Installation Manual - Complete Plants, Process Lines, & … Manual.pdf · ·...

Your Local Representative: JAMES R. MCQUAIDE LLC A TriState HVAC Equipment Company Account Manager: Rich O’Brien Union Hill Industrial Park, 1 Resource Drive (O) 610-862-3298 (M) 610-291-4026 West Conshohocken, PA 19428 Email: [email protected] www.tristatehvac.com Project Manager: Steve Rominger (O) 856-663-7600 (M) 484-535-2768 Email: [email protected]

Installation Manual Closed Circuit Cooling Towers

(Series FXV)

mailto:[email protected]�

http://www.tristatehvac.com/�

mailto:[email protected]�

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Warranties: Seller warrants that the equipment sold under this contract shall be free from defects in material and workmanship for a period of twelve (12) months from the date of equipment startup or eighteen (18) months from the date of shipment, whichever occurs first. The following original equipment components only are warranted against defects in materials and workmanship for a period of five (5) years from date of shipment: fans, fan shafts, fan motors, bearings, sheaves, gearboxes, driveshafts, couplings, and mechanical equipment support. Details of option-specific warranties follow:

• JE Premier SeriesTM Construction is warranted to be free from defects in material and workmanship for a period of five (5) years from date of shipment.

• EVERTOUGHTM Construction is warranted to be free from defects in material and workmanship for a period of five (5) years from date of shipment excluding heat transfer coils which are warranted to be free from defects in material and workmanship for a period of twelve (12) months from the date of equipment startup or eighteen (18) months from the date of shipment, whichever occurs first.

• TriArmor® Corrosion Protection System Cold Water Basins are warranted against leaks and corrosion for a period of five (5) years from date of shipment. For the purposes of this warranty, “corrosion” means red rust formation on the interior of the cold water basin panels due to a failure of the TriArmor® Corrosion Protection System. The leak or corrosion must be caused by a defect in the application of the TriArmor® Corrosion Protection System. This warranty does not apply to cold water basin field connections, field installed options or modifications by others.

• Welded 304 Stainless Steel Cold Water Basins are warranted against leaks for a period of five (5) years from date of shipment. Only leaks from the factory seams of the cold water basin are covered; this warranty does not apply to cold water basin field connections, field installed options or modifications by others.

• Replacement Parts provided by Seller under its original equipment warranty obligations are warranted against defects in materials and workmanship for a period of twelve (12) months from date of shipment or until expiration of their original warranty, whichever occurs first. Parts purchased after expiration of the original equipment warranty are warranted against defects in materials and workmanship for a period of twelve (12) months from date of shipment.

Written notice of any defect shall be given to Seller immediately upon discovery by Buyer, and shall fully describe the claimed defect. Defective parts shall be repaired or replaced F.O.B. point of shipment, provided that inspection by Seller verifies the claimed defect(s). This shall be Buyer's exclusive remedy. This warranty does not cover the costs of removing, shipping or reinstalling the equipment. Repairs made without the prior written approval of Seller shall void all warranties covering material and workmanship.

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Any descriptions of the product(s) in the contract are for the sole purpose of identification and do not constitute a warranty. In the interest of product improvement, Seller reserves the right to change specifications and product design without incurring any liability therefore. The foregoing express warranties or those set forth elsewhere on this document are the only warranties of Seller applicable to the product(s) sold under this contract. All other warranties, whether verbal or written, and all warranties implied by law, including any warranties of merchantability or fitness for a particular purpose, are hereby excluded. Failure on the part of Buyer or of other parties to properly maintain the product(s) sold under this contract, or the operation of such product(s), by Buyer and/or other parties under conditions more severe than those for which such product(s) were designed, shall void all warranties covering materials and workmanship. Seller's warranties do not apply to defects in product(s) for which payment in full has not been received by Seller, and said warranties do not cover normal wear and tear or the erosion, corrosion and/or deterioration of the product(s) from unusual causes. No warranties by Seller shall apply to accessories manufactured by others, inasmuch as they are warranted separately by their respective manufacturers, except as stated above. Buyer assumes liability for and shall bear the costs of compliance with all laws, regulations, codes standards or ordinances applicable to the location, operation and maintenance of the product(s) sold under this contract, including those requirements pertaining to the distances between such product(s) and air-conditioning system duct intakes. No representative or agent of Seller is authorized to enlarge upon the express warranties of Seller.

At James R. McQuaide, we are dedicated

to providing you cooling tower, heat

exchanger, water filtration parts, and

industry critical maintenance information.

Start-Up, Preventative Maintenance, and Upgrades for All Makes and Models

To maximize the operating life of your evaporative cooling system, our start-up and Preventative Maintenance Services will reduce the potential for unplanned downtime due to equipment failure and keep it operating at peak efficiency. Our Preventative Maintenance will provide you with services that are custom tailored to your equipment and operational requirements. You will be provided with:

Factory authorized start-up of cooling tower, controls, and VFD’s.

Complimentary inspection reports Regularly scheduled preventive

maintenance Detailed testing, measurement and

analysis of critical system components Suite of specialized services, customized

to meet your requirements and budget Service provided by factory trained

technicians

Please contact the following for all inquiries:

Parts BAC Cooling Towers & all other Cooling Tower Manufacturer’s

- Fans & Drives: Axial, Centrifugal, Shafts, Bearings, Belts, Powerbands, Sheaves, & Motors. - Water Distribution: Nozzles, Spray Branches, Basin Sweeper Piping, Pumps, Pump. Parts, PVC Float Valves, Brass Float Valves, Float Balls, Electronic Water Level Controls, Solenoid Valves, Suction Strainers. - Controls – Combined drive enclosures, pressure/temperature sensors, safety disconnects, basin heaters, basin heater controls, vibration cut-out switches, damper controls. - Retrofits – Replacement fill, ladders, handrails, platforms, increasing tower capacity, low sound alternatives, distribution retrofits, coils and coil casings, hardware and miscellaneous fittings. Please contact the following for all parts inquiries: Sheila Molodow: 610-862-8529

ABB Drives

Alfa Laval Heat Exchangers

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Allen "Stosh" Taylor: 610-862-8537 Richard Bishop: 215-419-7824

Inspection and Repair

Through our inspection and repair services, our technicians provide a complete detailed report, analysis of current operation and replacement part recommendations for your existing equipment. You will be provided with:

Operational Analysis Prompt response from BAC Factory

Trained Technicians Installation and testing of new components

by factory trained technicians Detailed recommendation on upgrades to

improve performance Inspection and operating condition report

Please contact the following for all inquiries: Allen "Stosh" Taylor: 610-862-8537 Richard Bishop: 215-419-7824

Puroflux Filters

Dolphin Chemical Free Water Systems

Equipment Replacement Often demands on your equipment have changed since the original specification requirements and installation of your cooling system. Our factory trained technicians can evaluate the operating efficiencies and capacity of your existing system and make Equipment Upgrade recommendations that will improve system performance and extend the useful life of your equipment.

Please contact the following for all inquiries: Steve Rominger: 484-535-2768

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Sent By:James R. McQuaide Company5824 Westfield Avenue Pennsauken NJ 08110 U.S.A.

