/ Marley Basic Control System /

User Manual 92-1320E

Warning

This manual contains vital information for the proper installation and operation of your cooling tower and the basic control system. Carefully read the manual before installation or operation of the tower. Failure to follow the instructions in this manual may result in substantial personal injury or death. Save this manual for future reference.

Table of Contents
Introduction.................................................................................................................2 Safety. ...........................................................................................................................3 Factory Installation.....................................................................................................4 Field Connection........................................................................................................6 AquaTower. ..........................................................................................................6 NC Tower Standard. ......................................................................................7 NC Tower Motor Outside Option...............................................................7 NC Tower Modular.........................................................................................8

Field Connection..................................................................................................... 10 Field Installed Systems Single Speed Motor. ....................................... 10 Field Installed Systems Two Speed Motor............................................ 11

Control System Operation.................................................................................... 12 Single Speed Manual. .................................................................................... 12 Two Speed Manual......................................................................................... 13 Single Speed Automatic............................................................................... 14 Two Speed Automatic. ................................................................................... 16

System Maintenance. ............................................................................................. 18 Contacts. ........................................................................................................... 18 Coils................................................................................................................... 18 Fuses and Thermal Overloads..................................................................... 18 Visual Inspections........................................................................................... 18

Single Speed Wiring Details 3 Phase. ........................................................... 19 Two Speed Wiring Details.................................................................................... 20 AC Starter Wiring Schematic.............................................................................. 22 Parts List Single Speed Motor....................................................................................... 31 Two Speed Motor. ...........................................................................................39

Trouble Shooting.....................................................................................................44

Introduction
The Marley Basic Control System purchased on this tower represents the most economical and reliable automatic control system available. Since the system is factory tested and all components are operationally tested, you can have condence the system will perform as specied. These instructionsas well as those offered separatelyare intended to assure that Field connections are completed properly and the control system serves you for the maximum possible time. Since product warranty may depend on your actions, please read these instructions thoroughly prior to operation. If you have questions about the operation and/or maintenance of this control system, and you do not nd the answers in this manual, please contact your Marley sales representative. When writing for information, or when ordering parts, please reference the Marley customer order number on the tag inside the door of the controlpanel.

Warning

Hazard of electrical shock or burn. Be sure to turn off power to panel before servicing. If working on equipment out of sight of panel disconnect, lockout using standard lock-out procedure.

Safety
The Marley control system uses UL listed components installed in accordance with the National Electrical Code. The location of the cooling tower and eld installation of the control system can affect the safety of those responsible for installing, operating or maintaining the tower and controls. However, since SPX Cooling Technologies does not control the tower location, or eld installation, we cannot be responsible for addressing safety issues that are affected by these items. The following safety issues should be addressed by those responsible for installation, maintenance or repair of the tower and controls: Access to and from the control panel (including the disconnectswitch). Proper grounding of electrical control circuits. Sizing and protection of branch circuits feeding the controlpanel. Qualification of persons who will install, maintain and service the electrical equipment. These are only some of the safety issues that may arise in the design and installation process. SPX strongly recommends that you consult a safety engineer to be sure that all safety considerations have been addressed. Other safety issues are addressed in literature supplied with your tower. You should closely review the literature prior to installing, maintaining or repairing your tower.

Factory Installation
The control panel bolts directly to the tower with spacers or to a bracket attached to the tower. The thermostat is bolted to the tower casing adjacent to the cold water basin depressed section. The capillary runs through a bushing in the tower casing and the bulb is installed vertically in a holder near the outlet for proper temperature measurement. The holder is glued to the cold water basin oor with a layer of sealer applied to its bottom ange and the bushing through which the capillary passes is lled with sealer to protect the capillary. A vibration limit switch is mounted near the Geareducer on larger towers and near the motor on belt driven towers. Liquid tight exible metal conduit connects all points which are to be wiredmotor, control panel, thermostat and vibration limit switch, if required. The conduit is installed with associated couplings, connectors and ttings approved for this conduit and is also supported by conduit clamps as required by code. After the completion of the conduit installation, the wiring is pulled through the conduit to each component. Pulling type ttings are used to provide access for pulling the wire and meeting the N.E.C. requirement for maximum number of bends allowed in each conduit run. All wire ends are tagged for identication and connections at each end are made at terminal blocks or by terminal connectors with fasteners.

Factory Installation
Overload units are selected based upon the full-load current as read from the motor nameplate. Fuses are selected based upon the motor voltage and fullload current (high speed current on two speed motors) as listed in the National Electric Code. The overload units are installed into the motor starter and the time delay fuses are installed into the fuse clips with the grooved end on the bottom. (A bar in the fuse clip requires the use of a time delay fuse which has a groove to t over the bar.) The time delay relay on the two speed control panel is adjusted for a 30 second or more delay and the thermostats are preset as follows: One Speed Two Speed Cut-in Temperature 85 F Cut-out Temperature 80 F 72F

The completed factory installation is tested by cycling the fan off and on both manually and automatically with the control panel switches and the thermostat respectively.

Field Connection
Note
The factory installation by Marley has been performed in accordance with the National Electrical Code using UL Listed components. All installation and wiring performed after leaving the factory must be performed in accordance with the latest revision of the National Electrical Code and any local codes to insure safe operation. The Marley Basic Control System has been factory tested to the fullest extent possible. Some equipment selections and options require the installation be completed in the eld. The following information is provided as an overview of the eld installation for the various options. Please refer to the drawings supplied with the tower for more detailed instructions to complete the installation.

Warning

HAZARD OF ELECTRICAL SHOCK OR BURN. BE SURE TO TURN OFF POWER to panel before servicing. If working on equipment out of sight of panel disconnect, lockout using standard lock-out procedure.

