engineering data

AV6800 and specifications

STEEL COOLING TOWER
AV Cooling Tower — Contents 2

Engineering Data

Schematic 4
Outlet Piping 14
Support 16
Freeze Prevention 18
Environmental 19
Application 20
Specifications / Base

Base 21
Thermal Performance 22
Performance Warranty 22
Design Loading 22
Construction 23
Mechanical Equipment 24
Fill, Louvers, and Drift Eliminators 25
Hot Water Distribution System 26
Casing, Fan Deck and Fan Guard 26
Access 26
Cold Water Collection Basin 27
Specifications / Options

Stainless Steel Options

All Stainless Steel Cooling Tower 28
Stainless Steel Collection Basin 28
Stainless Steel Distribution System 29
Control Options
Fan Motor Starter Control Panel 29
Terminal Box 30
Vibration Limit Switch 30
Basin Heater 31
Fan Motor Variable Speed Drive 31
Single-Point Power Connection 32
Motor Sequencer with RTD 33
Water Level Control System 33
Convenience and Safety Options
Hot Water Basin Access Platform 34
Hot Water Basin Guardrail System 34
Ladder Extension 34
Ladder Safety Cage 35
Mechanical Equipment Access Platform 35
Access Door Platform 35
Miscellaneous Options
Fan Cylinder Extensions 36
Equalizer Flume Weir Gates 36
Inlet Flow Control Valve 36
Variable Water Flow Distribution 36
FM Approval 37
Air Inlet Screens 37
Basin Sweeper Piping 37
High Wind Load/Seismic Design 37
Quiet Fan 38
Ultra Quiet Fan 38
AV Cooling Tower 3

AV towers are galvanized steel, factory-assembled, Pages 21 thru 27 indicate those paragraphs
general purpose crossflow cooling towers, designed which will result in the purchase of a basic cooling
to serve normal air conditioning and refrigeration tower—one that accomplishes the specified thermal
systems as well as light industrial loads. They evolve performance, but which will lack many operation—and
from a singleflow concept of towers pioneered maintenance-enhancing accessories and features
by Marley in the 1950s, and incorporate all of the that are usually desired by those people who are
design advancements that our customers have found responsible for the continued and continuing
valuable. They represent the current state of the art operation of the system of which the tower is part.
in this cooling tower category. It will also incorporate those standard materials
This booklet not only relates the language to use in which testing and experience has proven to provide
describing an appropriate AV cooling tower—but also acceptable longevity in normal operating conditions.
defines why certain items and features are important Pages 28 thru 38 provide paragraphs intended
enough to specify with the intention of insisting upon to add those features, components, and materials
compliance by all bidders. The left hand column of that will customize the tower to meet the user's
pages 21 thru 38 provides appropriate text for the requirements.
various specification paragraphs, whereas the right
hand column comments on the meaning of the
subject matter and explains its value.
AV Cooling Tower — Engineering Data: Schematic 4

AV6805

Use this data for preliminary layouts only.

Obtain current drawing from your Marley sales
representative.

UPDATE™ web-based selection software, available

at spxcooling.com/update provides AV cooling
tower model recommendations based on customer's
TOWER CL 8" INLET specific design requirements.

1'-115/16"
8" INLET CL

13'-0" INLET FACE 8'-43/4"

11'-111/4"
INSTALLED 11'-53/4"
HEIGHT

BASE OF
TOWER

HINGED ACCESS
DOOR
AV Cooling Tower — Engineering Data: Schematic 5

AV6805

Design
Shipping
Nominal Tons Motor Operating
Tower Model Wt/Cell
note 2 hp Wt/Cell
lb
lb

AV6805HAN 125 3
AV6805KAN 144 5
AV6805MAN 164 7.5
10108 5485
AV6805NAN 178 10
AV6805PAN 204 15
AV6805QAN 225 20

MARLEY HC VALVE CL INLET INLET FACE CL INLET SHORT RADIUS

(OPTION) ELBOW
31/2 " (BY OTHERS)
CL PIPING

12'-21/2"
8" INLET PIPING BASE OF 8" INLET PIPING
(BY OTHERS) TOWER (BY OTHERS)

INLET PIPING DETAILS

NOTE
1 Use this bulletin for preliminary layouts only. Obtain current 4 Outlet sizes vary according to gpm and arrangement. See pages 14
drawings from your Marley sales representative. All table data is per and 15 for outlet sizes and details.
cell. 5 Makeup water connection may be 1" or 2" dia., depending upon tower
2 Nominal tons are based upon 95°F HW, 85°F CW, 78°F WB and 3 heat load, water pressure, and desired connections. See page 14 for
gpm/ton. additional information.
3 Standard overflow is a 4" dia. in the collection basin floor.
AV Cooling Tower — Engineering Data: Schematic 6

AV6807

Use this data for preliminary layouts only.

Obtain current drawing from your Marley sales
representative.

UPDATE™ web-based selection software, available

at spxcooling.com/update provides AV cooling
tower model recommendations based on customer's
specific design requirements.
TOWER CL10" INLET

10 7/8"
10" INLETCL

11'-11" INLET FACE 12'-03/4"

11'-53/4"
INSTALLED
HEIGHT

BASE OF
TOWER

HINGED ACCESS
DOOR
AV Cooling Tower — Engineering Data: Schematic 7

AV6807

Design
Shipping
Nominal Tons Motor Operating
Tower Model Wt/Cell
note 2 hp Wt/Cell
lb
lb

AV6807HAN 164 3
AV6807JAN 177 4
AV6807KAN 189 5
AV6807LAN 201 6
AV6807MAN 215 7.5
AV6807NAN 230 10 13057 6899
AV6807PAN 263 15
AV6807QAN 293 20
AV6807RAN 318 25
AV6807SAN 337 30
AV6807TAN 372 40

MARLEY HC VALVE
(OPTION)
CL INLET INLET FACE CL INLET SHORT RADIUS
ELBOW
41/4 " (BY OTHERS)
CL PIPING

12'-4 3/4"
10" INLET PIPING BASE OF 10" INLET PIPING
(BY OTHERS) TOWER (BY OTHERS)

INLET PIPING DETAILS

NOTE
1 Use this bulletin for preliminary layouts only. Obtain current 4 Outlet sizes vary according to gpm and arrangement. See pages 14
drawings from your Marley sales representative. All table data is per and 15 for outlet sizes and details.
cell. 5 Makeup water connection may be 1" or 2" dia., depending upon tower
2 Nominal tons are based upon 95°F HW, 85°F CW, 78°F WB and 3 heat load, water pressure, and desired connections. See page 14 for
gpm/ton. additional information.
3 Standard overflow is a 4" dia. in the collection basin floor.
AV Cooling Tower — Engineering Data: Schematic 8

AV6809

Use this data for preliminary layouts only.

Obtain current drawing from your Marley sales
representative.

UPDATE™ web-based selection software, available

at spxcooling.com/update provides AV cooling
tower model recommendations based on customer's
specific design requirements.
TOWER CL10" INLET

10 3/4"
10" INLETCL

11'-11" INLET FACE 18'-03/8"

11'-53/4"
INSTALLED
HEIGHT

BASE OF
TOWER

HINGED ACCESS
DOOR
AV Cooling Tower — Engineering Data: Schematic 9

AV6809

Design
Shipping
Nominal Tons Motor Operating
Tower Model Wt/Cell
note 2 hp Wt/Cell
lb
lb

AV6809KAN 240 4.5

AV6809LAN 262 6
AV6809AAN 296 9
AV6809PAN 339 15
19098 9663
AV6809BAN 389 22.5
AV6809SAN 432 30
AV6809CAN 463 37.5
AV6809EAN 497 45

MARLEY HC VALVE
(OPTION)
CL INLET INLET FACE CL INLET SHORT RADIUS
ELBOW
41/4 " (BY OTHERS)
CL PIPING

12'-4 3/4"
10" INLET PIPING BASE OF 10" INLET PIPING
(BY OTHERS) TOWER (BY OTHERS)

INLET PIPING DETAILS

NOTE
1 Use this bulletin for preliminary layouts only. Obtain current 4 Outlet sizes vary according to gpm and arrangement. See pages 14
drawings from your Marley sales representative. All table data is per and 15 for outlet sizes and details.
cell. 5 Makeup water connection may be 1" or 2" dia., depending upon tower
2 Nominal tons are based upon 95°F HW, 85°F CW, 78°F WB and 3 heat load, water pressure, and desired connections. See page 14 for
gpm/ton. additional information.
3 Standard overflow is a 4" dia. in the collection basin floor.
AV Cooling Tower — Engineering Data: Schematic 10

AV6817

Use this data for preliminary layouts only.

Obtain current drawing from your Marley sales
representative.

