installed
Continuous water
in multiple layers. DF381 fill is
DF381 is a bottom supported low-clog thermoformed from .020 thick, UV
temperatures for most
log fill configuration. Open, angular inhibited, chemically-resistant PVC
PVC Film Fills should
cross-corrugations allow debris and (polyvinyl chloride). The material is
never exceed 125F.
biological growth foulant to pass, while extruded and manufactured to rigid Special high temperature
providing maximum surface area and specifications before forming, at one of PVC formulations and
turbulence to develop efficient heat Marley's plastics facility. thicknesses are available
transfer. Texturing creates thermal for water temperatures as
capability improvement with little effect In service now for over ten years at high as 165F.
on fouling. DF381 offers low pressure numerous installations throughout
drop in an aerodynamic, durable design. Europe, DF381 is now available
globally for any counterflow cooling
tower, regardless of a cooling tower's
age, design or manufacturer.

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Fill Film Fill

MVC20 Counterflow Film Fill

n High-performance low-clog
design
n Bottom supported
n Requires minimum number of
supports

Marley MVC20 anti-fouling film Marley MVC20 fill combines properties Each module consists of vertically
type fill consists of thermoformed related to a medias ability to allow channeled flat and corrugated surfaces,
corrugated sheets made of rigid substances to migrate through it, while which essentially avoids contact
polyvinyl chloride (PVC), impervious to maintaining thermal efficiencythis between the sheets, thus eliminating
decay, fungus and biological attack. The then allows for the use of film fill where water concentration. The horizontal
sheets are bonded to form modules fouling risks occur. corrugations and their location within
which can be dimensioned to fit any the sheet promote optimum mixing
application. of air and water. The flutes in
the MVC20 fill are vertically and
aerodynamically shaped resulting in a
reduction of pressure drop.

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Fill Film Fill

MC120 Counterflow Film Fill

n High-performance design
n Bottom supported
n Requires minimum number of
supports
n Log configuration
n Ideal replacement for Marley
MC47 counterflow fill

Marley MC120 is a high performance MC120 fill is thermoformed from


film fill system designed for factory- .015" thick, UV inhibited, chemically-
assembled counterflow towers offering resistant polyvinyl chloride (PVC). The
you several distinct advantages. flame spread rating is less than 25
per ASTM E-84 and is considered
Textured crossed corrugations provide self-extinguishing. The material is
the surface area and turbulence to extruded and manufactured to rigid
develop efficient heat transfer. The specifications before forming.
corrugations inherently establish
uniform fill sheet spacing at 0.45". Log packs are nominally 12" in air
travel height and 12" deep. Normal
pack length is 72" but packs are
available up to 120". Maximum air
travel height is 48".

Packs have a 12" staggered edge


on the air inlet side of the pack Staggered edge
that enhances performance and air
distribution.

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Fill Film Fill

FB20 Counterflow Film Fill

n Vertical-flute film fill


n Efficient thermal performance
n Low clog design
n Low maintenance
n Withstands foot traffic
n Resists erosion from water spray

Marleys FB20 clog-resistant film


Cooling Tower Know How
fill is constructed of fire-retardant
PVC sheets bonded to form blocks
of cooling media. The surface
Continuous water
microstructure facilitates air/water
mixing and increases the surface
temperatures for most
cooling area. The offset vertical flutes
PVC Film Fills should
provide directional changes in air
never exceed 125F.
and water flow to increase cooling Special high temperature
and promote thermal efficiency while PVC formulations and
substantially reducing the occurrence thicknesses are available
of fouling. for water temperatures as
high as 165F.

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Fill Film Fill

Cleanflow (AAFNCS) Counterflow Film Fill

n Vertical-flute film fill


n Low maintenance
n Low clog design
n Low pressure drop

Marleys Cleanflow anti-fouling film Cleanflow fill combines properties Each module consists of vertically
type fill consists of themoformed related to a medias ability to allow channeled flat and corrugated surfaces,
corrugated sheets made of rigid substances to migrate through it, while which essentially avoids contact
polyvinyl chloride (PVC), impervious to maintaining thermal efficiencythis between the sheets, thus eliminating
decay, fungus and biological attack. The then allows for the use of film fill where water concentration. The horizontal
sheets are bonded to form modules fouling risks occur. corrugations and their location
which can be dimensioned to fit any within the sheet promote optimum
application. mixing of air and water. The flutes in
the Cleanflow fill are vertically and
aerodynamically shaped resulting in a
reduction of pressure drop.

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Fill Film Fill

MC75 Counterflow Film Fill

n High Performance
n Hanging or bottom support
design
n Variable air-travel sizes
n Cross-corrugated design

Marley MC75 is a film fill system per ASTM E-84 and is considered The fill pack depth (air travel) is variable
designed for counterflow towers self-extinguishing. The material is to provide the proper heat transfer area
offering you several distinct advantages. extruded and manufactured to rigid within a single fill layer. If another layer
specifications before forming. of fill is necessary for situations where
Crossed corrugations provide the additional air travel is required, it will be
surface area and turbulence to develop Using Marley MC75 film fill in place of limited to only one. Limiting the number
efficient heat transfer. The corrugations existing splash type fill in counterflow of interfaces between packs minimizes
inherently establish uniform fill sheet towers usually means reduced fill restrictions that usually cause fill
spacing at 0.75. height, which translates into reduced clogging. MC75 counterflow fill can
pumping head. MC75 will also provide be hung from structural members
MC75 fill is thermoformed from greater cooling tower capacity, which or it can be bottom-supported in
.015 thick, UV inhibited, chemically- means your current performance level virtually all counterflow cooling towers,
resistant polyvinyl chloride (PVC). The will require less fan energy. regardless of a cooling towers age or
flame spread rating is less than 25
manufacturer.

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Fill Film Fill

MCR Counterflow Film Fill

n Vertical-flute film fill


n Hanging or bottom support
design
n Efficient thermal performance
n Low maintenance
n Low clog design

Marley MCR is a film fill system the number of restrictions where (fill height) is variable to provide the
designed to significantly reduce the risk biological growth begins. proper heat transfer area within a
of biological fouling while minimizing single fill layer. MCR counterflow fill
the loss of high-performance heat MCR fill is thermoformed from .015" can be hung from structural members
transfer. thick, chemically-resistant PVC or it can be bottom-supported in
(polyvinyl chloride). Material thicknesses virtually all counterflow cooling towers,
Open, offset vertical corrugations allow of .020" and thicker are also available. regardless of a cooling tower's age or
debris and biological growth foulant manufacturer.
to pass, while providing maximum MCR is easily adapted to any towers
surface area and turbulence to develop configuration. The fill pack depth
evaporative heat transfer. Smooth
surfaces without sharp intersections
maintain water velocities and reduce

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Fill Film Fill

MX Crossflow Film Fill

n High Performance
n Hanging fill design
n Integral louvers
n Integral triple-pass eliminators

Cooling Tower Know How

Always replace MX fill


with genuine Marley MX
fill in order to maintain
your FM approval rating.
Knock-off fill designs may
reduce performance and
void FM approval.