AquaTower
1. Incoming power and ground lines must be run through the opening provided on the top of the control panel. Conduit must be connected to the panel using a watertight or raintight tting. Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel. The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet. 2. After completing the electrical connections to the panel, provide power to the panel, operate the system in the manual mode and verify proper direction of fan rotation on the tower. If the direction of rotation is incorrect, turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel. 3. The temperature and differential set points have been preset at the factory. Check the settings and adjust as necessary to suit your operating requirements. Be sure to maintain adequate differential between the cut-in and cut-out settings or excessive cycling of the fan motor may occur and shorten equipment life.

Field Connection
NC TowerStandard
1. Install temperature sensing element in its nal position on the basin oor as near the basin outlet as possible. Sealer is used to attach the bracket to the basin oor. 2. Incoming power and ground lines must be run through the opening provided on the top of the control panel. Conduit must be connected to the panel using a watertight or raintight tting. Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel. The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet. 3. After completing the electrical connections to the panel, provide power to the panel, operate the system in the manual mode and verify proper direction of fan rotation on the tower. If the direction of rotation is incorrect, turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel. 4. The temperature and differential set points have been preset at the factory. Check the settings and adjust as necessary to suit your operating requirements. Be sure to maintain adequate differential between the cut-in and cut-out settings or excessive cycling of the fan motor may occur and shorten equipment life.

NC TowerMotor Outside Option

1. Insert the power leads and ground wire for the motor through the conduit opening in the motor junction box. Connect the conduit to the motor junction box. The motor power leads have been marked to match the motor leads for easy reconnection in the eld. Make pigtail connections at the motor using hardware to fasten motor lug to the ring terminal on the power lead wire from the control panel. Wrap the pigtail with insulation putty to smooth out the points and edges, wrap the pigtail completely with vinyl electrical tape. Connect the ground lead to the ground lug inside the motor conduit box. 2. Install temperature sensing element in its nal position on the basin oor as near the basin outlet as possible. Sealer is used to attach the bracket to the basin oor.

Field Connection
3. Incoming power and ground lines must be run through the opening provided on the top of the control panel. Conduit is connected to the panel using a watertight or raintight tting. Power connections are made at the top of the fusible disconnect located in the upper right hand side of the control panel. The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet. 4. After completing the electrical connections to the panel, operate the system in the manual mode and verify proper direction of fan rotation on the tower. If the direction of rotation is incorrect, turn off power supplying the panel and change any two power leads at the fusible disconnect switch in the control panel. 5. The temperature and differential set points have been preset at the factory. Check the settings and adjust as necessary to suit your operating requirements. Be careful to maintain adequate differential between the cut-in and cut-out settings or excessive cycling of the fan motor may occur and shorten equipment life.

NC TowerModular
1. After the modules have been assembled, run the conduit from the control panel to the motor and vibration switch. 2. Place the power leads and ground wire for the motor through the conduit opening in the motor junction box. Connect the conduit to the motor junction box. The motor power leads have been marked to match the motor leads for easy reconnection in the eld. Make pigtail connections at the motor using hardware to fasten motor lug to the ring terminal on the power lead wire from the control panel. Wrap the pigtail with insulation putty to smooth out the points and edges and wrap the pigtail completely with vinyl electrical tape. Connect the ground lead to the ground lug inside the motor conduit box. 3. If a vibration switch is installed, feed the wires through the conduit opening on the switch, connect the conduit to the threaded switch opening, connect the wires to the normally closed contacts of the vibration switch and connect the ground wire. Slope conduit away from switch if possible to avoid condensation in the switch.

10

Field Connection
4. Support the conduit at appropriate locations in accordance with the requirements of the National Electrical Code. 5. Install temperature sensing element in its nal position on the basin oor as near the basin outlet as possible. Sealer is used to attach the bracket to the basin oor. 6. Incoming power and ground lines must be run through the opening provided on the top of the control panel. Conduit must be connected to the panel using a watertight or raintight tting. Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel. The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet. 7. After completing the electrical connections to the panel, provide power to the panel, operate the system in the manual mode and verify proper direction of fan rotation on the tower. If the direction of rotation is incorrect, turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel. 8. The temperature and differential set points have been preset at the factory. Check the settings and adjust as necessary to suit your operating requirements. Be sure to maintain adequate differential between the cut-in and cut-out settings or excessive cycling of the fan motor may occur and shorten equipment life.

11

Field Connection
Field Installed Systems Single Speed Motor
1. Mount the control panel securely in an upright position. The disconnect switch on the control panel must be within sight of the equipment being operated and within 50 feet of that equipment or a separate disconnect switch must be provided. The best location will be at the same ambient conditions as the equipment since the overload and the motor are both temperature sensitive devices. 2. Mount the temperature switch and the vibration switch (if applicable) on the tower. Refer to the drawings supplied with the tower for details on installation of the switches. 3. Install conduit from the bottom of the control panel to the individual pieces of equipment requiring wiring. All conduit connections must be completed to provide a continuous raceway for the conductors prior to pulling the conductors through the conduit. All conduit must be supported properly in accordance with the National Electrical Code. 4. Mark the ends of the conductors for identication and pull them through the conduit. Be sure to provide a ground wire to all individual pieces of equipment. Connect the conductors to the appropriate terminal points in the control panel. 5. Make pigtail connections at the motor using hardware to fasten motor lug to the ring terminal on the power lead wire from the control panel. Wrap the pigtail with insulation putty to smooth out the points and edges and wrap the pigtail completely with vinyl electrical tape. Connect the ground lead to the ground lug in the motor conduit box. 6. Connect the wires for the vibration switch (if applicable) to the normally closed contacts of the switch. Connect the ground lead inside theswitch. 7. Install temperature sensing element in its nal position on the basin oor as near the basin outlet as possible. Sealer is used to attach the bracket to the basin oor. Insert the bulb into the holder. Fill the bushing where the capillary tube goes through the casing with sealer. 8. Incoming power and ground lines must be run through the opening provided on the top of the control panel. Conduit must be connected to the panel using a watertight or raintight tting. Power connections are made at the top of the fusible disconnect located in the upper right hand corner of the control panel. The ground wire must be connected to the ground bar located at the bottom of the control panel cabinet.