UPDATE™ web-based selection software, available

at spxcooling.com/update provides AV cooling
tower model recommendations based on customer's
specific design requirements.
TOWER CL10" INLET

10 7/8"
10" INLETCL

11'-11" INLET FACE 12'-03/4"

18'-0"
INSTALLED 17'-11 3/4"
HEIGHT

BASE OF
TOWER

HINGED ACCESS
DOOR
AV Cooling Tower — Engineering Data: Schematic 11

AV6817

Design
Shipping
Nominal Tons Motor Operating
Tower Model Wt/Cell
note 2 hp Wt/Cell
lb
lb

AV6817HAN 216 3
AV6817JAN 236 4
AV6817KAN 253 5
AV6817LAN 267 6
AV6817MAN 286 7.5
AV6817NAN 312 10 18800 9265
AV6817PAN 357 15
AV6817QAN 395 20
AV6817RAN 429 25
AV6817SAN 458 30
AV6817TAN 502 40

MARLEY HC VALVE CL INLET INLET FACE CL INLET SHORT RADIUS

(OPTION) ELBOW
4 1/4 " (BY OTHERS)
CL PIPING

18'-11"
10" INLET PIPING BASE OF 10" INLET PIPING
(BY OTHERS) TOWER (BY OTHERS)

INLET PIPING DETAILS

NOTE
1 Use this bulletin for preliminary layouts only. Obtain current 4 Outlet sizes vary according to gpm and arrangement. See pages 14
drawings from your Marley sales representative. All table data is per and 15 for outlet sizes and details.
cell. 5 Makeup water connection may be 1" or 2" dia., depending upon tower
2 Nominal tons are based upon 95°F HW, 85°F CW, 78°F WB and 3 heat load, water pressure, and desired connections. See page 14 for
gpm/ton. additional information.
3 Standard overflow is a 4" dia. in the collection basin floor.
AV Cooling Tower — Engineering Data: Schematic 12

AV6819

Use this data for preliminary layouts only.

Obtain current drawing from your Marley sales
representative.

UPDATE™ web-based selection software, available

at spxcooling.com/update provides AV cooling
TOWER CL INLET

tower model recommendations based on customer's

specific design requirements.

A
INLET CL

11'-11" INLET FACE 18'-01/2 "

18'-4 3/4"
INSTALLED
HEIGHT

18'-4 1/2"

BASE OF
TOWER

HINGED ACCESS
DOOR
AV Cooling Tower — Engineering Data: Schematic 13

AV6819

10" Inlet 12" Inlet Design

Shipping
Tower Model Nominal Tons Motor Operating
Wt/Cell
note 2 note 3 hp Wt/Cell
A C P A C P lb
lb

AV6819KAN 325 4.5

AV6819LAN 355 6
AV6819AAN 401 9
AV6819PAN 469 15
AV6819BAN 537 22.5 10 3⁄4" 4 1⁄4" 19'-3" 121⁄4" 4 7⁄8" 19'-3" 27115 13540
AV6819SAN 595 30
AV6819CAN 644 37.5
AV6819EAN 690 45
AV6819VAN 772 60

MARLEY HC VALVE CL INLET INLET FACE CL INLET SHORT RADIUS

(OPTION) ELBOW
C (BY OTHERS)
CL PIPING

P
INLET PIPING BASE OF INLET PIPING
(BY OTHERS) TOWER (BY OTHERS)

INLET PIPING DETAILS

NOTE
1 Use this bulletin for preliminary layouts only. Obtain current 4 Outlet sizes vary according to gpm and arrangement. See pages 14
drawings from your Marley sales representative. All table data is per and 15 for outlet sizes and details.
cell. 5 Makeup water connection may be 1" or 2" dia., depending upon tower
2 Nominal tons are based upon 95°F HW, 85°F CW, 78°F WB and 3 heat load, water pressure, and desired connections. See page 14 for
gpm/ton. additional information.
3 Standard overflow is a 4" dia. in the collection basin floor.
AV Cooling Tower — Engineering Data: Piping 14

OUTLET AND MAKEUP PIPING DETAILS Makeup Water Flow Required–gpm to maintain three (3) concentrations
Unless otherwise specified, single-cell towers normally Cooling "Range" (hot water° minus cold water°)
Tower
have a side-outlet suction appropriate for the design water gpm 5º F 10º F 15º F 20º F 30º F 40º F
flow rate—see page 15. This usually assures the lowest pos-
200 2 3 4 5 8 10
sible installed tower elevation. Side-suction connection pipes
400 3 5 8 10 15 20
extend roughly 3" outside the basin, and are beveled for
600 4 8 12 15 23 30
weld connection and also grooved for a mechanical coupling.
800 5 10 15 20 30 40
Outlet piping can be kept below the cold water basin
1000 7 13 19 25 38 50
level by choosing a bottom outlet connection in lieu of the
1500 10 19 29 38 57 75
side suction. Bottom outlet design conform to standard
class 125/150 ANSI pipe flange specifications. All outlet 2000 13 25 38 50 75 100

arrangements include easily removable debris screens. 3000 19 38 57 75 113 150

4000 25 50 75 100 150 200
Multicell towers, intended to operate together as a com-
mon unit, are joined by steel flumes between the collection 5000 32 63 94 125 188 250

basins. These flumes equalize the operating water level 6000 38 75 113 150 225 300
between basins and also provide a flow passage from cells 8000 50 100 150 200 300 400
not equipped with outlets or makeup valves, often eliminat-
ing the need to specify an outlet and makeup valve for NOTE
each cell on a multicell installation. Refer to sales drawings • If circulating water is to be maintained at 2 concentrations instead of 3,
to obtain flow values of suctions and bottom outlets for multiply table gpm values by 1.36 before sizing makeup valve.
multicell installations.
The best choice for a tower used with a remote or indoor
storage tank—see page 18—or on a concrete cold water
basin is usually a bottom outlet, with or without screen. Makeup Valve Flow Capacities–gpm

Pressure at Valve Inlet 1" Diameter 2" Diameter

MAKEUP while flowing–psig Valve Valve

The amount of water constantly evaporated from a 10 56 90

cooling tower varies directly with the heat load applied. 20 78 120
In addition to evaporation, water is normally lost to the 30 92 143
blowdown (bleed-off) necessary to maintain dissolved 40 106 160
solids concentration at an acceptable level in the circulat-
50 117 167
ing water system.
The AV tower is equipped with a float-operated, me-
NOTE
chanical makeup valves to automatically replenish this lost
• If makeup water pressure exceeds 50 psig, use pressure reducer ahead
water. The following tables, calculated for a concentration of valve.
of 3 times normal, indicate the rate of water loss, and the • For flow requirements exceeding the above limitations, use multiples of
size of valve(s) required. If your installation’s cold water the same size valve.
basin will drain by gravity to a remote storage tank, or if
you plan a separate means of controlling makeup water,
we offer a price reduction for deleting the makeup valve.

Maximum gpm Per Outlet Diameter

Outlet Diameter
Outlet Type Flow Type Model
4" 6" 8" 10" 12" 14" 16" 18" 20" 24"

pump flow w/ anti-vortex plate or gravity AV6805 157 355 630 993 1413 1729 2285 2509 3322 4019
Bottom flow w/ or w/o anti-vortex plate AV6807 thru AV6819 167 380 673 1061 1510 1848 2442 3164 3829 4896
pump flow w/o anti-vortex plate AV6805 thru AV6819 71 162 287 453 644 788 1042 1349 1676 2433

pump flow w/ anti-vortex plate or gravity AV6805 900 1595 2515 3578 4379
Sump flow w/ or w/o anti-vortex plate AV6807 thru AV6819 900 1595 2515 3578 4379
pump flow w/o anti-vortex plate AV6805 thru AV6819 630 1116 1761 2505 3065
Cased-Face AV6805 900 1595
pump flow only
Outlet AV6807 thru AV6819 900 1595 2515 3578

NOTE
1 F or gravity-flow situations (as to an indoor tank), use bottom outlet. outlet per cell. For multicell towers connected with collection basin flumes
Side outlet suction is not recommended for gravity flow. and less than one outlet per tower cell consult your Marley sales repre-
2 Gpm limits are based on single-cell or multicell towers with a single sentative for more specific information.
AV Cooling Tower — Engineering Data: Piping 15

WELDING
TOWER CL BEVEL MECHANICAL
COUPLING GROOVE

SUCTION HOOD

REMOVABLE
A TRASH SCREEN

SUCTION CONNECTION
SEE TABLE FOR SIZE TOP OF B
SUPPORT CL TOWER CELL
SECTON
CASED-FACE OUTLET CONNECTION

SUCTION OUTLET
CONNECTION
SEE TABLE
G SEE TABLE FOR SIZE
CL TOWER CELL TOWER COLLECTION
FOR SIZE CLOUTLET BASIN FLOOR
OVERFLOW
3" DIA NPTF
REMOVABLE
DRAIN AND CLEAN-OUT TRASH SCREEN
3" DIA NPTF OUTLET
1 1/2" DIA NPTF – 6805 ONLY CONNECTION

D
CL

C Section H
CL

NOTE BOTTOM OUTLET IS

CL CL CL ALSO AVAILABLE WITHOUT
BASE OF
F E TRASH SCREEN. TOWER
TOP OF
SUPPORT

DRAIN AND OVERFLOW CONNECTION BOTTOM OUTLET CONNECTION

OPTION
NOTE
• Standard overflow is a 4" dia. standpipe in the collection basin floor.
The standpipe removes for flush-out and draining.