Marley MX Fill is available in MX75 with previous designs, these eliminators Louvers are also integrally molded
configuration and higher-performing reduce drift emissions from the tower within the fill sheets preventing water
MX625 configuration. MX is a hanging by a factor of ten or more! Less drift from escaping and assuring precise air
film type cooling tower fill which means tower owners save on water and distribution throughout wide variations
spreads the water into a thin film, water treatment chemical expenses. in airflow. Unlike towers equipped
flowing over large vertical surfaces, This fill virtually eliminates the nuisance with separate external louvers, this
promoting maximum exposure to air caused by drift spotting on adjacent fill operates virtually ice-free even in
flow. This type of fill provides much buildings and property. For additional extremely cold weather.
more water surface exposure per cubic savings, the drift eliminators discharge
foot than splash type fill. air directly toward the fan. Discharge MX fill is thermoformed from PVC with
air, traveling in the right direction when a flame spread rating less than 25 per
MX fill incorporates highly efficient it leaves the eliminators, translates to ASTM E-84 and is considered self-
cellular drift eliminators, integrally lower fan horsepower. extinguishing. Therefore, the risk of fire
molded within the fill sheets. Compared damage is minimal.

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Fill Film Fill

MBX Crossflow Film Fill

n High efficient replacement


crossflow film-fill
n Single piece, full height design
n Durable design adaptable to any
crossflow fill configuration
n Thermoformed from 20 mil
(.020") thick PVC

Marley MBX fill is a high performing, MBX fill packs are available in various
bottom supported PVC pack fill heights and air travels from 24" to
with integral louvers and drift 48" and can be installed in almost any
eliminators, specifically designed for crossflow cooling tower regardless of
the Aftermarket. This fill will make tower age or manufacturer. Retrofit
installation easier and faster, while kits including MBX fill packs, fiberglass
at the same time offering great supports, stainless steel hardware and
cooling efficiency without major tower installation instructions are available.
modifications.
MBX fill is manufactured from inert
MBX fill incorporates highly efficient material, thus ensuring a long operating
cellular drift eliminators, integrally life with minimal maintenance. The
molded within the fill sheets. These wide sheet spacing prevents clogging
eliminators may reduce drift emissions and the integral drift eliminators do not
from the tower by a factor of 10 or require extra frames or retainers.
more.
MBX is thermoformed from 20 mil
Louvers are also integrally molded (.020") thick PVC with a flame spread
within the fill sheets preventing water rating less than 25 per ASTM E-84
from escaping and ensuring precise air and is considered self-extinguishing.
distribution throughout wide variations Therefore, the risk of fire damage is
in airflow. minimal.

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Fill Film Fill

M106 Crossflow Film Fill

n High Performance
n Bottom supported fill design
n Integral triple-pass eliminators
n Available with or without
eliminators
n Easily installed as a replacement
fill in non-Marley products

Marley M106 is a film-type cooling


tower fill. Water flowing down the fill
sheets forms a thin film on the surface
of the sheets. This type of fill provides
much more water surface exposure per
cubic foot than does splash-type fill.

This fill offers greater cooling efficiency, treatment chemical costs. The nuisance M106 fill is impervious to rot, corrosion,
which translates to colder water from of spotting adjacent buildings and and decay. The wide sheet spacing
present systems without an increase property due to cooling tower drift is prevents clogging ensuring minimal
in fan horsepower. Or, this improved virtually eliminated. maintenance and long service life.
efficiency can be used to save
horsepower and produce the same cold Options include eliminators for both M106 is easy and inexpensive to install
water temperature. vertical and horizontal discharge cooling in almost all crossflow cooling towers. It
towers. Guiding the discharge air in the requires minimal structural modification
M106 fill is also available with highly right direction further increases savings because it is bottom supported. The
efficient drift eliminators molded in fan horsepower. integral drift eliminators dont need
right into the fill sheets. Compared extra frames or retainers. M106
with older designs, these eliminators M106 is thermoformed from PVC provides more cooling capacity and
reduce water carryover (drift) from sheets with a maximum flame spread improved drift elimination in one easily
the tower by a factor of ten or more! rating of 25 per ASTM E-84. Therefore, installed pack.
Reduced drift means lower water and the risk of fire damage is minimal.

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Fill Splash Fill

Alpha Crossflow Splash Fill

n High performance
n Heavy duty
n Easy cleaning
n Direct replacement for wood lath fill

Marley Alpha fill will increase cooling FRP fill grids are extremely inert and The rounded upper surface of the fill
tower thermal performance capacity tough. Each fill bar is firmly attached bars and the smooth surface finish
(compared with wood lath on similar to the FRP grid to prevent premature facilitate cleaning.
spacing). Variable fill bar spacing wear on either the grid or the fill bars.
is available to provide the required The fill bars are designed to prevent
thermal performance. sagging, even after prolonged exposure
to a cooling tower environment.
Alpha fill bars are corrosion resistant
PVC extrusions which are supported by Alpha fill is a direct replacement for
FRP (fiberglass reinforced polyester) many types of wood lath fill. The FRP
grids. grid can be manufactured to fit virtually
any cooling tower regardless of its age
or manufacturer.

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Fill Splash Fill

Mesa Crossflow Splash Fill

n High performance
n Perpendicular and Parallel
configurations
n Easy cleaning
n Exceeds CTI Standard 136 for
strength, flammability and impact

Marley Mesa splash-fill advances the Mesa fill bars are extruded of corrosion
state of the art in cooling tower splash resistant PVC (polyvinyl chloride)
fill. manufactured at SPXs Kansas plastics
manufacturing facility. The unique
The enhanced thermal performance material formula used in the Mesa bar
of Mesa fill increases cooling tower meets or exceeds CTI Standard 136 for
capacity in most cases. Variable fill strength, flammability and impact. Each
bar spacings provide the required bar is firmly attached to the Marley
thermal performance with the minimal GridLoc polypropylene injection
fill material and installation time. Mesa molded support for use in crossflow
fill is installed parallel or perpendicular towers. GridLoc provides a nonabrasive
to the air flow depending on thermal support that eliminates the need for
performance requirements or existing bench supports.
cooling tower configuration.

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Fill Splash Fill

Ladder Crossflow Splash Fill

n High Performance
n High temperature capability
n Variable spacing
n Unique injection molded
polypropylene design

Marley Ladder fill provides highly Injection molded polypropylene Ladder Ladder fill can be installed in virtually
efficient water breakup to develop fill is extremely inert to chemical any crossflow cooling tower regardless
excellent heat transfer with low reaction. of its age or manufacturer.
resistance to airflow. The horizontal
spacing is variable to meet thermal Ladder fill is capable of 150F water
performance requirements. temperature operation.

