SPX Cooling Technologies Electric Heater 92 1322C User Manual

Marley Electric Basin Heater  
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User Manual 92-1322C  
 
/ Receiving and Inspection /  
The heater package is shipped directly from the vendor.  
1. Check all parts for any damage in transit. The carrier is responsible  
for the condition of the heater package upon arrival. If damage is appar-  
ent, note the freight bill accordingly. This will support your claim with the  
freight carrier.  
2. Check the nameplate on the enclosure and verify that the heaters and  
the control panel are rated for the correct voltage.  
3. Check the watt rating on each element and verify the sum of all elements  
is equal to the KW rating as ordered.  
4. The control panel is nameplated for the maximum amperage that the  
panel can safely control and may be equal to or greater than the actual  
amperagerequiredforyourheaterpackage.SeeInstallationInstructions  
on page 5 to calculate amperage required.  
3
 
/ Introduction /  
The purpose of a basin heater is to prevent water freezing in the cooling  
tower basin during periods of shutdown or standby operation. The heater  
system is sized according to tower model and location to give maximum  
protection against water freezing in the cold water basin. This heating  
system is not intended to protect the tower fill and other components  
from icing. Refer to Marley Technical Bulletin # H-002 "Operating Cooling  
Towers in Freezing Weather." Contact your Marley Sales Representative  
for a copy of this publication.  
The Marley basin heater system is manufactured by INDEECO, a leader  
in immersion heating equipment. The system is referred to as a "heater  
package"andconsistsofimmersionheaters,acontrolpanelandcombina-  
tion temperature / liquid level sensor with a 12'-0" cable length. The basic  
control panel contains a contactor(s) of sufficient capacity for the heater  
elements selected. In addition the panel contains a transformer to reduce  
line voltage to 24VAC for panel control power, and a solid state relay card  
to detect low temperature and low water conditions. The panel enclosure  
is rated NEMA 4X (liquid tight, noncorrosive) and the sensor cable is UL  
outdoor rated. The sensor probe is stainless steel with 12" NPT threads  
and a PVC bulkhead fitting for installation in the cold water basin.  
The panel may control more than one heating element, up to its nameplate  
KW rating for the voltage and phase stated. In addition to the components  
of the basic panel described above, available options are fusing, circuit  
breakers or disconnect switches. The circuit diagram located on the inside  
of the panel cover will indicate the panel configuration.  
The following defined terms are used throughout this manual to bring at-  
tention to the presence of hazards of various risk levels, or to important  
information concerning the life of the product.  
Indicates presence of a hazard which can cause severe personal  
injury, death or substantial property damage if ignored.  
Warning  
Caution  
Indicatespresenceofahazardwhichwillorcancausepersonalinjury  
or property damage if ignored.  
Indicatesspecialinstructionsoninstallation,operationormaintenance  
which are important but not related to personal injury hazards.  
Note  
4
 
/ Installation /  
For detailed information concerning installation, refer to the heater  
installation drawing provided with the cooling tower.  
Note  
Heater Element  
Install the heater element(s) in the depressed area of the cold water basin  
near the outlet. Provide clearance of 78" or more above the floor.  
A single centrally located heater can protect up to 300 square feet of basin  
surface area from ice damage. To protect larger surface areas, position  
several heaters so they protect equal areas. For multicell towers, no more  
than two cells may be protected by a single heater package. For three or  
more cells additional heater packages are necessary.  
The heater should never operate out of the water. It would become  
extremely hot (1500°F) and destroy the heater element and/or ig-  
nite nearby combustible materials. As a precaution and to prevent  
fires when the clearance between any part of a heater element and  
combustible materials is less than 10", install a sheet metal shield  
to reflect and dissipate the heat. The shield must not contact the  
heater element and should extend beyond the heater element in all  
directions as shown in Table 1.  
Caution  
Heater Clearance inches  
1
2
9
4
7
6
4
8
2
10  
0
Table 1  
Shield Extension inches  
10  
Heater Supports  
Install metal supports for the heater element where necessary to keep  
the unsupported length under 30". The number of supports required is  
as shown in Table 2.  
Heater Kilowatts  
1 - 9  
12-18  
1
Table 2  
Number of Supports  
None  
5
 