Dimensions

Tower Model A
B C D E F G H
10" 12"

AV6805 111⁄4" 4'-3 3⁄8" 4 3⁄4" 49⁄16" 1'-07⁄8" 2'-7" 11⁄2"

AV6807 8 ⁄2"
1
9 ⁄4"
3
6'-1 ⁄8"
1
6 ⁄16"
13
3" 1'-2 ⁄8"
5
4'-0 ⁄4"
3
111⁄16"

AV6809 101⁄8" 111⁄8" 9'-11⁄8" 6 13⁄16" 51⁄16" 1'-25⁄8" 4'-03⁄4" 33⁄4"

AV6817 8 ⁄2"
1
9 ⁄4"
3
6'-1 ⁄8"
1
6 ⁄16"
13
3" 1'-2 ⁄8"
5
4'-0 ⁄4"
3
111⁄16"

AV6819 101⁄8" 111⁄8" 9'-11⁄8" 6 13⁄16" 51⁄16" 1'-25⁄8" 4'-03⁄4" 33⁄4"

AV Cooling Tower — Engineering Data: Support 16

L
L OVERALL OF BASIN
OVERALL OF BASIN
1" D 1"
1" D 1"
CL ANCHOR ANCHOR CL
CL ANCHOR ANCHOR CL A BOLT BOLT
BOLT BOLT

ANCHOR CL
A

BOLT
ANCHOR CL
BOLT

A
HOLES FOR
3/4" DIA. ANCHOR BOLTS
HOLES FOR SEE GRILLAGE
3/4" DIA. ANCHOR BOLTS SUPPORT DRAWING
SEE GRILLAGE FOR DETAILS
SUPPORT DRAWING
FOR DETAILS
W S
W S
CL ANCHOR

CL ANCHOR
BOLT

BOLT

A
A B
TOWER COLLECTION TOWER COLLECTION
BASIN—AIR INLET FACE BASIN—AIR INLET FACE

SUPPORTING STEEL SUPPORTING STEEL

OPTION ONE OPTION TWO

Dimensions Design Operating Design Operating

Tower Model Weight/Cell Load at Anchor
L D W S A lb lb

AV6805 8'-4" 8'-2" 13'-0" 2'-7 ⁄2"

1
21⁄4" 10108 2681

AV6807 12'-0 ⁄4"3

11'-10 ⁄4"
3
11'-11" 11'-4" 3 ⁄4"
1
13057 3843

AV6809 18'-0 ⁄2"1

17'-10 ⁄2"
1
11'-11" 11'-4" 3 ⁄4"
1
19098 5301

AV6817 12'-0 ⁄4"3

11'-10 ⁄4"
3
11'-11" 11'-4" 3 ⁄4"
1
18780 5282

AV6819 18'-0 ⁄2"1

17'-10 ⁄2"
1
11'-11" 11'-4" 3 ⁄4"
1
27115 8117
AV Cooling Tower — Engineering Data: Support 17

L
OVERALL OF BASIN
1" D 1"
CL ANCHOR ANCHOR CL
A BOLT BOLT
ANCHOR CL
BOLT

TOWER
COLLECTION
HOLES FOR BASIN
1"
3/4" DIA. ANCHOR BOLTS
SEE GRILLAGE
SUPPORT DRAWING SUPPORT 3/4" WASHER REQD
FOR DETAILS BY OTHERS BY OTHERS
11'-4 1/2"
13'-0"
NORMAL
GAUGE

SECTION A
CL ANCHOR
BOLT

1'-51/4"

B
TOWER COLLECTION
BASIN—AIR INLET FACE

SUPPORTING STEEL
OPTION THREE – 6805 ONLY

TOWER MINIMUM BEARING WIDTH MUST BE

COLLECTION PROVIDED BY BEAM FLANGE OR BEARING
BASIN PLATE AT EACH ANCHOR BOLT LOCATION.
6"
3/4" WASHER REQD
BY OTHERS
ANCHOR BOLT LOCATION RELATIVE
TO BEAM ORIENTATION IS OPTIONAL
SUPPORT NORMAL
BY OTHERS GAUGE

VIEW B
NOTE
1 Use this bulletin for preliminary layouts only. Obtain current drawings 4 Tower may be placed on a flat concrete slab. Side outlet must be speci-
from your Marley sales representative for final design. fied. See pages 14 and 15 and consult your Marley application sales
2 Purchaser to provide tower support complete with holes and anchor representative.
bolts. Do not use studs! Anchor points must be framed flush and level 5 Tower may be supported from piers at each anchor bolt location, as a
at top. support alternative.
3 Design operating weight occurs with collection basin full to overflow
level. Actual operating weight varies with gpm and piping scheme.
AV Cooling Tower — Engineering Data: Freeze Prevention 18

When the ambient air temperature falls below 32°F, the STEAM JET BASIN HEATER
water in a cooling tower can freeze. Marley Technical Report
Penberthy Houdaille bronze steam jet heaters (1⁄4" to 3⁄4")
#H-003 “Cooling Towers and Freezing Weather” describes
are available for freeze protection (installation by others).
how to prevent freezing during operation. Available at spxcool-
Injectors install in a coupling provided in the side of the col-
ing.com or ask your Marley sales representative for a copy.
lection basin. Live steam, as required, is injected directly into
During shutdown, water collects in the cold water basin the water. Condensed steam adds water to the basin, and the
and may freeze solid. You can prevent freezing by adding heat excess will exit the overflow of the tower.
to the water left in the tower—or, you can drain the tower and
all exposed pipework at shutdown.
INDOOR STORAGE TANK
With this type of system, water flows from an indoor tank,
ELECTRIC BASIN HEATERS
through the load system, and back to the tower, where it is
An automatic basin water heater system is available con- cooled. The cooled water flows by gravity from the tower to
sisting of the following components: the tank located in a heated space. At shutdown, all exposed
water drains into the tank, where it is safe from freezing.
• Stainless steel electric immersion heater(s).
The amount of water needed to successfully operate
 Threaded couplings are provided in the side of the
—
the system depends on the tower size and GPM and on the
collection basin.
volume of water contained in the piping system to and from
• N EMA 4 enclosure containing: the tower. You must select a tank large enough to contain
—Magnetic contactor to energize heater. those combined volumes—plus a level sufficient to maintain a
—Transformer to convert power supply to 24 volts for flooded suction on your pump. Control makeup water accord-
control circuit. ing to the level where the tank stabilizes during operation.
—Solid state circuit board for temperature and
low-water cutoff.
Enclosure may be mounted on the side of the tower.
• C
 ontrol probe in the collection basin to monitor water
temperature and level.
Heater components are normally shipped separately for
installation by others.
 ote: any exposed piping that is still filled with water at
N
shutdown—including the makeup water line—should be
electrically traced and insulated (by others).
AV Cooling Tower — Engineering Data: Operational and Environment Awareness 19