12

Field Connection
9. After completing the electrical connections to the panel, provide power to the panel, operate the system in the manual mode and verify proper direction of fan rotation on the tower. If the direction of rotation is incorrect, turn off power supplying the panel and reverse any two power leads at the fusible disconnect switch in the control panel. 10. Check the temperature and differential settings and adjust as necessary to suit your operating requirements. Be sure to maintain adequate differential between the cut-in and cut-out settings or excessive cycling of the fan motor may occur and shorten equipment life.

Field Installed Systems Two Speed Motor

1. The installation is the same as for the single speed except direction of rotation must be checked on both speeds. If motor runs forward on one speed and backwards on the other, reverse any two wires at the motor starter connections for the speed that runs backwards. 2. The temperature switch on two speed systems has a differential that is preset by the manufacturer. The temperature setting is all that needs to be checked on this system. Remember the differential is all above the temperature setting on the two stage switch. Refer to Figure 2 on page16. 3. Set the pneumatic time delay relay for 30 seconds minimum time delay when switching from high to low speed. The time delay is adjusted by turning the air bleed screw on the top front side of the relay.

13

Control System Operation

The Basic Control System allows the operation of the cooling tower in either the manual or automatic mode. Automatic operation starts, stops and/or changes speed of the cooling tower fan motor based on cold water temperature. Cold water temperature obtained from an operating cooling tower will vary with the heat load, air wet-bulb temperature, water ow rate and air ow rate.

Note

When operating in the automatic mode care must be taken not to exceed ve starts per hour on the fan motor. For two-speed motors each speed is considered one start. Excessive cycling of the motor may reduce the life of the motor starter, motor and driven mechanical equipment. When operating in subfreezing weather, the opportunity exists for ice to form in the colder regions of the cooling tower. Your primary concern is to prevent the formation of destructive ice in the cooling tower ll. Care must be taken not to allow temperature control settings below 40 for automatic operation or unattended manual operation in subfreezing weather. Your understanding of cold weather operation will be enhanced if you read Marley Technical Report #H-003 Operating Cooling Towers in Freezing Weather and your cooling towers Installation, Operation, and Maintenance Instructions manual. Failure to comply with these instructions will result in damage to yourtower.

Note

Single Speed Manual Operation

1. Check all mechanical equipment to be sure it is free of obstructions and safe to operate. 2. Check all electrical equipment for proper connections and to be sure it is in good operating condition.

Note

A jumper or a normally closed device must be installed between points 5 and 7 (1 and 3 on single phase control panel) on the terminal block or the system will not operate. 3. Close and latch the control panel door. 4. Press the reset button on the outside door to reset all overloads to the operating condition. 5. Turn the Hand-Off-Auto selector switch to the Off position (centerposition).

14

Control System Operation

6. Be sure all personnel are clear of the rotating equipment. 7. Clear and remove any lock out tags on the disconnect switch, remove any locks and turn the disconnect switch to the On position. 8. Rotate the Hand-Off-Auto selector switch to the Handposition. 9. Depress the start push button until you hear the contactor engage, then release the button. 10. Check to be sure the fan rotation is correct. 11. Rotate the Hand-Off-Auto selector switch to the Off position to stop thefan.

Two Speed Manual Operation

1. Check all mechanical equipment in the driven system to be sure it is free of obstructions and safe to operate. 2. Check all electrical equipment for proper connections to be sure it is in good operating condition. Notea jumper or a normally closed device must be installed between points 6 and 7 on the terminal block or the system will not operate. 3. Close and latch the control panel door. 4. Press both reset buttons on the outside door to reset all overloads to the operating condition. 5. Turn the Hand-Off-Auto selector switch to the Off position. 6. Be sure all personnel are clear of the rotating equipment. 7. Clear and remove any lock out tags on the disconnect switch, remove any locks and turn the disconnect switch to the on position. 8. Select the desired speed on the High-Low selector switch. 9. Rotate the Hand-Off-Auto selector switch to the Hand position. The fan will start at the selected speed. 10. Change the motor speed by changing the position of the High-Low selector switch. Verify the time delay is at least 30 seconds when switching from High to Low speed.

15

Control System Operation

11. Check to be sure the fan rotation is correct at both speeds. 12. Rotate the Hand-Off-Auto selector switch to the Off position to stop thefan.

Single Speed Automatic Operation

1. Check all mechanical equipment in the driven system to be sure it is free of obstructions and safe to operate. 2. Check all electrical equipment for proper connection to be sure it is in good operating condition. Note-a jumper or a normally closed device must be installed between points 5 and 7 (1 and 3 on single phase control panel) on the terminal block or the system will notoperate. 3. Close and latch the control panel door. 4. Remove the cover from the temperature switch by removing the two screws in diagonally opposite corners of the cover. 5. Check the cut-in and cut-out settings on the temperature scale. These have been factory preset at 85 F for the cut-in temperature and 80F for the cut-out temperature. Adjust the settings as required to suit yourapplication. The minimum differential is 5 F. Increasing the differential will reduce the frequency of cycling the fan motor off and on resulting in longer equipment life. See Figure 1. 6. Replace the cover on the temperature switch. Be sure the gasket is tight against the case to prevent water from entering the switch. 7. Press the reset button on the outside door of the control panel to reset all overloads to the operating condition. 8. Turn the Hand-Off-Auto selector switch to the off position. 9. Be sure all personnel are clear of the rotating equipment. 10. Clear and remove any lock out tags on the disconnect switch, remove any locks and turn the disconnect switch to the on position.

