97 1188C

Printed in U.S.A.
NC SERIES
Assembly Manual
(for the following tower models)
97-1188C
NC1200 NC2200 NC3200 NC4200 NC5200 NC6200 NC7200 NCA200 NCB200
Manual 97-1188C
K/D Assembly Manual

NC Series
The Marley Cooling Tower Company
7401 W. 129th Street, Overland Park Kansas 66213 (913) 664-7400
Revision C ECO 99-1411 December 1999
As of date shown above The Marley Cooling Tower Co. unpublished-all rights reserved under the copyright laws.
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The location and orientation of the cooling tower can affect the safety of those responsible for installing, servicing or repairing the cooling tower. Since Marley does not dictate or determine where the tower is located or how it is oriented, Marley is not responsible for addressing the safety issues that are affected by the towers location or orientation. The following safety issues should be considered by those responsible for designing the tower installation. Failure to consider and address these issues may result in substantial personal injury or death to those involved in installing, servicing or repairing the cooling tower. * Access to and from the fan deck. * Access to and from maintenance access doors. * Access for cleaning and other service. * Potential access problems due to obstructions surrounding the tower. * The possible need for handrails around the fan deck. * The possible need for ladders (either portable or permanent) to gain access to the fan deck or maintenance access doors. * The possible need for safety cages around ladders. These are only some of the safety issues that may arise in the design process. Marley strongly recommends that you consult a safety engineer to be sure that all safety considerations have been addressed. Marley offers optional equipment that may assist you in addressing some of these safety issues. Contact your Marley representative for information on these optional items.
WARNING
CONFIDENTIAL- The contents of this document are confidential and constitute the exclusive property of the Marley Cooling Tower company and is intended for use in the construction (contractor) and maintenance (owner) of this cooling tower. This document and its contents may not be made public in any manner, distributed or loaned to others, or reproduced or copied either in whole or part without prior written consent of The Marley Company.
NC SERIES CONTENTS
Getting Started
color code ABOUT THIS MANUAL ...................................................................................................................... i MEASUREMENT SYSTEM .............................................................................................................. ii TOOLS AND SUPPLIES ................................................................................................................... ii PVC FILL STORAGE ........................................................................................................................ ii JOINT SEALING INSTRUCTIONS ...................................................................................................iii A FEW WORDS ABOUT FASTENERS ............................................................................................ v WHO TO CALL ................................................................................................................................ vi
Tower Assembly
COLLECTION BASIN ................................................................................ blue ........................... 1-1 COLUMNS .............................................................................................. yellow ........................... 2-1 ENDPLATES ........................................................................................... yellow ........................... 2-2 TORQUE TUBE ...................................................................................... yellow ........................... 2-3 BRACING ................................................................................................ yellow ........................... 2-5 LOUVER COLUMNS .............................................................................. yellow ......................... 2-10 TOP GIRT ............................................................................................... yellow ......................... 2-11 DISTRIBUTION BASIN ................................................................................ red ........................... 3-1 FAN DECK ................................................................................................ white ........................... 4-1 CASING .................................................................................................. yellow ........................... 5-1 FILL .......................................................................................................... green ........................... 6-1 ELIMINATOR PACKS .............................................................................. green ......................... 6-15 TIE-RODS ............................................................................................... yellow ........................... 7-1 LOWER FAN CYLINDER .......................................................................... white ........................... 7-2 MECHANICAL EQUIPMENT ......................................................................................................... 8-1 GEAREDUCER .............................................................................................................................. 8-4 MOTOR .......................................................................................................................................... 8-9 DRIVE LINE ................................................................................................................................. 8-16 FAN INSTALLATION & ADJUSTMENT ....................................................................................... 8-18
Miscellaneous
INLET PIPING & FLUME .......................................................................... white ........................... 9-1 DISTRIBUTION BASIN COVERS ............................................................. white ........................... 9-6 UPPER FAN CYLINDER & FAN GUARD ................................................. white ........................... 9-8 ACCESS DOOR ...................................................................................... yellow ........................... 9-9 DECALS ....................................................................................................................................... 9-10
Optional Equipment
OUTLET PIPING .......................................................................................................................... 10-1 FLOAT VALVE ............................................................................................................................. 11-1
Find Number Index .................................................................................................. 12-1

Note: Optional equipment not listed above is installed using separate installation drawings and bills of material. These documents are located within the literature package and should be reviewed prior to starting assembly. Optional equipment may affect assembly sequence.
97-1188C
NC SERIES GETTING STARTED

ABOUT THIS MANUAL
To obtain maximum efficiency, it is strongly recommended that this entire manual be read before starting assembly. This assembly manual illustrates a typical field assembly sequence of a basic tower. Some of the more commonly used options are also included. Refer to separate installation drawings for installation of special options and additional optional equipment. Review all manuals, drawings and bills of material prior to assembly. These documents are located in a Literature Kit packed with the tower. Contact Marley sales office if questions arise. All steel parts are tagged for identification, as shown below. Parts that have been shop modified, per contract, will have a separate tag affixed to the part adjacent to the tag that defines the Find number.
Code used in manufacturing process Find Number Item Number Stainless Steel Drawing Number
M35
Description
Find Number: This is a three digit alpha/numeric number that ties everything together. Used throughout this manual, in the text, it's the number in bold type M35, in the Figures, it's the number within the circle. It is also the first column in the BILL OF MATERIAL. In the bill of material, all tower components are listed in numerical order by this number. Item Number: This number is used by Marley to manufacture, modify and inventory the components of your cooling tower. Give these numbers to your Marley people if an item is missing or a replacement item is required. Drawing Number: (Reference only) This is the number of the drawing used to fabricate or modify this item. Description: (Reference only) All steel parts begin with SHT or ASSY followed by the size of the sheet used to fabricate the item or a description of the assembly. Your tower may have a few fiberglass items which begin GRP. Stainless Steel: This indicates when an item has been made from stainless steel. If the item is made from the standard galvanized material this will not be printed on the tag. Color Code: To help group parts together that are assembled in similar areas of the tower, many of the tower components are tagged with a colored stick-on dot. Reference the table of contents of this manual for the coding of the various tower components. Bills of material (BOM) are separate from drawings and this manual. At the top of each bill there is a Drawing Number, cell number and the drawing description which indicates if the items on that bill will be installed per this assembly manual or per a special installation drawing. There will be a BOM for each cell. The find number, item number, description and quantity of items are all cross referenced on the bill of material. If a number is missing or hard to read, check the illustrations in this assembly manual first and then the bill of material to see if you can find it. As the tower is prepared for assembly, the quantities of each item should be checked against the bill of material. If anything is missing or damaged tell your Marley people as soon as possible. Use the orientation drawings (Sales drawings) to define the location of parts in each cell. The BOM indicates the Find Number and the contract modifications made for specific items to be located in the indicated cell.
97-1188C
NC SERIESGETTING STARTED
MEASUREMENT SYSTEM
This manual uses both, the English System and the Systme International d'Units (S.I.) systems of measurement. Fasteners are denoted and supplied in conformance with the English System.
TOOLS AND SUPPLIES
HOIST. 2500 pound (1140kg) capacity. For hoisting of motor and Geareducer. 1/2" electric drill and bit set. Socket wrench set. You will be using 9/16" sockets a lot so its a good idea to have more than one. Combination wrenches. Mainly 9/16" up to 1 1/8". Adjustable wrenches are OK but not recommended. Screwdrivers. Torque wrench. 150 ft-lb (203 N-m) capacity Caulking guns. Required for application of sealant. Pipe wrenches. Drift pins (alignment tools). These are extremely important to help line up all the holes. You should have more than one.
Allen wrenches. Protractor level. For setting fan blade pitch. Dial Indicator kit. Marley Item No. 115311M. For drive shaft alignment. Needed for motor outside airstream option only. Scaffolding, portable stairs or other means of temporary access and support. Electric impact wrench (or air). Optional, really makes the job go fast. You can get by without one but if you can get one you should. Wear protective clothing, gloves, nonslip footwear, hard hat and safety glasses. Cooling towers are constructed of steel and could have burrs that can cause cuts. The surface of steel material may be slick. Protection from thrown or falling objects should be used at all times around a construction site. ACETONE solvent. About a gallon (4 liters) and plenty of clean cotton rags.
PVC FILL STORAGE
Stacked and nested fill sheets can be stored uncovered outdoors in winter, spring or fall for up to 4 weeks. In hot summer conditions it should not be left out uncovered.
ii
97-1188C

JOINT SEALING INSTRUCTIONS
Surface preparation instructions: The following information covering surface preparation applies to all sealed joints whether sealer Z11 or strip sealer Z12 or Z13 is being used. Years of experience has shown the instructions on surface preparation and sealing details do result in watertight joints. Inadequate attention to these details will result in joints that leak. Do not apply either sealer if temperature is below 40 Fahrenheit (5 Celsius). All flanges are to be straight. Rework kinks or bends that exist. Clean surfaces being sealed with acetone. If cloth is used, it must always be clean and dry. Exercise caution in using solvents, always read labels and instructions. Care should be taken not to wipe dirt or oil onto the cleaned surface from adjacent uncleaned area. Mating surfaces to be sealed must be kept clean and dry prior to assembly. No water, grease or dirt should contaminate cleaned area. Note that stainless steel requires a larger area to be cleaned because oil will recontaminate surfaces quickly. Oil will migrate through punched holes and around sheared edges. Application instructions for Sealer Z11 (Type A, B & C seals): Sealer Z11 comes in a 1/12th gallon (315ml) cartridge and is applied using a standard caulking gun. Apply sealer to the unassembled parts. The typical joint sealing details shown on this page and the following page are referenced throughout this manual. Care should be taken to fill voids and gaps at joints. After parts have been assembled, trowel excess sealant over joint, taking care to force sealant, back into joint, and not out of joint. Do not use solvent to aid in applying sealer as solvent adversely affects bonding of sealant to metal. Care should be taken to avoid leaving holes or air bubbles in sealant. Do not subject sealed joints to waterloading for 48 hours at temperatures of 70 Fahrenheit (21 Celsius) and above. Lower temperature will require a longer cure time. This symbol is used throughout the manual to indicate the locations where sealer Z11 is rerefers to a Type A seal which is quired. The a 3/8" (10mm) diameter bead of sealer Z11 laid along the centerline of a row of holes curving over each hole it passes. Reference detail at the right.
Water side of joint.
Fastener hole
Z11 Sealer 3/8" (10mm)

diameter bead
(Water on one side of joint)
Type A seal
This symbol is used throughout the manual to indicate the locations where sealer Z11 is rerefers to a Type B seal which is quired. The a 3/8" (10mm) diameter bead of sealer Z11 laid along the centerline of a row of holes curving completely around each hole it passes. Reference detail at the right.
Fastener hole
Z11 Sealer 3/8" (10mm)

diameter bead
Type B seal
97-1188C
iii
NC SERIESGETTING STARTED
Fastener hole Sealer 3/8" (10mm) Z11 diameter bead
This symbol is used throughout the manual to indicate the locations where sealer Z11 is rerefers to a Type C seal which quired. The is a 3/8" (10mm) diameter bead of sealer Z11 laid completely around each hole in a row of holes. Reference detail at the right.
Type C seal
Application instructions for Strip Sealer Z12 & Z13 (Type D & E seals): Strip sealer is supplied in 1/2" (12mm) Z13 and 1" (25mm) Z12 widths. It is intended that the 1" (25mm) wide sealer be used unless noted otherwise. Apply continuous pieces of strip sealer to the unassembled parts. Do not splice pieces except where turning a corner. Cut with a sharp instrument, do not stretch or tear. Gaps at joints and corners can be filled by stretching a piece of strip sealer to obtain the proper thickness. Then work it into the joint to fill gap and create an even surface. After parts are set together, use a drift pin or other pointed object to puncture sealer at each fastener hole, where required.
Fastener hole
Typical
This symbol is used throughout the manual to indicate the locations where a single layer of strip sealer Z12 or Z13 is required. Reference detail at the right.
Z12
or
Z13
Type D seal
This symbol is used on collection basin joints to indicate the locations where two layers of strip sealer are required. Align bottom edge of strip sealer Z13 with top edge of bolt holes. Align top edge of strip sealer Z12 with bottom edge of bolt holes. Reference detail at the right.
Fastener hole
Water side of joint.
Z13 Z12
Type E seal
iv
97-1188C

A FEW WORDS ABOUT FASTENERS
Stainless steel fasteners: Stainless steel fasteners are sensitive to galling. This is when you notice a sudden increase in the force needed to turn a nut before parts are clamped. Apply anti-seize compound included with the tower to the threads of the bolt before installing the nut. If a nut does not easily spin on a bolt do not try to force it. Chances are it will seize. Some extra hardware is included to replace problem hardware. Due to availability, 3/8" standard nuts and Loctite may have been substituted for 3/8" selflocking nuts. If this substitution has been made, do not apply the anti-seize compound to the stainless steel bolts. Insert bolt thru hole before applying Loctite. Loctite will act as a thread lubricant. Torque Requirements: The idealized standard fastener torque values for galvanized and stainless steel fasteners are shown in the table below. These values may vary in actual practice. Note that the values shown for stainless steel fasteners are based on the fasteners being lubricated with anti-seize compound.
FASTENER TORQUE
Bolt Diameter 3/8" 1/2" 3/4" Fastener Torque foot-lbs.(newton-meters) Galvanized 20 (27.1) 45 (61) 150 (203) * Stainless Steel 20 (27.1) 27 (37) 74 (100)
* Values based on fasteners lubricated with anti-seize compound. (Stainless steel only)
Loctite: Critical structural and mechanical attachments require extra protection against the nuts vibrating loose during tower operation. This is accomplished on galvanized fasteners by applying Loctite Z05 thread locking compound to the exposed threads of a bolt after the nut has been installed and tightened. Bolts should be installed with the threaded end up or horizontally. On stainless steel fasteners the use of anti-seize compound makes the use of Loctite ineffective. Therefore in these critical areas with stainless steel fasteners self-locking nuts have been substituted for the standard nuts and the Loctite will not be used. Z05 Z05 This symbol is used throughout the manual to indicate the locations where Loctite Z05 is required. Reference details at the right.
Typical bolted attachment with threaded end of bolt up or bolt installed horizontally.
97-1188C
STOP! WAIT! HOLD EVERYTHING!