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Jim Boyce: 610-389-5635

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lsFXV Closed Circuit Cooling Tower andCXV Evaporative CondenserTable of Contents..............................................................PageRecommended Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N60

Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N61

Initial and Seasonal Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N61

Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N62

Detailed Component Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N63

Cold Water Basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N63

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N63

Fan Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N64

Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N67

Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N68

Heat Transfer Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N68

Water Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N68

Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N69

Figure 1a - Single Side Air Inlet FXV/CXV

RecirculatingWater Pump

Coil Connection:FXV Fluid In/

CXV Refrigerant Out

Coil Connection:FXV Fluid Out/

CXV Refrigerant In

Access Door

Bleed Line and Valve

Air Inlet Louvers

Cold Water Basin

BACross® Fill with IntegralDrift Eliminators

Spray WaterDistribution System

Axial Fan(s)

BALTIDRIVE®

Power Train

N59...because temperature matters™

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N60 Baltimore Aircoil Company

Figure 1b - Dual Air Inlet FXV/CXV-T

Table 1: Recommended Maintenance Services[1]

Type Service Start-Up Monthly Quarterly Annually Shutdown

Insp ect and clean as necessary:

Inspect general condition of the unit[2] and checkunit for unusual noise or vibration

X X

Inspect cold water basin/Spray nozzles X X

Drain basin and piping X X

Inspect air inlet louvers X X

Check and adjust water level in basin X X

Check operation of make-up valve X X

Check and adjust bleed rate X X

Inspect unit finish X

Mechanical equipment system:

Check belt condition X X

Adjust belt tension[3] X X

Lubricate fan shaft bearings X X X

Lubricate motor base adjusting screw X X X

Check and lubricate optional gear drive See gear drive section for detailed instructions and schedule

Check drive alignment X

Check motor voltage and current X X X

Clean fan motor exterior X X

Check fan motor for proper rotation X

Check general condition of the fan X

Check and unplug fan drain holes (hollow blade fans) X

Check fan for uniform pitch X

Check fan for rotation without obstruction X X

Suction StrainerSpray Riser Pipe

Bleed Valve

Spray PumpAccess Door

Spray PumpMotor

Make-up Valve

Coil Connection:FXV Fluid In/CXV Refrigerant Out

Coil Connection:FXV Fluid Out/CXV Refrigerant In

Prime SurfaceCoil

Access Door

Air Inlet Louvers

Cold Water Basin

BACross® Fill with IntegralDrift Eliminators

Spray WaterDistribution System

BALTIDRIVE®

Power Train

Fan Guard

Casing

RemovableDrift

Eliminators

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WARNING: Do not per form any service on or near the fans , motors, drive s, or inside the unit withoutfi rst ensuri ng that the fans and the pumps are disc onnected and locked out .

NOTES:1. Recommended service intervals are for typical installations. Different environmental conditions may dictatemore frequent servicing.

2. When operating in ambient temperatures below freezing, the unit should be inspected more frequently.Refer to “Cold Weather Operation” on Page N102 for more details.

3. Tension on new belts must be readjusted after the first 24 hours of operation and quarterly, thereafter.

Operation and MaintenanceInitial and Seasonal Start-up

General• If the unit is mounted on vibration isolators or isolation rails, refer to the vibration isolation manufacturer’sguidelines before loading/unloading weight from the unit.

• Verify fan and spray pump motors are disconnected and locked out.• Conduct overall external inspection of the equipment. Check for leaks, corrosion, and any structuraldamage.

• Inspect piping and connections.

Cleaning• Drain the cold water basin with the strainer in place.• Clean and inspect the fan deck.• Remove all dirt and debris from the fan guard.• Clean all mechanical components, such as the fan and motor.• Flush the cold water basin interior to remove any accumulated dirt and debris.• Remove, clean, and replace the strainer.

Inspect ion

WARNING: Do not per form any service on or near the fans , motors, drive s, or inside the unit withoutfi rst ensuri ng that the fans and the pumps are disc onnected and locked out .

• Thoroughly inspect the fans for any mechanical or physical damage.• At seasonal start-up or after prolonged shutdown, check the motorinsulation with an insulation tester prior to the motor start-up.

• Prior to the seasonal start-up, check and adjust the belt tension orcheck gear drive oil levels. At the initial start-up, the belt tension maynot require adjustment as the drive will be properly tensioned at thefactory prior to shipment.

• Start the fan motor(s) and check for proper fan rotation. The fan shouldrotate in the direction of the arrow indicated on the fan cowl.

• Run the fan in manual mode for several minutes to check for anyunusual noise or vibrations.

• For the BALTIGUARD™ Fan System, BALTIGUARD PLUS™ FanSystem or 2-speed motors: check that the starter incorporates a 15second time delay when switching from high to low speed.

• Check that the float operated make-up valve is operating freely.

WARNING: Check to ensur e the controls for the fan motor are set to allow a maximum of 6 on-offcyc les per hour.

Figure 2 - Adjustable Motor Base

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Start -up

WARNING: Do not per form any service on or near the fans , motors, drives , or inside the unit withoutfi rst ensuri ng that the fans and the pumps are disc onnected and loc ked out .

• Prior to seasonal start-up, lubricate the motor base adjusting screw (see Figure 2) and the fan shaftbearings. At initial start-up, no bearing lubrication is required since the bearings are factory lubricated priorto shipment.

• Fill the cold water basin with fresh water to the overflow level via the make-up valve.o Water treatment for new installations: Initiate the biocide water treatment program at this time. Refer to“Biological Control” on Page N106 for more details.

o Water treatment for seasonal start-up or after a shutdown period in excess of 3 days: Resume thebiocide treatment program and administer a shock treatment of appropriate biocides prior to operatingthe fans. This will eliminate accumulated biological contaminants. Refer to “Biological Control” onPage N106 for more details.

• Set the make-up valve float so the water shuts off at the overflow level.• Start the spray pump and check for the proper rotation indicated by the arrow on the pump cover. Oninstallations where the unit pump was not furnished by BAC, a globe valve should be installed in the pumpdischarge line and the pump flow rate adjusted to the correct water flow and pressure (2 psig at sprayheader connection). Pressure greater than 10.0 psig may cause damage to the dis tribution system.

• Inspect the spray nozzles and heat transfer section.• Open the supply valve slowly until the design flow is reached, based on the pressure in the distributionsystem. Refer to “Water Distribution System” on Page N68 for more details.

• Open the valve in the unit bleed line, and adjust the bleed by closing or opening the valve.• Once the unit is operating, check the current and voltage of all three phases (legs) of the fan motor with aheat load on the unit under warm ambient conditions. The current must not exceed the nameplate ratings.

• Check the operation of the optional vibration cutout switch.

Afte r 24 hours of operat ion under thermal load, perform the foll owin g services:• Check the unit for any unusual noise or vibrations.• Check the operating water level in the cold water basin. Adjust the balancing valves if necessary.• Adjust make-up valve if necessary.• Check the belt tension and readjust if necessary.• Inspect the spray nozzles and heat transfer section.

Extended Shutdown

WARNING: Do not per form any service on or near the fans , motors, drives , or inside the unit withoutfi rst ensuri ng that the fans and the pumps are disc onnected and loc ked out .

Perform the fo llowing services whene ver the unit is shutdown in excess of 3 days:• If the unit is mounted on vibration isolators or isolation rails, refer to the manufacturer’s guidelines beforeloading/unloading weight from the unit.