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Fill Splash Fill

Omega Crossflow Splash Fill

n High performance
n Perpendicular and Parallel
configurations
n Easy cleaning
n Exceeds CTI Standard 136 for
strength, flammability and impact

Marley Omega splash fill advances the Omega fill bars are extruded of Omega bar's classic arch shape
state of the art in cooling tower splash corrosion resistant PVC (polyvinyl enhances structural characteristics
fill. chloride) manufactured at SPXs which prevents sagging, even after
Kansas plastics manufacturing facility. prolonged exposure to cooling tower
Enhanced thermal performance of The unique material formula used in environments.
Omega fill increases cooling tower the Omega bar meets or exceeds CTI
capacity in most all cases. Variable Omega fill and its support system are
Standard 136 for strength, flammability
fill bar spacings provide the required designed to be used in virtually all
and impact. Each bar is firmly attached
thermal performance with the minimum cooling towers regardless of a cooling
to FRP or stainless steel fill grids with
amount of fill material and installation tower's age or manufacturer.
unique injected molded polypropylene
time. Omega fill is installed parallel or benches designed to prevent premature
perpendicular to the air flow depending wear on the fill bar and the grid.
on thermal performance requirements
or existing cooling tower configuration.

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Fill Splash Fill

Permagrid Counterflow Splash Fill

n Extremely durable Ceramic Permagrid tile fill is the Characterized by large openings,
n 25 year guarantee most durable fill in the industry with a Permagrid tile is an excellent performer
n Easy cleaning guaranteed minimum of 25 years of in the high-solid contents environment
n Dirty water application of dirty water applications. Permagrid
service. Molded from domestic clay to
strict specifications, the clay is heat is set without mortar, adhesive or
fired to create a fill that is immune to mechanical connections so no regular
traditional fill deterioration problems. maintenance is necessary. The installed
Because this revolutionary tile fill is system is placed in a pattern designed
not affected by ultraviolet exposure to provide optimal thermal performance.
and fungal attack, cooling towers with
Permagrid tile fill are perfectly suited
for harsh operating environments
involving temperature extremes. This
tile fill exhibits low water absorption
such that it will withstand extreme
freeze-thaw environments common in
cold weather climates or free-cooling
applications.

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Fill Splash Fill

TrickleBloc Counterflow Splash Fill

n High Performance
n High density counterflow design
n Withstands foot traffic
n Unique extruded heat-fused
polypropylene design

SPXs patented TrickleBloc clog-


resistant splash fill is comprised of
extruded polypropylene cylinders,
heat-fused to form blocks of splash
media. The open weave of the vertical
cylinders provides even water flow and
promotes thermal efficiency. The lattice
design promotes splashing to help
facilitate self-cleaning.

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Fill Splash Fill

GridLoc Splash-Fill Support

Splash bars are easily inserted into the


grid and snapped into place.

Marley GridLoc splash-fill support is a The GridLoc design has a molded in The typical GridLoc arrangement will
polypropylene injection molded support shelf support at the top of the grid be in 4' x 6' bays with bars parallel to
for use in crossflow towers. The for attaching the grid to the structural air flow. The nominal window opening
GridLoc design has a pair of integral, members. The grid can be either nailed for bar spacing is 4" horizontal by 8"
opposing, downward sloping splash bar or screwed to the support member vertical. The GridLoc splash bar grips
grips attached to the vertical strands to avoid movement of the grid in the are compatible with many Marley splash
in each window to secure splash bars. horizontal plane. bar designs as well as commercially
The lower horizontal strand has a short available bars. GridLoc will retrofit on
pair of vertical nubs to center splash historic Marley Class 600 as well as
bars and provide a nonabrasive support other manufacturers crossflow cooling
that eliminates the need for bench towers.
supports.

1 800 462 7539 31


Eliminators Eliminators

XCEL TU Eliminators

n Cellular design
n Low pressure drop
n Very low drift rates
n Counterflow and crossflow
designs

Marley developed the first cellular drift The eliminator discharge angle XCEL eliminators require little
eliminator in the 1970s when eliminator is important enough to warrant two or no maintenance. If it becomes
designs were primarily ineffective separate eliminator designsone for necessary to clean them, care must
blade type configurations. Next, Marley crossflow and one for counterflow be taken not to physically damage
patented the XCEL generation of towers. Tests show the air direction the PVC eliminator packs. For
eliminators in the early 80s. No other leaving the eliminator is extremely loose deposits of silt, fibers, etc., a
eliminator could come close to XCEL importantimperfect designs create water spray can be used, provided
eliminators low drift rate and low additional work for the fan. This means the spray nozzle is kept moving
pressure drop. Now, virtually every either increased fan horsepoweror continually and the water pressure
eliminator is a nesting cellular PVC type reduced cooling tower performance. is not excessive (recommend less
design. The crossflow version features drainage than 30 psi). Chemical cleaning
slots within the eliminator pack to can also be done. If an acid product
XCELplus is a more advanced design ensure trapped drift is returned to the such as inhibited sulfamic acid or
that meets or exceeds todays wet side of the cooling tower. glycolic acid is used for chemical
demanding specifications for drift cleaning of a scale deposit (e.g.,
emissions without sacrificing fan Low drift rate is the primary goal of calcium carbonate), care must be
horsepower. Drift rates are currently eliminator design. XCELplus boasts taken that the acid does not attack
half that of the original XCEL design typical drift rates of .001% of the total other materials in the cooling tower
with equivalent pressure drop. GPM. Lower drift rates are available or system, such as steel. The acid
depending upon tower configuration. should be quickly and thoroughly
rinsed off all metal surfaces. Do not
use cleaning agents which contain
hydrocarbon solvents.

Buy Marley Parts.com 32


Service Info Eliminators

A Turn For The Better


It is widely accepted throughout the air-handling industry Some drift eliminator manufacturers overlook this fact
that turning vanes significantly enhance the performance and do not include turning vanes on their cellular drift
of any system that includes a major change in air flow eliminators. Serious performance problems can occur
direction. A crossflow cooling tower is such a system. Air because of this oversight.
enters the tower horizontally and must turn to the vertical
before it can exit through the fan stack. R & D investigations have demonstrated that some cellular
drift eliminators in crossflow towers actually reduce thermal
performance by 4% to 8%, because they direct the
discharge air inefficiently.

Discharge air from some cellular drift eliminators actually


enters the fan plenum at an angle below or near the
horizontal.

The fan energy is wasted because it must force the air


stream through a turn of more than 90. This resultant
ELIMINATOR increase in pressure loss reduces the total air flow through
45 TO 53 DISCHARGE
ANGLE the tower. Reduced air flow means reduced thermal
performance.
AIR FLOW
R & D studies have determined that these eliminators can
increase the fan horsepower required for a given cold
water temperature by as much as 25%or the owner will
be forced to accept an increase of up to 2F in cold water
temperatures.
Marley XCEL Drift Eliminators

Marley XCEL drift eliminators discharge air at an angle


of 45 to 53 with respect to the horizontal. The exact
angle depends on the specific eliminator and on the
slope of the tower frame.
The directional changes incorporated in Marleys
three-pass drift eliminator act as turning vanes to
induce the discharge air flow through a gentle turn ELIMINATOR
from the horizontal toward the vertical. 0 TO -15 DISCHARGE
ANGLE
AIR FLOW
To be sure of efficient cooling tower performance,
always demand that drift eliminators in large crossflow
towers must provide a discharge angle (as defined by
the angle of the last section of the eliminator itself) at
least 40 from the horizontal. Otherwise, unnecessary
and costly turning losses will occur in the plenum.
Other Cellular Drift Eliminators