16

Control System Operation

Figure 1
Sequence of Operation Basic System with Single Speed Motor
TEMPERATURE SWITCH CUT IN SET POINT MOTOR ON

RISING TEMPERATURE

ADJUSTABLE DIFFERENTIAL (5 F MINIMUM)

MOTOR OFF

TEMPERATURE SWITCH CUT OUT SET POINT

PENN - BASO Model A72AE-1 Thermostat

Turning the cut in adjustment screw located above the cut in scale changes the cut in set point. Turning the cut out adjustment screw located above the cut out scale changes the cut out set point. Cut out set point cannot be set above cut in set point.

11. Rotate the Hand-Off-Auto selector switch to the Auto position. The fan will now start and stop automatically based on cold watertemperature. The water is colder on the louver face than on the eliminator face of the ll in the cooling tower. The actual cold water temperature will be between these two extremes. For best accuracy we recommend the temperature measuring bulb be located near the basin exit in a vertical position. 12. Check to be sure the fan rotation is correct. (You may need to operate the system manually to verify fan rotation if the cold water temperature is below the cut-in set point.) 13. Rotate the Hand-Off-Auto selector switch to the Off position to stop thefan.

FALLING TEMPERATURE

17

Control System Operation

Two Speed Automatic Operation
1. Check all mechanical equipment in the driven system to be sure it is free of obstructions and safe to operate. 2. Check all electrical equipment for proper connection to be sure it is in good operating condition. Note: A jumper or a normally closed device must be installed between points 6 and 7 on the terminal block or the system will not operate. 3. Close and latch the control panel door. 4. Remove the cover from the temperature switch by removing the two screws in diagonally opposite corners of the cover. 5. Check the temperature setting on the dial. The temperature has been preset at 72 F at the factory. The differential is xed at 13 F and cannot be changed. Adjust the temperature as required to suit your application.

Note

The differential is built into the switch such that the cut-out temperature will be the temperature you read on the dial. See Figure 2.

Figure 2

Sequence of Operation Basic System with Two Speed Motor

OFF LOW ON HIGH

5 F 8 F RISING TEMPERATURE

OFF HIGH FALLING TEMPERATURE ON LOW

ON LOW SPEED 8 F 5 F

OFF LOW SPEED TEMPERATURE SWITCH DIAL SETTING

PENN - BASO Model A28MA-1 Thermostat

Adjustable temperature setting Factory set 5 F differential for each stage Factory set 8 F differential between stages

18

Control System Operation

6. Replace the cover on the temperature switch. Be sure the gasket is tight against the case to prevent water from entering the switch. 7. Press both reset buttons on the outside door of the control panel to reset all overloads to the operating condition. 8. Turn the Hand-Off-Auto selector switch to the off position. 9. Clear and remove any lock out tags on the disconnect switch, remove any locks and turn the disconnect switch to the on position. 10. Be sure all personnel are clear of the rotating equipment. 11. Rotate the Hand-Off-Auto selector switch to the Auto position. The fan will now start, stop and change speeds automatically based on cold water temperature.

Note

The water is colder on the louver face than on the eliminator face of the ll in the cooling tower. The actual cold water temperature will be between these two extremes. For best accuracy we recommend the temperature measuring bulb be located near the basin exit in a vertical position. 12. Check to be sure the fan rotation is correct. (You may need to operate the system manually to verify fan rotation if the cold water temperature is below the cut-in set point.) 13. Rotate the Hand-Off-Auto selector switch to the Off position to stop thefan.

19

System Maintenance
Warning
Hazard of electrical shock or burn. Be sure to turn off power to panel before servicing. If working on equipment out of sight of panel disconnect, lock out using standard lock-out procedure.

Contacts
The contacts inside the electromagnetic contactor, which connect the motor to the power source are the only components that experience wear in normal service requiring periodic replacement. Two years is not considered unusual for the service life of silver-alloy contacts. All service work such as replacement of the contacts should be performed by a qualiedelectrician.

Note

Contacts are replaced many times when this expense is not necessary. Contacts are not harmed by discoloration of the surface or slight pitting. We do not recommend ling them as dressing only removes contact material which is wasteful. Replacement is necessary only when the contact has worn thin.

Coils
Coils have an indenite service life under normal operating conditions. Coils generally operate improperly or fail because of unacceptable voltage or from mechanical abuse.

Fuses and Thermal Overloads

The fuses and overloads installed by Marley are the maximum size allowed by the National Electrical Code. If a fuse blows repeatedly, check the system for a short circuit or ground fault condition. The thermal overload units are both the solid state relay type and the melting alloy type and are reset by depressing the reset button. Overloads trip most frequently because of mechanical overloads or frequent cycling of the fan motor.

Visual Inspections
Visual inspections should be conducted during installation and at six month intervals. Check all connections for tightness. Vibration or improper installation can cause loose connections resulting in increased resistance to current ow. We recommend the use of copper wire only. During the visual inspection we recommend the use of compressed air and brushes to clean dirt from magnetic pole faces and contacts.