SOUND CONTROL As suggested in the aforementioned Technical Report,

Sound produced by an AV Series tower operating in it may also be advisable to specify a design wet-bulb
an unobstructed environment will meet all but the most temperature 1°F higher than normal to compensate for
restrictive noise limitations—and will react favorably to natural potential recirculation initiated by the enclosure. You’ll
attenuation. Where the tower has been sized to operate within benefit from discussing your project with your Marley sales
an enclosure, the enclosure itself will have a damping effect representative.
on sound. Sound also declines with distance—by about 6 dBA SYSTEM CLEANLINESS
each time the distance doubles. Cooling towers are very effective air washers. Atmospheric
All standard AV cooling towers are equipped with low dust able to pass through the relatively small louver
sound fans. This in combination with zero-splash crossflow openings will enter the circulating water system. Increased
film-fill results in a line of towers capable of meeting most concentrations can intensify system maintenance by clogging
noise limitations. Where noise at a critical point is likely screens and strainers—and smaller particulates can coat
to exceed an acceptable limit, several other options are system heat transfer surfaces. In areas of low flow velocity—
available—listed below in ascending order of cost impact: such as the cold water basin—sedimentary deposits can
• T
 he Marley "Quiet Package" includes the affordable provide a breeding ground for bacteria.
Quiet Fan mechanical option, optimized to achieve In areas prone to dust and sedimentation, you should
the lowest possible sound levels while maintaining consider installing some means for keeping the cold water
efficiency. basin clean. Typical devices include side stream filters and a
• A
 Marley Variable Speed Drive automatically minimizes variety of filtration media.
the tower’s noise level during periods of reduced load
and/or reduced ambient temperature without sacrificing WATER TREATMENT
the system’s ability to maintain a constant cold water
temperature. This is a relatively inexpensive solution, To control the buildup of dissolved solids resulting from
and can pay for itself quickly in reduced energy costs. water evaporation, as well as airborne impurities and biological
The natural nighttime reduction in wetbulb temperature contaminants including Legionella, an effective consistent
makes this a very feasible solution in most areas of the water treatment program is required. Simple blowdown may
world. It also eliminates fan cycling. In combination with be adequate to control corrosion and scale, but biological
a Marley Quiet Package, the Marley Variable Speed contamination can only be controlled with biocides.
Drive is capable of meeting all but the most restrictive An acceptable water treatment program must be
noise limitations. compatible with the variety of materials incorporated in a
• F
 or more severe cases requiring the lowest possible cooling tower—ideally the pH of the circulating water should
fan sound levels the Marley “Ultra Quiet” fan option is fall between 6.5 and 8.0. Batch feeding of chemicals directly
now available on most AV models. Tower height will into the cooling tower is not a good practice since localized
increase—obtain current sales drawings from your damage to the tower is possible. Specific startup instructions
Marley sales representative for accurate dimensions. and additional water quality recommendations can be found in
the AV Series User Manual which accompanies the tower and
• E
 xtreme cases may require inlet and discharge sound also is available from your local Marley sales representative.
attenuator sections—however, the static pressure loss For complete water treatment recommendations, consult a
imposed by attenuators may necessitate an increase in competent, qualified water treatment supplier.
tower size. This is the least desirable approach because
of the significant cost impact—and because of the
obstruction to normal maintenance procedures.
Although not an industry requirement, all published sound CAUTION
data on Marley cooling towers are in accordance with CTI The cooling tower must be located at such distance
ATC128 so you can be assured of sound data accuracy.
and direction to avoid the possibility of contaminated
discharge air being drawn into building fresh air intake
ENCLOSURE
Occasionally, cooling towers are located inside architectural ducts. The purchaser should obtain the services
enclosures for aesthetic reasons. Although AV Series towers of a Licensed Professional Engineer or Registered
adapt well to enclosures, the designer must realize the
potential impact of a poorly arranged enclosure on the tower’s Architect to certify that the location of the cooling
performance and operation. The designer must take care to tower is in compliance with applicable air pollution,
provide generous air inlet paths, and the tower’s fan cylinder
fire and clean air codes.
discharge height should not be lower than the elevation of the
top of the enclosure. Obtain a copy of Marley Technical Report
#H-004 "External Influences on Cooling Tower Performance"
from your Marley sales representative.
AV Cooling Tower — Engineering Data: Application 20

TYPICAL APPLICATIONS ALTERNATIVE SELECTIONS

The AV cooling tower can be used in normal applications In addition to the AV Series, we offer a full scope of Marley
requiring cold water for the dissipation of heat. This includes products in various designs and capacities to meet the special
condenser water cooling for air conditioning, refrigeration, and demands of specific applications.
thermal storage systems, as well as their utilization for free- spxcooling.com—visit us on the web for a complete list of
cooling in all of those systems. They are also used in the cool- products, services, publications and to find your nearest sales
ing of jacket water for engines and air compressors, and are representative.
widely applied to dissipate waste heat in a variety of industrial
and manufacturing processes.
CORROSION RESISTANCE
Choosing the all stainless steel construction option, the AV
can be confidently applied in unusually corrosive processes  uadraFlow®—fiberglass and stainless steel construc-
• Q
and operating environments. However, no single product line tion assures long service life in virtually any environment.
can answer all problems, and selective judgement should be Five-year full product warranty. Efficient PVC film fill.
exercised in the following situations Uniquely different and architecturally attractive.
 igma™—available in wood, fiberglass, HDG steel or
• S
APPLICATIONS REQUIRING ALTERNATIVE COOLING stainless steel structure. Field-erected for medium to
TOWER SELECTIONS large projects. Available in a wide range of sizes.
Efficient PVC film fill.
Certain types of applications are incompatible with any
cooling tower with PVC film fill—whether an AV or other
manufacturer's cooling tower of similar design. PVC is subject SPLASH FILL
to distortion in high water temperatures, and the narrow pas-  C® alpha—available in galvanized steel and stainless
• N
sages typical of film-type fill are easily clogged by turbid or steel, with splash-type fill. Excellent in “dirty water” ap-
debris-laden water. Some of the applications, which call for plications.
alternative tower designs are:
• E
 thylene glycol content—can plug fill passages as slime
and algae accumulate to feed on the available organic
materials.
• F
 atty acid content—found in processes such as soap
and detergent manufacturing and some food process-
ing, fatty acids pose a serious threat for plugging fill
passages.
• P
 articulate carry over—often found in steel mills and
cement plants, can both cause fill plugging, and can
build up to potentially damaging levels on tower struc-
ture.
• P
 ulp carry over—typical of the paper industry and food
processing where vacuum pumps or barometric con-
densers are used. Causes fill plugging which may be
intensified by algae.
 AV Cooling Tower — Specifications: Base 21

Specifications Specification Value

1.0 Base:

1.1 Provide an induced draft, crossflow type, ■ Your specification base establishes the type, configuration, base material, and
factory assembled, film fill, industrial physical limitations of the cooling tower to be quoted. During the planning and
duty, galvanized steel cooling tower situ- layout stages of your project, you will have focused your attention on a cool-
ated as shown on the plans. The limiting ing tower selection that fits your space allotment, and whose power usage is
overall dimensions of the tower shall be acceptable. Limitations on physical size and total operating horsepower avoid the
_____ ft wide, _____ ft long, and _____ introduction of unforeseen operational and site-related influences. Specifying the
ft high to the top of the fan guard. Total number of cells, and the maximum fan hp/cell will work to your advantage.
operating power of all fans shall not
exceed _____ hp, consisting of ___ @ The benefit of crossflow towers is that they are inherently easy to operate,
___ hp motor(s). Tower shall be simi- access, and maintain. Unlike counterflow towers, they have a spacious, full height
lar and equal in all respects to Marley plenum for easy access to all of the tower's internal components, and the water
Model ________. distribution system is readily open to view and cleaning.

1.2 The cooling tower shall be designed If your preference is for a stainless steel tower, or if your water or air quality sug-
for quiet operation, and shall pro- gests that the use of stainless steel is prudent, see stainless steel options on
duce an overall level of sound not page 28.
higher than _______ dB(A) mea-
sured at _______ ft from the location:
______________________. Sound levels
shall be measured with a Type 1 (preci-
sion) system and in full conformance
with ATC-128 test code published by
the Cooling Technology Institute (CTI).
The measurement system shall have a
real-time frequency analyzer and sepa-
rate microphones with an overall toler-
ance +/- 3 dB. All low sound options
shall be CTI Certified for thermal perfor-
mance.

Ladder and access platform

are optional accessories. See
Page 24 for specification
wording.

The ladder can be located on

either end of the platform by
simple field rearrangement of
handrails and posts.
 AV Cooling Tower — Specifications: Base 22

Specifications Specification Value

2.0 Thermal Performance:

2.1 The tower shall be capable of cooling ■ CTI Certification means that the tower has been
_____ gpm of water from ____ °F to tested under operating conditions and found
_____ °F at a design entering air wet- to perform as rated by the manufacturer under
bulb temperature of _____ °F, and its those circumstances. It assures the buyer that
thermal rating shall be Certified by the the tower is not intentionally or inadvertently
Cooling Technologies Institute. undersized by the manufacturer.

3.0 Performance Warranty:

3.1 CTI Certification notwithstanding, the ■ However,

 CTI certification alone is not sufficient to assure you that the tower will
cooling tower manufacturer shall guar- perform satisfactorily in your situation. Certification is established under relatively
antee that the tower supplied will meet controlled conditions, and towers seldom operate under such ideal circumstanc-
the specified performance conditions es. They are affected by nearby structures, machinery, enclosures, effluent from
when the tower is installed according to other towers, etc. Responsible and knowledgeable bidders will take such site-
Plans. If, because of a suspected ther- specific effects into consideration in selecting the tower—but the specifier must
mal performance deficiency, the Owner insist by the written specification that the designer/manufacturer guarantee this
chooses to conduct an on-site thermal “real world” performance. Any reluctance on the part of the bidder should cause
performance test under the supervi- you some concern.
sion of a qualified, disinterested third
party in accordance with CTI or ASME
standards during the first year of opera-
tion; and if the tower fails to perform
within the limits of test tolerance; then
the cooling tower manufacturer will pay
for the cost of the test and will make
such corrections as are appropriate and
agreeable to the Owner to compensate
for the performance deficiency.

4.0 Design Loading:

4.1 The structure and anchorage shall be ■ The

 design wind and seismic loads at the left are the minimum allowables for
designed to withstand a wind load any model in the line under accepted design standards. Some models can with-
of 50 psf while operating, based on stand greater loads. If your application requires higher loads, consult your Marley
International Building Code ASCE7-10, sales representative. These standards give you assurance that the tower can be
as well as a .3g seismic load. The tower shipped, handled, hoisted and ultimately operated in a normal cooling tower envi-
shall be designed to withstand shipping ronment.
and hoisting loads of 2g horizontal and
3g vertical. Handrails, where specified,
shall be capable of withstanding a 200
lb concentrated live load in any direc-
tion, and shall be designed in accor-
dance with OSHA guidelines. Fork lift
slots shall be provided in the basin side
supports to allow handling of the tower
at grade level.

