Spx Cooling Technologies Marley Aquatower Users Manual

Marley Aquatower to the manual b76e8b29-031a-4fd3-b6ee-fa05a7e09ea9

2015-02-06

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/ Marley Aquatower ® Cooling Tower /

/ The Aquatower Advantage /

■ PVC Film Fill with Integral Drift Eliminators and

■ Proven Performance. CTI Certified. Plus SPX stands by
its responsibility for reliable thermal performance. We

Louvers. If you’ve ever had to replace deteriorated

designed it. We rate it. We guarantee it!

eliminators or louvers, you’ll appreciate this advantage.
Now those components are molded right in the PVC fill

■ Induced-Draft Design. Save on fan power. The fan will

sheets. Integral honeycomb louvers keep the circulating

operate in a warm atmosphere even in winter, so you’ll

water inside your tower—and off your roof!

never have to work on frozen mechanical equipment.

■ Select Your Aquatower on Our Website. The Marley

■ Crossflow Design. Save on pump power because you

UPDATE web-based selection software—available at

only pay to move the water to the top of the tower. Gravity

www.spxcooling.com—provides Aquatower model

does the rest. The mechanical equipment and water

recommendations based on your specific design

distribution system are out where you can easily maintain

requirements

them.

■ Simple, Flexible Installation. Just mount the motor, belts

■ All-Season Reliability. Aquatowers perform as specified

and belt guard, install the outlet connection that suits

in the heat of summer. They respond well to energy

your needs—both side suction and bottom outlet are

management techniques in the spring and fall and

provided, complete with screens—and adjust the float

with appropriate fan controls, they can operate virtually

valve. Attach air-inlet screens on models 494A and larger

ice-free in the dead of winter. Plus they offer simple

and your Aquatower is ready for operation.

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.

/ The Marley Difference /

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.

Today’s Aquatower may be the most space/energyefficient cooling tower available. Your needs have dictated

Drift eliminators must be effective at the air velocities

constant technological improvement. Thousands of

where fill is most efficient. So, we’ve carefully designed

Aquatower users enjoy the benefits of eight major redesigns

both components to work together efficiently.

and dozens of minor improvements in the past 40 years. For

How many other cooling tower companies can offer

example, PVC film-fill enables the Aquatower to reject more

you this assurance? They may use Brand “A” nozzles with

heat per unit size. We also put the air inlet louvers and drift

Brand “B” fill and Brand “C” drift eliminators. When they all

eliminators right on the fill sheets. This new arrangement

come together, the whole may be less than the sum of the

saves you fanpower by improving airflow through the tower.

parts.

The Aquatower is a maintenance delight! You’ll

Our total system approach assures that all the

appreciate the way the Aquatower simplifies maintenance.

parts work together to provide you the greatest total

No hidden spray systems, tiny nozzles, or enclosed basins

performance.

here! You can easily replace and align V-belts from outside

And because we design specifically for cooling towers,

the tower. You won’t have the chore and expense that goes

all our components will provide many years of service with

with high-power, blower fan towers.

minimal maintenance.

All primary components of the Aquatower are open to

Every Aquatower cooling tower carries a full one-year

view. You can easily remove any debris from the upper basin

warranty. The Aquatower you buy from us will work on

or nozzles while the tower is in operation.

your job or we’ll make it right. Your warranty includes

Heavy mill galvanizing on all steel components prevents

thermal performance and every component of the tower.

base metal corrosion. You won’t have to worry about paint

The SPX Cooling Technologies warranty is your assurance

chips clogging your strainers and nozzles, because there is

of performance—for a full year.

no paint to flake off. Heavy galvanizing also protects much

The Aquatower has inspired many imitators. Only

better than paint.

SPX Cooling Technologies can offer you the original.