20

Single Speed Wiring Details 3 Phase

PANEL TERMINAL BLOCK INCOMING POWER L 1 L2 L3

IF MOTOR RUNS BACKWARDS SWITCH ANY TWO WIRES

NORMALLY CLOSED VIBRATION SWITCH (OR JUMPER AT 5 TO 7) NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED OVERLOAD TRIP ALARM (OPTIONAL) RANGE ADJUSTMENT SCREW

RED RED

5 7 6 12 9 11

GROUND

GREEN

Note: Terminal block numbers are shown out of order. Actual terminals are numbered in sequential order.
T 1 T 2T 3

RED

RED

GROUND

DIFFERENTIAL ADJUSTMENT SCREW

BLACK

BLACK

LINE M2

BLACK

RE

EN

SEE TABLE BELOW

GREEN

MOTOR

TEMPERATURE SWITCH SENSING BULB

MOTOR LEAD CONNECTIONS MOTOR TYPE SINGLE VOLTAGE DUAL VOLTAGE HI DUAL VOLTAGE LOW MOTOR LEADS TO STARTER T1 T1 T1&T7 T1 T2 T2 T2&T8 T2 T3 T3 T3&T9 T3 T4&T7 T5&T8 T6&T9 T4, T5, & T6 TIED TOGETHER MOTOR LEADS

TO TERMINALS T1, T2, & T3 AT STARTER

21

Two Speed, Single Winding Wiring Details

TERMINAL BLOCK NORMALLY CLOSED VIBRATION SWITCH (OR JUMPER AT 6 TO 7) NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED HIGH SPEED OVERLOAD TRIP ALARM (OPTIONAL) NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED LOW SPEED OVERLOAD TRIP ALARM (OPTIONAL) GREEN RED RED

GROUND

ADJUSTING SCREW

TIME DELAY RELAY (SET AT 30 SEC. OR MORE) INCOMING POWER L1 L 2 L 3

IF MOTOR RUNS BACKWARDS SWITCH ANY TWO WIRES

RED RED

RED RED RED RED RED

6 7 17 5 5 18 9 14 16

LOW SPEED

T1 T2 T3

T6 T4 T5

HIGH SPEED

Note: Terminal block numbers are shown out of order. Actual terminals are numbered in sequential order.

GROUND

PANEL

TEMPERATURE DIAL

Y B R

Y B R GREEN GREEN T1 T2 T3 T6 T4 T5

BLACK (TYP. ALL MOTOR LEADS)

MOTOR TEMPERATURE SWITCH JUMPER BAR SENSING BULB

22

Two Speed, Two Winding Wiring Details

TERMINAL BLOCK NORMALLY CLOSED VIBRATION SWITCH (OR JUMPER AT 6 TO 7) NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED HIGH SPEED OVERLOAD TRIP ALARM (OPTIONAL) NORMALLY OPEN CONTACTS FOR CUSTOMER SUPPLIED LOW SPEED OVERLOAD TRIP ALARM (OPTIONAL) GREEN RED RED

GROUND

ADJUSTING SCREW

TIME DELAY RELAY (SET AT 30 SEC. OR MORE) INCOMING POWER L1 L 2 L 3

IF MOTOR RUNS BACKWARDS SWITCH ANY TWO WIRES

RED RED

RED RED RED RED RED

6 7 17 5 5 18 9 14 16

LOW SPEED

T1 T2 T3

T11T12T13

HIGH SPEED

Note: Terminal block numbers are shown out of order. Actual terminals are numbered in sequential order.

GROUND

PANEL

TEMPERATURE DIAL

Y B R

Y B R GREEN GREEN T1 T2 T3 T11 T12 T13

BLACK (TYP. ALL MOTOR LEADS)

MOTOR TEMPERATURE SWITCH JUMPER BAR SENSING BULB

23

AC Combination Starter
3 Phase, Single Speed

120V FOR REMOTE OPTIONS

TB 5 5 6 6 7 9 11 12

(H1) PRI

CPT 6 GND F U 2 1 F U 3 2 4 SEC (X2) 5 (X1)

L1

L2

L3

L1 L2 1

M M

SOLID STATE OVERLOAD RELAY

T1 T2 T3

MOTOR

L3

3 TS

F U 2 3 (H1) PRI 2 4

F U 3

1 L1 8

2 L2 L3

5 (X1) SEC

CPT (X2) GND

10

(5)

SOLID STATE OVERLOAD RELAY

ALARM

3 OFF VIB. SW. HAND AUTO 5 7 X (7) 11 X

8 (11) 3 TS

10

OL

5 6

12 10 T2 T3 ALARM

9 (9) ALARM 3 (12) 6 (6)

OL T1

12

120V FOR REMOTE OPTIONS MOTOR

Connection Diagram Notes 1 Disconnecting means provided with controller. 2 Input Voltage Primary Connections per Transformer Nameplate. 3 Customers Remote Located Equipment

Grounding Service Conductor and Grounding Electrode Conductor Terminals Located in Bottom ofCabinet Field wiring by others

24

AC Combination Starter
208V and 230V, Single Phase, Single Speed

L1

L3

L1
1

T1

120V FOR REMOTE OPTIONS

TB 5 5 6 6 7 9 11 12

MOTOR

L2

T2

F U 2 3 (H1) PRI
2

F U 3 4 CPT (X2) GND

TS

1 L1 F U 2 (H1) 3 1 3 PRI F U 3 2 4 8

2 L2
3

5 (X1) SEC

2 4

10

(5)

VIB. SW.