4.2 The tower shall be structurally capable

of being supported at the four outer
corners of the tower cell. Alternatively,
the tower manufacturer shall provide
supporting steel to adapt tower to be
supported at four outer corners.
 AV Cooling Tower — Specifications: Base 23

Specifications Specification Value

5.0 Construction:

5.1 Except where otherwise specified, all ■ In the history of cooling towers, no other coating for carbon steel has exhibited
components of the cooling tower shall the success and longevity of galvanization in exposure to the normal cooling
be fabricated of heavy-gauge steel, tower water quality defined at left. No paints or electrostatically applied coatings,
protected against corrosion by G-235 however exotic they may be, can approach galvanization's history of success.
galvanizing. The tower shall be capable
of withstanding water having a pH of Except for those unusual operating situations where the circulating water may be
6.5 to 8.0; a chloride content (NaCl) up so laden with suspended solids, algae, fatty acids, product fibers, active organ-
to 500 ppm; a sulfate content (SO4) up isms reflected in BOD, and the like that plugging of the fill is a probability, rea-
to 250 ppm; a calcium content (CaCO3) sonable attention to the construction materials and/or their coatings is all that is
up to 500 ppm; and silica (SiO2) up to normally required.
150 ppm. The circulating water shall
contain no oil, grease, fatty acids, or If your preference is for a stainless steel tower, or if your water or air quality sug-
organic solvents. Fiberglass casing, gests that the use of stainless steel is prudent, see stainless steel options on
polyurethane barriers, and thermoset- page 28.
ting hybrids and the components that
are adhered to the sheet metal surface,
shall be considered non-recyclable and
not allowed.

5.2 The specifications, as written, are

intended to indicate those materials
that will be capable of withstanding the
above water quality in continuing ser-
vice, as well as the loads described in
paragraph 4.1. They are to be regarded
as minimum requirements. Where com-
ponent materials peculiar to individual
tower designs are not specified, the
manufacturers shall take the above
water quality and load carrying capabili-
ties into account in the selection of their
materials of manufacture.

Factory Assembly
 AV Cooling Tower — Specifications: Base 24

Specifications Specification Value

6.0 Mechanical Equipment:

6.1 Fan(s) shall be propeller type, incorpo- ■ Propeller-type

 fans require only half the operating hp of blower-type fans.
rating heavy duty aluminum alloy blades However, they should be readily adjustable to permit compensation for job site
attached to galvanized hubs with stain- conditions that may tend to overload the motor. The fans of one manufacturer
less steel U-bolts and hardware. Blades require the purchase of special positioners for each increment of fan blade pitch.
shall be attached to hubs with stainless
steel hardware, and shall be individu- Unless otherwise specified, motor speed will be 1800 RPM in 60 Hertz areas
ally adjustable. Fan(s) shall be driven and 1500 RPM in 50 Hertz areas. If you prefer the operating flexibility of two-
through an industrial grade system of speed operation, please specify the RPM to be 1800/900 (1500/750 in 50
V-belts, pulleys, and tapered roller bear- Hertz regions). Incidentally, two speed motors are a far better choice than sepa-
ings. Bearings shall be rated at 50,000 rate “pony” motors which simply double the problems indicated above.
hours, or greater.
If your preference is for a stainless steel tower, or if your water or air quality sug-
6.2 Motor(s) shall be ____ hp maximum, gests that the use of stainless steel is prudent, see stainless steel options on
NEMA Premium Efficiency, TEFC, 1.15 page 28.
service factor, variable torque, inverter
duty and insulated for cooling tower
duty. Speed and electrical character-
istics shall be ______ RPM, single-
winding, 3 phase, ____ hertz, ____
volts. Motor shall operate shaft-vertical
position for belt drive towers and in the
shaft-horizontal position for geardrive
towers. Nameplate power shall not be
exceeded at design operation. TEAO
motors are not acceptable.

6.3 The fan and fan drive assembly for each

cell shall be supported by a rigid, weld-
ed, hot dip galvanized steel structural
support that resists misalignment. The
mechanical equipment assembly shall
be warranted against any failure caused
by defects in materials and workman-
ship for no less than five (5) years fol-
lowing the date of tower shipment. This
warranty is limited to the fan, fan shaft,
bearings, and mechanical equipment
support. The motor, motor components,
sheaves and belt(s) are warranted by
their manufacturer.
 AV Cooling Tower — Specifications: Base 25

Specifications Specification Value

7.0 Fill, Louvers, and Drift Eliminators:

7.1 Fill shall be film-type, thermoformed ■ Louvers integral with the fill keep the flowing water within the confines of the fill.
of PVC, with louvers and eliminators The separate external louvers used by others permit water to escape the fill and
formed as part of each fill sheet. Fill form ice or produce an unsightly situation adjacent to the tower. If you plan to
shall be suspended from hot-dip galva- use your tower in the wintertime, particularly for free cooling, integral louvers will
nized structural tubing supported from put your operating concerns to rest.
the tower structure, and shall be ele-
vated above the floor of the cold water
basin to facilitate cleaning. The air inlet
face of the tower shall be free of water
splash-out.

7.2 Drift eliminators shall be PVC, triple- ■ Drift

 rate varies with design water load-
pass, and shall limit drift losses to no ing and air rate, as well as drift elimina-
more than 0.005% of the design gpm tor depth and number of directional
flow rate. changes. A drift rate of 0.001% is read-
ily available on many standard models.
If a lower rate is required, please discuss
with your Marley sales representative.

Drift Eliminators

Louvers

Fill Sheets
 AV Cooling Tower — Specifications: Base 26

Specifications Specification Value

8.0 Hot Water Distribution System:

8.1 An open basin above the bank of fill ■ Gravity-flow distribution basins are a feature of crossflow type towers, resulting
shall receive hot water piped to each in operating pump heads of from 10 to 20 feet less than that encountered in
cell of the tower. These distribution counterflow towers with pressurized spray systems. Also, these basins are out
basins shall be installed and sealed at where they can be easily inspected—even maintained—while the tower is in opera-
the factory with bolted connections. tion. Spray systems of counterflow towers, sandwiched between the top of the fill
Tap screws shall not be allowed. The and the drift eliminators, are extremely awkward to access and maintain.
basin shall , and shall be equipped with
removable, galvanized steel covers to If your preference is for a stainless steel tower, or if your water or air quality sug-
keep out leaves and debris, and to gests that the use of stainless steel is prudent, see stainless steel options on
retard the growth of algae. The water page 28.
distribution system shall be accessible
and maintainable during tower fan and
water operation.

8.2 The basin shall include an inlet hole

and bolt circle to accept a 125# flange
connection per ANSI B16.1. Removable,
interchangeable polypropylene nozzles
installed in the floor of these basins
shall provide full coverage of the fill by
gravity flow.

9.0 Casing, Fan Deck and Fan Guard:

9.1 The casing and fan deck shall be

heavy-gauge galvanized steel, and shall
be capable of withstanding the loads
described in paragraph 4.1. The top of
the fan cylinder shall be equipped with
a conical, non-sagging, removable fan
guard, fabricated of welded 5/16" and
7 gauge rods, and hot-dip galvanized
after fabrication.

10.0 Access:

10.1 Large galvanized steel access doors ■ The

 access doors on competitive towers may be 18" wide or smaller, which is
23" wide and a minimum of 52" high unreasonably small for a human being. Specifying the size of the door will cause
shall be located in both endwalls for those bidders to take exception, alerting you to a potential maintenance head-
entry into the cold water basin and fan ache. Two doors are standard on all towers so that access between cells of multi-
plenum area. Access doors shall be cell towers is assured.
operable from inside as well as outside
the tower
 AV Cooling Tower — Specifications: Base 27

Specifications Specification Value

11.0 Cold Water Collection Basin:

11.1 The collection basin shall be G-235 ■ Choose from side suctions and bottom outlets to accommodate a significant
galvanized steel and assembled with variety of piping schemes. Unless so specified, the tower you may be asked to
bolted connections. Tap screws shall not approve may only be available with one type of suction connection, requiring you
be allowed. The cold water basin shall to redesign your piping layout.
be heavy-gauge galvanized steel, and
The basins shall include the number and If your preference is for a stainless steel tower, or if your water or air quality sug-
type of suction connections required to gests that the use of stainless steel is prudent, see stainless steel options on
accommodate the outflow piping system page 28.
shown on the Plans. Suction connec-
tions shall be equipped with galvanized
debris screens. A factory-installed,
float-operated, mechanical makeup
valve shall be included. A 3" diameter
drain and a 4" diameter overflow shall
be provided in each cell of the tower.
The basin shall include a depressed
section into which accumulated silt can
be flushed to permit cleaning. The basin
floor adjacent to the depressed section
shall slope toward the depressed sec-
tion to prevent buildup of silt under the
fill area. Towers of more than one cell
shall include flumes for flow and equal-
ization between cells.
 AV Cooling Tower — Specifications: Options 28

Specifications Specification Value

Stainless Steel Options

All Stainless Cooling Tower ■ Where water quality falls outside the limits indicated in Paragraph 5.1, an all-
stainless tower is worthy of your consideration.
5.1 Replace paragraph 5.1 with the follow-
ing: Except where otherwise specified,
all components of the cooling tower
shall be fabricated of 301L stainless
steel. The tower shall be capable of
withstanding water having a chloride
content (NaCl) up to 750 ppm; a sulfate
content (SO4) up to 1200 ppm; a cal-
cium content (CaCO3) up to 800 ppm;
and silica (SiO2) up to 150 ppm. The
circulating water shall contain no oil,
grease, fatty acids, or organic solvents.
Fiberglass casing, polyurethane barriers,
and thermosetting hybrids and the com-
ponents that are adhered to the sheet
metal surface, shall be considered non-
recyclable and not allowed.