1 800 462 7539 33


Fans and Drives Geareducer

Geareducer Single Reduction

n Outstanding durability
n Designed specifically for cooling
tower duty
n 5 year oil change interval
n Minimum L10A service life of
100,000 hours on both input and
output shafts
n Gear sets meet or exceed the
requirements of AGMA
Quality No. 9
n Input shaft nitrile lip seals
n Premium seals available
n Output shaft sealed with a
maintenance-free labyrinth ring
n Timken tapered roller bearings

For over 40 years, the Marley Outstanding Geareducer engineering


Geareducer has been one of the most is only as good as the lubricant that Rebuild Kits Available
reliable geared speed reducers protects it. Thats why we took the
designed specifically for cooling tower next step and filled every System 5
service. Geareducer with Marley Gearlube Marley Geareducer kits
lubricant. offer a single consolidated
The reliability of the Geareducer comes
shipment of all the
from more than 100,000 units of In addition, several improvements to the
materials you need for
experience, and from Marleys attention System 5 Geareducer have been made
repair/rebuild including:
to exacting quality standards of design to take advantage of the extraordinary
gears, bearings, oil seals,
and manufacturing. Today, every Marley lubricating properties of Gearlube.
O-ring seals, shims and
Geareducer is tested under load at Weve equipped it with a strong magnet
oil
our factory. Then, its inspected and in the sump to trap metal particles
adjusted before shipment. generated during the initial break-in
period.

Buy Marley Parts.com 34


Fans and Drives Geareducer

Geareducer Single Reduction

Output RPM* Input hp Limitations** Empty


Reduction Oil Capacity
Model Weight
Ration 60 Hz 50Hz 60 Hz 50Hz US gallon
lb
2.13:1 832 692 7.5 7.5
2.61:1 679 564 7.5 7.5
10.1 67 .375
3.27:1 543 451 7.5 7.5
3.77:1 471 391 7.5 7.5
2.71:1 655 544 34 28
3.27:1 543 451 30 25
1800 3.75:1 473 393 25 19 210 2.4
4.09:1 434 361 21 17
4.80:1 370 307 15 12
2.71:1 655 544 57 49
3.27:1 543 451 51.5 44
2000 3.75:1 473 393 41.5 35.5 210 2.4
4.09:1 434 361 34.5 30
4.80:1 370 307 27 23.5
3.45:1 514 428 70 60
3.79:1 469 390 70 60
4.10:1 433 360 70 60
4.56:1 389 323 70 60
5.11:1 347 289 70 60
2200 5.50:1 323 268 61 53 350 2.5
6.12:1 289 240 50 43
6.50:1 272 226 47 41
7.33:1 241 201 32 28
8.67:1 204 170 29 25
3.45:1 514 428 143 121
3.79:1 469 390 133 110
4.10:1 433 360 103 90
4.56:1 389 323 88 75
5.11:1 347 289 80 70
2400 350 2.5
5.50:1 323 268 75 60
6.12:1 289 240 60 50
6.50:1 272 226 55 45
7.33:1 241 201 40 30
8.67:1 204 170 31 27
5.06:1 351 292 150 125
5.44:1 326 271 150 125
6.14:1 289 240 150 125
3000 6.85:1 259 215 150 125 1250 16.5
7.91:1 224 186 150 125
8.80:1 202 168 131 110
9.60:1 185 154 113 94

*Nominal input speed is assumed to be 1775 RPM at 60 Hz and 1475 RPM at 50 Hz


**Rated at AGMA 2.0 Service Factor

1 800 462 7539 35


Fans and Drives Geareducer

Geareducer Double Reduction

n Outstanding durability
n Designed specifically for cooling
tower duty
n Designed to meet or exceed the
requirements of CTI Std. 111
n Gear sets meet or exceed the
requirements of AGMA
Quality No. 9 to 11
n Minimum L10A service life of
100,000 hours on both input and
output shafts
n Input shaft nitrile lip seals
n Premium seals available
n Output shaft sealed with a
maintenance-free labyrinth ring
n Timken tapered roller bearings
n Two-stage (spiral bevel/helical)
gear reduction for efficient power
transmission

Marley Industrial Geareducers start-up and during subsequent speed these commercial speed reducersand
are manufactured and designed changesanchor the fan against lateral the thermal performance of the cooling
specifically for cooling towers in movement in response to rotational towers on which they are installed
large industrial and power plant forcesand contribute as little as often suffer.
applications. In shape and function, possible to power transmission losses
their design goes beyond normal as well as the generation of noise. SPX Cooling Technologies is the only
AGMA requirementsboth to maximize major manufacturer whose gearboxes
air movement through the tower, and to Given these requirements, many are designed uniquely for cooling
minimize the impact of maintenance. manufacturers of mechanical tower service. And, since we warrant
equipment provide acceptable speed not only the Geareducer, but the
Although the primary function of a reducers. Designed for more forgiving thermal performance of the cooling
Geareducer is to reduce the speed of commercial applications, these units towers on which they operate as well,
the driver (usually an electric motor) are often unprepared for the rigors development, design, and manufacture
to a speed which is conducive to good and peculiarities of cooling tower are taken very seriously. This has
fan performance, it must satisfy other service, such as the corrosive effects resulted in an unequalled history of
criteria as well. For example, it must of operation (often intermittent) within trouble-free operation.
provide primary support for the fan an exceedingly humid environment.
withstand the shock loads imposed at As a result, both the life expectancy of

Buy Marley Parts.com 36


Fans and Drives Geareducer

Geareducer Double Reduction

Output RPM* Input hp Limitations** Empty


Reduction Oil Capacity
Model Weight
Ration 60 Hz 50Hz 60 Hz 50Hz US gallon
lb
7.89:1 225 187 125 100
8.80:1 202 168 150 150
9.62:1 185 153 150 150
32.2 10.16:1 175 145 150 125 1700 9.0
11.18:1 159 132 150 150
12.93:1 137 114 150 125
14.64:1 120 100 150 125
9.93:1 179 149 150 125
10.35:1 171 143 125 100
3400 2810 18.5
11.16:1 159 132 150 125
12.97:1 137 114 150 125
9.64:1 184 153 257 217
10.83:1 164 136 251 212
3600 11.55:1 154 128 218 184 3000 18.5
12.98:1 137 114 213 180
14.84:1 119 99 188 159
9.64:1 184 153 316 272
10.83:1 164 136 316 272
11.55:1 154 128 304 263
12.18:1 146 121 326 274
12.98:1 137 114 304 263
13.24:1 134 111 251 217
4000 3200 18.5
13.81:1 129 107 290 244
14.88:1 119 99 251 217
15.84:1 112 93 251 214
16.49:1 108 89 204 175
18.54:1 96 80 204 175
19.72:1 90 75 204 174

*Nominal input speed is assumed to be 1775 RPM at 60 Hz and 1475 RPM at 50 Hz


**Rated at AGMA 2.0 Service Factor

1 800 462 7539 37


Fans and Drives Geareducer Oil

Geareducer Oil

Filled with Reliability

It is critical to the operational life of a


transmission to utilize a satisfactory
lubricant that includes the correct
viscosity grade and additives.
Additionally, it should be within the
specific limitations of contaminants and
fill volume throughout the machines
lifetime.
The advanced formulation of Gearlube Cooling Tower Know How
Marley Gearlube is a premium quality can extend the service life of any
synthesized hydrocarbon lubricant gear box, especially the System 5
that is specially formulated to deliver Geareducer.
extended life without oxidation or loss If lubricants, other than
of lubricity. It is free of undesirable Also available, non-synthetic Marley Marley oils are used,
elements that can produce sludge, Turbine mineral oil is in accordance with they must not contain
deposits and corrosionand a superior the most recent edition of AGMA 9005 any additivessuch
extended life lubricant than normal requirements for rust and oxidation as detergents or E.P.
petroleum oil. inhibited gear oils. additiveswhich are
adversely affected by
moisture and could
reduce the service life
of the Geareducer.