Call us if you need help of any kind assembling this cooling tower. If you're missing a part, we'll replace it. If a part is damaged, we'll get you a new one. Call us. We're standing by to solve any assembly problem you might have. Below is a complete list of Marley's sales representatives in the US and Canada. If you need help determining the representative in your area please call 913.664.7400 or check the internet at www.marleyct.com.
Birmingham, Alabama Palmer & Lawrence, Inc. Anchorage, Alaska James P. Sheldon Company Edmonton, Alberta International Cooling Tower Inc. Phoenix, Arizona Holbrook & Associates, Inc. Little Rock, Arkansas Woodbury-Beach Company Vancouver, British Columbia Esko Industries Ltd. Los Angeles, California Marley Cooling Tower San Diego, California Delta-T Systems, Inc. San Francisco, California California Hydronics Corporation Santa Rosa, California Marley Cooling Tower Denver, Colorado J.L. Hermon & Associates, Inc. Hamden, Connecticut The Bernard M. Packtor Company Washington, D.C. Environmental & Power Systems Inc. Jacksonville, Florida French & Company, Inc. Miami, Florida Middleton & Associates, Inc. Orlando, Florida Aqua Air Products, Inc. Pensacola, Florida R.M. Tugwell & Associates, Inc. Tampa, Florida Aqua Air Products, Inc. Atlanta, Georgia Marley Cooling Tower Honolulu, Hawaii Mechanical Systems Corp. Chicago, Illinois Marley Cooling Tower Indianapolis, Indiana Keller-Rivest, Inc. Marshalltown, Iowa R.S. Stover Company Louisville, Kentucky P.L. Sherman Company, Inc. New Orleans, Louisiana Fischer Engineering, Ltd. Shreveport, Louisiana Zimmerman, Inc. Winnipeg, Manitoba Power & Mine Supply Co., Ltd. Baltimore, Maryland H.P. Rodgers, Inc.
Boston, Massachusetts R.T. Forbes Company, Inc. Detroit, Michigan RBE, Inc. Grand Rapids, Michigan Hedrick Associates Minneapolis, Minnesota The Gorgen Company Jackson, Mississippi Ward Mechanical Equipment Kansas City, Missouri Marley Cooling Tower St. Louis, Missouri Midwest Machinery Company Billings, Montana Clapper Company, Inc. Omaha, Nebraska R.S. Stover Company Las Vegas, Nevada Ampco, Inc. St. John, New Brunswick Trane Company Inc. Albuquerque, New Mexico James, Cooke & Hobson, Inc. Albany, New York F.R. Foote Company, Inc. New York, New York Marley Cooling Tower Rochester, New York The Johnston Equipment Co., Inc. Charlotte, North Carolina PACE, Inc. Greensboro, North Carolina PACE, Inc. Raleigh, North Carolina PACE, Inc. Fargo, North Dakota Therm-Air Sales Corporation Halifax, Nova Scotia Conrad Trane Sales Cincinnati, Ohio Marley Cooling Tower Cleveland, Ohio The Craun-Liebing Company Columbus, Ohio Tower Equipment Company Oklahoma City, Oklahoma Process Equipment Company Tulsa, Oklahoma Process Equipment Company, Inc. Ottawa, Ontario Mechanical Trade Sales Sarnia, Ontario EFI Ironross Thunder Bay, Ontario Power & Mine Supply Co., Ltd.
Toronto, Ontario Marley Cooling Tower Portland, Oregon Oregon Air Reps, Inc. Harrisburg, Pennsylvania H & H Sales Associates Philadelphia, Pennsylvania Marley Cooling Tower Pittsburgh, Pennsylvania P.F. Sherman Company Montreal, Quebec Enviroair Industries Inc. Quebec City, Quebec Evap-Tech Inc. Saskatoon, Saskatchewan Power & Mine Supply Co., Ltd. Columbia, South Carolina PACE, Inc. Greenville, South Carolina PACE, Inc. Knoxville, Tennessee Ferguson Equipment Company Memphis, Tennessee T.J. O'Brien Engineering Co. Nashville, Tennessee Johnson & Scott, Inc. Austin, Texas Dreher & Associates, Inc. Corpus Christi, Texas Lewis Mechanical Sales Dallas, Texas Slack Buckner Systems El Paso, Texas James, Cooke & Hobson, Inc. Fort Worth, Texas Slack Buckner Systems Houston, Texas Marley Cooling Tower San Antonio, Texas Dreher & Associates, Inc. Salt Lake City, Utah Holbrook & Associates, Inc. Richmond, Virginia Frank Howell Company, Inc. Seattle, Washington Olympic Engineered Sales, Inc. Milwaukee, Wisconsin Chipley & Zeman, Inc.
vi
NC SERIES TOWER ASSEMBLY
To avoid damaging sealing washers use the impact wrench on the side opposite the sealing washer wherever possible.
A01
Note: If required, 6" (152mm) dia. hole for standpipe overflow is typically installed opposite of the planned motor location. See outlet piping key plan and/or contract sales drawing for special requirements. or X12 Stainless steel basin X02 Galvanized basin
W22 A02 W32
V07
A01 A02
D
A03 A02
Strip sealer Z12
Find No.
V07
X02 Galvanized basin

Galvanized basin W02 or
Description
X12 Stainless steel basin
V07 3/8"x1" Bolt W02 3/8" Lock Washer W22 3/8" Flat Washer W32 3/8" Sealing Washer X02 3/8" Nut X12 3/8" Self-locking Nut
NC1200 thru NC4200
Figure 1-1
COLLECTION BASIN
The assembly site for the basin and tower should be flat, level and clean. It should also allow for access to fasteners beneath the collection basin. During assembly, locate the head of bolts either on the exterior of tower or in a uniform manner for a better appearing finished product. Sealing washers, when specified, should be placed against the basin floor or side as shown in details to prevent leaks at the fasteners. A flat washer should be placed between the sealing washer and nut or bolt head to reduce the possibility of damage to the sealing washer while tightening fastener. Please observe the sealing
97-1188C
details to insure a watertight basin. Note: Refer to Basin Orientation drawing and Bills of Material for location of parts modified for per contract requirements. Begin assembly of the collection basin by attaching the forklift floor panels A02 to the depressed section floor panel A01. Refer to Figure 1-1 for models NC1200 thru NC4200 and Figure 1-2 for models NC5200 thru NC7200, NCA200 and NCB200. Next, attach the forklift stiffeners A03. On models NC5200 thru NC7200, NCA200 and NCB200 attach additional stiffeners A04.
PAGE 1-1

Strip sealer Z12
D
V07 A01
or
A02 X12 Stainless

steel basin
Note: If required, 6" (152mm) dia. hole for standpipe overflow is typically installed opposite of the planned motor location. See outlet piping key plan and/or contract sales drawing for special requirements.
A02 W02
Galvanized basin
A01 W22
A02
W32 A04 A03 A04
V07 A03 V07 X02 Galvanized basin

or Galvanized basin W02
NC5200 thru NC7200, NCA200 & NCB200

Figure 1-2
Find No.
Description
97-1188C
I
PAGE 1-2

Attach the remaining floor panels A05 (and A06 on models NC4200 thru NC7200, NCA200 and NCB200) along with end panel A09 per Figure 1-3 for models NC1200 thru NC3200 or Figure 1-4 for models NC4200 thru NC7200, Galvanized NCA200 and NCB200.
basin Stainless steel basin Galvanized basin
Find No.
Description
Top row of holes only.
E
X12
or
W22
W02
X02
Strip sealer Z13 on top, Z12 on bottom
A05 A09 A05 V07
A05
V07
W22
A05
Galvanized basin
NC1200 thru NC3200
Figure 1-3
W02
Galvanized basin Stainless steel basin
X02
X12 or
PAGE 1-3
97-1188C

Top row of holes only. Strip sealer Z13 on top, Z12 on bottom
Find No.
Description
X12 Stainless
or
steel basin
V07
X02 Galvanized basin W22 A06 A09

Galvanized basin
A09 W02 A06 A05

E
W22
Galvanized basin
V07 A06 A05

W02
W22 X02
or
W22
E
X12
A05
V07
I
Figure 1-4

PAGE 1-4
97-1188C

Find No.
Description
V07 3/8"x1" Bolt W02 3/8" Lock Washer

Cold water basin end
X02 3/8" Nut X12 3/8" Self-locking Nut
V07
Galvanized basin W02

or
X12 Stainless steel basin A16
NCA200 & NCB200 (Viewed from underside of basin)
Figure 1-5
Models NCA200 and NCB200 require attachment of end stiffeners A16 as shown in Figure 1-5.
97-1188C
PAGE 1-5
A21
See Figure 1-7
A07
A13 A20
A20 A07
Note: If collection basin side requires cutout, check label on part for correct face orientation.
A21
NC4200 thru NC7200
Figure 1-6
Following the assembly of the floor panels, on models NC1200 thru NC7200, the basin sides A07, A20 and A21 are spliced together and attached. Also, the corner seals A13 are installed at this time. Refer to Figure 1-6 and Figure 1-7 for models NC1200 thru NC7200.
PAGE 1-6
97-1188C

Find No.
Description
Find No.
Description
V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt V21 3/4"x1 1/2" Bolt W02 3/8" Lock Washer W05 3/4" Lock Washer W22 3/8" Flat Washer W23 1/2" Flat Washer W30 3/4" Flat Washer W32 3/8" Sealing Washer W33 1/2" Sealing Washer W35 3/4" Sealing Washer
X02 3/8" Nut X03 1/2" Nut X04 3/4" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
X02
or
X15 3/4" Self-locking Nut

Apply around holes, along Galvanized edges, and on X02 basin back side of or both flanges. Stainless X12 steel basin
X12
A13 W32
W02 basin W22
Galvanized
Strip sealer Z12
A20
Strip sealer Z13 on top, E Z12 on bottom Top row of holes only.
X04 Galvanized V07

or basin
X15 steel basin
Stainless
W05
Galvanized basin Galvanized basin Stainless steel basin
W02
Galvanized basin
V07 W30 W35 W33 V19 W23 V31 V07
X03
or
X13
D
V31
A07
Strip sealer Z12
NC1200 thru NC4200 only
NC4200 thru NC7200

97-1188C
Figure 1-7
PAGE 1-7
A21 A22
See Figure 1-9

A13
A07 A20
A23
A20 A23 A07 A21 A22

Note: If collection basin side requires cutout, check label on part for correct face orientation.
NCA200 & NCB200
Figure 1-8
On models NCA200 and NCB200, the basin sides A07, A20 and A21 are attached to the floor and end panels first. Splice plates A22 and A23 are then attached where the sides meet. Corner seals A13 are also installed at this time. Refer to Figure 1-8 and Figure 1-9.
PAGE 1-8
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Find No.
Description
Find No.
Description
V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt V21 3/4"x1 1/2" Bolt
W02 3/8" Lock Washer W03 1/2" Lock Washer W05 3/4" Lock Washer W22 3/8" Flat Washer W30 3/4" Flat Washer
Galvanized basin Apply around holes, along edges, and on back side of both flanges.
X02
or
W32 3/8" Sealing Washer W35 3/4" Sealing Washer X02 3/8" Nut X03 1/2" Nut X04 3/4" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
W02 A13
X12
W22 V07
Galvanized W03 basin
B
X15 3/4" Self-locking Nut

E
Strip sealer Z12
W32

or
X13 Stainless
steel basin
Strip sealer Z13 on top, Z12 on bottom Galvanized X02 or basin Stainless X12 steel basin
V07 A20 V19 W30 V31 A23 W35 W05

Galvanized basin Galvanized basin Stainless steel basin
D
Strip sealer Z12
W02
X04
V07
X15 or
A07
Galvanized basin
Apply strip sealer Z13 vertically, along edge of both basin sides at splice. Apply strip sealer Z12 horizontally, directly above floor attachment bolts, overlapping vertical strips.
NCA200 & NCB200

97-1188C
Figure 1-9
PAGE 1-9

All models require additional stiffeners under the sloping collection basin floor. Models NC1200 thru NC3200 use two floor stiffeners A12 and one end stiffener A10 on each side of the tower. See Figure 1-10. On model NC4200 three floor stiffeners A12 and two end stiffeners A10 per side are used as shown in Figure 1-11. Figure 1-12 shows the stiffener installation on models NC5200 thru NC7200, NCA200 and NCB200. Model NC5200 uses 5 floor stiffeners A12 per side, model NC6200 uses 6 per side, model NC7200 uses 7 per side, and models NCA200 and NCB200 use 9 per side. On model NC7200, one stiffener on each side is installed in the opposite direction as the others. All five of these models use two each per side of end stiffeners A10 and A11. V07
W22 V07 W32

C
V07
Galvanized basin
W02 A10
To avoid damaging sealing washers use the impact wrench on the side opposite the sealing washer wherever possible. Galvanized basin Stainless steel basin
Find No.
Description
X02
or
A12
PAGE 1-10
X12
NC1200 thru NC3200 (Viewed from underside of basin)

97-1188C
Figure 1-10
V07 W22 A10
V07
W32 V07 A10
X02 Galvanized
basin or
X12 steel basin
Stainless
Galvanized basin
W02 W02
Galvanized basin
X02 Galvanized
or basin
A12
Find No.
X12 steel basin
Stainless
Description
NC4200 (Viewed from underside of basin)
Figure 1-11
97-1188C
PAGE 1-11

V07
W22 W32 V07 A11

C
V07 W22 W32 X02 Galvanized

or basin
X12 steel basin W22
Stainless
A10
W32
A11 V07 A10

Galvanized basin
W02
Galvanized basin
W02
X02 Galvanized
or
Find No.
basin
X12
Description
Stainless steel basin
A12
(10 required on NC5200) (12 required on NC6200) (14 required on NC7200) (18 required on NCA200 and NCB200)
PAGE 1-12
NC5200 thru NC7200, NCA200 & NCB200 (Viewed from underside of basin)
Figure 1-12
97-1188C

The collection basin assembly is completed with the installation of the fill support angles A14. These angles must be orientated with the bottom flange pointing in the direction shown so that notches in the vertical flange will accommodate fill tubes. See Figure 1-13 for models NC1200 thru NC4200 or Figure 1-14 for models NC5200 thru NC7200, NCA200 and NCB200. If access to the underside of the collection basin will be available, the fill support angles may be installed during fill installation if desired. Extra attention to sealer application is required. V07
If access to the underside of the collection basin will be available the fill support angles may be installed during fill installation if desired. Extra attention to sealer application is required.
A14
W32 W22
Galvanized basin
Find No.
Description
V07 3/8"x1" Bolt W22 3/8" Flat Washer W32 3/8" Sealing Washer X02 3/8" Nut X12 3/8" Self-locking Nut
X02
or
X12
NC1200 thru NC4200

97-1188C
Figure 1-13
PAGE 1-13

Find No.
Description
V07
A14
W32 W22
Galvanized basin
X02
or
If access to the underside of the collection basin will be available the fill support angles may be installed during fill installation if desired. Extra attention to sealer application is required.
X12
Figure 1-14
PAGE 1-14
97-1188C
Remember, if you are having any problems assembling this cooling tower, help is just a phone call away.
Before proceding, retighten (check torque) of fasteners on each cold water basin joint. Sequential installation of fasteners may have loosened previously tightened fasteners.
97-1188C
PAGE 1-15

NOTE: It is critical that all bolted connections in the structural support of mechanical equipment remain tight. Thread locking compound has been provided to apply to threads of galvanized bolts after final torquing. Because stainless steel hardware requires the use of an anti-seize compound, thread locking compound should not be used. Instead self-locking nuts are used on stainless steel bolts.
Refer to Figure 2-1 for installation of column D01 and bottom cross bracing clip D02 or D03 to collection basin.
COLUMNS
Find No.
Description
D01
X15 Stainless
or
steel basin Galvanized
X04 basin
D02 D03
W30
W35
V32
Figure 2-1
97-1188C
PAGE 2-1

Find No.
Description
X15
or
Stainless steel tower Galvanized
V19 1/2"x1 1/2" Bolt V31 3/4"x1 1/2" Bolt V32 3/4"x2" Bolt X03 1/2" Nut X04 3/4" Nut X13 1/2" Self-locking Nut X15 3/4" Self-locking Nut
D39 D40
X04 tower
D35 V31 Motor side with standard motor X13 Stainless

or
X15 Stainless
or
steel tower Galvanized
NC1200
X04 tower
M38
X03 tower
V32
D39 Motor side with MOA
V19
NC1200
Figure 2-2 ENDPLATES