Stainless Steel Collection Basin: ■ The cold water basin is the only part of the tower that is subject to periods of
stagnant water, concentrated with treatment chemicals and customary contami-
11.1: Replace paragraph 11.1 with the fol- nants. It is also the most expensive and difficult part of any tower to repair or
lowing: The collection basin shall be replace. For these reasons, many customers—particularly those who are replacing
welded 301L stainless steel construc- older towers—choose to specify stainless steel cold water basins.
tion. Only low-carbon stainless steel
alloys will be accepted in order to Also, see the notes on page 27 regarding the standard Cold Water Collection
minimize the risk of intergranular corro- Basin. They apply equally well to the stainless steel basin.
sion in the weld zones. The basin shall
include the number and type of suction
connections required to accommodate
the outflow piping system shown on
the plans. Suction connections shall
be equipped with stainless steel debris
screens. A factory-installed, float-
operated, mechanical make-up valve
shall be included. An overflow and drain
connection shall be provided in each
cell of the cooling tower. The basin floor
shall slope toward the drain to allow
complete flush out of debris and silt
that may accumulate. Towers of more
than one cell shall include a method
for flow and equalization between cells.
The basin shall be accessible and main-
tainable while water is circulating. All
steel items that project into the basin
shall also be made of stainless steel.
 AV Cooling Tower — Specifications: Options 29

Specifications Specification Value

Stainless Steel Distribution Basin: ■ The corrosion potential of contaminated water increases with temperature—and
these basins see the hottest water in the tower. If your design hot water tempera-
8.1: Replace paragraph 8.1 with the follow- ture is over 125°F, or if your operating system can produce excursions beyond
ing: An open 301L stainless steel basin that point, you would be well advised to consider this option.
shall receive hot water piped to each
cell of the tower. These basin compo- It would also be advisable to change the fill support tubes in Para. 7.1 from galva-
nents shall be installed and sealed at nized structural tubing to 300 stainless steel structural tubing. See notes regard-
the factory and assembled with bolted ing Section 8.0 on page 26.
connections. Tap screws shall not be
acceptable due to their potential to
develop leaks. The basins shall be
equipped with removable, stainless steel
covers capable of withstanding the
loads described in paragraph 4.1. All
components of these basins, with the
exception of the nozzles, shall be stain-
less steel. The water distribution system
shall be accessible and maintainable
during tower fan and water operation.

Control Options

Fan Motor Starter Control Panel: ■ If it is your opinion that the control system for the cooling tower be part of the
tower manufacturer’s responsibility, we are in wholehearted agreement with you.
6.4 
Add the following paragraph to the Who better to determine the most efficient mode and manner of a cooling tower’s
Mechanical Equipment section: Each operation—and to apply a system most compatible with it—than the designer and
cell of the cooling tower shall be manufacturer of the cooling tower?
equipped with a UL / CUL 508 listed
control panel in a NEMA 3R or 4X out- Marley variable speed drives are also available for enhanced temperature control,
door enclosure capable of controlling energy management and mechanical equipment longevity. See specifications on
single-speed or two-speed motors as page 31.
required, and designed specifically for
cooling tower applications. The panel
shall include a main circuit breaker with
an external operating handle, lockable
in the off position for safety. Full volt-
age non-reversing magnetic starter
shall be controlled with a thermostatic
or solid-state temperature controller.
Door mounted selector switches shall
be provided to enable automatic or
manual control and wired for 120VAC
control. Control circuit to be wired out to
terminal blocks for field connection to
a remote vibration switch, overload trip
alarms and remote temperature control
devices. The temperature controller shall
be adjustable for the required cold-
water temperature. If a thermostatic
controller is used it shall be mounted
on the side of the tower with the tem-
perature sensing bulb installed in the
cold-water basin using a suspension
mounting bracket. If a solid-state tem-
perature controller is used the controller
will be door mounted on the control
➠
 AV Cooling Tower — Specifications: Options 30

Specifications Specification Value

panel. The solid state temperature con-

troller will display two temperatures, one
for outgoing water and the other for set
point. Water temperature input shall be
obtained using a three-wire RTD with
dry well in the outlet water piping and
wired back to the solid-state tempera-
ture controller in the control panel.

Terminal Box: ■ The Marley Terminal Box simplifies all electrical connections to the cooling tower
motor and optional control accessories.
6.4 Add the following paragraph in the
Mechanical Equipment section: A • Eliminates wiring errors in the field
factory installed terminal box shall be • Reduces field wiring labor and materials
furnished and mounted to the outside • Provides an external access location to internal cooling tower wiring
of the tower where applicable. The fan • NEMA 4X fiberglass enclosure suitable for corrosive applications
motor and optional components—includ- • Terminal points are well identified
ing the vibration switch and water • UL 508 assembly
level probes—shall be factory wired to
terminal points inside the terminal box.
Optional tower components which ship
loose, including the oil level switch and
immersion heaters shall be field wired
to the terminal box. Enclosure shall be
NEMA 3R or NEMA 4X with hinged
and lockable door meeting UL and CSA
standards. Terminal box shall include
lockable stainless steel snap-latch door
fasteners, terminal blocks marked with
wire numbers, sub-pan and a wiring dia-
gram. Complete assembly shall be built
to UL 508A standards. Conduit entry
and exit points shall be the bottom of
the enclosure preventing water collec-
tion in the enclosure.

Vibration Limit Switch: ■  Unless specified otherwise, an

IMI Sensors mechanical vibration
6.4 Add the following paragraph in the switch will be provided. The require-
Mechanical Equipment section: A ment for manual reset assures that
vibration limit switch in a NEMA 4X the cooling tower will be visited to
housing shall be installed on the determine the cause of excessive
mechanical equipment support and vibration.
wired to the shutdown circuit of the fan
motor starter or VFD. The purpose of
this switch will be to interrupt control
power voltage to a safety circuit in the
event of excessive vibration causing the
starter or VFD equipment to de-ener-
gize the motor. It shall be adjustable for
sensitivity and include a means to reset
the switch.
 AV Cooling Tower — Specifications: Options 31

Specifications Specification Value

Basin Heater: ■ The Marley basin heater components

described at left represent our rec-
11.2 Add the following paragraph in the ommendation for a reliable automatic
Cold Water Basin section: Provide system for the prevention of basin
a system of electric immersion heat- freezing. They are normally shipped
ers and controls for each cell of the separately for installation at the job-
tower to prevent freezing of water in site by the installing contractor. When
the collection basin during periods of purchased in conjunction with the
shutdown. The system shall consist enhanced Control System option,
of one or more stainless steel electric however, they are customarily factory-
immersion heaters installed in threaded mounted and tested.
couplings provided in the side of the
basin. A NEMA 4 enclosure shall house When zinc ions are present in basin water, copper immersion heaters
a magnetic contactor to energize heat- must not be used. Insist upon stainless steel.
ers; a transformer to provide 24 volt
control circuit power; and a solid state The ambient air temperature that you insert in the specifications should be the
circuit board for temperature and low lowest 1% level of winter temperature prevalent at site.
water cutoff. A control probe shall be
located in the basin to monitor water
level and temperature. The system shall
be capable of maintaining 40°F water
temperature at an ambient air tempera-
ture of __ °F.