Buy Marley Parts.com 38


Service Info Sound

Geareducer Sound Levels


More Than Quiet

Although the primary function of a


94
cooling tower speed reducer is to reduce
the speed of the driver (usually an electric 90
motor) to a speed which is conducive 87

GEAR BOX SOUND LEVELS dBA


to good fan performance, it must satisfy
82
other criteria as well. For example, it must
80 78
provide support for a large fan, withstand
the shock loads imposed at start-up and
during subsequent speed changes, and
70
anchor the fan against lateral movement
in response to rotational forces. Plus it
must contribute as little as possible to
power transmission losses as well as the
generation of noise. MARLEY AMARILLO MARLEY AMARILLO
22.3 A22 32.2 A32
SPX Cooling Technologies is the only 5.50 RATIO 11.18 RATIO
major manufacturer whose gearbox is
designed uniquely for cooling tower
duty. Since SPX warrants not only its
Geareducer, but the thermal performance
of the cooling tower as well, design and
manufacturing is taken very seriously. This Sound Check
has resulted in a history of trouble-free
operation unequalled in the cooling tower
industry. The Marley Series 22.3 was
up to 4 dBA quieter than the
Marley vs Amarillo Amarillo Series A22. Both
Sound measurement testing of cooling products having the same
tower gear speed reducers was conducted gear ratio.
by National Technical Systems (NTS) in The Marley Series 32.2 was
1998. Concurrent testing was conducted 7 to 10 dBA quieter than the
on Marley and Amarillo gear speed Amarillo Series A32. Both
reducers in accordance with SAE J2101 products having the same
at various speeds and loads. gear ratio.
Lower sound levels were measured for
These sound levels were recorded under
Marley gear speed reducer products in fully loaded conditions.
both comparison groupings tested.

1 800 462 7539 39


Fans and Drives Backstop

Sprag-Clutch Backstop

The Marley integral Sprag-Clutch When operating, the outer race is


Specifications
Backstop is custom designed and stationary and the inner race is rotating.
configured specifically for a Marley When facing the input shaft of the
Geareducer with input shaft diameters Geareducer, the forward (over-running)
of 2.375" and 2.625". Also referred to as direction is clockwise. The backstop shall have a
a sprag clutch anti-rotation device, these torque capacity of at least
units are designed to prevent reverse In contrast to conventional sprag clutch 1100 ftlb (1490 N.m)
rotation of the fan, Geareducer and devices which may continuously wear, and shall be capable of
motor. Designed specifically for use with this device utilizes a "Lift-off" sprag continuous overrunning
the current 32.2, 3400, 3600 and 4000 functionality which alleviates the wear operation at 1800 rpm
Geareducer models, they can also be issue once typical rotation speeds are
utilized to fit legacy 32.1T, 34.3T, 34.4, 36 reached.
and 38 Geareducer models. This feature greatly diminishes the friction
and heat generated, thus promoting
longevity for both the clutch unit and the
Geareducer itself.

Buy Marley Parts.com 40


Fans and Drives Fan Cylinder

Reflex RTM Fan Cylinder

Having designed and manufactured 21st century manufacturing technology The green benefit of the closed-
cooling tower fan cylinders since has enabled further advancement and molding process is the virtual
the 1930s, Marley began producing the introduction of the new Marley elimination of VOC emissions because
FRP (fiberglass) fan cylinders in Reflex RTM industrial fan cylinder, the resin is injected and cured in a
1958, which quickly became the offering a more dimensionally accurate, sealed, closed mold. And because
accepted standard within two years high quality surface finish, better fit and the lay-up process is now dry, a more
time. With considerable modeling and robust structural integrity. A light RTM precise laminate can be achieved,
full scale testing, this experience led (resin transfer molding) closed-molding with no hand-working of resin-soaked
to the development of several new process lends itself to increased materials, no cleaning requirements for
fan cylinder designs for a variety of durability for the final product, and application equipment, no hand tools
tower types and fan sizes. One such ensures laminate thickness and weight using hazardous chemicals and no
development resulted in the Reflex consistency. Because the cavities are chemical disposal concerns.
velocity recovery cylinder in the 1980s, infused using rigid forms in the ribs,
and is the standard design still in use there is no porosity or potential sites
today for 10 diameter and larger fans. for delamination or structural fracture
to begin. Therefore, the cylinder load
capacity is greatly enhanced.

1 800 462 7539 41


Fans and Drives Axial Fans

H3 Fan

n True twisted airfoil design


n Solid cast aluminum alloy
n Infinite pitch adjustment
n Machined aluminum hub
n 54" through 216" diameter
n Stainless steel hardware
standard

Cooling Tower Know How

Axial fans require only half


the operating horsepower
Marley H3 cast aluminum alloy fans are A true airfoil blade, designed of centrifugal blower fans
standard equipment on various Marley specifically for cooling towers offering
product lines. All H3 fan assemblies efficient quiet operation and long
incorporate machined aluminum hubs service life. Available in 54" through
with stainless steel hardware. All H3 216" fan diameters.
fan blades are adjustable in pitch, to
take full advantage of rated horsepower
or to compensate for unusual job site
restrictions.

Buy Marley Parts.com 42


Fans and Drives Axial Fans

X7 Fan

n True airfoil quiet design


n Lightweight extruded aluminum alloy
n Infinite pitch adjustment
n Galvanized ductile iron hub
n 66" through 168" diameter

Marley X7Fan with U-Style hub

The Marley X7 fan is designed


for induced-draft cooling tower
applications, offering distinct
advantages over other fan designs. The
Marley FlareTip blade enhancement
provides increased performance
overcoming tip clearance losses
aiding the movement of air next to the
fan cylinder.

The wide chord blade design is well The blade end caps are injection Each blade is secured to the hub with
suited for low noise operation as molded impact-resistant, polypropylene two stainless U-bolts that allow blades
well, delivering superior air flow and with a section on the upper surface to to be easily rotated to adjust desired
pressure capability at reduced speed. allow for consistent fan pitch setting. pitch angle, delivering precise utilization
The high performance X7 airfoil is one of fan horsepower.
Additionally, all blades are match-
of the most efficient in the industry
moment weight balanced, allowing Superior strength, excellent quality,
today.
all X7 blades to be interchangeable light weight and outstanding
without the need to rebalance the performance makes the X7 fan an
entire fan assembly. outstanding choice for cooling tower
applicationsand best of all its a
Marley fan.