The endplates D35 (and D39 on motor side of NC1200) are connected to the columns per Figure 2-2. On the motor side of model NC1200, an endplate stiffener (D40 on towers with standard motor location or M38 on towers with MOA) is also required.
PAGE 2-2
97-1188C

TORQUE TUBE
Attach torque tube assembly D36 to endplates on models NC1200 thru NC4200 using top holes in endplates. See Figure 2-3.
X15 Stainless
or
X04 tower
D36
V31
Find No.
Description
V31 3/4"x1 1/2" Bolt X04 3/4" Nut X15 3/4" Self-locking Nut
NC1200 thru NC4200
Figure 2-3
97-1188C
PAGE 2-3

Find No.
Description
On models NC5200 thru NC7200, NCA200 and NCB200 use bottom three holes to attach torque tube assembly D36 to endplates. Refer to Figure 2-4.
D36
X15 Stainless
or
X04 tower
V31
Figure 2-4
PAGE 2-4
97-1188C
V31
D37 X15 Stainless

or steel tower Galvanized
D38
X04 tower
NC1200 and NC2200
Figure 2-5
BRACING
Begin bracing installation by attaching top clips D37 and D38 to torque tube assembly. See Figure 2-5 for models NC1200 and NC2200.
Find No.
Description
97-1188C
PAGE 2-5
V31
D37 X15 Stainless

or steel tower Galvanized
X04 tower D38
Figure 2-6
Refer to Figure 2-6 for bracing top clip D37 and D38 installation on models NC3200 thru NC7200, NCA200 and NCB200.
Find No.
Description
PAGE 2-6
97-1188C

or
X15 Stainless
X04
steel tower Galvanized tower
Attach bracing channels D05 to top and bottom bracing clips. See Figure 2-7 for models NC1200 and NC2200.
D05 V31
D05
D05
D05 X15 Stainless V31

Find No.
or
Description
X04 basin
NC1200 and NC2200

97-1188C
Figure 2-7
PAGE 2-7

or
X15 Stainless
X04
Find No.
Description
D05 V31
D05
D05 X15 Stainless

or
X04 basin V31
NC3200 and NC4200 Refer to Figure 2-8 for models NC3200 and NC4200. Attach bracing channels D05 to top and bottom bracing clips.
PAGE 2-8
Figure 2-8
D05
97-1188C

or
X15 Stainless
X04
Models NC5200 thru NC7200, NCA200 and NCB200 require two bracing channels D05 and D06 that attach to top and bottom bracing clips. See Figure 2-9.
V31
D05
D05 D06
D06 D06
V31
Find No.
Description
X15 Stainless

97-1188C
Figure 2-9
or
X04 tower
PAGE 2-9

LOUVER COLUMNS
Find No.
Install louver columns D24 and D25 to collection basin per Figure 2-10.
Description
V19 1/2"x1 1/2" Bolt W03 1/2" Lock Washer W23 1/2" Flat Washer W33 1/2" Sealing Washer X03 1/2" Nut X13 1/2" Self-locking Nut
D25 D24
W23 W33
V19

or Galvanized basin
W03
Figure 2-10
97-1188C
PAGE 2-10

TOP GIRTS
Model NC1200 utilizes a three piece girt E01, E26 and E27, with stiffeners E28 that must be sub-assembled before setting in place. See Figure 2-11. Attach girt assembly to center columns, but do not bolt to louver columns at this time. E27 V07 X02 tower
or Galvanized
X12 Stainless
Galvanized
steel tower
X03 tower E28 E01
E01 E28
E27 V31 E26
E26 E27 E01
E28 X04 tower

or Galvanized
X15 Stainless
steel tower
Find No.
Description
V07 3/8"x1" Bolt V31 3/4"x1 1/2" Bolt X02 3/8" Nut X04 3/4" Nut X12 3/8" Self-locking Nut X15 3/4" Self-locking Nut
97-1188C
Figure 2-11
NC1200
PAGE 2-11

Galvanized tower
X04 or X15 Stainless

steel tower
V31 E32
E32
E01
V31 X04 tower

or Galvanized
X15 steel tower
Stainless
NC2200 and NC3200 Models NC2200 and NC3200 use a two piece girt E01 and E32 that splice together at the center of the tower per Figure 2-12. Attach girts to center columns, but do not bolt to louver columns at this time.
PAGE 2-12
Figure 2-12
Find No.
Description
97-1188C

E27
V31
E27
X04 tower
or
Galvanized
X15 Stainless
steel tower
NC4200 thru NC7200, NCA200 & NCB200 If you have a model NC4200 thru NC7200, NCA200 and NCB200 connect girt E27 to the center columns as shown in Figure 2-13.
97-1188C
Figure 2-13
Find No.
Description
PAGE 2-13

Find No.
Description
C14 2" (50mm) 12" (305mm)
C15
V07
W22
24" (610mm) C08
3" (75mm) V07
C01
C03
Apply sealer around holes, along edges, and on back side of both flanges of C08. (Typical)
W32
W22 X02
or
C02 W32
E
X12
C08 W32 W22
W22
Top row of holes only. Galvanized basin Stainless steel basin
X02
or
X12
W22
V07
See the DECALS section of this manual for Surface Preparation & General Application Instructions.
NC1200 thru NC6200 & NCA200
Figure 3-1
DISTRIBUTION BASIN
Before beginning basin assembly, be sure to study Figures 3-1 thru 3-3. The same attention to sealing details is required here as on the collection basin to ensure watertightness. The importance of sealing properly the first time cannot be overstated.
97-1188C
Begin basin assembly by attaching sides C02 and C03 to floor panel C01. Attach corner seals C08 and apply decals C14 and C15. See Figure 3-1 for models NC1200 thru NC6200 and NCA200.
PAGE 3-1

Models NC7200 and NCB200 assemble similarly, but have an additional deflector C04 on the eliminator side of the basin. See Figure 3-2.
C14 12" (305mm)
2" (50mm)
I
V07 W22
C15 C01 24" (610mm) C08 3" (75mm) W32

C03
V07 W22
Apply sealer around holes, along edges, and on back side of both flanges.
X02
or
W22
W32 C08
C02
X12 C04
E
W32
X02
or
W22
X12
V07
Find No.
Description
PAGE 3-2
NC7200 & NCB200
Figure 3-2
See the DECALS section of this manual for Surface Preparation & General Application Instructions.
97-1188C

Required on galvanized towers with stainless steel distribution basins only. This side Opposite side
W22
X12
Strip sealer Z12
D
E11
or
or Galvanized basin
X02
E12
W32
V07
C05 W22 V07

E
This side Opposite side
E26
or
W32
E01
Figure 3-3
Bottom row of holes only.
Find No.
Description
On models NC4200 thru NC7200, NCA200 and NCB200 the sides of the basin are put on at this time. If you have a galvanized tower with stainless steel distribution basins, stainless steel liners are required. Attach basin side E01 or E26, liner E11 or E12 (if required), and deflector C05 as shown in Figure 3-3.
97-1188C
PAGE 3-3

Find No.
Description
Basin floor stiffeners are installed next. Install center stiffener C06 on model NC1200 thru NC3200 per Figure 3-4.
V07
I
W32
W22
W32 W02 Galvanized C06

basin
W22
V07
X02
or
X12
NC1200 thru NC3200

PAGE 3-4
97-1188C
Figure 3-4

Find No.
Description
Model NC4200 requires center stiffener C06 installed per Figure 3-5.
I
V07
V07
W22 W32
W32
Galvanized basin
C06
W02 W22 V07
X02
X12 or
Figure 3-5
NC4200
97-1188C
PAGE 3-5

Install center stiffener C06 on models NC5200 and NC6200 as shown in Figure 3-6. Model NCA200 has two stiffeners that install similarly, but are equally spaced on the floor instead of being at the center.
Find No.
Description
V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt W02 3/8" Lock Washer W23 1/2" Flat Washer W33 1/2" Sealing Washer X02 3/8" Nut X03 1/2" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
I
V19
V07 W33
W23
C06 W02 Galvanized

basin
W33
X03
W23 V19
X13 or
X02 X03 Galvanized basin

or
X12 or
NC5200, NC6200 & NCA200

PAGE 3-6
97-1188C
Figure 3-6

Model NC7200 requires back to back center stiffeners C06 installed per Figure 3-7. Model NCB200 has two sets of stiffeners that install similarly, but are equally spaced on the floor instead of being at the center.
Find No.
Description
I
V19
W33 V07 W23
W33 C06
Galvanized basin
W02
X03
W23 V19 X02
X13 or
Galvanized basin
X12 or
X03
X13 or
NC7200 & NCB200
Figure 3-7
97-1188C
PAGE 3-7

Find No.
Description
On models NC5200 thru NC7200 additional floor stifferners C07 are installed between the center stiffener and the basin side per Figure 3-8. Models NCA200 and NCB200 have additional stiffeners that install similarly, but are centered between existing stiffeners. V07
W22
C07
W02
Galvanized basin or Galvanized basin
X02
X12

PAGE 3-8
97-1188C
Figure 3-8

Galvanized basin
X02 or X12 W32

C
W22
C16
NC1200 thru NC3200
Figure 3-9
V07
Find No.
Description
Install tie rod clips C16 to distribution basin per Figure 3-9 on models NC1200 thru NC3200.
97-1188C
PAGE 3-9

Galvanized basin
X02 or X12 W32

C
W22
C16
V07
Figure 3-10
Find No.
Description
Install tie rod clips C16 to distribution basin per Figure 3-10 on models NC4200 thru NC7200, NCA200 and NCB200. Note that clip does not attach to basin side at this time.
PAGE 3-10
97-1188C

If a handrail package is to be installed on models NC4200 thru NC7200, NCA200 and NCB200 a post clip E31 should be installed at this time as shown in Figure 3-11. If a handrail is not required, the top hole provided for the clip attachment must be plugged with the fasteners provided. V19
Find No.
Description
V07
E31
W33
W23
Galvanized basin
I
or
W02

Galvanized basin
X03 or X13 NC4200 thru NC7200, NCA200 & NCB200

PAGE 3-11
Figure 3-11
97-1188C

Stainless X12 Required on steel basin galvanized towers or Strip sealer Z12 with stainless D Galvanized steel distribution basin X02 basins only.
X13
or
Stainless steel basin basin
Find No.
Description
E11
X03 Galvanized
Galvanized basin
D
W32 W22
W03
If required
W32
E
W22
Strip sealer Z12
E12
C05
V07 V19 E02

Distribution Basin Assembly
Top row of holes only. Strip sealer Z12 on top, Z13 on bottom
E
Bottom row of holes only.
E02 E11
If required
The distribution basin is set into place between the girts at this time on models NC1200 thru NC3200. Refer to Figure 3-12. If you have a galvanized tower with stainless steel distribution basins, stainless steel liners are required. Attach bolts thru girt, liner E11 or E12 (if required), basin, and deflector C05.
PAGE 3-12
NC1200 thru NC3200

97-1188C
Figure 3-12

W05
Galvanized tower or
X15 Stainless steel tower
X04 Galvanized tower

or
W03 Galvanized tower
V31
V19
Find No.
Description
V19 1/2"x1 1/2" Bolt V31 3/4"x1 1/2" Bolt W03 1/2" Lock Washer W05 3/4" Lock Washer X03 1/2" Nut X04 3/4" Nut X13 1/2" Self-locking Nut X15 3/4" Self-locking Nut
On models NC4200 thru NC7200, set basin in place and attach to center girts and louver columns as shown in Figure 3-13.
NC4200 thru NC7200

97-1188C
Figure 3-13
PAGE 3-13

Galvanized tower or
W05 E30
X04 Galvanized tower X13 Stainless steel tower
or
E31 V31
V19 E30
Find No.
Description
V19 1/2"x1 1/2" Bolt V31 3/4"x1 1/2" Bolt W03 1/2" Lock Washer W05 3/4" Lock Washer X03 1/2" Nut X04 3/4" Nut X13 1/2" Self-locking Nut X15 3/4" Self-locking Nut
E31
On models NCA200 and NCB200, set basin in place and attach to center girts with splice plates E30 and E31 and bolt to louver columns as shown in Figure 3-14.
PAGE 3-14
NCA200 & NCB200

97-1188C
Figure 3-14

FAN DECK
Find No.
Description
After the distribution basins are in place the fan deck may be installed. Begin by attaching fan deck channels E13 to top girts per Figure 4-1.
V07 3/8"x1" Bolt W02 3/8" Lock Washer X02 3/8" Nut X12 3/8" Self-locking Nut
Stainless steel tower Galvanized tower
X12
or
X02 V07
E13
Figure 4-1
97-1188C
PAGE 4-1
Install hoisting clips E03 to top girts as shown in Figure 4-2.
Find No.
Description
V32 3/4"x2" Bolt W05 3/4" Lock Washer W30 3/4" Flat Washer X04 3/4" Nut X15 3/4" Self-locking Nut
Stainless steel tower Galvanized tower Galvanized tower
X15
or
E03
X04
W05
W30
E03 V32
Figure 4-2
PAGE 4-2
97-1188C

Fan deck sheets are attached next. Model NC1200 uses 2 each of fan deck sheets E09 and E15 as shown in Figure 4-3. Basin cover support E14 is sandwiched between fan deck and distribution basin. If your tower was not ordered with optional lubeline, cover lubeline access hole with cover plate E10. If your tower was not ordered with optional ladder and handrail, plug holes for handrail post clips and walkway in top girt flange. V07
Plug post clip holes
T07 E09 E10 V07 W22

Apply strip sealer Z13 to mating surfaces under fan sheet. Paper backing does not need to be removed.
V07
V07
V19 E14 W02
E15
Galvanized tower Plug walkway holes
Galvanized tower
T07 W22
W02 Galvanized basin
W02
X12 Stainless
or tower
steel tower

or
W02 X12 steel tower

or Stainless Galvanized tower
X02 Galvanized
X12 Stainless
steel basin
X02
Galvanized tower
Find No.
Description

or
X13 Stainless
steel tower
T07 3/8"x1" Tap Screw V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt W02 3/8" Lock Washer W03 1/2" Lock Washer
Figure 4-3
NC1200
W22 3/8" Flat Washer X02 3/8" Nut X03 1/2" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
97-1188C
PAGE 4-3

E09 T07 E10 V01
V07 W22
V19 V07
V07
E15
E14
Plug walkway holes Galvanized tower
W02
T07
Galvanized basin
W02 W22 X12 Stainless

or tower steel tower

or
X11
Galvanized tower
X02 Galvanized
X12 Stainless
steel basin
W03
W02
Galvanized tower
Find No.
Description
Galvanized tower X03 Stainless steel tower X13 or
X12 Stainless
or
steel tower
T07 3/8"x1" Tap Screw V01 1/4"x3/4" Bolt V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt
NC2200 and NC3200 Models NC2200 and NC3200 use 2 each of fan deck sheets E09 and E15 as shown in Figure 4-4. Basin cover support E14 is sandwiched between fan deck and distribution basin. If your tower was not ordered with optional lubeline, cover lubeline access hole with cover plate E10. If your tower was not ordered with optional ladder and handrail, plug holes for handrail post clips and walkway in top girt flange.
PAGE 4-4
Figure 4-4
W02 3/8" Lock Washer W03 1/2" Lock Washer W22 3/8" Flat Washer X02 3/8" Nut X03 1/2" Nut X11 1/4" Self-locking Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
97-1188C