• Drain the cold water basin and all the piping (excluding the coils) that will be exposed to freezingtemperatures. Heat trace and insulate all exposed piping.

• Clean all debris, such as leaves and dirt, from the interior and exterior of the unit.• Clean and flush the water distribution system and cold water basin with the basin strainer in place.• Leave the cold water basin drain open so rain and melting snow will drain from the unit.• Clean the basin strainer and re-install.• Cover the fan discharge opening to keep out dirt and debris.• Lubricate the fan shaft bearings, motor base, and motor base adjusting screw.• Close the shut off valve in the make-up water line (supplied by others), and drain all exposed make-upwater piping. Heat trace and insulate all exposed piping.

• Inspect the protective finish on the unit. Clean and refinish as required. Refer to “Corrosion Protection” onPage N106 for more details.

• Secure the fan motor starting device in the “OFF” position to ensure personal safety in case of futureinspection or service.

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Detailed Component Maintenance ProceduresColdWater BasinThe fluid to be cooled is circulated inside the tubes of the unit's heat exchanger. Heat flows from the processfluid through the coil to the spray water outside which is cascading over the tubes. The spray water collects inthe cold water basin, passes through the suction strainer and is pumped back to the distribution system. Thecold water basin is constructed from one of the following materials of construction:• Galvanized steel• Thermosetting Hybrid Polymer• Welded Type 304 stainless steel

Water Levels

Table 2: ColdWater BasinWater Levels

• The make-up valve controls the operating level, which is maintained at the levels shown in Table 2.• The operating water level in the cold water basin will vary with system thermal load (evaporation rate), thebleed rate employed, and the make-up water supply pressure.

• Check the operating water level monthly, and readjust the float when necessary to maintain therecommended operating level.

Inspect ion and Maint enance

WARNING: Openings and/or submerged obs tructions may exist in the bottom of the cold water basin.Use caut ion when walking inside this equipment.

• Inspect the cold water basin regularly. Remove trash or debris accumulated in the basin or on the strainer.• Quarterly, or more often if necessary, drain, clean, and flush the entire cold water basin with fresh water.This will remove the silt and sediment, which normally collects in the basin during operation. If notremoved, sediment can become corrosive and deteriorate the protective finish of metallic basins.

• When flushing the basin, leave the strainer in place to prevent the sediment from re-entering the system.• Remove the strainer after the basin has been flushed.• Clean and replace the strainer before refilling the basin with fresh water.• Adjust the float to maintain the design operating level. See Table 2: “Cold Water Basin Water Levels.”

FanThe FXV and CXV use an axial fan. Thoroughly inspect the fan for damaged or deteriorated fan blades andreplace the fan as required.

Inspect ion and Maint enance• If the unit is already in operation, while the fan is running, check for any unusual noise or vibration.• With the fan off and the motor locked out and tagged, check the general condition of the fan:

o Inspect for any loose or missing bolts in the fan shaft bushing, the fan hub, and the fan shaftbearing(s).

o Check the fan blades for looseness, first by twisting the blade by hand; and then, by moving the bladetip up and down. There should be no play or slippage.

o Inspect each blade for excessive scale build-up that could cause vibration.o Check each blade, in the area of the shank, for any signs of cracking. If cracking is found, the fanmotor should be locked out immediately. Contact your local BAC Representative for assistance.

Model Number At Overflow Level (in.) At Operating Level (in.)

FXV-4xx, CXV-64 to CXV-206 15” 10”

FXV-6xx, CXV-196 to CXV-305,CXV-310 to CXV-481, CXV-420 to CXV-610,CXV-620 to CXV-962, CXV-N465 to CXV-N687

15” 7-1/2”

FXV-288-xxx, CXV-T645 to CXV-T1888 14” 10-1/2”

FXV-364-xxx 13-1/2” 10-1/2”

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• Tip Clearance: Check the clearance between the tip of the blade and the fan cowl. The clearance shouldbe within 5/16” to 1/2” for single air inlet FXV/CXV and within 1/2” to 7/8” for dual air inlet FXV/CXV-T.

• Drain Holes: On hollow blades, the drain hole in the blade tip should be unobstructed. (Hint: Use a pieceof wire to probe the hole.)

• Blade Pitch : Check to ensure that the blades are all at the same pitch. If uncertain, measure the pitch withan inclinometer. All blades should be within -1/2° to 0° .

• Rotation : Turn the fan by hand to ensure that it moves freely with no rough spots, binding or othermalfunctions that could cause vibration or fan motor overload. While rotating the fan, check the bladetracking. All blades should track within a 3/4” to 1” band at any single point around the cowl.

• Direction of Rotation: On initial start-up, or if the fan motor has been rewired, bump the fan motor andnote the direction of rotation. It should rotate in the direction indicated by the arrow on the fan cowl.

• Operation : On initial start-up, run the fan in the manual position for several minutes and check for anyunusual noises or vibration.

Fan Drive System

BALTIDRIVE® Power Train/BALTIGUARD™ andBALTIGUARD PLUS™ Fan SystemThe BALTIDRIVE® Power Train consists of a solid-backed, multi-groove,neoprene/polyester belt rated for cooling tower service, and corrosion-resistant sheaves. These components provide high reliability with lowmaintenance requirements.

The BALTIGUARD™ Fan System consists of two standard single-speedfan motors and drive assemblies. One drive assembly is sized for fullspeed and load, and the other is sized for approximately 2/3 speed andconsumes only 1/3 the design horsepower.

The BALTIGUARD PLUS™ Fan System builds on the advantages of the BALTIGUARD™ Fan System byadding a VFD to one of the motors.

Inspection and Maint enanc e:• These drives require a periodic check of the belt condition and, when necessary, tension adjustment. Therecommended service intervals are as follows:o Ini tial Start-up : Servicing is not required prior to initial unit start-up. The drive has been tensioned andaligned at the factory.

o Seasonal Star t-up : Readjust the belt tension.o Operati on : After the first 24 hours of operation, readjust the belt tension on a new unit start-up orinstallation of a new belt. Thereafter, check the belt condition monthly, and adjust tension asnecessary. Readjust tension at least once every 3 months.

• Belt tension check:o Place a straight edge along the belt from sheave to sheave as shown in Figure 4a, or use a tapemeasure as shown in Figure 4b, to measure belt deflection.

o Apply a moderate force by hand (approximately 40 lbs/18.1 kg) evenly across the width of the belt inthe center of the span between the sheaves.

o There is adequate belt tension if the belt deflects between 1/4” and 3/8” as shown in Figures 4a and4b.

Belt Tension

DRIVEN SHEAVEDRIVEN SHEAVEBELTBELT

DRIVER SHEAVEDRIVER SHEAVE

STRAIGHT EDGESTRAIGHT EDGE

1/4” TO 3/8” DEFLECTION = PROPER BELTTENSION 3/8” DEFLECTION = PROPER BELT TENSION

D DRIVEN SHEAVEDRIVEN SHEAVEBELTBELT

DRIVER SHEAVEDRIVER SHEAVE

TAPE MEASURETAPE MEASURE

1/4” TO 3/8” DEFLECTION = PROPER BELTTENSION3/8” DEFLECTION = PROPER BELT TENSION

Figure 4a Figure 4b

Figure 3 - BALTIGUARD™ FanSystem

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• Belt tension adjustment (if required):o Loosen the lock nut on the motor base adjusting screw.o Turn the motor base adjusting screw clockwise to tension the belt, or counterclockwise to relieve belttension. During adjustment of belt tension, rotate the drives several times by hand to evenly distributethe tension throughout the belt.