1 800 462 7539 43


Fans and Drives Axial Fans

Ultra Quiet Fan

n True airfoil quiet design


n FRP blades
n Infinite pitch adjustment
n Machined aluminum hub
n 84" through 168" diameter
n Stainless steel hardware
standard

The Marley Ultra Quiet Fan represents Common Applications for Hotels and Residential Areas At
the top-of-the-line of new generation Ultra Quiet Fans night ambient noise levels are lower
in super quiet fansthe FRP blades which may make a cooling tower seem
have been developed to meet the most HospitalsNoise concerns may be louder to anyone nearby. Hotel guests
stringent noise limitations. The fans paramount near medical facilities where or residential neighbors shouldnt have
permit variable pitch adjustment and quiet and rest are necessary. to contend with a cooling tower fan
feature a simplified hub design. cycling on and off at night.
Universities and Office Buildings
Whenever HVAC equipment is near
people, unwanted noise may be a
concern. For example, conducting a
meeting or teaching a class in a room
with cooling equipment outside is an
unwelcome distraction.

Buy Marley Parts.com 44


Fans and Drives Axial Fans

HP7i Fan

n True twisted airfoil design


n Fiberglass vinyl ester laminate
n Single piece construction
n Heavy duty steel hub assembly
n 72" through 168" diameter
n Stainless steel hardware
standard

Marley HP7i fans are designed The HP7i blade is a single piece The skin of the HP7i is made with top-
specifically for cooling tower composite design ensuring structural quality fiberglass reinforced vinyl ester
applications, offering distinct integrity. Fan blades with bolted or that is infused with pigment for even
advantages over other types of fans. glued connections between the blade distribution across the laminate. There
The Marley FlareTip blade enhanced shank and airfoil section introduce are multiple layers of surface veil on the
for low sound operation, delivers an additional mechanical joint under blade surface leading to superior UV
maximum air flow and pressure stress. The one piece composite design protection compared to fans with only a
capability at reduced speed. ensures the integrally molded leading- painted exterior.
edge will not come off or fail and the
blade will handle the toughest cooling Blades attach to the fan hub using a
tower applications. heavy-galvanized iron ring integrally
molded with each fan blade. By
loosening the hub attachment
hardware, blades can easily be rotated
to achieve desired pitch, permitting
maximum utilization of fan horsepower.

1 800 462 7539 45


Fans and Drives Axial Fans

HP7000 Fan

n True twisted deep airfoil design


n Fiberglass reinforced vinyl ester
laminate
n Single piece construction
n Heavy duty dual-plate heavy
galvanized steel hub assembly
n 168" through 394" (10 meter)
diameter
n Stainless steel hardware
standard
others

Marley HP7000 fans are designed Constructed in one continuous


specifically for industrial cooling piece, with a consistent moment
tower applications, offering distinct weight, HP7000 blades are inter-
advantages over other types of changeable without the need to
fans. The Marley FlareTip blade rebalance the fan assembly.
enhancement provides increased A nylon leading edge erosion
performance overcoming tip clearance barrier is molded into each blade
losses, aiding the movement of air next to ensure long service. Marley HP7000
to the fan cylinder. The wide blade
design is well suited for low sound The hollow blade is designed Close-up views of other manufacturer and
with a deep section airfoil making Marley HP7000 fan blade samples after 300
operation, delivering superior air flow
the HP7000 strong, yet light and hours in the same erosion test chamber.
and pressure capability at reduced
speed. easy to handle.

The skin of the HP7000 is made with


top-quality fiberglass reinforced vinyl
ester that is infused with pigment for
even distribution across the laminate.
There are multiple layers of surface veil
on the blade surface leading to
superior UV protection compared to
fans with only a painted exterior.

Buy Marley Parts.com 46


Fans and Drives Driveshafts

Series 400 Driveshaft

n Low maintenance
n Easy to install
n Easy to align
n Long service life
n Corrosion resistant
n Easily interchanged

Series 400 carbon-fiber driveshafts Low maintenanceNo intermediate prolong alignment and transmit less
provide a lightweight, low maintenance couplings or bearings. You realize vibration to the motor and gearbox.
alternative to stainless steel driveshafts. extensive savings in maintenance All materials are specially selected
costs. The yoke and flange coupling for cooling tower duty and longer life.
Marley neoprene flexible bushings are design, featuring flexible bushings, has The composite tube prevents transient
easier to install and align than others been proven for more than 30 years start-up vibration.
using stainless steel torque elements. on the Marley Series 301 driveshaft.
Series 400 driveshafts are designed for This system is more tolerant of Corrosion resistantMaterials such as
fans up to 10 meters in diameter and misalignment, with lower thrust forces composite carbon fiber, epoxy, stainless
for motors up to 300 hp. transmitted to motor and Geareducer steel, and others help prevent corrosion.
bearings, than conventional driveshafts.
The Marley Series 400 carbon fiber Easily interchangedOwners with
driveshafts offer you the following Easy to install/easy to alignOne-piece Marley 301 stainless steel driveshafts
benefits: design eliminates hard-to-reach can upgrade to the Series 400 simply
intermediate bearings. Installation by exchanging their existing driveshaft
requires fewer steps. The tube and tube assembly with the new carbon
flange is lightweight, easily handled by fiber tube assembly and using the
two workers. existing driveshaft yokes.

Long service lifeRugged design


includes carbon fiber/epoxy composite
tube with stainless steel flanges and
neoprene flexible elements. Also,
vibration is internally dampened to

1 800 462 7539 47


Fans and Drives Driveshafts

Marley Driveshaft Specs

OVERALL LENGTH

ENGAGEMENT ENGAGEMENT

TUBE DIAMETER

GEAREDUCER MOTOR BORE


BORE

DISTANCE BETWEEN SHAFT ENDS (DBSE) YOKE DIAMETER

Driveshaft Maximum Maximum Overall Maximum Yoke Tube


Bore Range
Series Horsepower Length DBSE Diameter Diameter
Q1 7.5 48" 45.25" 5.625" 1.125" 1" - 1.5"
6Q 60 86.5" 80.75" 6" 2.5" 1" - 2.375"
175 75 115.5" 109.75" 8" 4" 1" - 3.125"
250 150 115.5" 109.75" 8" 4" 1" - 3.375"
301 300 143.5" 136.25" 12.375" 6.625" 1" - 3.9375"
400 300 180.5" 173.25" 12.375" 6.625" 1" - 3.9375"

Buy Marley Parts.com 48


Fans and Drives Driveshafts

Comp-DS Driveshaft

n Low maintenance
n Easy to install
n Modern construction
n Easy to align
n Long service life
n UV and corrosion resistant
n Easily interchanged

Comp-DS composite driveshafts provide Carbon-fiber, unitized


a high-performance, lightweight and flexible element
low-maintenance alternative to steel
driveshafts.