T07 E09 E10 V07 V01
W22
E16 V07
V19
E15
Plug walkway holes
T07 W22 Galvanized

tower
W02 E14
Galvanized basin
W02 X12 Stainless

or tower steel tower

or
X02 Galvanized X11 W03

Galvanized tower
X12 Stainless
steel basin
X03 or X13
Stainless steel tower
Galvanized tower
Find No.
Description
T07 3/8"x1" Tap Screw V01 1/4"x3/4" Bolt
Figure 4-5
NC4200 Model NC4200 uses 2 each of fan deck sheets E09, E15 and E16 as shown in Figure 4-5. Basin cover support E14 is sandwiched between fan deck and distribution basin. If your tower was not ordered with optional lubeline, cover lubeline access hole with cover plate E10. If your tower was not ordered with optional ladder and handrail, plug holes for handrail post clips and walkway in top girt flange.
97-1188C
V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt W02 3/8" Lock Washer W03 1/2" Lock Washer W22 3/8" Flat Washer X02 3/8" Nut X03 1/2" Nut X11 1/4" Self-locking Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
PAGE 4-5

Find No.
Description
T07 3/8"x1" Tap Screw V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt W02 3/8" Lock Washer W03 1/2" Lock Washer W22 3/8" Flat Washer X02 3/8" Nut X03 1/2" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
Galvanized tower
V07
Models NC5200 thru NC7200, NCA200 and NCB200 use 2 each of fan deck sheets E09, E15 and E16 as shown in Figure 4-6. Basin cover support E14 is sandwiched between fan deck and distribution basin. If your tower was not ordered with optional lubeline, cover lubeline access hole with cover plate E10. If your tower was not ordered with optional ladder and handrail, plug holes for handrail post clips and walkway in top girt flange. E09 T07 E10
X02 or X12
E15
W22
Stainless steel tower Plug post clip holes
V19
V07
W02
Galvanized tower
V07
E15
Plug walkway holes
E16
Galvanized tower
W02 E14
Galvanized basin
T07
W22
Galvanized tower
W02
W03

or Galvanized tower
X12 Stainless steel

basin
X03 or X13 X02 or X12

Galvanized tower

97-1188C
Figure 4-6
PAGE 4-6

After fan deck sheets are in place, install stiffeners under fan deck. Model NC1200 requires one diagonal stiffener E17 in each corner of fan deck as shown in Figure 4-7.
Find No.
Description
V07
Apply a bead of sealer Z11 to top of angle
E17
Galvanized tower
W02

or
Figure 4-7
NC1200
97-1188C
PAGE 4-7
V07
E18
E17
Galvanized tower
W02

or
NC2200 thru NC4200
Figure 4-8
Find No.
Description
Models NC2200 thru NC4200 require two diagonal stiffeners E17 and E18 in each corner of fan deck as shown in Figure 4-8.
PAGE 4-8
97-1188C
Models NC5200 thru NC7200, NCA200 and NCB200 require two diagonal stiffeners E17 and E18 in each corner of fan deck and an additional stiffener E19 installed parallel to each top girt as shown in Figure 4-9.
V07
E18
E17 W02
Galvanized tower
E19
Galvanized tower
W02

Find No.
Description
or
Figure 4-9
97-1188C
PAGE 4-9
(This page intentionally left blank.)

CASING
Begin casing installation of casing in the plenum area. On motor side of model NC1200, refer to Figure 5-1 and attach casing sheets D07 and D08 to the top girt and the collection basin. See page 5-8 for typical attachment details. On this model only, the center casing sheet is dependent upon motor selection and is installed in the mechanical equipment section of this manual.
D08
D07
Apply strip sealer Z13 to columns before installing casing. After installing casing, run a bead of sealer Z11 at all casing seams.
NC1200 Motor Side

97-1188C
Figure 5-1
PAGE 5-1

On side opposite motor, on model NC1200, install casing sheets D07, D08 and D10 as shown in Figure 5-2. See page 5-8 for typical attachment details.
D08 D10
D07
NC1200 Side Opposite Motor

PAGE 5-2
97-1188C
Figure 5-2

On models NC2200 and NC3200, install casing sheets D07, D08, D10, D11 and D12. Use channel stiffeners D33 as indicated in Figure 5-3. See page 5-8 for typical attachment details.
D33
D08
D10
D33
D07 D12
D11
NC2200 and NC3200

97-1188C
Figure 5-3
PAGE 5-3

On model NC4200, install casing sheets D07, D08 and D10 as shown in Figure 5-4. See page 5-8 for typical attachment details.
D08
D10
D07
Figure 5-4
NC4200
PAGE 5-4
97-1188C

On model NC5200, install casing sheets D07, D08, D10, D11 and D12. Use channel stiffeners D33 as indicated in Figure 5-5. See page 5-8 for typical attachment details.
D08 D33
D10
D33
D07
D12
D11
Figure 5-5
NC5200
97-1188C
PAGE 5-5

D43 On models NC6200 and NCA200 install casing sheets D07, D08, D10, D11, D12 and D43. Use channel stiffeners D33 as indicated in Figure 5-6. See page 5-8 for typical attachment details.
D08
D43
D33 D33 D10
D07 D12
D11
NC6200 & NCA200
Figure 5-6
PAGE 5-6
97-1188C

On models NC7200 and NCB200 install casing sheets D07, D08, D10, D11 and D12. Use channel stiffeners D33 as indicated in Figure 57. See page 5-8 for typical attachment details.
D33 D08
D10
D33
D07 D12
D11
NC7200 & NCB200

PAGE 5-7
Figure 5-7
97-1188C

V07 or V19 V07
X12
Galvanized tower or Galvanized tower
W02 or W03
X02
Galvanized tower
X02 or X03
or
D33
When required
Casing to Top Deck Attachment
X12 or X13
Galvanized W02 tower
Casing to Casing Attachment
Galvanized basin
X02 or X12
Galvanized tower
X02 or X12
V07
W02
Galvanized basin
W02
Galvanized basin
W32 T07
In fill area
Casing to Collection Basin Attachment

Find No.
V07
Bolt head on outside of tower
Typical Other Casing Attachment
Description
Find No.
T07 3/8"x1" Tap Screw V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt W02 3/8" Lock Washer W03 1/2" Lock Washer W32 3/8" Sealing Washer
PAGE 5-8
Description
X02 3/8" Nut X03 1/2" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut
97-1188C
T07
W32
B03
D
B07
Strip sealer Z12
Find No.
Description
B07
T07 3/8"x1" Tap Screw W32 3/8" Sealing Washer
B03
Fill
Before beginning, determine which side of tower the fill will be installed from. Sufficient space is required on one side of the tower to allow fill tubes to be installed in the collection basin (this will be a space approximately equal to the width of the tower). Once this is determined, the first step is to install the casing on the opposite side. If you have a model NC1200 thru NC4200 refer to Figure 6-1. Locate casing sheet B03, and attach tube support B07.
97-1188C
NC1200 thru NC4200

PAGE 6-1
Figure 6-1
T07
W32
B03
D
B07
Strip sealer Z12
B07
Find No.
Description
If you have a model NC5200, NC6200 or NCA200 refer to Figure 6-2. Locate casing sheet B03, and attach tube support B07.
B03
NC5200, NC6200 & NCA200

PAGE 6-2
97-1188C
Figure 6-2

If your model is an NC7200 or NCB200, locate casing sheets B01 thru B04 and assemble with channel stiffeners D33 as shown in to Figure 6-3. B04 D33
Galvanized tower
V07
Strip sealer Z13
W02
B03
X02 Galvanized
or tower
B02
X12 Stainless steel tower B01
NC7200 & NCB200
Figure 6-3
Find No.
Description
D33
97-1188C
PAGE 6-3
T07
W32
Strip sealer Z12
B07
B07
Find No.
Description
Continue on with models NC7200 and NCB200 by attaching tube support B07. See Figure 6-4.
Casing assembly
NC7200 & NCB200
Figure 6-4
PAGE 6-4
97-1188C

Find No.
Description
T07 3/8"x1" Tap Screw V07 3/8"x1" Bolt W02 3/8" Lock Washer W32 3/8" Sealing Washer X02 3/8" Nut X12 3/8" Self-locking Nut
D33
Apply strip sealer Z13 on top flange of assembled casing. Attach casing to collection basin, top girt, louver column and existing casing as shown in Figure 6-5. Casing to casing attachments require the use of channel stiffeners D33.
V07
Galvanized tower
V07 X02 Galvanized tower

or Galvanized
W02 W02 tower
Strip sealer Z12 *
Galvanized tower
X02
or
V07
X12
Interior face of casing assembly * Apply strip sealer by placing edge of sealer against the edge of the holes. Fold the sealer around the corner onto the vertical face of the casing sheet.
D33
Casing assembly
T07
W32
Figure 6-5
97-1188C
PAGE 6-5
V06
B10
Viewed from Underside of Distribution Basin
Figure 6-6
Find No.
Description
V06 1/4"x4" Bolt
Slip fill support tubes B10 thru holes in tube support and slide retaining bolt V06 from the top, thru the slot in tube support and on thru the holes in the support tube. This prevents the tube from slipping out of support. See Figure 6-6.
PAGE 6-6
97-1188C

Temporary Hanger Fasten rope or wire thru nozzle holes in distribution basin and thru 3/4" (19mm) diameter holes in Marley supplied supports.
Louvers
B27
Temporary tube support
B08
Indexing spacer Eliminators (NC1200 thru NC6200 & NCA200)
B11
Viewed from Underside of Distribution Basin
Figure 6-7
B12
Temporary tube supports B27 are supplied with the tower to assist with the fill installation (wire or rope must be supplied by the erector). Refer to Figure 6-7 and install tempory fill tube support approximately 12" (305mm) from center of tower as shown. Thera are two types of fill sheets, B11 and B12, which are installed alternately to form a properly spaced fill pack. It is important that the fill packs be installed correctly or the cooling tower will not perform at full capacity. You can tell the difference between an A fill sheet B11 and a B fill sheet B12 by the rotation of the indexing spacer formed within the fill sheet.
97-1188C
With temporary tube support in place, begin by installing one A fill sheet and water deflector B08 with the short flange bent towards the first fill sheet. Continue fill sheet installation (first a B sheet, and then an A sheet) until the number of sheets recommended to be to the left of the fill partition have been installed, (see Figure 6-9 for models NC1200 thru NC4200, Figure 6-10 for models NC5200, NC6200 and NCA200 or Figure 6-11 for models NC7200 and NCB200) plus two additional sheets. The edges of the sheets should form a honeycomb pattern on the louver and eliminator faces as they are installed. If any of the sheets "nest" together, you have installed two identical sheets together.
PAGE 6-7
If tube retainers make fill installation difficult and access to the underside of collection basin is available, retainers may be installed as the fill is moved into place. See Figure 6-12A.
B27
After installing the recommended number of fill sheets, install a second temporary support toward the ends of the tubes. Remove first support and slide fill into final position. A lubricant on the surface of the tube may facilitate sliding the fill.
Fill sheets should form a honeycomb pattern.
Figure 6-8
Tower models NC1200 thru NC3200 do not require U-bolt supports, so fill partition is installed next. Tower models NC4200 thru NC7200, NCA200 and NCB200 require U-bolt supports on the upper fill tubes. First, compress the fill simulating a tight installation. Next, determine between which fill sheets U-bolts should be installed by locating slots in distribution basin floor and projecting straight down. Install U-bolts N98 per Figure 6-13A.
97-1188C
With the recommended number of fill sheets on the support tubes, install another temporary tube support B27 on the outside of the fill as shown in Figure 6-8. Remove the first temporary support and slide the fill sheets over against the casing. If lower fill tube retainers are not already in place, they should be installed as fill is being moved into place. For location of lower fill tube retainers, see Figure 6-12.
PAGE 6-8

Find No.
Description
Galvanized tower
X02 or X12 Stainless steel tower W02 Galvanized tower

Apply a bead of sealer Z11 around and between holes before installing deflectors. Apply an additional bead of sealer along top edge of deflector after it is in place.
A1
B15
V07
Apply sealer Z12 on flat surface across deflectors on both eliminator and louver faces.
B1
B10 B08
B11 & B12

Alternating fill sheets
B13
Recommended Fill Sheet Quantities Model A B + Last Sheet Total NC1200 NC2200 NC3200 NC4200 49 65 65 73 49 57 57 65 98 122 122 138
NC1200 thru NC4200 B11 or B12

Last fill sheet
Figure 6-9
If the fill pack is not tight, use additional fill sheets from pad provided.
97-1188C
PAGE 6-9

Find No.
Description
Galvanized tower
X02 or X12 Stainless steel tower W02 Galvanized tower

A1
V07
B15
B10
B1
B08
B11 & B12

B14 B13
Recommended Fill Sheet Quantities Model NC5200 NC6200 NCA200 A 89 97 120 B + Last Sheet 81 89 98 Total 170 186 218
NC5200, NC6200 & NCA200 B11 or B12

Last fill sheet
Figure 6-10
PAGE 6-10
97-1188C

Find No.
Description
X12 Stainless steel

or tower
X02 tower
Galvanized
W02 Galvanized
tower
A1
B15
V07
B10
B1
B08
B11 & B12

B14
B13
Recommended Fill Sheet Quantities Model A B + Last Sheet Total NC7200 NCB200 97 104 89 114 186 218
NC7200 & NCB200 B11 or B12

Last fill sheet
PAGE 6-11
Figure 6-11
97-1188C

A
Fill supports
Two times A plus B equals the Total number of fill sheets.
Figure 6-12
Recommended Fill Sheet Quantities Model A B Total NC1200 NC2200 NC3200 NC4200 NC5200 NC6200 NC7200 NCA200 NCB200 11 11 11 11 32 32 32 48 48 76 100 100 116 106 122 122 122 122 98 122 122 138 170 186 186 218 218 The fill partition will be installed next per Figure 6-9, 6-10 or 6-11. Sub-assemble the fill partition before installing in tower. Models NC5200 thru NC7200, NCA200 and NCB200 must have eliminator side B13 attached to louver side B14. All models have water deflectors B15 at the top that bolt together with partition sandwiched between. Install in tower in the same mannor as the fill sheets. Deflectors on fill partition are to extend over the first fill sheet next to the partition. Seal ends of deflectors, under hot water basin deflectors, using strip sealer Z12.
97-1188C
PAGE 6-12

Find No.
Description
W21 1/4" Flat Washer X11 1/4" Self-locking Nut
N35
X11 W21
Fill tube