/ Schematic /
D

TOWER CL INLET

VERTICAL
DISCHARGE
(OPTION-NOTE 3)

MOTOR

INLET PIPING
(BY OTHERS)

CL SIDE OUTLET

USE FOR
STATIC LIFT

TOWER COLLECTION
BASIN

B
TOWER CL OUTLET

CL BOTTOM OUTLET

AIR INLET ELEVATION

SIDE ELEVATION
Dimensions

Tower
Model

Nominal Tons
note1

C note 2

490A

902

1292

1610

402

175

610

490B

902

1292

1610

402

175

610

492A

1206

1543

2248

432

241

1219

492B

1206

1543

2248

432

241

1219

493A

1816

1549

2248

432

241

1524

493B

1816

1549

2248

432

241

1524

D
note 3

note 3

E
note 6

Motor
kW

Piping
Connection
Outlet
Inlet
note 6

1318

.25

2" F

1318

.75

2" F

203

1956

.75

4" M

203

1956

1.5

4" M

203

1956

1.5

4" M

203

1956

2.2

4" M

494A

1816

1972

2743

608

292

1829

3251

235

2403

1.5

6" MC

494B

1816

1972

2743

608

292

1829

3251

235

2403

2.2

6" MC

494C

1816

1972

2743

608

292

1929

3251

235

2403

3.7

6" MC

495A

2426

1975

2743

608

292

2134

3251

235

2403

3.7

6" MC

495B

2426

1975

2743

608

292

2134

3251

235

2403

5.5

6" MC

496A

111

3035

1984

2953

589

292

2743

3345

235

2610

3.7

6" MC

496B

126

3035

1984

2953

589

292

2743

3345

235

2610

5.5

6" MC

1. Nominal tons are based upon 35°C HW, 29.5°C CW, 25.5°C WB

and .68 m3/hr per ton. The Marley UPDATE web-based selection
software provides Aquatower model recommendations based
on specific design requirements.

2. Minimum clearance for adequate air supply. Consult your Marley
sales representative or your local distributor if this clearance is
impractical for your job.
3. 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.

4. Motors are 400 volt, 3-phase TEFC.
5. Motor, belt and belt guard ship uninstalled. Installation by others.
6. Outlet 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 coverplate provided. Pump suction should use side outlet. See page 9
for size and flow capacities of bottom outlets.
7. Overflow is a 2" F connecton located in side of collection basin.
8. Drain is a 2" F connection located in collection basin floor.
9. Makeup valve connection is 3/4" M located in tower side.

/ Support /

25mm

L
F

CL ANCHOR

ANCHOR CL
BOLT

W G

CL ANCHOR

BOLT

16mm DIAMETER HOLES
CL ANCHOR

CL ANCHOR

TOWER
COLLECTION BASIN

AIR INLET FACE

TOWER
COLLECTION BASIN

G
A W

16mm DIAMETER HOLES

AIR INLET FACE

SUPPORTING STEEL PLAN

OPTION TWO

OPTION ONE
TOWER
COLLECTION
BASIN

TOWER
COLLECTION
BASIN

25mm

MIN. BEARING WIDTH
AT EACH ANCHOR BOLT

NORMAL
GAUGE

SUPPORT
(BY OTHERS)

SECTION A

Tower
Model

VIEW B
Dimensions

25mm

ANCHOR CL
BOLT

BOLT

ANCHOR CL
BOLT

BOLT

L
F

25mm 25mm

Shipping Weight

Maximum
Operating
kg

Maximun
Operating Load
at Anchor
kg

Wind Load kg
Max. Vertical
Reaction at
Anchor

Max. Horizontal
Reaction at
Anchor

490A-490B

902

1019

851

915

198

343

492A-492B

1206

1260

1156

1067

337

633

158

161

493A-493B

1816

1206

1765

1067

445

905

226

238

129

494A-49B

1816

1680

1765

1524

634

1337

334

252

161

495A-495B

2426

1680

2375

1524

797

1294

437

338

213

496A-496B

3035

1680

2985

1524

951

2155

539

497

290

494A-494C

1816

1680

1765

1524

816

1519

380

316

234

495A-495B

2426

1680

2375

1524

968

1920

480

338

234

496A-496B

3035

1680

2985

1524

1178

2382

596

497

290

Models with Vertical Discharge Hood Option

1. Use this bulletin for preliminary layouts only. Obtain current drawings from your Marley sales representative or your local distributor.
2. Purchaser to provide tower supports complete with holes and bolts
for anchorage. All supports must be framed flush and level at top.
Maximum deflection to be 1/360th of span, not to exceed 13mm.
3. Maximum weight occurs with basin full to overflow level at shutdown.
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 Importance Factor of 1.00 per Section 1634—Towers Not on a Building.