/ Installation /  
Control Panel  
The control panel is suitable for outdoor mounting, and may be mounted  
on the tower, but not inside the tower. Wire the heaters to the panel. Wire  
the panel to the branch circuit supplying power to the heater.  
The field supplied branch circuit disconnect switch and the branch circuit  
protective device (fusing or circuit breaker) shall be sized in accordance  
with the NEC/CEC rules for actual load. The total heater load can be  
calculated as shown below.  
If the heater control panel is furnished with an optional disconnect, in-  
stallation of the panel in relationship to the heater element shall be in  
accordance with the NEC/CEC rules.  
The main incoming conduit hub and the main power termination points are  
sized for total nameplate KW and voltage. The actual load for a particular  
installationmaybeless.Eithercomputetheactualloadontheheatercontrol  
panel to determine the sum total KW of all the heaters connected to it or  
use the nameplate rating to determine the wire size required. To calculate  
amp draw for a particular installation use the following formulas:  
KW x 1000  
= Amperage for Single Phase Applications  
Voltage  
or  
KW x 1000  
= Amperage for Three Phase Applications  
1.7312 x Voltage  
Should water be drained, either intentionally or accidentally, from  
the basin, the basin heater MUST be checked manually to insure the  
power source to the heating element is OFF. Although equipped with  
a low liquid level sensor probe, contaminants on or around the probe  
may cause false readings allowing the element to remain energized  
under low or no water conditions. Do not re-energize the unit until  
the sensor probe is fully submerged in water.  
Caution  
IF THE UNIT IS ENERGIZED WHILE THE SENSOR PROBE IS NOT  
FULLY SUBMERGED IN WATER, COMBUSTION/FIRE MAY RESULT,  
WHICHCOULDDAMAGEORDESTROYTHETOWERANDMAYCAUSE  
DAMAGE TO PERSONS OR PROPERTY NEARBY.  
6
 
/ Installation /  
Temperature / Water Level Sensor Assembly  
This basin heater package is equipped with a combination tempera-  
ture/liquid level sensor and may have a thermal cutoff switch. Both  
are safety devices that must not be altered or changed in any man-  
ner. Disabling either safety feature may result in combustion and/  
or fire, which could cause damage or destroy the tower and may  
cause damage to persons or property nearby. Failure of one or both  
safety devices requires that the control panel be de-energize and  
tag circuit out for maintenance. Do not re-energize the unit until all  
safetydevicesarefullyoperationalinaccordancewithmanufacturer's  
specifications.  
Warning  
The sensor assembly is factory installed to the control panel. Do not at-  
tempt to lengthen or shorten the cord. Sensor assemblies with various  
lengths up to 99'-0" are available and may be specified at the time of  
purchase for additional cost.  
Install the sensor probe in the cold water basin at least 1" above the high-  
est point of the heater element and at least 6" away from the heater. The  
probe should be installed in the coldest part of the basin for maximum  
protection. It should extend into the open basin a minimum of 4". A12" NPT  
PVC bulkhead fitting is provided on the sensor for mounting through the  
basin wall. Provide an 158" clearance hole through the basin wall. Remove  
the nut from the bulkhead fitting and insert the sensor probe through the  
hole. Hand tighten the mounting nut onto the fitting, holding the bulkhead  
fitting to avoid twisting the cord. Lightly tighten the nut.  
7
 