Vertical distance from top of fill tube to distribution basin floor.
Figure 6-13A
A
N98 Install one per tube (NC4200 thru B08 Water deflector
Model NC4200 NC5200 NC6200 NC7200 NCA200 NCB200
A 8 15/16" (227mm) 8 1/16" (205mm) 8 1/16" (205mm) 8 1/16" (205mm) 8 1/16" (205mm) 8 1/16" (205mm)
NC7200) or two per tube (NCA200 & NCB200)
Remove the temporary support at the right end of the fill tubes. Note: be sure the U-bolts are in place (on NC4200 thru NC7200, NCA200 and NCB200) before removing the temporary support. Continue installing fill sheets as described earlier until all but the last sheet are in place. Note: if the final fill sheets are difficult to install use a sheet of plywood with ropes near the top and bottom of the fill to compress and hold the fill while the last sheets are installed. Make sure fill pack is tight. If additional fill sheets can be added, do so. Install water deflector B08 with the top bent flange toward the casing (see Figure 6-13B). Install the final fill sheet.
97-1188C
First and last fill sheets thould be between the casing and the water deflectorB08. Top deflector flange should be angled toward casing. Casing Fill sheets
Figure 6-13B
PAGE 6-13

Find No.
Description
Strip sealer Z12

D
V06
T07 3/8"x1" Tap Screw V06 1/4"x4" Bolt V07 3/8"x1" Bolt W02 3/8" Lock Washer W32 3/8" Sealing Washer X02 3/8" Nut X12 3/8" Self-locking Nut
B07 V07
Strip sealer Z12 *
* Apply strip sealer by placing edge of sealer against the edge of the holes. Fold the sealer around the corner onto the vertical face of the casing sheet.
Interior face of casing assembly
W32
Galvanized W02 tower Models NC1200 thru NC4200 have only one tube.
T07
Slip tube support B07 over fill tubes and slide bolt V06 thru slot in support and thru holes in end of tube as shown in Figure 6-14. Install lower fill retainer tubes B10 or B17 thru the cutouts in the collection basin and into the holes in the fill. Note: lower tubes install easier from the left side of the fill, when viewed from the louvers. This may not be possible due to tower location. Also, a light oil or soap on the tubes can help. After the lower tubes are in place install coverplates B18 as shown. Note: on multiple tower installation, coverplates must be installed on side between towers, before next cell is set in place. Apply strip sealer Z12 to tube support B07 and casing sheet B01 (or casing assembly on models NC7200 and NCB200) as shown. Maneuver casing into place and attach to collection basin, girt, and tube support. Install remaining casing by refering back to Casing Section and Figures 5-1 thru 5-7.
PAGE 6-14
X02 Galvanized
or tower
X12 steel tower
Stainless
B18
B
W32 W32 T07 T07 B01 B10

or
B17 same material as the upper tube.
When the lower tube is not the
Figure 6-14
97-1188C

Eliminator Packs
Eliminator packs are required on models NC7200 and NCB200. See Figure 6-15 for model NC7200. Attach eliminator support angles A16 to bottom fill supports and eliminator support D18 to eliminator support angles. Attach top eliminator retainer D23 to distribution basin end. Eliminator packs are installed by pushing up under the top retainer and setting over lip on bottom eliminator tray. Install eliminator packs D19 beginning against the casing on the right side and continuing towards the fill partition. The pack next to the fill partition must be cut to fit snug against the right side of the fill partition, with the remainder of the pack placed on left side of partition. Continue adding full width packs until they no longer fit. Measure remaining space, cut the last pack 1" (2.54 mm) wider and install for a tight fit.
Stainless steel tower Distribution basin end
X12 or
Galvanized tower X02
V07 D23
Find No.
Description
D19
Typical
V07
D18
Fill partition
Galvanized tower Stainless steel tower
X02
or
Fill support Cut off last pack this side so eliminator pack will set flush. Fill side Fill side
X12
A16 W02
Galvanized tower
97-1188C
V07
Section A-A Figure 6-15

NC7200
Discharge side
Discharge side
PAGE 6-15

See Figure 6-16 for model NCB200. Attach eliminator support angles A16 to bottom fill supports and eliminator support D18 to eliminator support angles. Attach top eliminator retainer D23 to distribution basin end. Eliminator packs are installed by pushing up under the top retainer and setting over lip on bottom eliminator tray. Install eliminator packs beginning with 4.8" (122 mm) wide pack D20 against the casing on the right side and continuing towards the fill partition with 9.6" (244) wide packs D19. The pack next to the fill partition must be cut to fit snug against the right side of the fill partition, with the remainder discarded. Begin on left side of fill partition with D19 and continue until they no longer fit. Measure remaining space, cut the last pack 1" (2.54 mm) wider and install for a tight fit.
Stainless steel tower Distribution basin end
X12 or
Galvanized tower X02
V07 D23
Find No.
Description
D20
First pack only
D19
Typical
V07
D18
Fill partition
X02
or
Fill support Cut off last pack this side so eliminator pack will set flush. Fill side Fill side
X12
A16 W02
Galvanized tower
PAGE 6-16
V07
Section A-A Figure 6-16

NCB200
Discharge side
Discharge side
97-1188C

or
V32
Figure 7-1 shows the tie-rod installation on the louver face. Connect tie-rods D27 to collection basin end at the bottom and tie-rod clip at the top. Secure tie-rods where they cross using U-bolt D41. Note that galvanized U-bolts come with a plate and nuts for installation, but on stainless steel towers the plate D42 and nuts are seperate items.
TIE RODS
D27
D27
Find No.
Description
D41 Galvanized tower
or
V32 3/4"x2" Bolt W30 3/4" Flat Washer W35 3/4" Sealing Washer X01 1/4" Nut X04 3/4" Nut X15 3/4" Self-locking Nut
D41 D42 X01 Stainless steel tower
D27
X04
X15 or
W35 V32
Figure 7-1
W30
97-1188C
PAGE 7-1

Refer to Figure 7-2 for lower fan cylinder orientation on models NC1200 thru NC4200 and NCA200 or to Figure 7-3 for models NC5200 thru NC7200 and NCB200. Install 1/4" bolts (with threaded end up) around cutout in fan deck using sealing washers W31 as retainers to hold bolts in place. Lower
LOWER FAN CYLINDER
fiberglass fan cylinder segments E20 (and E21 on models NC1200 thru NC4200 and NCA200) over bolts as shown in Figure 7-4A. Note: before tightening fasteners, making splice joints, or installing doweling fasteners, refer to the Fan Adjustment section.
E20 E21
E20
E21
NC1200 thru NC4200 & NCA200

PAGE 7-2
97-1188C
Figure 7-2
E20
E20
NC5200 thru NC7200 & NCB200 Make adjustments, then splice cylinder segments together using existing holes in cylinder as a template, drill (3) 7/16" (11mm) holes and install fasteners as shown in Figure 7-4B. Drill doweling holes in each cylinder segment at approximately 22 1/2 off tower centerline and install doweling fasteners as indicated in Figure 7-5A. After tightening fasteners, bolt cylinder to fan deck stiffeners.
Figure 7-3
97-1188C
PAGE 7-3
X11 E21
or
W21
E20
Find No.
Description
V04 1/4"x1 1/2" Bolt (all thd.) V07 3/8"x1" Bolt
W31
W21 1/4" Flat Washer W22 3/8" Flat Washer W31 1/4" Sealing Washer X11 1/4" Self-locking Nut X12 3/8" Self-locking Nut
W21 V04 Cylinder to Deck Attachment
Stainless steel fasteners used on all towers.
Figure 7-4A
E20 or E21
W22
X12
V07
W22
Use cylinder as a template to drill holes.
Cylinder Splice
PAGE 7-4
97-1188C
Figure 7-4B

T10
X11
Drill (2) 1/4" (6mm) diameter holes thru fan deck in each cylinder segment, countersink, and install fasteners (bolt head up).
Doweling Installation
Figure 7-5A
X11
Find No.
Description
W11
T10 1/4"x1" Flat Head Bolt V02 1/4"x1" Bolt (all thd.) W11 1/4" Oversize Washer X11 1/4" Self-locking Nut
W11 V02 Cylinder to Stiffener Attachment

97-1188C
Figure 7-5B
PAGE 7-5

MECHANICAL EQUIPMENT
The previously installed torque tube assembly that spans the width of the tower has a plate for each, the motor and Geareducer to sit on. The motor utilizes channel supports that produce the correct elevation and the Geareducer may or may not have similar supports, depending on tower model. On towers with motor outside airstream (MOA) option, the motor is placed on a special support outside the tower and a driveshaft is used as the drive line between motor and Geareducer. Review tower model, motor frame, and motor location on tower being assembled and refer to the table on this page for corresponding figure numbers to use in this manual.
Note that standard motor location is on the side opposite of the 6" (152mm) diameter hole in the collection basin floor.
Tower Model NC1200 & NC1210 NC1220
Motor Frame 184T, 213T, 215T, 254T & 256T 213T & 215T 254T, 256T & 284TS 215T 254T, 256T, 284T, 284TS, 286T & 286TS 324TS 324T & 326T 215T
Required Figure Numbers Standard Motor MOA Option Location 8-2, 8-4, 8-11 & 8-16 8-3, 8-4, 8-9, 8-11 & 8-17 8-2, 8-5, 8-12 & 8-16 8-3, 8-5, 8-9, 8-12 & 8-17 8-2, 8-5, 8-13 & 8-16 8-3, 8-5, 8-9, 8-13 & 8-17 8-6, 8-12 & 8-16 8-6, 8-14 & 8-16 8-6, 8-15 & 8-16 8-6, 8-15 & 8-16 8-7, 8-12 & 8-16 8-7, 8-11 & 8-16 8-7, 8-14 & 8-16 8-8, 8-11 & 8-16 8-8, 8-14 & 8-16 8-8, 8-15 & 8-16 8-6, 8-9, 8-12 & 8-17 8-6, 8-9, 8-14 & 8-17 8-6, 8-9, 8-15 & 8-17 8-6, 8-9, 8-15 & 8-17 8-7, 8-10, 8-12 & 8-17 8-7, 8-10, 8-11 & 8-17 8-7, 8-10, 8-14 & 8-17 8-8, 8-10, 8-11 & 8-17 8-8, 8-10, 8-14 & 8-17 8-8, 8-10, 8-15 & 8-17
NC2200 thru NC4200 NC4200 NC5200 thru NC5220
254T & 256T 284T,286T,324T,326T & 364T 215T, 254T & 256T NC5230 thru NC7200, NCA200 284T, 286T,324T, 326T, & NCB200 364T & 365T NC7200, NCA200 404T & 405T & NCB200
97-1188C
PAGE 8-1

On model NC1200, the casing installed in the motor area is dependent upon the motor location. When the motor is in the standard location it will project thru the casing and therefore requires a motor cover. See Figure 8-2. The motor cover may come in three pieces as shown, or on smaller motors, a one piece design is used. Both designs install similarly. Install motor cover D50 (and D51 if required) as shown.
Galvanized tower
V07

or
W02
X12 steel tower
Stainless
D51 D50
V07
X02
or
X12 W02 Galvanized

tower
D51

or
X12 steel tower
Stainless
W02 Galvanized tower V07
Find No.
Description
NC1200 only
Figure 8-2
PAGE 8-2
97-1188C

On model NC1200 with the MOA option, install center casing sheet D50 as shown in Figure 8-3.
D50
Galvanized tower
W02
V07
X02
or
X12 X02 Galvanized tower

or
X12 steel tower
Stainless
V07
Find No.
Description
NC1200 only
Figure 8-3
97-1188C
PAGE 8-3

Find No.
Description
V19 1/2"x1 1/2" Bolt V22 1/2"x2 1/2" Bolt W03 1/2" Lock Washer W23 1/2" Flat Washer X03 1/2" Nut X13 1/2" Self-locking Nut
Series 10 Geareducer
X03
M20 W03 W23 M33 M32 toward back of Geareducer. W23 V19
Position flange with slots
X03
or
X13 W03 W23
M33 W23
M41
Use as required to eliminate gaps.
Galvanized tower
V22
W23
W03
Galvanized tower

or
X13 steel tower
Stainless
V19
Do not apply anti-seize compound to stainless steel Geareducer hold down bolts. Loctite will be applied to these attachments later.
NC1200 and NC1210
Figure 8-4
GEAREDUCER INSTALLATION
The Geareducer type and installation is dependent upon what model cooling tower is being assembled. Models NC1200 & NC1210 use a Series 10 Geareducer installed on a support. Attach Geareducer support stiffeners M33 to
PAGE 8-4
Geareducer support M32, adding spacers M41 as required. Attach support to plate on torque tube assembly and Geareducer M20 to support, as shown. See Figure 8-4.
97-1188C

Refer to Figure 8-5 for installation of a Series 20 Geareducer M20 on model NC1220.
Find No.
Description
V30 5/8"x2 1/2" Bolt W04 5/8" Lock Washer W29 5/8" Flat Washer X05 5/8" Nut
X05
W04
W29
M20
W29 V30
Figure 8-5
NC1220
97-1188C
PAGE 8-5
Models NC2200 thru NC4200 use a Series 20 Geareducer M20 installed per Figure 8-6.
M20 X05
W04
W29
W29
V30
Find No.
Description
NC2200 thru NC4200
Figure 8-6
PAGE 8-6
97-1188C

On model NC5200 thru NC5220 attach Geareducer supports M32 and M33 to plate on torque tube assembly and then the Series 20 Geareducer M20 to supports. See Figure 8-7.
X05
or
Galvanized tower Stainless steel tower Galvanized tower
X03
or
M20 Series 20
Geareducer
X14
X13 W04
X05
Galvanized tower
W04 W29
(Over slots only)
W03
W29
W23
M32 slots toward back of

Geareducer.
Position flange with
Position flange with slots toward back M33 of Geareducer.
W29
V29
Find No.
Description
V19 1/2"x1 1/2" Bolt V29 5/8"x2" Bolt V30 5/8"x2 1/2" Bolt W03 1/2" Lock Washer W04 5/8" Lock Washer W23 1/2" Flat Washer W29 5/8" Flat Washer X03 1/2" Nut X05 5/8" Nut X13 1/2" Self-locking Nut X14 5/8" Self-locking Nut
97-1188C
V19 W29
V30
NC5200 thru NC5220

PAGE 8-7
Figure 8-7

Models NC5230 thru NC7200, NCA200 and NCB200 use a Series 22 Geareducer M20 that attaches directly to the plate on the torque tube assembly. Models NC7200, NCA200 and NCB200 require stiffener plates M24 under the back Geareducer feet. Refer to Figure 8-8.
M20
X05
W04
W29
Find No.
Description
V30 5/8"x2 1/2" Bolt V49 5/8"x3" Bolt W04 5/8" Lock Washer W29 5/8" Flat Washer X05 5/8" Nut
M24 W29
NC7200, NCA200 & NCB200 only
V30 NC5230 &

or NC7200,
NC6200 only

PAGE 8-8
Figure 8-8
V49 NCA200 &
NCB200 only
97-1188C

Do not remove these two bolts! Square holes in motor support are to clear bolt heads.

or
X13 steel tower
Stainless
M37 M29
M36 V32
V19

or
NC1200 thru NC4200 with MOA option
Figure 8-9
X15 steel tower
Stainless
If your tower has the MOA option, you must install a motor support on the outside of the casing. For models NC1200 thru NC4200 refer to Figure 8-9. The motor support is bolted to the tower using the same holes that attach the torque tube assembly. Leave the bottom two bolts on each side in place and remove the top two bolts. Attach motor support M29 on outside of tower with support angles M36 and channels M37 on inside of tower as shown.
97-1188C
MOTOR INSTALLATION
Find No.
Description
V19 1/2"x1 1/2" Bolt V32 3/4"x2" Bolt X03 1/2" Nut X04 3/4" Nut X13 1/2" Self-locking Nut X15 3/4" Self-locking Nut
PAGE 8-9