• When the belt is properly tensioned, retighten the locking nut on the motor base adjusting screw.

NOTE: There should be no “chirp” or “squeal” when the fan motor is started.

Alignment:• Check the drive alignment annually to ensure maximum belt life.• Drive alignment check and adjustment:

• Place a straight edge across the driver and the driven sheaves as shown in Figure 5a for standarddrives and in Figure 5b for the BALTIGUARD™ Fan System or the BALTIGUARD PLUS™ FanSystem.

• The straight edge should contact all four points as shown in Figure 5a indicating proper drivealignment.

• There should be no more than 1/16” deviation from four points of contact.• In case of realignment, loosen the motor sheave and align it with the fan sheave. Allow 1/4” for draw-up as the bushing screw is retightened.

Gear Drive System (Optional for Dual Air Inlet FXV/CXV-T Only)

Initial Start-up:• BAC ships all gear drives filled with oil. The initial oil level should be at or near the middle of the oil levelsight glass.

• Internally mounted gear drives are factory installed, aligned, and tightened. Double check all gear drivefasteners after the unit has been installed.

• On units with externally mounted motors, install and align the motor and driveshaft in accordance withBAC’s installation instructions. Recheck the alignment and all external fasteners after 2 weeks of operation.

• Prior to the start-up, check all fittings on the gear drive to ensure that there are no visible leaks. ReferFigure 6 for locations of the gear drive fittings.

Figure 6 – Single Reduction Gear Drive

Air Breather Plug

Oil Level Sight Glass

Drain Plug

Name Plate

Points of Contact

StandardDriverSheave

1/16”MAX

1/16”MAX

BALTIGUARD™ &BALTIGUARD PLUS™ Fan System Driver Sheave

StraightEdge

DrivenSheave

Points of Contact

Points of Contact

1/16”MAX

1/16”MAX

1/16”MAX

1/16”MAX

StandardDriverSheave

P

Figure 5a - Standard Drive Alignment Figure 5b - BALTIGUARD™ Fan SystemDrive Alignment

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Change Interv al:• Initi al oil change : Replace the original oil after 500 hours or 4 weeks of operation, whichever comes first.• After the initial oil change, change the oil every 2500 hours or 6 months, whichever comes first.• Drain the oil at operating temperature through the drain plug.• Refill the gear drive through the air breather port with the recommended type (Table 3 and 4) and amountof lubricant (Table 5). Refer to Figure 6 for locations of these components.

Inspection and Maint enanc e:• Maintain the oil level at or near the middle of the oil level sight glass. The oil level should always be visiblein the sight glass window when the unit is not operating/energized, and the oil is at ambient temperature.

• Check oil level weekly with the unit idle.• Add oil if level is below the oil level sight glass.• The standard oil provided is mineral oil. Synthetic lubricants are also available as an option (see Table 4).• Refer to Table 5 for normal operating oil capacity of each gear drive.• Refer to Table 6, Table 7 or the gear drive nameplate for specific gear model number for each unit.• Periodically check to ensure proper alignment of all system components.• Check to ensure that all bolts and external fasteners are tight.• BAC recommends daily visual inspections and observation for oil leaks and unusual noises and vibrations.If any of these occur, shutdown the unit until the cause is found and corrected.

Routi ne Mainte nanc e Dur ing Operation:• Periodically recheck the alignment and tighten external fasteners as necessary. No special break-inprocedures are required.

• Excessive noise or vibration at initial operation is an indication of one or more of the following:o Misalignmento Imbalance of the fan or other rotating partso Improperly adjusted fan bladeso Operation at the mechanical equipment resonant frequency

WARNING: If noi se or vibra tion persists, shut the unit down and correc t the cause before cont inuingoperat ion.

• Installations with 2-speed motors: When slowing from high speed, allow a minimum 15-second time delayfor the fan to slow down before energizing the low-speed winding.

CAUTION: When reversing the direction of rotation, allow the fan to come to a complete stop beforerestart ing the motor .

• During periods of inactivity, the lubricant does not constantly lubricate the internal parts of the gear drive,leaving the gear drive susceptible to corrosion. Therefore, the following special precautions are necessaryduring periods of inactivity:o For best results, let the gear drive cool for approximately 4 hours after shutdown.o Start the fan and let it run for approximately 5 minutes. This will coat the internal parts of the geardrive with cool oil.

o Thereafter, run the fan for 5 minutes once a week, throughout the shutdown period to maintain the oilfilm on the internal parts of the gear drives.

• During seasonal shutdown:o Completely fill the gear drive with oil through the air breather plug.o Cover the gear drive with a tarpaulin or other protective covering.o Drain the excess oil before returning the gear drive to service at the end of the seasonal shutdownperiod.

Lubri cation:• Use only rust and oxidation inhibited gear oils in accordance with AGMA (American Gear Manufacturer’sAssociation), Standard 9005-E02.

• Refer to Table 3 and Table 4 for general operating conditions, AGMA lubricant number and correspondingISO Grade.

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• When the ambient temperature exceeds 180°F (82°C) or the gear drive is started at an ambienttemperature less than 20°F (-7°C), a synthetic lubricant is recommended. When mineral oils are used inoperation at ambient temperature less than 20°F (-7°C) lube oil heaters are required. Each unit hasprovisions for an internal oil reservoir heater. Heaters and synthetic oil are extra cost accessories and canbe ordered with new units or may be ordered and installed in existing units.

• The vertical and horizontal shafts are equipped with grease lubricated dual seals. Relubrication is notrequired.

Table 3: Recommended Mineral Oils Table 4: Recommended Synthetic Lubricants

NOTE: Do not mix synthetic lubricants and mineral oils. Attempt to use only one brand of lubricant at all times.

Synthet ic Lubric ants :• Refer to Table 4 for general operating conditions, AGMA lubricant number, and corresponding ISO Grade.• Certain gear drive components might be incompatible with the various base stocks used to makelubricants. Contact your local BAC Representative prior to using any synthetic lubricant not listed.

Table 5: Normal Operating Oil Capacity

Table 6: Gear Model/Unit - Standard Fan Table 7: Gear Model/Unit - Low Sound Fan

Fan MotorsFXV and CXV units use cooling tower duty, premium efficient, totally enclosed, single-speed, single-winding,reversible ball bearing type motor(s).

Inspect ion and Maint enance• Clean the outside of the motor at least quarterly to ensure proper motor cooling.• After prolonged shutdowns, check the motor insulation with an insulation tester prior to restarting the motor.

Gear Model Gallons Liters

65 0.5 2

85 1 4

110 2 8

135 3 11

155 5.5 21

175 5.5 21

Ambient Temperature at Gear Drive: -20˚F to 150˚F (-29˚C to 66˚C)

AGMA Lubricant Number: 5S

ISO Grade: 220

Manufacturer Oil Type*

Chevron OilConocoMobil Oil

Clarity 220 SyntheticSyncon 220 - R70 OilSHC 630

* List of brand names is for the purpose ofidentifying types and should not to be construed asexclusive recommendations.