Marleys patent pending, unitized, LightweightThe lightweight, UV and Corrosion Resistant Materials
carbon-fiber flexible elements with permanently bonded, tube and All materials are specially selected for
slip-fit, stainless steel hubs are easier to flange assembly is easily handled by cooling tower duty and are constructed
install and align than others using steel technicians without the need for lifting to provide maximum protection against
torque elements. Comp-DS driveshafts equipment. The reduction in rotating corrosion and UV attack.
are designed for fans up to 10 meters in mass also results in lower radial loads
diameter and for motors up to 300 hp. on motor and Geareducer bearings. PerformanceThe composite tube
prevents transient start-up vibration and
Marleys Comp-DS composite Modern ConstructionRobust diminishes some of the initial, peak-
driveshafts offer the following benefits: composite design is comprised of high torque impulse realized during hard-
strength fiberglass and/or carbon- starting. High torque ratings allow the
Low Maintenance - Ease of Installation fiber reinforced tubes in a tough epoxy Comp-DS design to accommodate high
The full-floating design has no matrix along with fiberglass flanges and motor power ratings in an expanded
intermediate couplings or bearings. The urethane encased, carbon-fiber flex- speed range.
simple hub design and corresponding elements. Additionally, the quantity of
unitized flex-elements, require less labor components and hardware is minimized. Easily interchangedOwners with
to install and maintain than previous Marley 301 stainless steel driveshafts or
designs. Series 400 composite tube driveshafts
may directly replace their existing
assembly with the Comp-DS series.

1 800 462 7539 49


Fans and Drives Close Couplings

SofTork MC Coupling

n Quiet operation
n No axial separation of hubs
n Corrosion resistant materials and
coatings
n Simple to install
n Balancing not required at 1800
rpm
n Fast and easy flexible element
replacement
n Accommodates misalignment in
the angular and parallel directions
as well as end float

Flexible element, tire type coupling


CLAMP RING COUPLING designed specifically for cooling tower
HALF applications. Couplings consist of two
cast ductile-iron, electro-galvanized
CLAMP RING
BOLT hubs and clamp rings with stainless
steel fasteners.
n Outstanding vibration dampening
characteristics
n Shock load cushioning ideal for
VFD use
n High degree of flexibility to
accommodate misalignment

FLEXIBLE
ELEMENT

Buy Marley Parts.com 50


Fans and Drives Motors

Cooling Tower Duty Motors

n Three-part corrosion resistant


epoxy paint coating on exterior
and interior surfaces
n V-ring slingers on both end
shields, plus an external water
slinger/flinger
n Service factor: 1.25 up to 100 hp,
1.15 from 125 hp and up
n Automatic drain plugspressure
compensated

Marley cooling tower duty motors utilize Marley cooling tower motors meet
a double-dip and bake impregnation or exceed all NEMA Premium Cooling Tower Know How
process for the insulation system to and CEE requirements for energy
increase mechanical endurance and efficiency. These TEFC motors are
moisture resistance. Additionally, an built according to NEMA specifications TEFC motors offer
epoxy paint coating system is used and designed for operation in moist or additional benefits over
externally and internally to inhibit dusty atmospheric conditions without TEAO motors whose only
corrosion. Multiple end-bell drains allow affecting useful life. Motors are NEMA source of cooling is the
for quick removal of condensation Design B and maintain exceedingly flow of air produced by the
regardless of the motor mounting high breakdown and locked rotor cooling tower fan
positon. Automatic terminal box drain torque while providing the highest rated
plugs, a rubber lead separator, V-ring efficiency levels
slingers on both end-shields and an
additional external water slinger all aid
in increasing the motor's longevity.

1 800 462 7539 51


Controls Motor Controls

Can-Do Fan Motor Control Panel

Electrical components:
n External disconnect handle
with padlocking provisions to
meet lockout tag-out safety
requirements
n Main circuit breaker with thermal
and magnetic overload protection
n Door mounted H-O-A selector
switch. Speed selector switch for
two speed applications
n Adjustable motor overload
n User terminal points for
connecting field devices:
Two wire vibration switch
interface for starter shut down Options:
NEMA 3R outdoor cabinet* with
if vibration switch trips
the following features:
1 N.O. motor overload trip n Pilot lights
contact for feedback to n Rain shield n Status contacts for BMS interface
customers alarm system or n Solid-state temperature controller
n Mounting flanges located top and
BAS bottom with readout display
Cold water temperature n Piano hinge n Integrated basin heater controls
thermostat connections for n Lock off capabilities with temperature probe and
starter ON OFF control n Hex head screw type hold heater contactor
n Wiring diagram laminated and n Integrated water level controls
downs for door
mounted on inside of door n Warning labels (Make-Up, Hi and Lo alarm
n UL and CUL listed assembly
* optional NEMA 4X fiberglass cabinet contacts)
n GFI power receptacle (for trouble
for corrosive locations
light and power tool)
n Factory installed and wired control
panel on select towers
n DE-ICE reversing circuit for two-
speed applications only

Buy Marley Parts.com 52


Controls VFD Drives

Variable Speed Drive

n 6 Pulse PWM drive with IGBT


switching and integrated bypass
design
n Main circuit breaker disconnect
with thermal and short circuit
protection
n Field selectable bypass mode of
operation
n UL Listed

Marley fan motor Variable Speed Drive The standard VFD requires a speed De-Icing function standard with auto
systems are designed to combine reference input signal from a remote canceling timed run of 20 minutes
absolute temperature control with ideal source such as a building automation maximum
energy management. The cooling tower system or RTD with 420mA
user selects a cold water temperature transmitter. VFD will accept a 420mA, The Marley Premium VFD drive is not
and the drive system will vary the fan 020mA or 110VDC signal. Speed intended to be controlled by building
speed to maintain that temperature. may also be controlled with the or process automation systems. No
Precise temperature control is onboard keypad. external controller required. Included
accomplished with far less stress to the is an integrated temperature controller
Marley Premium Variable Speed and RTD sensor for mounting into the
mechanical equipment components.
Drive features: tower outlet water piping.
The improved energy management
provides fast payback to the user. Automatic Bypass circuit standard. This
feature transfers the fan motor from
the drive to a temperature modulating
bypass contactor if the VFD faults out
on specific fault parameters allowing
continuous operation of the tower.

1 800 462 7539 53


Controls Basin Heater

Basin Heater

n Pre-engineered, UL Listed / CSA


approved package for freeze
protecting cooling tower basins
n Stainless steel heating elements
n Complete control package

Basin Heating Element


Basin Heater Control
Panel with Low Water
Safety Circuit

The system usually consists of one or


more stainless steel electric immersion Cooling Tower Know How
heaters installed in threaded couplings
provided in the side of the basin. A
NEMA 4 enclosure houses a magnetic Submerged in basin water,
contactor to energize heaters; a in which zinc ions are
transformer to provide 24-volt control present, copper immersion
circuit power; and a solid-state circuit heaters must not be used.
board for temperature and low water Insist upon stainless steel.
cut-off.