Do not remove these two bolts! Square holes in motor support are to clear bolt heads.

or
X12 steel tower
Stainless
V07 M29 X03 Galvanized tower

or
X13 steel tower
Stainless
M37
V32
M36 V19 X04 Galvanized tower

or Stainless
X15 steel tower
Find No.
Description
V07 3/8"x1" Bolt V19 1/2"x1 1/2" Bolt V32 3/4"x2" Bolt X02 3/8" Nut X03 1/2" Nut X04 3/4" Nut X12 3/8" Self-locking Nut X13 1/2" Self-locking Nut X15 3/4" Self-locking Nut
NC5200 thru NC7200, NCA200 & NCB200 with MOA option
Figure 8-10
For models NC5200 thru NC7200, NCA200 and NCB200 refer to Figure 8-10. The motor support is bolted to the tower using the same holes that attach the torque tube assembly. Leave the middle two bolts on each side in place and remove the top and bottom bolts. Attach motor support M29 on outside of tower with support channel assembly M36 and channels M37 on inside of tower as shown.
97-1188C
PAGE 8-10

Motor
X02 184T, 213T & 215T

or
X03 254T & 256T
I
or
Do not apply anti-seize compound to stainless steel motor hold down bolts. Loctite will be applied to these attachments later.
W02 184T, 213T & 215T W03 254T & 256T
The motor will set on supports that vary in height dependent upon tower model and motor frame. If your tower model and motor frame are listed below, refer to Figure 8-11. Install motor to support as shown. W22 184T, 213T & 215T
or
W23 254T & 256T
V07 184T
or
V09 213T & 215T

or
V22 254T & 256T
M25
Position flange with slots toward back of motor.
Figure 8-11
Find No.
Description
V07 3/8"x1" Bolt V09 3/8"x1 1/2" Bolt
Tower Model NC1200 thru NC1210
Motor Frame 184T 213T & 215T 254T & 256T
A 2 1/8" (54mm) 2 1/8" (54mm) 2" (51mm)
V22 1/2"x2 1/2" Bolt W02 3/8" Lock Washer W03 1/2" Lock Washer W22 3/8" Flat Washer W23 1/2" Flat Washer X02 3/8" Nut X03 1/2" Nut
97-1188C
PAGE 8-11

Find No.
Description
Motor
X02
V09 3/8"x1 1/2" Bolt V19 1/2"x1 1/2" Bolt W02 3/8" Lock Washer W03 1/2" Lock Washer W22 3/8" Flat Washer W23 1/2" Flat Washer
W02
X02 3/8" Nut X03 1/2" Nut X13 1/2" Self-Locking Nut
I
A M35
M25 with slots toward

back of motor.
Position flange
M34
W23 V19
W22 V09 X13 Stainless W23

or steel tower tower
Figure 8-12
M42
X03 Galvanized W03 Galvanized Tower
If your tower model and motor frame are listed below, refer to Figure 8-12. Install motor to supports M25 and stiffeners M34 and M35 with spacers M42 as shown. Tower Model
Motor Frame 213T & 215T 215T 215T
A 2 3/16" (56mm) 1 7/8" (48mm) 2 1/8" (54mm)

97-1188C
NC1220 NC2200 thru NC4200 NC5200 thru NC5220

PAGE 8-12

If your tower model and motor frame are listed below, refer to Figure 8-13. Install motor to supports M25 and M26 as shown. X03
Motor
I
Find No.
W03
A
Description
M26
W23
M25
Figure 8-13
Tower Model NC1220 Motor Frame 254T 256T 284TS
97-1188C
V22
A 3 1/2" (89mm)
B 2 5/16" (59mm) 4" (102mm) 3 9/16" (90mm)

PAGE 8-13

If your tower model and motor frame are listed below, refer to Figure 8-14. Install motor to supports M25 and stiffeners M34 and M35 with spacers M42 as shown.
X03
Motor
I
Find No.
W03
A
Description
M35
V19 1/2"x1 1/2" Bolt V22 1/2"x2 1/2" Bolt W03 1/2" Lock Washer W23 1/2" Flat Washer X03 1/2" Nut X13 1/2" Self-locking Nut
M34
M25
W23 V19 M42
W23
V22
Figure 8-14
Galvanized Tower
W03
X13 Stainless
or
steel tower tower
Tower Model NC5200 thru NC5220 NC5230 thru NC7200
Motor Frame 254T & 256T 215T 254T & 256T
A 2 11/16" (68mm) 2 7/16" (62mm) 2 9/16" (65mm)
X03 Galvanized
PAGE 8-14
97-1188C

If your tower model and motor frame are listed below, refer to Figure 8-15. Install motor to supports M26 and/or M25 as shown.
Motor 324T 326T 364T 365T 254T 256T 284T 284TS 286T 286TS
I
Find No.
X05
or
X03
Description
or Position flange with slots toward back of motor.
V22 1/2"x2 1/2" Bolt V30 5/8"x2 1/2" Bolt W03 1/2" Lock Washer W04 5/8" Lock Washer W23 1/2" Flat Washer W29 5/8" Flat Washer X03 1/2" Nut X05 5/8" Nut
W03
256T 284T 284TS 286T 286TS
W04 254T M25 or M26

324T 326T 364T 365T
A B
M25 W23 or
Tower Model NC2200 thru NC4200
Motor Frame 254T 256T 284T 286TS 284T
B 1 15/16" (49mm)
2 1/4" (57mm)
3 11/16" (94mm) 2 1/8" (54mm) 3 11/16" (94mm) 1 3/4" (44mm) 3 1/4" (83mm) 2 3/8" (60mm) 3 7/8" (98mm) 3 3/8" (86mm) 1 3/8" (35mm) 2 7/8" (73mm) 1 5/8" (41mm) 3 3/8" (86mm) 2 7/8" (73mm)
254T W29 256T 284T 324T 284TS 326T 286T 364T 286TS 365T
V22 or
254T 256T 284T 284TS 286T 286TS
V30
324T 326T 364T 365T
NC5200 thru NC5220
286T 324T 326T 364T 284T 286T 324T 326T 364T & 365T
3 1/4" (83mm) 2 7/8" (73mm) 3 1/8" (79mm) 2 7/8" (73mm) 1 5/8" (41mm) 2 7/8" (73mm)
Figure 8-15

97-1188C
PAGE 8-15
I
Find No.
Motor 404T 405T 324T 326T X04 324TS or
X05
Description
V30 5/8"x2 1/2" Bolt V33 3/4"x2 1/2" Bolt W04 5/8" Lock Washer W05 3/4" Lock Washer W29 5/8" Flat Washer W30 3/4" Flat Washer X04 3/4" Nut X05 5/8" Nut
W04 or
324T W05 326T 404T 324TS 405T
A B
M25 or M26
M25
404T 405T 324T 326T W30 324TS or
W29
Figure 8-16
If your tower model and motor frame are listed below, refer to Figure 8-16. Install motor to supports M26 and/or M25 as shown.
Tower Model NC2200 thru NC4200 NC4200 NC7200, NCA200 & NCB200
PAGE 8-16
V30 or
324T V33 326T 324TS 404T 405T
Motor Frame 324TS 324T 326T
A 1 3/8" (35mm) 2 7/8" (73mm)
B 1 1/8" (29mm) 2 5/8" (67mm) 4 1/8" (105mm) 1 1/2" (38mm)

97-1188C
404T & 405T 1 1/2" (38mm)

X13 Stainless
or steel tower tower
W03
Galvanized tower
X03 Galvanized
M27 for installation and
See Service Manual alignment instructions Geareducer (Assembled to torque tube)
W23
Motor (Assembled to supports)
V19 Y56 Y56 As

As required
required
Figure 8-17 DRIVELINE INSTALLATION
See Mechanical Equipment Hold Down Fasteners section for alignment pin installation.
For standard installation of motor inside the tower refer to Figure 8-17. Line up motor and Geareducer shafts approximately 1/2" to 1" (13 to 25mm) apart and connect motor supports to torque tube assembly. Install drive coupling M27 using shims Y56 as required to align drive coupling. Refer to Close Coupling Service Manual for installation instructions. After installing drive coupling, coat motor and Geareducer shafts with paint.
97-1188C
Find No.
Description
V19 1/2"x1 1/2" Bolt W03 1/2" Lock Washer W23 1/2" Flat Washer X03 1/2" Nut X13 1/2" Self-locking Nut
PAGE 8-17

X13
or Stainless steel tower tower
Y56 As
required
X03 Galvanized
M28
See Service Manual for installation and alignment instructions
Geareducer (Assembled to torque tube)
T06
W03
Galvanized tower
M31 W23 M31

As required
M30
Y56
Motor (Assembled to supports)
V19
See Mechanical Equipment Hold Down Fasteners section for alignment pin installation.
Install on this side of support only.
M39
Find No.
Description
T06 1/4"x3/4" Tap Screw V19 1/2"x1 1/2" Bolt W03 1/2" Lock Washer W23 1/2" Flat Washer X03 1/2" Nut X13 1/2" Self-locking Nut
M40 support. Required on
Install on both sides of NC1200 & NC2200 only.
MOA only For optional MOA (Motor Outside Airstream) installation refer to Figure 8-18. Coat motor shaft, Geareducer shaft and bores of driveshaft yokes with lubricant Z21. Slide driveshaft guard M30 around driveshaft M28 and install driveshaft on motor and Geareducer shafts. Using the Driveshaft Service Manual, determine motor location, based on shaft engagement indicated.
PAGE 8-18
Figure 8-18
Use shims Y56, as required, to align driveshaft. After installing driveshaft, coat motor and Geareducer shafts with paint. Install guard clips M31 on inside of casing. Slide guard thru hole in casing against motor, and use clips as templates to drill (2) 3/16" (5mm) diameter holes in guard, and attach to clips. On models NC1200 and NC2200, apply low head room decal M40 to both sides of support at dimensions shown. Attach M.E. installation decal M39 to right side of support above caution decal on models NC1200 and NC2200 or in lower position on all other models.
97-1188C

FAN INSTALLATION & ADJUSTMENT
Before lower fan cylinder is secured in place, install fan M51, set fan blade pitch to contract requirements and adjust fan blade tip clearance, tip track, and fan tilt as indicated in Figure 8-19. Fan blades should be pitched at a location where the fan hub is level and parallel with fan deck. Each blade must be rotated and pitched at the same reference point as the first blade pitched. Tower must be plumb and cylinder centered around fan to provide proper tip clearance. Use longest blade and check all around cylinder for tip clearance. Be certain each blade is in its furthest out position.
All blades when rotated past the same location on cylinder must be same distance from fan deck within 3/8" (10mm) NC1200 thru NC5200 or 1/2" (13mm) NC6200, NC7200, NCA200 & NCB200. Any single blade must be same distance from fan deck to fan Fan cylinder blade around perimeter of cylinder within a range of one inch (25mm). Fan blade Fan cylinder Fan blade If not within tolerance recheck blade, blade attachment and fan pitch. Adjust by shimming Geareducer while maintaining alignment with motor.
Tip Track Check
Fan Tilt Check
M51 Fan
Inside of cylinder A 1/8" (3mm)
A
Pitching boss
Fan blade pitch angle 1/2 Fan blade
Fan rotation
Figure 8-19
Fan Blade Pitch Detail
Section A-A
Tower Model
Adjust by repositioning Geareducer within cylinder or by adjusting fan cylinder

97-1188C
Blade Tip Clearance Check
NC1200 thru NC5200 3/8" (10mm) NC6200 thru NC7200, 1/2" (13mm) NCA200 & NCB200
PAGE 8-19

Fastener Torque at Motor and Geareducer Hold-Down Fasteners Only Fastener Torque foot-lbs. (Newton-meters) Bolt Diameter Galvanized Stainless Steel (Unlubricated) (Unlubricated 3/8" 30-32 (41-43) 34-36 (46-48) 1/2" 5/8" 3/4" 64-66 (87-90) 135-140 (183-190) 220-230 (298-312) 85-90 (115-122) 125-130 (169-176) 195-205 (264-278)
Y55
On models with Series 20 or 22 Geareducer, after rechecking alignment, drill thru support and drive pin to project an equal distance above Geareducer foot and below support.
(This detail applies to both, standard motor and motor outside airstream installations. Detail shows motor inside tower.) After all driveline and fan adjustments have been made refer to Figure 8-20. Tighten each motor and Geareducer nut 5 to 10 ft-lbs (7 to 13 N-m) less than specified torque while holding bolt head. Retighten nuts to specified torque. Bolt heads may be tightened while holding nut if nut is not accessible with torque wrench. Now apply
PAGE 8-20
Figure 8-20
thread locking compound Z05 to all bolt threads. On towers with a Series 20 or 22 Geareducer, two drive pins Y55 are used to retain alignment. Using pilot holes in Geareducer feet, drill a 23/64" (9mm) diameter hole thru support and drive pin thru to project an equal distance above Geareducer foot and below support.
97-1188C
Drill 1/4" (6 mm) diameter hole thru fan deck in fan cylinder, countersink, and install fasteners.
T10
X11
Figure 8-21
After making fan adjustments, secure fan cylinder in position by drilling (2) 1/4" (6 mm) diameter holes approximately 22 1/2 degrees off tower centerline in each cylinder quadrant, countersink, and install fasteners (bolt head up) in each hole as shown.
97-1188C
Find No.
Description
T10 1/4"x1" Flat Head Bolt X11 1/4" Self-locking Nut
PAGE 8-21
NC SERIES MISCELLANEOUS
Inlet piping and fasteners supplied by others
INLET PIPING & FLUME
N45
If tower is not using the optional HC valves, inlet piping is attached directly to the distribution basin. See Figure 9-1A. Note that inlet piping and fasteners are supplied by others. If HC valves N40 are to be installed, they are attached as shown in Figure 9-1B. A full face gasker N45 is used between valve and distribution basin and a ring gasket N39 is used between valve and inlet piping.
Inlet piping supplied by others
Distribution basin floor
X04
Figure 9-1A
X04
6" and 8" dia. valves
V35
or
N39 N40
10" dia. valve
V42
I
Find No.
Piping, supports, design of piping and supports, and restraint of lateral piping loads is the responsibility of others.
Half bolts are threaded into tapped holes in valve body, the other half bolts require nuts. Full face gasket
Description
W35 6" and 8"

or
dia. valves
N45 with bolt circle
V32 3/4"x2" Bolt V35 3/4"x3" Bolt (all thrd.) V42 7/8"x5" Bolt (all thrd.) V46 7/8"x2" Bolt W20 7/8" Flat Washer W30 3/4" Flat Washer W35 3/4" Sealing Washer W36 7/8" Sealing Washer X04 3/4" Nut X06 7/8" Nut
W36 10" dia. valve
Distribution basin floor
W30 6" and 8"

or
dia. valves
V32 6" and 8"