Ambient Temperature at Gear Drive: 20˚F to 120˚F (-7˚C to 49˚C)

AGMA Lubricant Number: 5

ISO Grade: 220

Manufacturer Oil Type*

Atlantic RichfieldChevron OilCities Service OilConocoExxonGulf OilMobil OilPennzoilPhilips PetroleumShell OilSun OilTexacoTotal

Duro 220Machine Oil A W 220Citgo Pacemaker 220Hydroclear Multipurpose R&O Oil 220Teresstic 220Harmony 220DTE Oil BBPennzbell TO 220Magnus 220Morlina 220Sunvis 9220Regal 220 R & O, Code 1531Carter 220

Model Number Gear Model

FXV-288-xxM 85

FXV-288-xxN,O,P,Q,R and FXV-364-xxN,O,P 110

CXV-T6xx, CXV-T7xx, CXV-T876-PM 110

FXV-364-xxQ,R 135

CXV-T827, CXV-T857, CXV-T876, CXV-T906 135

FXV-264-xxS 155

CXV-T857-SM, CXV-T944 155

Model Number Gear Model

FXV-288-xxM,N,O,P,Q,R 135

CXV-T6xx, CXV-T717, CXV-T729, CXV-T729-OM,CXV-T763

135

CXV-T717-RM, CXV-T792 155

FXV-364-xxN,O,P,Q,R,S 175

CXV-T791, CXV-T8xx, CXV-T9xx 175

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Adj usta ble Motor BaseCoat the motor base slides and adjusting screws (refer to Figure 2 on Page N61) every 3 months using goodquality corrosion inhibiting grease such as one of those recommended for lubricating the fan shaft bearingsbelow.

WARNING: Check to ensure the controls for the fan motor are set to allow a maximum of 6 on-offcyc les per hour.

Fan Shaft BearingsTwo pillow block ball bearings support the fan shaft. Each bearing is equipped with a lubrication fitting and aslinger/locking collar to keep out moisture.

Inspect ion and Maintenance• Lubricate the bearings with only a manual grease gun. Do not use high-pressure grease guns since theymay rupture the bearing seals.

• Lubricate the bearings with only one of the following compatible water resistant greases* which are suitablefor ambient temperatures ranging from -65ºF (-53.9ºC) to +250ºF (121.1ºC).

*NOTE: List of brand names is for identification only and are not exclusive recommendations.

• Lubricate the bearings as follows:o Ini tial Start-up : Normally, no lubrication is required since the bearings have been lubricated at thefactory prior to shipment. However, if the unit has been stored at the job site for more than 1 year,both bearings should be lubricated with new grease before initial operation. When lubricating, purgethe old grease from the bearing by gradually adding greas e until a bead of new greas e appearsat the seal on the unde rside of the bearing.

o Seasonal Star t-up : Purge both bearings with new grease prior to start-up.o Operati on : Purge bearings every 2,000 hours of operation or once every 3 months, whichever occursfirst.

o Extended Shutdown : Purge bearings with new grease prior to any prolonged storage or downtime.

Heat Transfer Section

Fil l and Dri ft Elimin atorThe FXV and CXV have PVC fill with integral drift eliminators.

Inspection and Maint enanc e:• Inspect and clean the fill with the integral eliminators at least quarterly.• The inspection procedure is as follows:

o Shut off the fan and the spray pump.o Inspect the fill for obstructions, damage and fouling.

• Remove any obstructions from the fill.• Remove any minor fouling chemically. Contact your local water treatment consultant for advice.• Major fouling requires cleaning and flushing. Follow the procedures listed in “System Cleaning”, PageN107.

Water Distribution SystemThe hot water is distributed through a corrosion resistant polyvinyl chloride (PVC) system. The fill and drifteliminators are also made of PVC, which requires no protection against rot, decay, rust, or biological attack.

Inspect and clean the spra y nozzles and heat trans fer section each month.

Amoco - Rycon Premium #3 Exxon - Polyrex® EM Shell - Alvania #3Chevron - SRI Exxon - Unirex N™ Shell - Dolium “R”Citgo - Polyurea MP2™ MobilGrease® - AW2 SKF - LGHP2™Conoco - Polyurea 2™ Shell - Alvania RL3™ Unocal 76 - Unilife Grease™

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The inspection procedure is as follows:• Shut off the fan, but leave the spray pump running.• Check to see if the nozzles are producing the spray pattern shown inFigure 7.

• Clean any nozzles which are clogged. If necessary, the nozzle andrubber grommet may be removed for cleaning.

• Inspect the coil surface. Any corrosion, damage, or obstructions mustbe corrected.

Caution: Do not use steam or high pres sure water to clean PVCeliminato rs or materials other than steel.

Water Level ControlThere are two types of water level controls used on BAC units:• Mechanical make-up valve assembly• Optional electric water level control package

The FXV/CXV water make-up valve assembly is located on the air inlet face.

Mechanical Make-up Valve AssemblyA float-operated mechanical water make-up assembly is furnished as standard equipment on the unit. Thestandard make-up assembly consists of a corrosion resistant make-up valve connected to a float armassembly actuated by a polystyrene-filled plastic float. The float is mounted on an all-thread rod held in placeby wing nuts. The cold water basin operating water level can be adjusted by repositioning the float and all-thread rod using the wing nuts provided.

NOTE: If the unit has been ordered with the optional electric water level control package or is intended forremote sump application, a mechanical water make-up valve will not be provided.

Inspection and Maintena nce:• Inspect the make-up valve assembly monthly and adjust if necessary.• Inspect the valve annually for leakage. Replace the valve seat if necessary.• Maintain the make-up water supply pressure between 15 psig and 50 psig for proper operation. BACrecommends a surge protector (provided by others) for pressures over 50 psig.

• Set the initial basin water level by adjusting the wing nuts, so that the make-up valve is completely closedwhen the water level in the cold water basin is at the overflow connection.

• With the design thermal load and the average water pressure (15 to 50 psig) at the valve, the above settingwill produce operating water levels as stated in Table 2 on Page N63.

• If the thermal load is less than the design load at the time of unit start-up, the procedure may produceoperating levels greater than those shown in Table 2. If operating levels are higher than specified, readjustthe float in order to attain the recommended operating level.

• Closely monitor the water level in the cold water basin and adjust the level if necessary during the first 24hours of operation.

• Operating at the recommended water level will ensure that the unit basin contains sufficient water volumeto prevent air entrainment in the circulating pump during system start-up.

Opt ional Elect ric Water Level Contro l PackageAs an option, an electric water level control package is available in lieu of the mechanical make-up assembly.The package consists of a probe-type liquid level control assembly and a slow-closing solenoid valve.Stainless steel electrodes, factory-set at predetermined lengths, extend from an electrode holder into the coldwater basin.

Inspection and Maintena nce:• Clean the stainless steel electrodes periodically to prevent accumulations of scale, corrosion, sludge orbiological growth, which could interfere with the electrical circuit.

• The water level is maintained at the recommended operating level regardless of the system thermal load.Therefore, it is not recommended that the operating level be adjusted.

• During the start-up of units equipped with the electric water level control package, by-pass the control unitin order to fill the unit to the overflow connection.