/ Operation /  
Operating Instructions  
To operate the heater system, visually check that the water level is above  
the sensor probe before energizing the power supply. The temperature  
controlispresetat4F. Thesystemwillnotenergizeunlessthewaterlevel  
is above the sensor probe and the temperature of the water is below the  
45° set point. The solid state relay card located in the control panel has  
a green and a red LED—see Figure 1. In a "ready" condition, with water  
level above the sensor probe and temperature above 45°F both these  
LEDs will be off. If the red LED is illuminated this indicates a low water  
condition and the heaters will not operate. If the green LED is illuminated  
the heater elements are on.  
SOLID STATE RELAY CARD  
Figure 1  
Table 3  
RED  
PROBE  
BLK  
RED  
BLK  
COM  
NC NO  
SHIELD  
BASIN  
LED INDICATORS  
Red  
OFF  
ON  
Green  
OFF  
OFF  
ON  
Ready, No Demand  
Low Water Level  
Heater On  
OFF  
Should water be drained, either intentionally or accidentally, from  
the basin, the basin heater MUST be checked manually to insure the  
power source to the heating element is OFF. Although equipped with  
a low liquid level sensor probe, contaminants on or around the probe  
may cause false readings allowing the element to remain energized  
under low or no water conditions. Do not re-energize the unit until  
the sensor probe is fully submerged in water.  
Caution  
IF THE UNIT IS ENERGIZED WHILE THE SENSOR PROBE IS NOT  
FULLY SUBMERGED IN WATER, COMBUSTION/FIRE MAY RESULT,  
WHICHCOULDDAMAGEORDESTROYTHETOWERANDMAYCAUSE  
DAMAGE TO PERSONS OR PROPERTY NEARBY.  
8
 
/ Operation /  
Testing above Freezing Temperatures  
Under normal operating conditions the heaters will be turned on at a  
water temperature between 40° and 45°F, and turned off when the water  
temperature exceeds 45°F. For testing the system at temperatures above  
45°F there are two methods as follows:  
Method A  
1. Disconnect power to the control panel using standard lockout proce-  
dure for safety.  
2. Remove the panel cover  
3. Remove the sensor wires connected to terminals T1 and T2 on the  
relay circuit board.  
SOLID STATE RELAY CARD  
Figure 2  
RED  
PROBE  
BLK  
RED  
BLK  
COM  
NC NO  
SHIELD  
RESISTOR  
BASIN  
4. Connect a 1.5K ohm resistor (included in panel) across T1 and T2  
terminals—see Figure 2.  
5. Replace panel cover and verify probe is submerged in tower basin  
water.  
6. With panel cover in place turn on power supply to the system. An au-  
dible CLICK should be heard as the contactor engages. If this does not  
happen, refer to the Troubleshooting section of this manual.  
7. If the system tests OK turn off power, remove the panel cover and re-  
move the resistor. Replace sensor wires T1 and T2 and replace the cover.  
Turn system on.  
9
 
/ Operation /  
Method B  
1. Disconnect power to the heater control panel using standard lockout  
procedures for safety.  
2. Drain basin until the water level is below the probe allowing removal of  
the probe. Make sure water still covers the heater elements.  
3. Place the probe in a container of ice water making sure both metal parts  
of the probe are submerged but not the cord.  
4. Energize the heater control panel. Allow 5 min. for the probe tempera-  
ture to stabilize.  
5. An audible CLICK should be heard as the heater contactor engages. If  
this does not happen, refer to the Troubleshooting section.  
10  
 
/ Operation /  
Deicing  
If the temperature/water level sensor assembly becomes encased in ice  
the heaters will not operate. Ice provides inadequate conductivity for the  
sensor probe to detect operational water level. To operate heaters in this  
situation and melt the ice follow these procedures.  
1. Disconnect power to the control panel using standard lockout proce-  
dures for safety.  
2. Remove the panel cover.  
3. Install a jumper wire between relay terminals G1 and G2—see  
Figure 3.  
JUMPER  
SOLID STATE RELAY CARD  
RED  
Figure 3  
PROBE  
BLK  
RED  
BLK  
COM  
NC NO  
SHIELD  
BASIN  
4. Replace panel cover.  
5. Energize the system and listen for contactor closing.  
6. Operate the system until ice is melted around the sensor probe.  
7. After ice is melted, de-energize the system, remove the jumper, check  
all connections and place the system back in operation.  
Do not leave the heating system unattended during this procedure.  
There is no low water protection with this jumper in place.  
Caution  
11  
 