OFF HAND AUTO 7 X 11 (7) X (11)

START M
3

10

OL 6

CPT ALARM 5 12 6 OL T1 10 T2 5 ALARM

SEC (X2) (X1) 6 5 GND

TS

9 (9) 12 ALARM 3 (12) 6 (6)

120V FOR REMOTE OPTIONS

MOTOR

Connection Diagram Notes 1 Disconnecting means provided with controller. 2 Input Voltage Primary Connections per Transformer Nameplate. 3 Customers Remote Located Equipment Field wiring by others

25

AC Combination Starter
120V Single Phase, Single Speed

L1

L2

L1 1

T1

MOTOR 2 M T2

1 L2

120V FOR REMOTE OPTIONS

TB 1 1 2 2 3 5 7 8 1 L1 4 2 VIB. SW. 1 2 L2

TS

(1)

(3)

OFF HAND AUTO X X 7

4 (7)

START

OL

M 3 TS

5 (5)

1 2

ALARM OL

8 6 T2 1 ALARM 8

ALARM 3 (8) (2) 2

T1

MOTOR

120V FOR REMOTE OPTIONS

Connection Diagram Notes 1 Disconnecting means provided with controller. 2 Customers Remote Located Equipment Field wiring by others

26

AC Combination Starter
3 Phase, Two Speed, One Winding

TIME DELAY RELAY (57)

9 (65)
(66) (31) (43)

L1

L2

L3

(13) (21)

(58)

15
(14) (22) (A1) TB 5 5 5 6 6 7 9 14 16 17 18

TR

12
(A2) (32) (44) FU2

(H1)

120V FOR CUSTOMERS REMOTE USE

4 19

FU3 FU1

PRI

4 CPT

2 6

5 SEC (X1) (X2) 6 GND

1 1 L1 2 L2 L3

15

12

11

11

12

14

SOLID STATE OVERLAND RELAY ALARM

10

SOLID STATE OVERLAND RELAY

15

17 HOL 13

ALARM

6 18 LOL 12 13

LI

Connection Diagram Notes 1 Disconnecting means provided with controller. 2 Input Voltage Primary Connections per Transformer Nameplate. 3 Customers Remote Located Equipment Field wiring by others

T6

POWER TERMINAL BLOCK

L2

L3

LI

T4

T5

T1

POWER TERMINAL BLOCK

L2

L3

T2

T3

TO MOTOR

Connection Diagram
See page 26 for Elementary Diagram.

27

AC Combination Starter
3 Phase, Two Speed, One Winding

SOLID STATE OVERLOAD RELAY

L1 L2 14 L3
1

PENN STAT 16 Y LOW HIGH R R B B Y

L L HOL

H H

SOLID STATE OVERLOAD RELAY

STANDARD TEMP. CONTROLLER

LOL

T1 T2 T3 T6 T4 T5 MOTOR

SOLID STATE OVERLOAD RELAY

F U 2 3 (H1) PRI
2

F U 3 4 CPT (X2) GND

H H

BULB SENSOR

OPTIONAL TEMP. CONTROLLER MARLEY SMART SYSTEM ORANGE 16 BLUE ORANGE 14

3

SOLID STATE OVERLOAD RELAY

(X1) SEC

BLUE

9 (6)

VIB. SW.

OFF HAND AUTO 7 X (7)

HIGH

LOW X

(9)

TR 10 H 11

12

LOL HOL 13

24 VAC SENSOR (DRY WELL) 7 16

X
3

14 (14)
3

15

14 TEMP. CONTROL TR HIGH ALARM 12

9 HIGH ALARM 17 LOW ALARM

18

LOW ALARM

120V FOR CUSTOMERS REMOTE USE

Elementary Diagram
See Page 25 for Connection Diagram.

SPEED LOW HIGH

L1 T1 T6

L2 T2 T4

L3 T3 T5

OPEN T4, T5, T6

TOGETHER T1, T2, T3

28

AC Combination Starter
3 Phase, Two Speed, Two Winding

TIME DELAY RELAY (57) 9 (65) (66) (31) (43) 12 (A2) (32) (44) 3
2 1

(13) (21)

(58) 15

L1

L2

L3

(14) (22) (A1)

TR

120V FOR CUSTOMERS REMOTE USE

TB 5 5 5 6 6 7 9 14 16 17 18 1 L1

3 4 19

FU2 FU3 FU1

1 2 6

(H1)

PRI

4 CPT

5 SEC (X1) (X2) 6 GND

1 2 L2 L3

15

12

11

11

12

14

SOLID STATE OVERLAND RELAY

ALARM

10

SOLID STATE OVERLAND RELAY

ALARM

15

17 HOL 13 L2 L3

6 18 LOL 12 13 LI
POWER TERMINAL BLOCK

LI

Connection Diagram Notes 1 Disconnecting means provided with controller. 2 Input Voltage Primary Connections per Transformer Nameplate. 3 Customers Remote Located Equipment Field wiring by others

T11

POWER TERMINAL BLOCK

L2

L3

T12

T13

T1

T2

T3

TO MOTOR

Connection Diagram
See Page 28 for Elementary Diagram.

29

AC Combination Starter
3 Phase, Two Speed, Two Winding

SOLID STATE OVERLOAD RELAY

L1 L2 14 L3
1

PENN STAT 16 Y LOW HIGH R R B B Y

L L HOL

SOLID STATE OVERLOAD RELAY

STANDARD TEMP. CONTROLLER

LOL

T1 T2 T3 MOTOR

SOLID STATE OVERLOAD RELAY

F U 2 3 (H1) PRI
2

F U 3 4 CPT (X2) GND

H H

SOLID STATE OVERLOAD RELAY

T11 T12 T13

BULB SENSOR

OPTIONAL TEMP. CONTROLLER MARLEY SMART SYSTEM ORANGE 16 BLUE ORANGE 14

3

(X1) SEC

BLUE

9 (6)

VIB. SW.

OFF HAND AUTO 7 X (7)

HIGH

LOW X

(9)

TR 10 H 11

12

LOL HOL 13

24 VAC SENSOR (DRY WELL) 7 16

X
3

(14)
3

14

15

14 TEMP. CONTROL TR HIGH ALARM 12

9 HIGH ALARM 17 LOW ALARM

18

LOW ALARM

120V FOR CUSTOMERS REMOTE USE

Elementary Diagram
See Page 27 for Connection Diagram.