Figure 7 - Nozzle Spray Pattern

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RReeccoommmmeennddeedd SSppaarree PPaarrttssBAC parts are the “Perfect Fit” for your cooling tower. These parts are specifically designed, engineered andmanufactured to work in a cooling tower environment. They are the right parts, at competitive pricing levels, andBAC offers the best deliveries in the industry.

BAC stocks most common repair and retrofit parts in our Parts DepotSM and can ship other parts, often overnight,from any of our three manufacturing facilities strategically located in California, Delaware, and Illinois. In addition,most BAC Representatives maintain a local inventory of commonly used parts.

Even with this fast delivery capability, it is still recommended that certain essential, emergency repair parts bemaintained in your local inventory, to minimize any potential downtime.

Basic Recommended Spare PartsBearing set

Float valve or repair kit

Float ball

Solenoid valve (if unit is equipped with electric water level control)

Powerband or set of belts

Spray nozzle kit with grommets

Basin heater and low water cut out

Door gasket

Strainer (inlet and suction)

Fan and sheave bushings

Pump seal and gasket kit for coil products

Automatic bearing greaser refill kit

Parts to Consider if Extended Downtime is a ConcernSpray pump for coil products

Fan or fan wheel

Fan shaft

Sheave set

Fan motor

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lsCommon Operation & Maintenance SectionTable of Contents..............................................................PageVariable Frequency Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N101Remote Sump Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102Fan Section Icing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102Coil Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N103Basin Water and Internal Piping Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N104

Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N104Corrosion and Treatments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N105Corrosion and Scale Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N105Chemical Treatment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N106Passivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N106Biological Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N106System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N107

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N107Bleed Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N107

Basin Heater and Stand Alone Heater Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N109Basin Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N109Stand Alone BAC Heater Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N109

Electronic Vibration Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N110General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N110

Instructions for Installing Field Connections (Equalizer/Bypass/Outlet) on a Cold Water Basin with theTriArmor® Corrosion Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N111Factory Authorized Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N112

Variable Frequency Drive Operation• Applications utilizing variable frequency drives (VFDs) for fan motor control must use inverter duty motors

built in compliance with NEMA standard MG-1, Part 31.• The standard efficiency fan motors are not intended for inverter duty and will not be warranted if so

applied.• On installations with variable frequency motors, do not operate the standard gear drives below 450 RPM

motor speed (gear input speed). For speeds less than 450 RPM, a low speed option gear drive must besupplied.

• Continued operation at a resonant frequency condition will result in torsional vibrations within the gear,which can damage system components. The most common indicator of torsional vibrations is an unusualrumbling or grinding noise from the gear drive at a sharply defined speed. The noise will disappear whenthe speed is increased or decreased. This noise is not indicative of a defect but results when the vibratorytorque exceeds the drive torque causing the gear teeth to separate and clash together very rapidly. Onvariable frequency applications, avoid operation close to a resonant speed by locking out resonantfrequency ranges.

• At start-up, increase the variable frequency drive from 0 RPM to maximum motor speed. Graduallyincrease the speed and observe the unit for the onset of any unusual rumbling or grinding at specificspeeds. These resonant speeds (+/- 10%) should be “locked out” by the variable speed drive. Continuousoperation at resonant speeds can result in fan failure and possible personal injury or damage.

• Please refer to the manufacturerʼs variable frequency drive recommended start-up procedure for furtherinformation or consult with your local BAC Representative for any VFD applications. For projects with BACcontrols, visit www.BaltimoreAircoil.com.


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Remote Sump ApplicationThe water level in the basin of the equipment designed for remote sump operation is a function of thecirculating water flow rate; water outlet connection size, quantity and location, and outlet piping size andconfiguration. The remote sump unit is supplied without a water make-up assembly, and the basin operatinglevel during remote sump operation is fixed.

ColdWeather OperationBAC products can be operated at subfreezing ambient temperatures provided proper operating methods areestablished and diligently followed.

Inspection and Maintenance• Carry out the frequent visual inspections and routine maintenance services during operation in subfreezing

weather.• Ensure all controls for capacity and freeze protection are set properly and functioning normally.• Prevent excessively high water levels and possible overflow of the cold water basin due to over pumping,

clogged strainers, or make-up valve malfunction.• Resolve any icing condition that may severely develop to damage the unit or the supports or impair the

system performance.

Fan Section Icing ProtectionThere are three basic operational methods which can be used to provide the systemʼs required cooling:Temperature Setting, Fan Control, and Dry Operation*. The method of controls employed on a givenapplication depends upon the climatic extremes which are expected, the variations in heat load that will beencountered, and the compatibility of the control system with other portions of the installation. Effective icingcontrol in subfreezing ambient conditions will require a combination of these three methods.

*NOTE: Dry Operation applies only to closed circuit cooling towers and evaporative condensers.

Temperatur e Sett ingLow leaving fluid temperature promotes ice formation. During operation in subfreezing ambient temperatures,maintain the leaving fluid temperature as high as possible. Ensure the unit operates with the maximumpossible heat load. The recommended minimum fluid temperature is:• 43°F (6.1°C) for Crossflow Cooling Towers• 42°F (5.5°C) for Counterflow Cooling Towers• 50°F (10°C) for Closed Circuit Cooling Towers with water (non-glycol)• 45°F (7.2°C) for Closed Circuit Cooling Towers with glycol

Fan Cont rolReduce the unit capacity by cycling fans thus modulating the airflow through the unit. Rapid on-off cycles cancause the fan motor to overheat. Set the controls to allow a maximum of 6 on-off cycles per hour. Periodically,cycle the fans off to prevent ice formation and/or to melt ice that accumulates on the intake louvers orcombined inlet shields and face of the fill.

Fan Cycli ng: Operate each unit with the highest thermal load it can handle, rather than evenly dividing thetotal heat load across all cells. During prolong periods, bypass the idle units and drain the basins.

Multi-Speed Motor s: If the unit is equipped with 2-speed motors or BALTIGUARD™/BALTIGUARD PLUS™Fan System, operation at a lower speed may be sufficient to prevent icing. When 2-speed motors are used,the motor starter should include a minimum 15 second time delay when switching from high to low speed.

Variable Frequency Drives: VFDs offer the most precise method of capacity control, by modulating fan motorspeed. When using VFDs, avoid operating at or near “critical speeds.” Units with VFDs require inverter dutymotors.

In subfreezing ambient temperatures, cycle the fan off for 5 minutes every 15 to 20 minutes for each cell. If icecontinues to build on the louvers, decrease the on-time. Observe inlet louvers of the towers every 4 to 8hours.

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NOTE: Modulating the water flow rate to the unit is NOT a recommended method of controlling coolingcapacity.

Dry Operation (for Models VF1, VFL, VC1, VCA, VCL, and HXV)One method of protecting fans from icing is dry operation. Dry operation of the closed circuit cooling tower orevaporative condenser protects fans from ice formation due to mist and splash from the cold water basin.

Coil Freeze ProtectionUse an industrial grade inhibited glycol solution for protection against coil freeze-up. When the use of glycol isnot practical, the system must be designed to meet both minimum flow and minimum temperaturerequirements.• Recommended solutions are an industrial grade inhibited ethylene glycol or propylene glycol solution.• The Product & Application Handbook provides the coil volumes for Models FXV, HXV, VF1, and VFL. Coilvolume for CXV, VC1, VCL, and VCA condenser models using liquid cooling circuits is job specific.