Fan Motor Variable Speed Drive:

ACH550 VFD System ■ Marley Variable Speed Drive systems are designed to combine absolute tempera-
ture control with ideal energy management. The cooling tower user selects a cold
6.4 Add the following paragraph in the water temperature and the drive system will vary the fan speed to maintain that
Mechanical Equipment section: A com- temperature. Precise temperature control is accomplished with far less stress to
plete UL listed Variable Speed Drive the mechanical equipment components. The improved energy management pro-
system in a NEMA 1 indoor, NEMA 12 vides energy savings to the user.
indoor or NEMA 3R outdoor enclosure
shall be provided. The VFD shall use Motors operated on a VFD shall carry a service factor of 1.0. When operating on
PWM technology with IGBT switching. a VFD, the drive parameters should be programmed to limit the current to motor
VFD output switching signal shall be nameplate hp. Adjust the Motor specification accordingly.
programmed to not cause mechanical
vibration issues with backlash in gear- Applications requiring a cable distance between VFD and motor of over 100 feet
box teeth or vibration issues associated requires a separate DV/DT motor filter to be installed and wired at the drive. This
with long driveshafts. The VFD shall be filter protects the motor from damaging high voltage spikes on the motor wind-
programmed for variable torque applica- ings, inherent with long lead runs.
tions and shall catch a fan spinning in
the forward or reverse direction without
tripping. VFD panel construction shall
include a main disconnect with short
circuit and thermal overload protection
with external operating handle, lock-
able in the off position for lock-out
tag-out safety procedures. A service
switch directly ahead of the VFD shall
be provided for voltage isolation during
VFD maintenance. An integrated full
voltage non-reversing bypass starter
shall be furnished allowing fan motor
operation if VFD has failed. The VFD
system shall receive a speed reference
➠
 AV Cooling Tower — Specifications: Base 32

Specifications Specification Value

signal from the building management

system monitoring the tower cold-water
temperature. As an option to receiv-
ing the speed reference signal from a
building management system, the drive
must have the capability to receive a
4-20 mA temperature signal from an
RTD transmitter. The VFD shall have
an internal PI regulator to modulate fan
speed maintaining set point tempera-
ture. The drive’s panel shall display the
set-point temperature and cold-water
temperature on two separate lines. The
bypass shall include a complete mag-
netic bypass circuit with the capability
to isolate the VFD when in the bypass
mode. Transfer to the bypass mode shall
be manual in the event of VFD failure.
Once the motor is transferred to the
bypass circuit the fan motor will run at
constant full speed. Operator controls
shall be mounted on the front of the
enclosure and shall consist of Start and
Stop control, Bypass/VFD selection,
Auto/Manual selections and manual
speed control. To prevent heating prob-
lems in the cooling tower fan motor the
VFD system shall de-energize the motor
once 25% motor speed is reached and
cooling is no longer required. The cool-
ing tower manufacturer shall supply
VFD start-up assistance.

Single-Point Power Connection: ■ A main circuit breaker disconnect provides a true single point power connection
for cooling tower controls. Contractor connects a single power source and the
6.4 Add the following paragraph in the panel provides power feeds, controls and voltages for tower controls. Typically
Mechanical Equipment section: Each each cell of a tower requires one SPPC panel.
cell of the cooling tower shall be
equipped with a UL/CUL 508 listed
control panel in a NEMA 3R or 4X out-
door enclosure. The panel shall accom-
modate a single source power supply
feeder and include electrical circuits
and components to power and control
all electrical cooling tower components
for a single cell. The panel shall include
a main circuit breaker with an external
operating handle, lockable in the off
position for safety. Controls integrated
into the panel shall include a fan motor
starter, basin heater controls and water
level controls. In the event a VFD is
furnished for the fan, a feeder breaker
in the panel to a remote mounted VFD
shall be provided.
 AV Cooling Tower — Specifications: Options 33

Specifications Specification Value

Motor Sequencer with RTD: ■ Marley sequencer controls help extend the life of the fan motors with automatic
lead stage rotation. The sequencing controllers prevent the same motor from
6.4 Add the following paragraph to the always starting first in the normal sequence of operation. Every 24 hours a differ-
Mechanical Equipment section: A ent motor becomes the lead stage, equalizing the wear on all motors.
complete system including a sequencer
control panel with temperature RTD and
a one-speed or two-speed starter panel
for each cell shall be provided. The
sequencer shall be furnished to auto-
matically stage multiple fans in a cool-
ing tower lineup. Staging shall be based
on a programmed set point temperature
and the cold-water discharge represent-
ing the total cold water temperature
leaving a tower. Enclosure shall be
either NEMA 12 indoor or NEMA 4X
outdoor with hinged and lockable door
meeting UL508 or CUL508 standards.
Sequencer operating two speed motors
may be configured to cycle through as
LO1 – LO2 – LO3 – HI1 – HI2 – HI3
as a default setting or optional setting
as LO1 – HI1 – LO2 – HI2 – LO3 –
HI3. Indicator lights used to display
which cells are energized and at which
speed shall be provided on the enclo-
sure door. Indication of running status
of each cell and speed shall be brought
out to user terminal blocks for remote
monitoring. An optional remote set point
control via a 4-20mA signal shall be
available to remotely control the set
point value.

Water Level Control System: ■ Solid-state liquid level controls provide you with state-of-the-art systems to con-
trol and monitor the water level in your cooling tower collection basin. Relays
11.2 Add the following paragraph to the operating in conjunction with suspended stainless steel electrode probes monitor
Cold Water Basin section: Provide a basin water levels, providing simple solenoid-valve water make-up or discrete on/
water level control system including a off signals to more sophisticated automation controls. Optional configurations
NEMA 4X control panel, water level might include make-up along with high and low water level alarm and cutoff, or
probes and probe stilling chamber. The pump cutoff. Packaged systems including any of these variations are available.
control system shall monitor the water Consult your Marley sales representative or download literature number ACC-
level in the cold-water basin to deter- NC-9 from spxcooling.com for additional information.
mine level events used for cold-water
make-up, high and low alarms or pump
shut down. The control panel shall use
electromechanical relays providing
power for the make-up solenoid and
electrical contacts for alarm and pump
shutdown control circuits. Probes shall
be contained in a vertical stilling cham-
ber to stabilize the water in the cold-
water basin. Probes shall have replace-
able stainless steel tips and level height
shall be field adjustable.
 AV Cooling Tower — Specifications: Options 34

Specifications Specification Value

Convenience and Safety Options

Hot Water Basin Access Platform: ■ Periodic

 inspection and maintenance of a cooling tower
distribution system is fundamental to preserving maximum
10.2 Add the following paragraph in the cooling system efficiency. All cooling towers—crossflow or
Access section: Provide an external counterflow—are subject to clogging to varying degrees
platform near the top of the louver face by waterborne contaminants such as pipe scale and sedi-
for access to the hot water distribution ment. Therefore, safe and easy access to these compo-
system. The platform shall be galvanized nents is of significant value to the operator.
steel bar grating, supported by galva-
nized steel framework attached to the Access can be provided in a number of ways, including por-
tower. The platform shall be surrounded table ladders or scaffolding, but for maximum safety and convenience, a factory
by a handrail, kneerail, and toeboard. A installed Marley access platform with guardrails makes this task as safe and user-
permanently attached 1'-6" wide alu- friendly as possible. Further, its location on the side of the tower does not add to
minum ladder with 3" I-beam side rails the height of the unit, preserving architectural integrity. See graphic, Page 21. It
and 1.25" diameter serrated rungs shall also saves the owner time and money, in that maintenance personnel may devote
extend from the base of the tower to their time to inspection rather than searching for ladders or erection of portable
the top of the handrail. scaffolding.

Hot Water Basin Guardrail System:

10.2 Add the following paragraph in the

Access section: The area surrounding
the hot water basin of the tower shall
be equipped with a guardrail complete
with knee rail and toeboard, designed
according to OSHA guidelines and fac-
tory welded into subassemblies for ease
of field installation. Posts, top rails and
knee rails shall be 1.5" square tubing.
The guardrail assembly shall be hot
dipped galvanized after welding and
capable of withstanding a 200 pound
concentrated live load in any direction.
Posts shall be spaced on centers of
8'-0" or less. A 1'-6" wide aluminum
ladder with 3" I-beam side rails and
1.25" diameter rungs shall be perma-
nently attached to the end wall casing
of the tower, rising from the base of the
tower to the top of the guardrail.

Ladder Extension: ■ Many towers are installed such that the base of the tower is 2'-0" or more above
the roof or grade level. This makes it difficult to get up to the foot of the attached
10.2 Add the following to the end of the ladder. The ladder extension alleviates this problem. Marley ladder extensions are
Hot Water Basin Access Platform available in standard 5'-0" and 11'-0" lengths.
paragraph: Provide a ladder exten-
sion for connection to the foot of the
external ladder. This extension shall
be long enough to rise from the roof
(grade) level. The installing contractor
shall be responsible for cutting the lad-
der to length; attaching it to the foot of
the tower ladder; and anchoring it at its
base.
 AV Cooling Tower — Specifications: Options 35

Specifications Specification Value

Ladder Safety Cage: ■ To meet OSHA guidelines, towers whose distribution basin access platforms are
20'-0" or more above roof or grade, and which are equipped with external lad-
10.2 Add the following to the end of the ders, should have safety cages surrounding the ladders.
Hot Water Basin Access Platform
paragraph and the Hot Water
Guarderail System: A heavy gauge gal-
vanized steel safety cage shall surround
the ladder, extending from a point 7'-0"
to 8'-0" above the foot of the ladder to
the top of the distribution basin access
platform handrail.

Ladder Safety Gate: ■ A galvanized steel self-closing gate located at the guardrail level of the fan deck,
exterior motor access platform and access door platform. Stainless steel is avail-
10.2 Add the following to the end of para- able with the stainless guardrail option.
graph 10.2: A steel, self-closing gate 
shall be provided at the guardrail level
of the ladder.