or
dia. valves
W20 10" dia. valve
V42 10" dia. valve
Figure 9-1B
97-1188C
PAGE 9-1
Find No.
Description
C12
V07 C11 C10
C09 NC7200 only
NC7200 only C09
W02
Galvanized basin
C09
Galvanized basin
X02
or
NC1200 thru NC7200 Assemble the distribution basin flumes on models NC1200 thru NC7200 by attaching flume supports C09 to center flume C10. On model NC7200, supports must be added to end flume sections C11 and C12 also. See Figure 9-2.
PAGE 9-2
97-1188C
Figure 9-2
Refer to Figure 9-3 for distribution basin flume assembly on models NCA200 and NCB200. Attach flume supports C09 to center flume C10 and to end flume sections C11and C12 as shown.
C12
V07 C11
C10 C09
C09
C09 W02
Galvanized basin
Galvanized basin
X02
or
NCA200 & NCB200
Figure 9-3
Find No.
Description
97-1188C
PAGE 9-3
V07
Nozzle
W32 X02
W22
Flumes (assembled on previous page)
Figure 9-4
Find No.
Description
Install plastic nozzles by firmly pressing into 1 3/4" (44mm) diameter holes in basin floor. Attach outside flumes to distribution basin as shown in Figure 9-4. Slide center flume into place under distribution basin inlet, and attach as indicated.
PAGE 9-4
V07 3/8"x1" Bolt W22 3/8" Flat Washer W32 3/8" Sealing Washer X02 3/8" Nut
97-1188C
Find No.
Description
X03
W23
V26 1/2"x6" Bolt (all thd.) W23 1/2" Flat Washer X03 1/2" Nut
V26
Figure 9-5
Install support bolt for inlet flume per enlarged detail in Figure 9-5.
97-1188C
PAGE 9-5
T07
C13
Two center deflectors required on models NCB200 only.
C13
T07
Find No.
Description
T07 3/8"x1" Tap Screw
Figure 9-6
Attach water deflectors C13 to distribution basin floor on models NC7200 and NCB200 as shown.
PAGE 9-6
97-1188C
X42 W32 E22 or E23
X02
W02
V12
Figure 9-7 DISTRIBUTION BASIN COVERS
Begin distribution basin cover installation by attaching bolt, lock washers and standard nut in lower horizontal flange of distribution basin inlet end as shown in Figure 9-7. Install distribution basin cover E22 (and E23 on some models) by slipping one end of cover between fan deck and cover support, sliding other end over previously installed bolt, and securing with sealing washer and wing nut. Refer to Figure 9-7 for cover configuration on your specific model.
97-1188C
Find No.
Description
V12 3/8"x2 1/2" Bolt (all thd.) W02 3/8" Lock Washer W32 3/8" Sealing Washer X02 3/8" Nut X42 3/8" Wing Nut
PAGE 9-7
E22 E23
NC1200
E23 E22
NC2200 & NC3200
E22
NC4200
E22
NC5200, NCA200 & NCB200
E22
E23 E22
NC6200 & NC7200
Partial Plan Views

PAGE 9-8
97-1188C
Figure 9-8
X11 N97 V09 D32 W12 X01 W12 W02 W21 W01 V04 D31
Lower fan cylinder
D31 D34 V09 W12
T07
X11 W02 W21 X02
W12
X02 W23 Five 1/2" washers used as

spacers.
Apply a 3/8" (10mm) dia. bead of sealer around the perimeter to eliminate any rattles.
Fan deck
Threaded end of existing 1/4" bolt
Figure 9-9
Find No.
Description
Fan cylinder segments D31 are installed on top of the lower cylinder that extends down from fan deck. Segments are to straddle tower centerline (except models NC1200 & NCA200 thru NCC200) and be orientated as shown in Figure 9-9. A single piece fan guard is provided on models NC1200 thru NC3200. Models NC4200 thru NC7200, NCA200 and NCB200 use a two piece fan guard and require guard splice hardware. On models with a two piece fan guard, guard D32 is installed first and a splice clip N97 is used to retain guard D34.
97-1188C
UPPER FAN CYLINDER & GUARD
T07 3/8"x1" Tap Screw V04 1/4"x1 1/2" Bolt (all thd.) V09 3/8"x1 1/2" Bolt W01 1/4" Lock Washer W02 3/8" Lock Washer W11 1/4" Oversize Washer W12 3/8" Oversize Washer W23 1/2" Flat Washer X01 1/4" Nut X02 3/8" Nut X11 1/4" Self-locking Nut
PAGE 9-9
Models NC3200 thru NC7200, NCA200 & NCB200 use three hinges per door.
D14
D13 T04 D28 T06
T04
X09 D14 T03

Description
W43 D16
Find No.
D15
T03 #10x1/2" Mach. Screw T04 1/4"x1/2" Cap Screw T06 1/4"x3/4" Tap Screw W43 #10 Flat Washer X09 #10 Nut
D28
Figure 9-10 ACCESS DOOR
As shown in Figure 9-10, attach male portion of hinges D14 to the casing sheet, and the female portion to the access door D13. Set the door in place and attach rubber door bumpers D28. Access door should open and close smoothly before fasteners attaching hinges to casing are tightened. Next, install handle D15 and latch D16. Slots have been provided where the latch attaches to the access door, check the operation of the latch and adjust as necessary.
PAGE 9-10
D28
D13
97-1188C
DECALS
Note: Decals are an important part of the tower assembly. Decals and nameplates provide instructions, identifications, cautions and warnings deemed necessary for proper maintenance. Surface Preparation Surface must be clean and dry. Oil and dirt may be removed with solvent (such as acetone) or commercial detergent. Finally wash the area with warm water and dry with a lint-free cloth. Ultimate adhesion will occur 24-48 hours after application. Application should not be undertaken if temperature is below 35 F (2 C) or humidity is greater than 95%. General application instructions Peel off backing paper, taking care to avoid dirt contamination of the exposed adhesive. On larger decals with slit back removal of half of the backing paper before and the other half during installation is beneficial for ease of alignment and installation. Carefully apply the decal to the desired location with light pressure to avoid any distortion of vinyl. This is the time to remove the other half of backing paper on larger decals. Once positioned, smooth out with the aid of a squeegee or toweling. If air bubbles occur, puncture with a pin or needle and smooth down with the squeegee. The finished decal should be completely flat.
Install one decal N34 on each end of the collection basin per Figure 9-11.
N34 end of tower
One on each
Figure 9-11
97-1188C
PAGE 9-11
N32
N33 N34 N35 N43

(If required) N37
N36
N38 (If required) N30 Y50
N31
Install extra motor nameplate at this location. Using top two holes in nameplate as a template, drill two .130" (3mm) diameter holes and attach with rivets Y50.
Find No.
Description
Y50 1/8" Pop Rivet
NC1200 and NC4200 See Figure 9-12 for installation of remaining decals on models NC1200 and NC4200. First install serial number plate N30, patent number decal N31, inspection decal N35, and warning decal N43 to the motor side of tower. Install
PAGE 9-12
Figure 9-12
warning and caution decals N32, N33, N34 & N36 to both sides of the tower. Add CTI decal N37 and Factory Mutual decal N38 to motor side of tower, if required. Below decals on casing sheet, install the extra motor nameplate supplied with motor.
97-1188C
N32 N33 N34 N35 N43 N37
(If required)
N36
(If required)
N38
N30 Y50
N31
Install extra motor nameplate at this location. Using top two holes in nameplate as a template, drill two .130" (3mm) diameter holes and attach with rivets Y50.
Find No.
Description
Y50 1/8" Pop Rivet
NC2200, NC3200, NC5200 thru NC7200, NCA200 & NCB200
Figure 9-13
Remaining decals on models NC2200, NC3200, NC5200 thru NC7200, NCA200 and NCB200 are installed per Figure 9-13. First install serial number plate N30, patent number decal N31, inspection decal N35, and warning decal N43 to the motor side of the tower. Install
97-1188C
warning and caution decals N32, N33, N34 & N36 to both sides of the tower. Add CTI decal N37 and Factory Mutual decal N38 to motor side of tower, if required. Below decals on casing sheet, install the extra motor nameplate supplied with motor.
PAGE 9-13
Cut stripe decal D30 to lengths required based on tower model. Install stripe decal and logo decal D29 at dimensions shown in Figure 9-14.
18" 23" (457mm) (584mm)
A
D29 D30 Model NC6200
only
D30
Tower Model NC1200 NC2200 NC3200 NC4200 NC5200 NC6200 NC7200 NCA200 NCB200
A 24 1/2" (622mm) 24 1/2" (622mm) 38" (965mm) 38" (965mm) 38" (965mm) 38" (965mm) 42" (1067mm) 38" (965mm) 42" (1067mm)
B 20 3/8" (518mm) 19 1/4" (489mm) 19 1/4" (489mm) 38 3/8" (975mm) 38 3/4" (984mm) --18 3/4" (476mm) 20" (508mm) 18 3/4" (476mm)
C ----------38 3/4" (984mm) -------
Figure 9-14
PAGE 9-14
97-1188C
NC SERIES OPTIONAL EQUIPMENT

Find No.
Description
T07 3/8"x1" Tap Screw V07 3/8"x1" Bolt W22 3/8" Flat Washer W32 3/8" Sealing Washer X02 3/8" Nut
Stainless steel fasteners must be used on stainless steel basins to avoid loss of connection.
Install with flanges toward hood
Q03 Hook top over

hood flange
Q02
(2 required) Install in hood to create or break air tight seal.
T07 X02 Q00
Q01
Collection basin depressed section
W32 V07 Q02

Install with flanges toward hood
W22
Collection basin side
Overflow & drain connections (not present when tower has standpipe drain & overflow)
Side Outlet Suction
Figure 10-1
OUTLET PIPING
The following details explain the installation of the four possible types of outlet piping connections that your tower may have. A tower may not require an outlet if it is flumed to another tower. The flume and flume weir gate installations are also covered in this section. The various types of outlets are the side outlet suction, the sump, bottom outlet with screen and bottom outlet without screen. The side suction is installed in the collection basin side. The other outlets, when used, are located in the depressed section floor. The collection basin may be connected to another tower with a flume. Refer to the contract
97-1188C
work order, outlet piping key plan drawing, and/or the contract sales drawing to determine what equipment you have and the correct installation location for it. The side outlet suction Q01 is installed per Figure 10-1 by attaching it to the inside of the collection basin using gasket Q00. Two suction screens Q02 are set in place between the depressed section sides and the suction hood with the flanges facing down toward the hood. A third screen Q03 is hooked over the top of the flange on the end of the hood.
PAGE 10-1

Find No.
Description
V09 3/8"x1 1/2" Bolt W12 3/8" Oversize Washer W22 3/8" Flat Washer W32 3/8" Sealing Washer X02 3/8" Nut
Sump installation is per Figure 10-2. Sump may be rotated 90 or 180 provided outlet piping will clear supporting steel. Lay strips of gasket Y10 around sump opening in depressed section floor. Set sump Q04 in place and use as a template to drill 7/16" (11mm) diameter holes thru gasket. Attach sump to floor and seal around perimeter. On fiberglass sumps, install plastic tank adapter Q06 and pipe cap Q07 in the bottom of the sump as a drain (on steel sumps, pipe plug Q07 is installed in the coupling in the front of the sump).
V09 W22 W32 W12
Q04
Fiberglass sump only
After sump is installed, apply a bead of sealer around perimeter of sump, force into seam, and spread out evenly.
Q07 Q06
Under oversized washer
Apply a bead where strips butt.
Fiberglass sump only
Y10
X02
Install two layers thick with corners overlapped. Do not leave gaps where strips butt. Sump may be used as a template to drill 7/16" (11mm) diameter holes in gasket strips.
PAGE 10-2
Figure 10-2
Sump
Q06 Drain plug
(Steel sump only)

97-1188C

Sump Screen On sumps with high flows, a screen assembly with anti-vortex plate is used. (See "Anti-vortex Plate" installation detail.)
Q96 using outlet piping fasteners. Q14
Fiberglass sumps only. Install
Figure 10-3
Sump Screen
Outlet piping and fasteners Supplied by others.
Clean surfaces and apply a 3/8" (10mm) dia. bead of sealer around and between all holes on sump plate and outside of sump.
I
97-1188C
See Figure 10-3 for the typical attachment of customer piping using gasket Q14. A sump plate Q96 is used on the inside of fiberglass sumps only. After piping has been install set sump screen (if required) in place over the sump opening. On sumps with higher flows, a screen assembly with anti-vortex plate is used instead of the sump screen shown. See "Anti-vortex Plate" installation detail. The tower is not designed to support additional piping loads. DO NOT SUPPORT PIPING FROM THE TOWER.
PAGE 10-3

The typical attachment of customer piping for bottom outlet or equalizer connection using gasket Q14 is shown in Figure 10-4. The tower is not designed to support additional piping loads. DO NOT SUPPORT PIPING FROM THE TOWER.
Q14
Clean surfaces and apply a 3/8" (10mm) dia. bead of sealer around and between all holes under basin where gasket attaches.
Figure 10-4
Bottom Outlet
Outlet piping and fasteners Supplied by others.
PAGE 10-4
97-1188C

Bottom Outlet Screen Place between mudsills. For bottom outlets with high flow rates, a screen assembly with anti-vortex plate is used. (See "Anti-vortex Plate" installation detail.)
V07 W22
W32
Q24
Find No.
Description
C
X02
Screen and Mudsills When a screen is needed with the bottom outlet, it is installed as shown in Figure 10-5. Attach mudsills Q24 to basin floor and set screen between them. On bottom outlets with higher flow rates, a screen assembly with anti-vortex plate is used. See "Anti-vortex Plate" installation detail.
PAGE 10-5
Figure 10-5
97-1188C

Q22 Q23
Q23
Q22
Find No.
Description
Q20 Q21
V07 3/8"x1" Bolt W02 3/8" Lock Washer W22 3/8" Flat Washer X02 3/8" Nut X12 3/8" Self-locking Nut
or
Tower Model NC1200 thru NC6200 & NCA200 NC7200 & NCB200
A 6" (152mm) 7" (178mm)

W02 Galvanized basin W22
On towers with higher outlet flows, an antivortex plate is required. Assemble anti-vortex plate Q20, screens Q22 and Q23, and retainers Q21 as shown in Figure 10-6. Adjust screens or cut wire if required to allow bolts to pass thru. Position anti-vortex assembly in depressed area of collection basin centered over outlet.
A
V07
Anti-vortex Plate
PAGE 10-6
97-1188C
Figure 10-6

Q00 X02
W22 V07
W32
Q11
Coverplates are used to close off the openings in the collection basin sides. Various configurations of coverplates are possible, but they all attach similarly. Refer to Figure 10-7A for drain and overflow coverplate Q11 with gasket Q00, or Figure 10-7B for blank coverplate Q10 with gasket Q00. These are the two most common coverplates used.
Drain & Overflow Coverplate
Figure 10-7A
Q00
X02
W22 V07
W32
Find No.
Q10
Description
97-1188C
Figure 10-7B
Blank Plate
PAGE 10-7
Take care not to cross thread the PVC standpipe when threading into the steel coupling assembly.
Q48
V07
W22
W32
Find No.
Description
Q47
X02 Standpipe Overflow
Figure 10-8A
All towers must have an overflow and drain, either as the standard standpipe in the collection basin floor or at the optional coverplate location. The standpipe overflow and drain is installed per Figure 10-8A. Bolt coupling assembly Q47 to the bottom of the collection basin floor at the 6" (152mm) diameter hole and bolt pattern. Install standpipe Q48. The standpipe is PVC unless an optional heater element is close by, then a steel standpipe will be installed with teflon tape (supplied by others) to provide a watertight seal. If optional coverplate drain and overflow is being used, and coverplate drain is not being plumbed, install pipe plug Q18 per Figure 10-8B.
PAGE 10-8
Q18
Coverplate Drain Plug