Minimum OperationWhen a glycol solution is not utilized, operate the system to meet both of the following conditions.• Maintain the minimum recommended flow through the coil at all the times (see Table 5).• Maintain a minimum heat load on the circulating fluid so that the temperature of the fluid leaving the coilwill not fall below 50°F (10°C).

• To maintain the leaving fluid temperature at 50°F (10°C) when the process load is extremely light or shutoff, apply an auxiliary heat load to the circulating fluid.

Table 1: Minimum Coil Flow

Positive Closure Damper Hood and InsulationThe amount of auxiliary heat required can be substantially reduced by the use of a positive closure damperhood and insulation. The heat loss data can be found in the corresponding product section of this handbook.

Emergency Coil DrainDo not drain the coil as a normal method of freeze protection. Frequent draining promotes corrosion inside thecoil tube. However, draining is acceptable as an emergency method of freeze protection if the coil is notprotected by a glycol solution. If the coil is not protected, an automatic drain valve and vacuum breaker arerecommended to drain the coil if flow stops or fluid temperature drops below 50°F (10°C) when the ambienttemperature is below freezing. Contact your local BAC Representative for guidelines on the installation of anemergency coil drain system.• Further protection against coil freeze-up is possible with the installation of an alarm to alert personnel whenthe temperature of the fluid leaving the coil falls below 50ºF (10°C).

• For evaporative cooling applications only, the glycol solution will maintain the leaving fluid temperature aslow as 45°F (7.2°C). Contact your local BAC Representative for necessary precautions.

Model Number Minimum CoilFlow (GPM)

FXV-4xx 75

FXV-Q44x 150

FXV-6xx 110

FXV-Q6xx, FXV-T6xx 220

FXV-288, F-288-2Tx, 364-x1x 275

FXV-364-2Tx, 364-xQx 550

HXV-6xx 110

HXV-Q6xx 220

VF1-009,VF1-018,VF1-027, VF1-036

50

Model Number Minimum CoilFlow (GPM)

VF1-048 75

VF1-072 100

VF1-096, VF1-144N 125

VF1-144, VF1-216N 200

VF1-192, VF1-288N 250

VF1-288, VF1-432 400

VFL-012 thru VFL-048 65

VFL-072 thru VFL-096 125

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BasinWater and Internal Piping Freeze Protection

Cold Water Basin Prot ecti onThe basin water could freeze when the unit is shut-down and exposed to subfreezing ambient temperatures.

Indoor Sump : The ideal method of protection is a remote sump located in a heated indoor area. When thecirculating pump stops, the water in the connecting piping will drain by gravity to this indoor sump.

Basin Heaters : On applications without a remote sump, provide heat to the cold water basin. Electricalimmersion heaters, steam coils or hot water coils can provide the required function. Contact your local BACRepresentative for details.

Electric Water Level Cont rol : An electric water level control will maintain the proper water level regardless ofthe thermal load or variations in make-up water supply pressure. The two-position, slow closing solenoid valveprovided in the BAC electric water level control package also minimizes valve freezing problems.

Heat Trac ing: Heat trace and insulate all exposed water piping including pump piping below the overflowlevel, external header cleanout (PT2 only) and make-up water lines with electrical heater tape.

Piping Freeze Prot ect ion• Eliminate all water in the optional EASY CONNECT® Piping Arrangement (Series 3000) and in all internal

piping when the tower is idle.• It is essential to drain water from the EASY CONNECT® Piping Arrangement and internal piping whenever

the potential for freezing temperatures exits. Drain the water by using 1/2” NPT drain port located on theinboard side of the EASY CONNECT® Piping Arrangement.

• There are three recommended methods for draining the piping:o Preferre d: Install a normally open 1/2” solenoid valve on the 1/2” drain connection of the EASY

CONNECT® Piping Arrangement. Wire the valve in the pump circuit such that the valve closes whenthe pump is energized. Select the solenoid valve to operate with a minimum pressure differential of 0psi, which is required to limit the static head imposed on the valve from the water column.

o Install a 1/2” manual valve on the 1/2” drain connection of the EASY CONNECT® Piping Arrangement.Open the valve during the cold weather operation. Keep the valve closed during the warm weather toachieve full thermal performance.

o Remove the 1/2” plug from the 1/2” drain connection of EASY CONNECT® Piping Arrangement duringthe cold weather operation. Reinstall the plug during the warm weather to obtain full thermalperformance.

Corrosion ProtectionBAC products are constructed of corrosion-resistant materials. The fill is made of a polyvinyl chloride (PVC),which requires no protection against rot, decay, rust or biological attack.

Other materials listed below are used in the equipment construction:

Galvani zed Steel Compone nts: Inspect the galvanized steel components for blemishes or corrosion. Wirebrush and recoat the affected areas with a cold galvanizing compound such as zinc rich compound (ZRC).

Thermose tting Hybr id Polym er Components: Galvanized steel components protected with theThermosetting Hybrid Polymer may develop scratches, scrapes or blemishes. Touch up these with a repair kit(BAC Part No. 16-133P). In the unlikely event that the damage is more extensive than simple scratches orminor blemishes, contact your local BAC Representative.

Stainles s Steel Component s: Inspect stainless steel components for signs of blemishes or corrosion. Cleanwith stainless steel wool as necessary. If more extensive corrosion is prevalent, contact your local BACRepresentative.

Fibergl ass Reinfor ced Poly ester (FRP) Compone nts : Series 3000, dual air inlet FXV, and CXV-T productsare provided with FRP casing panels as standard. Inspect the casing panels for accumulation of dirt and cleanthem with soap and water as necessary.

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TriArmor ® Corros ion Protection Syst em: Inspect components protected with the TriArmor® CorrosionProtection System for signs, deep scratches or blemishes, especially in areas with field penetrations. Touchthese up with either rubberized polyurethane caulking such as Vulkem® or a repair kit available through BAC(BAC Part No. RK1015).

Pult rude d Fiberglass Reinf orced Polyester (PFRP) Compo nents: Series 3000 Cooling Towers areoptionally provided with PFRP hot water basins. Inspect the basin panels for accumulation of dirt and cleanthem with soap and water as necessary.

Corrosion and Treatments• Corros ion – Red rust on steel components and “white rust” on galvanized surfaces will affect the longevity

of the unit.• Scale Formation – Scale not only reduces heat transfer and system efficiency, but also may lead to under

deposit corrosion.• Biologic al Fouling – Slime and algae formations may reduce heat transfer, promote corrosion, and harbor

pathogens such as Legionella.

Since the quality of the ambient air and make-up water varies significantly from job site to job site, BACstrongly recommends obtaining the services of a competent water treatment specialist prior to the initial start-up of the evaporative cooling equipment. Additionally, to protect against the risk of Legionella contamination,never operate the cooling equipment without adequate biological control.

Corrosion and Scale Control• To control corrosion and scale, maintain the water chemistry of the recirculating water within certain

parameters. The specific measures required vary from system to system and are dependent on thechemistry of the make-up water, the metallurgy of the piping and heat transfer devices exposed to therecirculating water, and the temperatures at which the system will be operating.

• Bleed/blowdown, the continuous flow of a small portion of the recirculating water to a drain, is used tocontrol the concentration of dissolved solids. On rare occasions, this may be adequate to control scale andcorrosion. More often, however, chemical scale and corrosion inhibitors are necessary, which raise theallowable level of dissolved solids without the risk of scale and corrosion.