Use this data for preliminary layouts only.
Obtain current drawing from your Marley sales
representative.
The Marley UPDATE web-based selection software
—available at spxcooling.com provides
Aquatower model recommendations based on
customer's specific design requirements.

/ Construction And Components /
■ Water Distribution System

■ Fill/Louvers/Drift Eliminators

Warm water flows through external piping (not included

Fill sheets include integral louvers and drift eliminators,

with the tower) into a splash box chamber at the top of the

designed to minimize resistance to airflow. This patented

Aquatower. A splash box prevents the incoming water from

arrangement prevents water from escaping the fill sheets,

spilling out of the basin and helps provide uniform water

assuring proper heat transfer throughout wide variations in

distribution. Water then flows by gravity from the basin

airflow. Users find this fill operates ice-free even in extremely

through nozzles to the fill.

cold weather.
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.

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

MX Fill

resist clogging. Nozzles are easy to remove and replace if

■ Cold Water Collection Basin

you ever want to change the design water flow rate.

The Aquatower’s 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
Spiral-target distribution nozzle

outlet connection not used.

/ Construction And Components /
■ 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 maintenance all drive components are
accessible from outside the tower.

Fan drive motor showing adjustable base and belt guard

■ 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.

■ 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
Fan and fan guard. Guard is easily removed for access to
fan and drive belts

fabrication. The galvanized steel belt guard encloses both
belts and pulleys. Guards are easily removed for servicing.

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

■ Construction and Finish

available.

Aquatowers offer the corrosion protection of Z-600
galvanized providing long term protection for the steel.
Assembly hardware is also galvanized.

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.
7

/ Freeze Prevention /
■ Indoor Tank Method

When the ambient air temperature falls below 0°C, the
water in a cooling tower can freeze. Marley Technical Report
#H-003 “Operating Cooling Towers in Freezing Weather”

In this type of system, water flows from an indoor tank,

describes how to prevent freezing during operation. Ask your

through the load system, and back to the tower, where it is

Marley sales representative for a copy or download from our

cooled. The cooled water flows by gravity from the tower to

website.

the tank located in a heated space. At shutdown, all exposed
water drains into the tank, where it is safe from freezing.

Water collects in the cold water basin during shutdowns,

The table on page 9 lists typical drain-down capacities

and may freeze solid. You can prevent freezing by adding
heat to the water left in the tower. Or, you can drain the tower

for all Aquatower models. Although we do not produce

and all exposed piping at shutdown.

tanks, many of our representatives offer tanks supplied by
reputable manufacturers.
The amount of water needed to successfully operate

■ Electric Basin Heaters

the system depends on the tower size, flow and the volume
of water contained in the piping system to and from the

Provide an electric immersion heater for each cell of the
tower to prevent freezing of water in the collection basin

tower. You must select a tank large enough to contain those

during periods of shutdown. The rod type heater is installed

combined volumes—plus a level sufficient to maintain

in the side of the cold water basin.

a flooded suction on your pump. Control makeup water

according to the level where the tank stabilizes during

Each heater will include an integral thermostat, set

operation.

point nominally 4°C but adjustable to suit local operating

You should always use a bottom outlet for this type of

requirements.

piping system. The following table lists the flow capacities for

Any exposed piping that is still filled with water at

bottom outlets.

shutdown —including the makeup water line—should be
electrically traced and insulated (by others).