SPEED LOW HIGH

L1 T1 T11

L2 T2 T12

L3 T3 T13

OPEN T11, T12, T13 T1, T2, T3

30

This page intentionally left blank.

31

Parts Schematic
Single Speed, Single Phase

3 1 6

9 8 2

32

Parts List
1/3 hp through 3/4 hp, Single Speed, 120V and 230V, Single Phase
Item Description
1 2 3 4 5 6 7 8 9 Contact Kit Melting Alloy Overload Contact Unit with Alarm Circuit Magnet Coil (Starter) Fuse Clips (for 250V and 0-30 Amps) Transformer (Transformer not included on 120V systems) Terminal Blocks Fuse Blocks (not included on 120V systems) H-O-A Selector Switch Contact Blocks (for Selector Switch) 1 1 A74955 A74956 6 A74952

Quan.
1

Part No.
A74930

1 1 1

A74935 A74936 A74940

33

Parts Schematic
Single Speed, Three Phase

3 1 6

9 8 2

34

Parts List
1/3 hp through 3/4 hp, Single Speed, 208V, 230V and 460V, Three Phase

Item Description
1 2 Contact Kit Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 4 5 6 7 8 9 Magnet Coil (Starter) Fuse Clips (for 250V and 0-30 Amps) Transformer 240 or 480 Volts 208 Volts Terminal Blocks Fuse Blocks H-O-A Selector Switch Contact Blocks (for Selector Switch) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
1

Part No.
A74930

C00683 C00682 B56497 B56498 B56499 B56500 B56501 1 1 A74936 A74940

1 1 6 2 1 1

A74944 A74945 A74952 A74953 A74955 A74956

35

Parts List
1 hp through 7 1/2 hp, 208V, Single Speed 1 hp through 10 hp, 240V, Single Speed 1 hp through 15 hp, 480V, Single Speed

Item Description
1 2 Contact Kit Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 4 5 6 7 8 9 Magnet Coil (Starter) Fuse Clips (250V and 0-30 Amps) (600V and 0-30 Amps) (250V and 31-60 Amps) Transformer (240 or 480 Volts) (208 Volts) Terminal Blocks Fuse Blocks H-O-A Selector Switch Contact Blocks (for Selector Switch) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
1

Part No.
A74931

C00683 C00682 B56497 B56498 B56499 B56500 B56501 1 A74936

1 1 1

A74940 A74941 A74941

1 1 6 2 1 1

A74944 A74945 A74952 A74953 A74955 A74956

36

Parts List
10 hp, 15 hp, and 20 hp, 208V, Single Speed 15 hp and 20 hp, 240V, Single Speed 20 hp, 25 hp, and 30 hp, 480V, Single Speed

Item Description
1 2 Contact Kit Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 4 5 6 7 8 9 Magnet Coil (Starter) Fuse Clips (600V and 0-30 Amps) (250V and 31-60 Amps) (600V and 31-60 Amps) Transformer (240 or 480 Volts) (208 Volts) Terminal Blocks Fuse Blocks H-O-A Selector Switch Contact Blocks (for Selector Switch) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
1

Part No.
A74932

C00683 C00682 B56497 B56498 B56499 B56500 B56501 1 A74937

1 1 1

A74941 A74941 A74942

1 1 6 2 1 1

A74946 A74947 A74952 A74953 A74955 A74956

37

Parts List
25 hp, 208V, Single Speed 25 hp and 30 hp, 240V, Single Speed 40 hp through 100 hp, 480V, Single Speed

Item Description
1 2 Contact Kit Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 4 5 6 7 8 9 Magnet Coil (Starter) Fuse Clips (250V and 61-200 Amps) (600V and 200 Amps) Transformer (240 or 480 Volts) (208 Volts) Terminal Blocks Fuse Blocks H-O-A Selector Switch Contact Blocks (for Selector Switch) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
1

Part No.
A74933

C00683 C00682 B56497 B56498 B56499 B56500 B56501 1 A74938

1 1

A74943 A74943

1 1 6 2 1 1

A74948 A74949 A74952 A74953 A74955 A74956

38

This page intentionally left blank.

39

Parts Schematic
Two Speed

10

5 6

7 3 1 13 11

12 13 2

40

Parts List
1 hp through 3 hp, 208V, Two Speed 1 hp through 3 hp, 240V, Two Speed 1 hp through 5 hp, 460V, Two Speed

Item Description
1 Contact Kit 2 Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 Magnet Coil (Starter) 4 Pneumatic Timing Relay, 120V, 60Hz 5 Magnet Coil (Timing Relay) 6 Snap Switch (Timing Relay) 7 Fuse Clips (250V and 0-30 Amps) (600V and 0-30 Amps) (250V and 31-60 Amps) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
2

Part No.
A74930

C00683 C00682 B56497 B56498 B56499 B56500 B56501 2 1 1 1 A74936 A74958 A74959 A74960

1 1 1

A74940 A74941 A74941

8 Transformer (240 or 480 Volts) (208 Volts) 1 1 9 2 1 1 2 A74946 A74947 A74952 A74953 A74961 A74955 A74956

9 Terminal Blocks 10 Fuse Blocks 11 High/Low Selector Switch 12 H-O-A Selector Switch 13 Contact Blocks (for Selector Switch)

41

Parts List
5 hp and 7 1/2 hp, 208V, Two Speed 5 hp and 7 1/2 hp, 240V, Two Speed 7 1/2 hp and 10 hp, 480V, Two Speed

Item Description
1 Contact Kit 2 Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 Magnet Coil (Starter) 4 Pneumatic Timing Relay, 120V, 60Hz 5 Magnet Coil (Timing Relay) 6 Snap Switch (Timing Relay) 7 Fuse Clips (250V and 0-30 Amps) (600V and 0-30 Amps) (250V and 31-60 Amps) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
2