97-1188C
Figure 10-8B
X12 Stainless steel basin W22 W32

or
Install in all remaining holes after installing longer bolts.
V07
W32 Q13
W22
Q00
If weir plate is required, install in second holes from top and bottom on sides and V12 fourth holes from ends on top and bottom.
Find No.
Description
Figure 10-9
Flume Frame
V07 3/8"x1" Bolt V12 3/8"x2 1/2" Bolt (all thd.) W22 3/8" Flat Washer W32 3/8" Sealing Washer X02 3/8" Nut X12 3/8" Self-locking Nut
97-1188C
If collection basins of multiple cell towers are to be connected together, a flume is required. Attach flume frame Q13 to outside of collection basin, where flume is to be located, using gasket Q00 per Figure 10-9.
PAGE 10-9

Find No.
Description
V07 3/8"x1" Bolt W22 3/8" Flat Washer W32 3/8" Sealing Washer
IMPORTANT! Flumes are not a walking surface. Flumes that are 18" (457mm) long and longer have a caution decal which should be orientated on top.
Apply a 1/2" (13mm) diameter bead of sealer around and between holes on flume collars.
W32
Q11
Q15
W22 V07
W22
Q11 W32
Apply a 1/2" (13mm) diameter bead of sealer around and between holes where joggle will overlap.
Q15
Collection basin side
Figure 10-10
Flume
If collection basins of multiple towers are to be connected together, a flume is installed per Figure 10-10. Note that towers must be aligned before attempting to install flume in place. Sealing of the flume connections is critical to prevent leaks. Apply a 1/2" (13mm) bead of sealer Z11 as indicated, around and between
PAGE 10-10
all holes on both flume collars. Install nonjoggled flume corners Q11 first. Apply another bead of sealer around and between holes where joggle will overlap on flume. Complete flume installation by installing joggled flume corners Q15.
97-1188C
If weir gate option is being used, refer to Figure 10-11 for installation details. Set gasket Q19 in place over protruding attachment bolts. Slide weir gate Q16 in place and tighten evenly.
Find No.
Description
W02 3/8" Lock Washer X02 3/8" Nut

Q16 W02 Q19 X02
Figure 10-11
Weir Plate
97-1188C
PAGE 10-11

Galvanized basin X02 or Stainless X12 steel basin Galvanized basin
V07
W02 Q25
Q38
Q26
Reuse existing fasteners
Q27 Q28
Q35
Install decal on outside of casing to the left of the float valve hole.
FLOAT VALVE
The float valve is used to control water make-up and is normally provided on all towers. Multi-cell towers may not require a float valve in each cell unless weir plates are used to isolate individual cells. Float valve components to be used will depend on outlet piping and other options in basin. Refer to Outlet Piping Drawing for float valve location and orientation. Figure 11-1 shows the standard float valve installation. Start by attaching water inlet assembly Q25 to the casing. Using pipe joint compound Z04, install a 45 elbow Q26 to the end of the inlet assembly and then install a close nipple Q27. Next install the float valve Q28 (make sure valve opening is pointing down). Install float and valve stem assembly Q31. Coat exposed pipe threads with rust inhibiting paint. See your NC Owners Manual for adjustment of float valve. Install decal Q35 on outside of tower casing, to the left of the float valve inlet (see decal section of this manual for surface preparation and general application instructions). If makeup piping is not to be attached immediately, install plastic thread protector Q38 on inlet assembly.
97-1188C
Q31
Standard Float Valve

Find No.
Figure 11-1
Description
PAGE 11-1

V02 Q36 Q33 Q26
C
Find No.
Description
V02 1/4"x1" Bolt V07 3/8"x1" Bolt
Q25
W21 W01
W01 1/4" Lock Washer W02 3/8" Lock Washer W21 1/4" Flat Washer W22 3/8" Flat Washer W32 3/8" Sealing Washer X01 1/4" Nut
Q32 X02 basin

or Galvanized
Q34
Galvanized basin
Q28
X01
X12
W02
X02 3/8" Nut X12 3/8" Self-locking Nut
V07 W22 W32
X02 basin
or
Galvanized Stainless steel basin
Q39 V07
X12
Q31
Galvanized basin X02 or Stainless X12 steel basin
Figure 11-2 shows the across basin float valve installation for models NC1200 and NC2200. Start by attaching support angle Q39 to collection basin and float valve support Q34 to angle. Install water inlet assembly Q25 to the casing as shown. Using pipe joint compound Z04 on all pipe connections, connect 90 elbow Q26, pipe Q27, a second 90 elbow Q26, pipe Q33, a third 90 elbow Q26, pipe Q32, and float valve Q28 (make sure valve opening is pointing down). Install float and valve stem assembly Q31. Coat exposed pipe threads with rust inhibiting paint. See your NC Owners Manual for adjustment of float valve. Use pipe clamp Q36 to secure piping to float valve support. Install decal Q35 on outside of tower casing, to the left of the float valve inlet (see decal section of this manual for surface preparation and general application instructions). If makeup piping is not to be attached immediately, install plastic thread protector Q38 on inlet assembly.
PAGE 11-2
Galvanized basin
W02 Q25
V07
Q38
Q26
Q33
Q27 Q35
Accross Basin Float Valve NC1200 and NC2200

97-1188C
Figure 11-2

Q36 Q33 Q26 Q25 W21 Q28
Galvanized basin
C
V02
Find No.
Description
V02 1/4"x1" Bolt V07 3/8"x1" Bolt W01 1/4" Lock Washer W02 3/8" Lock Washer W21 1/4" Flat Washer W22 3/8" Flat Washer
X02 X01 V07
W01
Galvanized basin
or Stainless X12 steel basin
W32 3/8" Sealing Washer X01 1/4" Nut X02 3/8" Nut X12 3/8" Self-locking Nut
Q34
W02
W22
Galvanized basin
X02
or
Q39 V07
W32
Galvanized basin X02
Galvanized basin
Q31 X12
W02 V07 Q38 Q25
Figure 11-3 shows the across basin valve installation for models NC3200 thru NC7200, NCA200 and NCB200. Start by attaching support angle Q39 to collection basin and float valve support Q34 to angle. Install water inlet assembly Q25 to the casing as shown. Using pipe joint compound Z04 on all pipe connections, connect full coupling Q32, pipe Q33, 90 street elbow Q26, and float valve Q28 (make sure valve opening is pointing down). Install float and valve stem assembly Q31. Coat exposed pipe threads with rust inhibiting paint. See your NC Owners Manual for adjustment of float valve. Use pipe clamp Q36 to secure piping to float valve support. Install decal Q35 on outside of tower casing, to the left of the float valve inlet (see decal section of this manual for surface preparation and general application instructions). If makeup piping is not to be attached immediately, install plastic thread protector Q38 on inlet assembly.
97-1188C
or Stainless floatsteel basin
Q32
Q33
Q35
Accross Basin Float Valve NC3200 thru NC7200, NCA200 & NCB200
PAGE 11-3
Figure 11-3
Q37
Apply a small bead of sealer around hole plug before installing into hole.
Figure 11-4
On diagonally opposite side of the tower from where the float valve inlet is installed, or on both sides of tower if it has no float valve, a hole plug Q37 is installed in the casing per Figure 11-4.
PAGE 11-4
97-1188C
NC SERIES FIND NUMBER INDEX
Find Number Index

A
A01 A02 A03 A04 A05 A06 A07 A09 A10 A11 A12 A13 A14 A16 A20 A21 A22 A23 1-1 1-1 1-1 1-1 1-3 1-3 1-6, 1-8 1-3, 1-4 1-10 1-10 1-10 1-6, 1-8 1-13 1-5, 6-15, 6-16 1-6, 1-8 1-6, 1-8 1-8 1-8
C14 C15 C16
3-1 3-1 3-9, 3-10
D
D01 2-1 D02 2-1 D03 2-1 D05 2-7, 2-8, 2-9 D06 2-9 D07 5-1, 5-2, 5-3, D08 5-1, 5-2, 5-3, D10 5-2, 5-3, 5-4, D11 5-3, 5-5, 5-6, D12 5-3, 5-5, 5-6, D13 9-10 D14 9-10 D15 9-10 D16 9-10 D18 6-15, 6-16 D19 6-15, 6-16 D20 6-16 D23 6-15, 6-16 D24 2-10 D25 2-10 D27 7-1 D28 9-10 D29 9-14 D30 9-14 D31 9-9 D32 9-9 D33 5-3, 5-5, 5-6, D34 9-9 D35 2-2 D36 2-3, 2-4 D37 2-5, 2-6 D38 2-5, 2-6 D39 2-2 D40 2-2 D41 7-1 D42 7-1 D43 5-6 D50 8-2, 8-3 D51 8-2
5-4, 5-5, 5-6, 5-7 5-4, 5-5, 5-6, 5-7 5-5, 5-6, 5-7 5-7 5-7
B
B01 B02 B03 B04 B07 B08 B10 B11 B12 B13 B14 B15 B17 B27 6-3 6-3 6-1, 6-2, 6-3 6-3 6-1, 6-2, 6-4, 6-14 6-7, 6-9, 6-10, 6-11, 6-13 6-6, 6-9, 6-14 6-7, 6-9, 6-10, 6-11 6-7, 6-9, 6-10, 6-11 6-9, 6-10, 6-11, 6-12 6-10, 6-11, 6-12 6-9, 6-10, 6-11, 6-12 6-14 6-7, 6-8
5-7, 6-3, 6-5
C
C01 3-1 C02 3-1 C03 3-1 C04 3-2 C05 3-3, 3-12 C06 3-4, 3-5, 3-6, 3-7 C07 3-8 C08 3-1 C09 9-2, 9-3 C10 9-2, 9-3 C11 9-2, 9-3 C12 9-2, 9-3 C13 9-6
97-1188C
E
E01 E03 E09 E10 E11 E12 E13 E14 E15 E16 2-11, 2-12, 2-13, 3-3 4-2 4-3, 4-4, 4-5, 4-6 4-3, 4-4, 4-5, 4-6 3-3, 3-12 3-3, 3-12 4-1 4-3, 4-4, 4-5, 4-6 4-3, 4-4, 4-5, 4-6 4-5, 4-6
PAGE 12-1
NC SERIES FIND NUMBER INDEX

E17 E18 E19 E20 E21 E22 E23 E26 E27 E28 E30 E31 E32 4-7, 4-8, 4-9 4-8, 4-9 4-9 7-2 7-2 9-7 9-7 2-11, 3-3 2-11, 2-13 2-11 3-14 3-11, 3-14 2-12 Q01 Q02 Q03 Q04 Q06 Q07 Q10 Q11 Q13 Q14 Q15 Q16 Q18 Q19 Q20 Q21 Q22 Q23 Q24 Q25 Q26 Q27 Q28 Q31 Q32 Q33 Q34 Q35 Q36 Q37 Q38 Q39 Q47 Q48 Q96 10-1 10-1 10-1 10-2 10-2 10-2 10-7 10-7, 10-10 10-9 10-3, 10-4 10-10 10-11 10-8 10-11 10-6 10-6 10-6 10-6 10-5 11-1, 11-2, 11-3 11-1, 11-2, 11-3 11-1, 11-2 11-1, 11-2, 11-3 11-1, 11-2, 11-3 11-2, 11-3 11-2, 11-3 11-2, 11-3 11-1, 11-2, 11-3 11-2, 11-3 11-4 11-1, 11-2, 11-3 11-2, 11-3 10-8 10-8 10-3
M
M20 M24 M25 M26 M27 M28 M29 M30 M31 M32 M33 M34 M35 M36 M37 M38 M39 M40 M41 M42 M51 8-4, 8-5, 8-6, 8-7, 8-8 8-8 8-11, 8-12, 8-13, 8-14, 8-15, 8-16 8-12, 8-13, 8-14, 8-15, 8-16 8-17 8-18 8-9, 8-10 8-18 8-18 8-4, 8-7 8-4, 8-7 8-12, 8-14 8-12, 8-14 8-9, 8-10 8-9, 8-10 2-2 8-18 8-18 8-4 8-12, 8-14 8-19
V
V06 6-6, 6-14
N
N30 N31 N32 N33 N34 N35 N36 N37 N38 N39 N40 N43 N45 N97 N98 9-12, 9-13 9-12, 9-13 9-12, 9-13 9-12, 9-13 9-11, 9-12, 9-13 6-13, 9-12, 9-13 9-12, 9-13 9-12, 9-13 9-12, 9-13 9-1 9-1 9-12, 9-13 9-1 9-9 6-8, 6-13
Y
Y10 10-2 Y55 8-20 Y56 8-17, 8-18
Z
Z04 Z05 Z21 11-1, 11-2, 11-3 8-20 8-18
Q
Q00 10-1, 10-7, 10-9
PAGE 12-2
97-1188C

97 1188C

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NC1200 NC2200 NC3200 NC4200 NC5200 NC6200 NC7200 NCA200 NCB200

K/D Assembly Manual

The Marley Cooling Tower Company

7401 W. 129th Street, Overland Park Kansas 66213 (913) 664-7400

Revision C ECO 99-1411 December 1999

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OUTLET PIPING .......................................................................................................................... 10-1 FLOAT VALVE ............................................................................................................................. 11-1

Find Number Index .................................................................................................. 12-1

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NC SERIES GETTING STARTED

TOOLS AND SUPPLIES

PVC FILL STORAGE

NC SERIES GETTING STARTED

Z11 Sealer 3/8" (10mm)

(Water on one side of joint)

Z11 Sealer 3/8" (10mm)

Water side of joint.

NC SERIES GETTING STARTED

STOP! WAIT! HOLD EVERYTHING!

NC SERIES TOWER ASSEMBLY

W22 A02 W32

X02 Galvanized basin

X12 Stainless steel basin

NC1200 thru NC4200

NC SERIES TOWER ASSEMBLY

A02 X12 Stainless

X02 Galvanized basin

W32 A04 A03 A04

V07 A03 V07 X02 Galvanized basin

X12 Stainless steel basin

NC5200 thru NC7200, NCA200 & NCB200

NC SERIES TOWER ASSEMBLY

Strip sealer Z13 on top, Z12 on bottom

A05 A09 A05 V07

Strip sealer Z13 on top, Z12 on bottom

Top row of holes only.

NC1200 thru NC3200

NC SERIES TOWER ASSEMBLY

X02 Galvanized basin W22 A06 A09

A09 W02 A06 A05

Top row of holes only.

Strip sealer Z13 on top, Z12 on bottom

V07 A06 A05

Strip sealer Z13 on top, Z12 on bottom

Top row of holes only.

NC4200 thru NC7200, NCA200 & NCB200

NC SERIES TOWER ASSEMBLY

V07 3/8"x1" Bolt W02 3/8" Lock Washer

X02 3/8" Nut X12 3/8" Self-locking Nut

Galvanized basin W02

X02 Galvanized basin

X12 Stainless steel basin A16

NCA200 & NCB200 (Viewed from underside of basin)

NC SERIES TOWER ASSEMBLY

See Figure 1-7

NC4200 thru NC7200

NC SERIES TOWER ASSEMBLY

X15 3/4" Self-locking Nut

W02 basin W22

Strip sealer Z12