/ Troubleshooting /  
Please refer to the Caution statement on Page 6 and the Warning  
statement on Page 7 of this manual before performing the following  
Troubleshooting procedures.  
Caution  
If the system fails to operate, check the following:  
1. Check water temperature. Systems will turn on between 40° and 45°F  
and turn off above 45°F.  
2. Check water level. Water must completely cover the sensor probe.  
3. Make sure the sensor is not encased in ice. See Deicing procedure.  
The following checks should be made by a qualified electrician.  
Caution  
4. Remove panel cover and check incoming electrical power for proper  
voltage. Make sure all phases are present. Correct as required.  
5. If water level is adequate, temperature is 40°F or lower and power is  
present, observetheLEDsontherelaycircuitboard. TheredLEDindicates  
low water level or ice around the probe and the green LED indicates the  
heaters are energized.  
A. If the red LED is on and the sensor probe is submerged in water—no  
ice—this indicates the sensor probe is defective. Confirm by discon-  
necting power and placing a jumper across terminals G1 and G2—see  
Figure 3. Reconnect power. If the red LED is now off and the green  
LED is on, the system is now operating. Replace sensor probe.  
B. If the green LED is on and the heaters are not operating, the problem  
is either the contactor, the relay circuit board or the heater elements.  
To determine which, observe the panel while power is disconnected  
and reconnected.  
1. If the contactor operates with an audible CLICK and no heat results  
the heater element is defective. Check voltage at the heater side of  
the contactor to confirm voltage is present. Check each line with a  
clamp-on amp meter. If voltage is present and no current is flowing,  
this indicates the element is defective and must be replaced. As an ad-  
ditionalcheck,disconnect power,removewiresfromthecontactorand  
check the element with an ohm meter for measurable resistance.  
12  
 
/ Troubleshooting /  
2. If the contactor does not operate, check voltage across terminal N  
on the circuit board and NO on the relay mounted on the circuit board  
—21-29 volt required. If voltage is present across the coil—N to NO—  
the contactor coil is defective and the contactor must be replaced. If  
voltage is not present, the circuit board relay is defective and the circuit  
board must be replaced.  
C. If the green LED is off and the red LED is also off the problem is either  
the circuit board, the sensor probe, or the transformer. To determine  
which check as follows:  
1. Disconnect power and remove wires T1 and T2 from the circuit  
board. Replace with the 1.5K ohm resistor provided. See Figure 2.  
If the system now works, the sensor probe is defective and must be  
replaced. If the system does not work, go to step 2.  
2. Reconnect power and take a voltage reading across N and 24/240  
on the circuit board—21-29 volts required. If proper voltage is not  
present the transformer is defective and must be replaced. If proper  
voltage is present go to step 3.  
3. Take a voltage reading across N and NO—21-29 volts required. If  
proper voltage is not present, replace circuit board.  
6. The sensor assembly can be checked for accuracy in the following  
manner.  
Remove wires T1 and T2 from the circuit board and measure ohm  
readings across these wires. Measure the water temperature that the  
probe is being exposed to. Compare with the following values.  
Temp °F  
0
ohms  
4273  
3126  
2312  
1633  
1305  
1138  
765  
Table 4  
10  
20  
32  
40  
45  
60  
75  
525  
85  
412  
13  
 
/ Parts List /  
1
2
24  
240 120  
N
CT  
3
4
RED  
GREEN  
SH T1 T2 G1 G2  
5
Replacement Parts  
1
Transformer 120V/24V.............................................. B52465D  
Transformer 208V/24V.............................................. A79270D  
Transformer 240V/24V.............................................. B91566D  
Transformer 480V/24V.............................................. B09608D  
Transformer 600V/24V.............................................. B62553D  
Contactor 50 amp, 600V, 24 volt coil........................ C32328D  
Solid State Relay Card.............................................. A79269D  
Sensor Probe with 12' cord...................................... A81137D  
Sensor Probe with 22' cord...................................... B07688D  
–contact Marley for other cord lengths  
2
3
4
5
Heater Element—contact Marley for specific heater elements  
Call your Marley Sales Representative for replacement parts. For the location  
of your Marley Sales Representative call 913·664·7400 or check the web at  
spxcooling.com.  
14  
 
 
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7401 WEST 129 STREET OVERLAND PARK, KANSAS 66213 UNITED STATES 913 664 7400 [email protected] spxcooling.com  
In the interest of technological progress, all products are subject to design and/or material change without notice.  
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©2008 SPX Cooling Technologies, Inc. Printed in USA  
Manual 92-1322C  
 

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