Mechanical Equipment Access ■ Periodic inspection and maintenance of cooling tower fans, motors and other
Platform: rotating equipment is fundamental to preserving maximum cooling system effi-
ciency. All mechanical draft cooling towers—forced or induced draft—are subject
Available only on AV6817 and AV6819 to vibration and wear. Therefore, safe and easy access to these components for
models. inspection and maintenance is of significant value to the operator.
10.2 Add the following paragraph in the
Access section: An internal ladder shall Access can be provided in a number of ways, including portable ladders or
extend upward from the plenum walk- scaffolding, but for maximum safety and convenience, a factory installed Marley
way to an elevated fiberglass bar grat- access platform with guardrails makes this task as safe and user-friendly as pos-
ing platform convenient for the care and sible. See graphic below. It also saves the owner time and money, in that main-
maintenance of the tower's mechanical tenance personnel may devote their time to inspection rather than searching for
equipment. The platform shall be sur- ladders or erection of portable scaffolding.
rounded by an OSHA compliant guard-
rail system welded into subassemblies
for ease of installation.

Access Door Platform:

10.2 Add the following paragraph in the

Access section: There shall be an
access platform at the base of the
tower extending from the vertical ladder
to the access door. The platform shall
be surrounded by an OSHA compliant
guardrail system welded into subas-
semblies for ease of installation. The
walking surface of the platform shall be
perforated to provide a non-slip surface
for personnel safety.
 AV Cooling Tower — Specifications: Options 36

Specifications Specification Value

Miscellaneous Options

Fan Cylinder Extensions: ■ Extensions are available in 113⁄4" increments to a maximum extension height of
6'-101⁄4". Such extensions may be considered necessary in order to elevate the
9.1 Insert the following after the first sen- discharge beyond the bounds of an enclosure. Discuss applicability with your
tence: Fan cylinder extensions shall be local Marley sales representative.
provided to elevate the fan discharge to
a height of ___ ft. above the top of the
standard fan cylinder.

Equalizer Flume Weir Gates: ■ Where it is your intention to be able to operate other cells of the tower while the
flume cover plate is installed, separate outlet connections, float valves, and over-
11.2 Add the following paragraph under flows must be provided for each cell. Likewise, this would require separate sen-
Cold Water Collection Basin: The sors and controls for basin heater systems, if installed.
interconnecting flume between cells
shall be equipped with a removable
cover plate to permit the shutdown of
one cell for maintenance purposes, or to
permit independent cell operation.

Inlet Flow Control Valve: ■ Marley inlet flow-control valves have been a favorite
of users since the 1950s. They remain serviceable
8.3 Add the following paragraph under Hot for the life of the tower and provide a continuing
Water Distribution System: A heavy- means of flow-regulation between hot water basins—
duty, industrial grade flow-control valve and between cells of multi-cell towers as well.
shall be provided at the inlet to the hot
water basin. The valve shall permit both
flow balancing on multicell towers and
temporary shut-off for maintenance
of selected cells. Valve shall have a
machined cast iron body, with stainless
steel operating stem, and heavy-duty
locking handle.

Variable Water Flow Distribution:

8.2 Add the following to the end of this

paragraph: The water distribution sys-
tem shall be equipped with a method to
operate under variable flow conditions
while maintaining a uniform air-side
pressure drop through the fill to maxi-
mize cooling efficiency and minimize
the risk of ice and scale formation in
the fill. System must accommodate
flow rates down to _______% of design
flow.
 AV Cooling Tower — Specifications: Options 37

Specifications Specification Value

FM Approval: ■ This could have a very beneficial effect upon your fire insurance premiums.
Towers not able to meet FM requirements may require the inclusion of a fire
Available only on multi-cell towers. protection sprinkler system to achieve a comparable level of insurance premium
5.3 Add the following paragraph in the cost. Even if you are not insured by FM, this requirement ensures that each cell
Construction section: For applications will contain any fire that may occur without losing the ability of limited operations
of two or more cells, the tower shall be and capacity.
listed in the current FM Approval Guide
(approvalguide.com) and conform to
the FM Approval Standard for Cooling
Towers, Class Number 4930 that is
approved for use without sprinkler sys-
tems. The tower shall have successfully
passed full scale fire testing, static and
cyclic wind pressure testing, large mis-
sile impact testing (for Zone HM), and
structural design evaluation as admin-
istered by FM Approvals. A copy of the
FM Approval Certificate of Compliance
dated November 2013 or later shall be
available upon request.

Air Inlet Screens: ■ In wooded or windy areas, these screens help to keep leaves or blowing debris
out of the cooling tower and circulating water system.
9.1 Add the following paragraph to the
Casing, Fan Deck and Fan Guard
section: The air inlet faces of the
tower shall be covered by 1" mesh hot-
dipped galvanized welded wire screens.
Screens shall be secured to removable
galvanized U-edge frames. Screens
shall be designed to permit full access
to the cold-water basin by removal of
one panel on each air inlet.

Basin Sweeper Piping: ■ PVC sweeper piping and nozzles.

11.2 Add the following paragraph to the

Cold Water Collection Basin sec-
tion: The cold water basin shall be
equipped with PVC sweeper piping
with plastic nozzles. The piping shall
be factory installed under the fill and
designed to force all dirt and debris to
the depressed section of the collection
basin.

High Wind Load/Seismic Design: ■ High wind load designs greater than 30 psf and up to 100 psf are available.
It is important to consult the local code official for actual requirements. Some
4.1 Replace this paragraph with the follow- manufacturers may claim their tower is capable but have never had the design
ing: The tower structure, anchorage and reviewed by a licensed structural engineer. Not requiring this review for high wind
all its components shall be designed by and seismic regions can be dangerous to you and the public.
licensed structural engineers, employed
by the tower manufacturer, per the
international building code to withstand
a wind load of ______ psf, as well as
➠
 AV Cooling Tower — Specifications: Options 38

Specifications Specification Value

a ______ seismic load. The fan deck

and hot-water basin covers shall be
designed for 50 psf live load or a 200
lb concentrated load. Guardrails, where
specified, shall be capable of withstand-
ing a 200 lb concentrated live load in
any direction, and shall be designed in
accordance with OSHA guidelines.

Quiet Fan: ■ The Marley "Quiet Package" includes the affordable Quiet Fan mechanical option,
optimized to achieve the lowest possible sound levels while maintaining efficiency.
6.1 Replace paragraph 6.1 with the follow- In combination with a Marley Variable Speed Drive, this package is capable of
ing: Quiet Fan(s) shall be propeller type, meeting all but the most restrictive sound limitations.
incorporating a minimum of seven heavy
 ip Speed—unlike thermal performance, no certification program exists for sound.
T
duty aluminum alloy blades attached
While Marley conducts actual sound tests on all its configurations, there are a few
to galvanized hubs with stainless steel
ways for the client to ensure they get a quiet tower.
U-bolts and hardware and shall be indi-
vidually adjustable. Fan(s) shall be driven • One is to conduct a field sound test after installation. On-site testing after
through an industrial grade system of installation can, however, be inaccurate depending on the environment.
V-belts, pulleys, and tapered roller bear-
• Another is to conduct a sound test at the factory. However both can be cost
ings. Bearings shall be rated at 50,000
prohibitive for smaller applications.
hours, or greater.
• Specifying fan blade tip speed is one way to physically force the tower selection
to be quiet. Tip speed is easily checked by multiplying the fan RPM by the fan
circumference at the blade tip (π fan dia). Over 12,000 ft/min is considered high
by most people. 10,000-12,000 is considered typical and expected. 8,000-10,000
would be considered low sound. Below 8,000 is difficult to hear above the water
noise.

Ultra Quiet Fan: ■ For more severe cases requiring the lowest possible fan sound levels, the
Marley “Ultra Quiet Fan” option is now available on all AV models. Tower height
6.1 Replace paragraph 6.1 with the fol- may increase slightly—obtain current sales drawings from your Marley sales
lowing: Ultra Quiet Fan(s) shall be representative for accurate dimensions.
propeller-type, incorporating wide-
chord acoustic geometry, corrosion and
fire resistant marine grade aluminum
blades and aluminum hubs. Blades
shall be resiliently mounted to fan hub
and individually adjustable. Fan blades
shall be open cavity with suitable drain-
age to avoid accumulation of moisture.
Foam filled blades are not allowed due
to potential moisture contamination of
the foam core causing an imbalance
of the fan leading to vibration issues.
Fan(s) shall be driven through an
industrial grade system of V-belts,
pulleys, and tapered roller bearings.
Bearings shall be rated at 50,000
hours, or greater
 AV cooling tower
E N G I N E E R I N G DATA A N D S P E C I F I CAT I O N S

SPX COOLING TECHNOLOGIES, INC.

7401 WEST 129 STREET AV-TS-18 | ISSUED 3/2018
OVERLAND PARK, KS 66213 USA © 2017-2018 SPX COOLING TECHNOLOGIES, INC | ALL RIGHTS RESERVED
913 664 7400 | spxcooling@spx.com In the interest of technological progress, all products are subject to design and/or
spxcooling.com material change without notice.