Basin Heater Selection
Tower
Model

-12°C Ambient

-25°C Ambient

Tank Heater

Component
Heater

Tank Heater

Component
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

493B

2 kW

3 kW

494A

2 kW

3 kW

4 kW

3 kW
3 kW

494B

2 kW

3 kW

4 kW

494C

2 kW

3 kW

4 kW

3 kW

495A

3 kW

6 kW

4.5 kW

495B

3 kW

6 kW

4.5 kW

496A

3 kW

4.5 kW

6 kW

496B

3 kW

4.5 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.
Options 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.
8

/ Field Assembly /
■ Field Assembly

Drain-Down Capacity
Tower Model

Range of Tower Design m3/hr

Maximum Drain-Down
litres

3.4 - 5.9

106

490A
490B

492A
492B

493A
493B

494A
494B
494C

495A
495B

496A
496B

If you choose to assemble your Aquatower at the job site,
your Aquatower will be shipped unassembled with complete

6.2 - 11.6

114

11.8 - 19.3

125

19.5 - 34.7

136

4.77 - 12

185

largest Aquatower components for each model. You can

12.6 - 209

204

use this information to plan your rigging and transportation

21 - 34.3

227

34.5 - 47.9

246

needs.

7.5 - 18.8

291

Unassembled tower shipment may add 3 to 5 weeks to

assembly instructions.
The following table shows the sizes and weights of the

19 - 32.7

318

normal lead times. Your Marley sales representative will be

32.9 - 54

356

glad to help you plan for your unique needs.

54.2 - 74.5

382

13.6 - 32

507

32.3 - 51.5

549

51.7 - 85.4

613

85.6 - 127.8

674

18.6 - 43.6

689

43.8 - 61.3

727

61.5 - 116.5

829

116.7 - 173.3

912

23.6 - 44.5

863

44.7 - 64.9

920

65.1 - 112.8

1026

113.1 - 218.7

1211

Component Sizes and Weights
Tower Model

490A
490B

492A
492B

Volumes shown are maximums for the flowrate ranges indicated.
Actual volumes will usually be less. Contact your local Marley sales
representative for more specific information.

493A
493B

Bottom Outlet Maximum m3/hr
Outlet Diameter

Tower
Model

10"

492A - 492B

494A
494B
494C

Component

Size mm

Collection Basin End

305 x 330 x 914

Weight kg
7

Collection Basin Floor

76 x 762 x 813

Front Panel

51 x 914 x 112

Casing Panel

51 x 102 x 132

Distribution Basin

203 x 406 x 813

Collection Basin End

356 x 406 x 122

Collection Basin Floor

76 x 914 x 112

Front Panel

51 x 122 x 173

Casing Panel

51 x 660 x 1600

Distribution Basin

203 x 406 x 112

Collection Basin End

356 x 406 x 183

Collection Basin Floor

76 x 914 x 1727

Front Panel

51 x 940 x 183

Casing

51 x 660 x 1600

Distribution

203 x 406 x 173

Collection Basin End

457 x 457 x 1829

Collection Basin Floor

102 x 864 x 1727

Front Panel

51 x 1117 x 1829

Casing Panel

51 x 1016 x 1930

29
24

493A - 493B

Distribution Basin

203 x 711 x 1727

494a - 494B - 494C

142

Optional Discharge Side

51 x 1041 x 1956

495A - 495B

193

Optional Discharge Floor

229 x 1143 x 1727

496A - 496B

193

1. Maximum m3/hr applies to both pump and gravity flow piping systems. The outlet piping on gravity flow systems must have sufficient
vertical drop to overcome all other head losses in the system.
2. Bottom outlet is not available on Models 490A and 490B.

495A
495B

496A
496B

Note: For economical transportation, Aquatowers are normally
packaged unassembled when shipped from the UK by sea or air
freight.

Collection Basin End

457 x 457 x 2438

Collection Basin Floor

102 x 864 x 2338

Front Panel

51 x 1118 x 2438

Casing

51 x 1016 x 1930

Distribution Basin

203 x 711 x 2337

Optional Discharge Side

51 x 1041 x 1956

Optional Discharge Floor

229 x 1143 x 1600

19
36

Collection Basin End

457 x 457 x 3048

Collection Basin Floor

102 x 864 x 2946

Front Panel

51 x 1168 x 3048

Casing Panel

51 x 1016 x 2134

Distribution Basin

203 x 711 x 2946

Optional Discharge Side

51 x 1143 x 1956

Optional Discharge Floor

229 x 1143 x 1956

/ Options /

Option

Description

Option

Field Assembly

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.