Part No.
A74931

C00683 C00682 B56497 B56498 B56499 B56500 B56501 2 1 1 1 A74936 A74958 A74959 A74960

1 1 1

A74940 A74941 A74941

8 Transformer (240 or 480 Volts) (208 Volts) 1 1 9 2 1 1 2 A74946 A74947 A74952 A74953 A74961 A74955 A74956

9 Terminal Blocks 10 Fuse Blocks 11 High/Low Selector Switch 12 H-O-A Selector Switch 13 Contact Blocks (for Selector Switch)

42

Parts List
10 hp, 208V, Two Speed 10 hp and 15 hp, 240V, Two Speed 15 hp, 20 hp and 25 hp, 480V, Two Speed

Item Description
1 Contact Kit 2 Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 Magnet Coil (Starter) 4 Pneumatic Timing Relay, 120 V, 60 Hz 5 Magnet Coil (Timing Relay) 6 Snap Switch (Timing Relay) 7 Fuse Clips (250V, 31-60 Amps; 600V, 0-30 Amps) (600V and 31-60 Amps) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
2

Part No.
A74932

C00683 C00682 B56497 B56498 B56499 B56500 B56501 2 1 1 1 A74937 A74958 A74959 A74960

1 1

A74941 A74942

8 Transformer (240 or 480 Volts) (208 Volts) 1 1 9 2 1 1 2 A74946 A74947 A74952 A74953 A74961 A74955 A74956

9 Terminal Blocks 10 Fuse Blocks 11 High/Low Selector Switch 12 H-O-A Selector Switch 13 Contact Blocks (For Selector Switch)

43

Parts List
15 hp, 20 hp and 25 hp, 208V Two Speed 20 hp, 25 hp and 30 hp, 240V Two Speed 30 hp, 40 hp and 50 hp, 480V Two Speed

IItem Description
1 Contact Kit 2 Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 Magnet Coil (Starter) 4 Pneumatic Timing Relay, 120 V, 60 Hz 5 Magnet Coil (Timing Relay) 6 Snap Switch (Timing Relay) 7 Fuse Clips (250V, 61-200 Amps) (600V, 61-200 Amps) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
2

Part No.
A74933

C00683 C00682 B56497 B56498 B56499 B56500 B56501 2 1 1 1 A74938 A74958 A74959 A74960

1 1

A74943 A74943

8 Transformer (240 or 480 Volts) (208 Volts) 1 1 9 2 1 1 2 A74950 A74951 A74952 A74953 A74961 A74955 A74956

9 Terminal Blocks 10 Fuse Blocks 11 High/Low Selector Switch 12 H-O-A Selector Switch 13 Contact Blocks (For Selector Switch)

44

Parts List
30 hp and 40 hp, 208V Two Speed 40 hp and 50 hp, 240V Two Speed 60 hp, 75 hp and 100 hp, 480V Two Speed

IItem Description
1 Contact Kit 2 Solid State Overload Relay (SQ. D Number) Type SFB20 Type SSC20 Type SS020 Type SS120 Type SS220 Type SS320 Type SS420 3 Magnet Coil (Starter) 4 Pneumatic Timing Relay, 120V, 60 Hz 5 Magnet Coil (Timing Relay) 6 Snap Switch (Timing Relay) 7 Fuse Clips (250V, 61-200 Amps) (600V, 61-200 Amps) FLA 1.5A-4.5A FLA 3A-9A FLA 6A-18A FLA 9A-27A FLA 15A-45A FLA 30A-90A FLA 45A-135A

Quan.
2

Part No.
A74934

C00683 C00682 B56497 B56498 B56499 B56500 B56501 2 1 1 1 A74939 A74958 A74959 A74960

1 1

A74943 A74943

8 Transformer (240 or 480 Volts) (208 Volts) 1 1 9 2 1 1 2 A74950 A74951 A74952 A74953 A74961 A74955 A74956

9 Terminal Blocks 10 Fuse Blocks 11 High/Low Selector Switch 12 H-O-A Selector Switch 13 Contact Blocks (For Selector Switch)

45

Troubleshooting Guide
Fan Does Not Start Power disconnected. Fuses blown. Overloads tripped. Vibration switch tripped or jumper wire missing

Nuisance Tripping

Sustained overload. Check for equipment grounds or shorts. Check motor winding resistance, fan pitch, drive reduction ratios, air ow restrictions on tower fans and tower loading. Loose connections. Excessive motor cycling. Increase temperature differential until a maximum of ve starts per hour is achieved on the fanmotor.

Contact Chatter

Broken shading coil. Low voltage. Intermittent supply voltage.

Contact Welding

Abnormal inrush of current. Check for grounds, shorts or excessive overload currents. Insufficient tip pressure. Replace contact springs. Low voltage preventing magnet from sealing. Chattering contacts.

Short Contact Life

Filing or dressing. Excessive cycling of fan motor. Increase temperature differential on temperature switch. Weak contact pressure. Replace contact spring. Short circuits. Loose connections.

46

Troubleshooting Guide
Cooked Coil Sustained overload. Overvoltage or undervoltage condition. Mechanical damage resulting in shorted turns. Dirt or rust on pole faces increasing air gap. Loose connections in control circuit. Intermittent supply voltage causing chattering. Transient voltage spikes.

47

7401 WEST 129 STREET | OVERLAND PARK, KANSAS 66213 UNITED STATES | 913 664 7400 | spxcooling@spx.com | spxcooling.com
In the interest of technological progress, all products are subject to design and/or material change without notice. 2010 SPX Cooling Technologies, Inc. | Printed in USA

Manual 92-1320E