Buy Marley Parts.com 54


Controls Motor Sequencer

Multicell Motor Sequencer

n Simple to install and operate


n Eliminate multiple fan
thermostats
n Single set point stages multiple
fans

Marley performance-matched Marley controls help extend the life The sequencer can easily be configured
sequenceravailable in either 8 or 16 of the fan motors with automatic for single or two speed motor systems.
stage systemswill stage multiple fan lead stage rotation. The sequencing On two speed systems, the unit can
cells of a cooling tower from a single controllers prevent the same motor be set to cycle through a Lo1-Lo2-
temperature measurement location from always starting first in the normal Lo3-Hi1-Hi2-Hi3 or Lo1-Hi1-Lo2-
based upon a single temperature set sequence of operation. Every 24 hours Hi2-Lo3-Hi3 sequence. The controller
point. Old mechanical thermostats with a different motor becomes the lead recognizes the two speed motor
staggered set points on each cooling stage equalizing the wear on all motors. settings and only uses low speed as a
tower fan cell are no longer necessary. lead stage. Adjusting the temperature
set point and activating cells can easily
be accomplished at the unit.

1 800 462 7539 55


Controls Water Level Probes

Liquid Level Control

Marley liquid level controls provide


you with state of the art systems to
control and monitor the water level in
your cooling tower collection basin.
Relays operating in conjunction with
suspended stainless steel electrode
probes monitor basin water levels,
providing simple solenoid-valve water
makeup or discrete on/off signals
to more sophisticated automation
controls. Up to seven probes may
be provided in a single head unit.
Optional configurations might include
any configurtation of the following
combinations:

n Water level make-up with a


solenoid valve
n High and low alarming back to a
BMS
n High level cut-off for pump Electrode Probe installed in a Marley NC
control crossflow cooling tower
n Low level cut-off for pump control

Stainless steel 303 conductivity probe


tips are suspended from a PVC conduit
box using flexible wire providing a
means to monitor water level when
used with a Marley LLC control panel.
Each probe is furnished with 20 feet of
wire for connection to the Marley LLC
control panel. If longer wire is required Adjustable electrode probe system
the probe wire may be spliced in the (stilling chamber removed)
field. Each probe is furnished with
a cord grip which may be loosened
allowing probe height adjustment.

Each probe is furnished with 20 feet


of wire

Buy Marley Parts.com 56


Controls Water Makeup

LLC Water Level Control Panel

LLC Control Panel Features:


n NEMA 4X Fiberglass Enclosure
n Mounting flanges located top and bottom
n Outdoor rated
n Stainless steel continuous hinge
n Swing out lid with stainless steel clamps
n Lock-off capabilities
n 14" high x 12" wide enclosure for
configurations up to 4 cards
n 18" high x 16" wide enclosure for
configurations up to 6 cards

Electrical Components:
n Main breaker disconnect
n HAND-OFF-AUTO selector switch for manual
fill control when makeup card is used
n Output contact for makeup card is internally
powered with 120 VAC for use by customer
n User terminal points for connecting field
devices e.g. solenoid, water level probes and
alarm devices
n Terminal strip raised for easy access
n Wiring diagram and User Manual secured in
literature pocket inside the panel door
n Built to UL and CUL standards
n Single enclosure for all control cards
n Level cards as required for following
conditions:
- Make up
- Hi alarm
- Lo alarm
- Hi level cutout
- Lo level cut out

1 800 462 7539 57


Controls Vibration Switch

M-5 Vibration Switch

n Meets all requirements for


mechanical switches on one
package
n Weatherproof and optional hazard
area rating
n Local and optional remote reset
with startup delay
n SPDT or (2)SPDT switch output
contacts

The Marley M-5 vibration switch is


designed to meet all requirements
for mechanical switches in a single,
affordable package. This unit provides
economical vibration protection for
cooling tower mechanical equipment.
DPDT CONTACTS SPDT CONTACTS
An inertia sensitive mechanism
1 1
activates a snap-action switch with
2 2
SPDT output contacts if the vibration
exceeds an adjustable setpoint. 3 3
4
The M-5 contacts can be used to 5
activate an alarm or initiate equipment 6
shutdown. The housing is weatherproof GRN CASE GRN CASE
with an optional hazardous area rating.

User Wiring Diagrams

Buy Marley Parts.com 58


Rental Cooling Towers

Temporary Cooling

n Disaster response
n Maintenance outages
n Repair/replacement cooling

A sense of urgency that gives new


meaning to the word fleet.

In this business, every minute of cool


water flow, and every minute variation
in water temperature counts, regardless
of whether you provide emergency
backup or increase production capacity.

Because it all equates to profits.

Marley Temporary Cooling Solutions


is geared entirely toward making your
performance our priorityincluding a
fleet of ultra-efficient induced-draft
towers, and regional support teams who
are on the ground and ready to move.

1 800 462 7539 59


Services Reconstruction

Aftermarket Services

n Repair and reconstruction


n Inspection and condition reports
n Performance testing
n Maintenance plans

Whether investing in a new plant


or operating an existing system,
cooling tower maintenance is critically
important to operational efficiency,
equipment longevity, and regulatory
compliance. Regular service by
experienced teams helps ensure your
cooling systemand your bottom line
is not compromised by unexpected
failure, giving you the peace of mind to
focus on your business.

For many older towers, reconstruction


is a cost-effective alternative to
replacement. Our reconstruction Let our cooling system experts help
experts work with our engineering staff your maintenance experts. We can
to make old towers as good as newif contract with you to provide as much
not better! hands-on maintenance assistance as
you need.
Our reconstruction specialists have
been trained to analyze the condition Performance Testingyou cant know
of your cooling equipmentand its how much any reconstruction effort
capability to be successfully repaired, has improved your tower unless you
rebuilt, or upgraded. Your SPX Cooling know how your tower is performing
Technologies sales representative can now. Our staff of Testing and Ratings
arrange an inspection of your cooling Engineers can help you to gain that
system. vital information.

Buy Marley Parts.com 60


Publications Fundamentals

Cooling Tower Fundamentals

Cooling Tower Fundamentals is devoted to the


implementation of water cooling systems which satisfy
design and environmental requirements with sound
engineering and responsible cost. Over 100 pages
devoted to design, components, usage and testing. First
published in 1967, Fundamentals has evolved to one of
the most popular cooling tower reference
guides available. Now you can own the
latest edition for free. Contact your sales
representative for a copy or download at
spxcooling.com.

1 800 462 7539 61


Maintenance Schedule

Maintenance Service Monthly Semi-annually Seasonal Startup or Annually

Inspect General Condition and Operation x x

Observe Operation of:

Mechanicalmotor, 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

Distribution basin, nozzles and collection basin x x

Fan motor exterior x x

Check:

Collection water basin level x x

Blowdownadjust as required x x

Geareducer Drive (if equipped):

Check for loose fasteners including oil drain plug x

Check for / repair oil leaks x x

Check oil level 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 (grease 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

Buy Marley Parts.com 62


cooling tower parts
reference guide
AU T U M N 2 0 1 1

S PX C O O L I N G T E C H N O LO G I E S , I N C .
Lenntech
7401 W 129 STREET
info@lenntech.com Tel. +31-152-610-900
OVERLAND PARK, KANSAS USA www.lenntech.com Fax. +31-152-616-289
P: 913 664 7400
F: 913 664 7439
E: spxcooling@spx.com
spxcooling.com

In the interest of technological progress, all products are subject to design and/or material change without notice

ISSUED 11/2011 PRG-11B


COPYRIGHT 2011 SPX Corporation