Stainless Steel
Construction

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

Factory-installed control center in
IP55,IEC enclosure mounted on tower
casing. Complete with thermostat controller for single or two-speed motors to
maintain chosen cold water temperature.

Vertical
Discharge
Hood

This option is available on Models 494A
and larger. It provides vertical discharge
of the air leaving the tower. Hoods are
galvanized steel. They ship separately
for installation by others. A large access 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.

Description

/ Specifications /

Base: Furnish and install an induced-draft, crossflow, factory-

Fill, Louvers and Drift Eliminator: Fill shall be film-type,

assembled, steel cooling tower of ____ cell(s), as shown

thermoformed PVC, with louvers and drift eliminator

on plans. Tower shall be similar and equal in all respects

formed as part of each fill sheet. Fill shall be suspended

to Marley Series 4900 Aquatower, Model _______. Tower

from hot dip galvanized structural tubing supported from

must be warranted by the manufacturer for one year from

the upper tower structure, and shall be elevated above

date of shipment.

the floor of the cold water basin to facilitate cleaning. Air
inlet faces of the tower shall be free of water splash-out.

Performance: Tower shall cool ____ m3/hr of water from ____ °C

Guaranteed drift losses shall not exceed 0.005% of the

to ____ °C at a design entering air wet-bulb temperature

design flow rate.

of ____ °C and its thermal rating shall be certified by the
Cooling Technology Institute.

Hot Water Distribution System: An open basin above the fill
bank shall receive hot water piped to each cell of the

Construction: Structural components of the tower, including

tower. The basins shall be equipped with removable

the cold water basin, framework, mechanical equipment

covers to keep out debris. This basin shall be installed and

supports, casing, hot water basin, and fan cylinder shall

sealed at the factory. Water shall enter the basin through

be fabricated of heavy-gauge steel, protected against

a removable wave-suppressor splash box. The basin

corrosion by Z-600 galvanizing per BS EN 10327:2004.

shall be no less than 162mm deep to provide adequate

All components subjected to factory welding shall be hot

freeboard against overflow and splash-out. Removable

dip galvanized after fabrication per BS EN 150 1461:1999.

and replaceable polypropylene nozzles installed in the

Cold galvanizing is not acceptable.

floor of the basin shall provide full coverage of the fill by

Motor: Motor(s) shall be ____ kW, Totally Enclosed, specially

gravity flow. Nozzles must all have the same orifice size

insulated for cooling tower duty. Speed and electrical

and be spaced symmetrically in both longitudinal and

characteristics shall be 1500 (or 1500/750) RPM, singlewinding, ____ phase, ____ hertz, ____ volts. The motor
must be located out of the saturated discharge air

transverse directions.
Cold Water Basin and Accessories: The cold water basin shall
be factory sealed. For maximum installation flexibility,

stream.

basin accessories shall include both a side suction

Mechanical Equipment: Fan(s) shall be adjustable-pitch

connection and a hole and bolt circle in the basin floor

propeller type. Fan shall be driven through V-belt(s) with a

suitable for gravity flow. Both connections shall include

minimum service factor of 1.5 based on full motor kW and

a debris screen and anti-cavitation device. A factory-

protected with a belt guard. The fan and fan pulley shall

installed, float-operated, mechanical makeup valve shall

be supported by oil lubricated tapered roller bearings in

be included, having a 3⁄4" diameter inlet connection.

a cast iron housing with externally accessible remote oil
reservoir for easy maintenance.

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

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Spx Cooling Technologies Marley Aquatower Users Manual

Marley Aquatower to the manual b76e8b29-031a-4fd3-b6ee-fa05a7e09ea9

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