• Keep the chemically treated water within the guidelines given in Table 2. In cases where bleed/blowdownalone is being employed for corrosion and scale control, without chemical treatment, your water treatmentspecialist may recommend more conservative limits than those shown in Table 2.

Table 2: Quality Guidelines for Chemically Treated CirculatingWater

Notes:1. Galvanized steel units require passivation in order to prevent white rust (refer to passivation below).2. Hardness and alkalinity limits may be exceeded under certain circumstances. Consult your water treatment

specialist for recommendations.3. The conversion factor used to determine conductivity is 0.625 (TDS = 0.625 x Conductivity).

Property of Water Recommended Level

pH 6.5 to 9.0[1]

Hardness as CaCO3 30 to 750 ppm[2]

Alkalinity as CaCO3 500 ppm maximum[2]

Total Dissolved Solids (TDS) 1500 ppm maximum

Conductivity 2400 micromhos[3]

Chlorides250 ppm maximum Cl

(410 ppm maximum as NaCl)

Sulfates 250 ppm maximum

Silica 150 ppm maximum

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Chemical Treatment RequirementsChemical treatment programs must meet the following requirements:• The chemicals must be compatible with the unit materials of construction as well as other materials used in

the system (pipe, heat exchanger, etc.).• Chemical scale and corrosion inhibitors, particularly acid (if used), should be introduced into the circulating

water through automatic feeders. This should be done at a point in the system where total mixing anddilution occur, before reaching the evaporative cooling equipment. The preferred injection point for chemicalscale and corrosion inhibitors is on the discharge side of the system circulating pump(s). These chemicalsshould not be batch fed directly into the unitʼs cold water basin or water distribution system, as this canseverely damage areas directly contacted.

• When chlorine is added to the system, free residual chlorine should not exceed 1 ppm, except as noted instart-up and shutdown section. Exceeding this limit may accelerate corrosion.

Passivation• Passivation is the formation of a protective, passive, carbonate layer on galvanized steel surfaces.• On the newly installed units, to provide maximum protection from corrosion, take special measures to

passivate galvanized steel surfaces.• To ensure proper passivation of the galvanized steel, keep the pH of the circulating water between 7.0 to

8.2 for four to eight weeks after start-up, or until new zinc surfaces turn dull gray in color.• If white deposits form on galvanized steel surfaces after the pH is returned to normal service levels, it may

be necessary to repeat the passivation process.

NOTE: Stainless steel cold water basins and basins protected by the TriArmor® Corrosion Protection Systemor Thermosetting Hybrid Polymer do not require passivation. However, if the upper structure isgalvanized steel, passivation is required.

Biological Control• The warm, oxygen and nutrient rich environment inside evaporative cooling equipment provides an ideal

environment conducive to the growth of algae, slime, and other micro-organisms. Uncontrolled, this canreduce heat transfer, promote corrosion, and promote the growth of potentially harmful organisms such asLegionella. To avoid biological contamination and minimize the risk of Legionella, initiate the biocidetreatment program at start-up and continue on a regular basis thereafter in accordance with the treatmentsupplier’s instructions.

• Bleed/blowdown or chemical treatment used for corrosion and scale control alone is not adequate forcontrol of biological contamination.

• Introduce solid or granular biocides through a chemical “pot” feeder installed in parallel with the systemcirculating pump. Diluted liquid biocides may be added directly to the cold water basin.

• If ozone water treatment is used, at no point should concentrations exceed 0.5 ppm.• Initial Start-up and Start-up Following a Shutdown Period:

o To minimize the risk of biological contamination during a shut-down period of three days or more, it isrecommended that the entire system (evaporative cooling equipment, system piping, heat exchangers,etc.) be drained.

o To resume operation of a drained system and at initial start-up, clean all debris from the cold waterbasin and fill the system with fresh water. Then execute one of the following biocide treatmentprograms while operating the circulating pump and prior to operating the unit fans:• Resume treatment with the biocide that was used prior to shut-down. Then run the pump only

while maintaining the maximum recommended biocide residual for a sufficient duration (residualand time will vary with the biocide) as recommended by the water treatment supplier. Start thefan only after this treatment period is completed.

• Check the pH of the circulating water and, if necessary, adjust it to 7.0 - 7.6 pH. Then, runningthe pump only, treat the system with sodium hypochlorite to maintain a level of 4 to 5 mg/l (ppm)free chlorine (as Cl2) over a 6 hour period. Test kits for measuring the free residual of chlorine arecommercially available. Start the fan only after this treatment period is completed.

• When it is not practical to drain the system during shut-down periods, install a by-pass line with shut-offvalves to permit the recirculating water to circulate throughout the system, including the unit basin, whilebypassing the fill section of the evaporative cooling equipment (fans should remain off).

• Treat the system as per one of the above-described methods prior to restarting the unit.

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System Cleaning

Syst em Cleanin g (for Models Series V and Low Profile V (VF1, VFL), HXV, and FXV)With proper precautions, prior to start-up circulate an alkaline solution which can be used to clean condenserwater systems through a closed circuit cooling tower. The necessary precautions include:• Limit the duration of the cleaning to 1, or at the most 2 days.• The temperature of the solution should never exceed 100ºF (37.8°C).• The maximum concentration of chemicals in the circulation solution should not exceed any of the following:

o 5% Sodium Hydroxideo 5% Sodium Metasilicateo 2% Sodium Carbonateo 2% Tetra Sodium Pyrophosphateo 0.5% Trisodium Phosphateo 0.5% Sodium Nitrateo 5-10% Butyl Cellosolve

Coi l Cleaning (for Models Series V and Low Profile V (VF1, VFL), HXV, and FXV)Both the inside and outside of the heat exchange coil may require occasional cleaning. The chemicals usedmust be compatible with the materials being treated. For example, the standard coil outside is galvanizedsteel. The inside of the coil is black carbon steel. For finned coils, the coil cleaning must be careful not todamage the fins (outside of the coils) and the coils themselves. For specific recommendations on coilcleaning, contact a qualified consultant.

Weld Byproduct Cleaning (for Models CXV, VCL, VC1, and VCA)The installation and manufacturing processes commonly used for field assembly of steel-piped systems mayleave weld byproducts inside coils and connecting piping (especially in refrigeration systems). It is commonpractice to install filters and/or strainers that remove contaminants during initial system operation. Shortly aftersystem startup, the filters and/or strainers should be cleaned or replaced.

Water TreatmentA proper water treatment program, administered under the supervision of a competent water treatmentspecialist, is an essential part of routine maintenance to ensure the safe operation and longevity ofevaporative cooling equipment, as well as other system components.

Bleed Rate• In evaporative cooling, evaporation of a small portion of the recirculating spray water as it flows through the

equipment causes the cooling effect. As this water evaporates, the impurities originally present remain inthe recirculating water. The concentration of the dissolved solids increases over time and can reachunacceptable levels.

• In addition, airborne impurities are often introduced into the recirculating water. If these impurities andcontaminants are not effectively controlled, they can cause scaling, corrosion, and sludge accumulationsthat reduce heat transfer efficiency and increase system-operating costs, potentially shortening the usefullife of the equipment.

• The degree to which dissolved solids and other impurities build up in the recirculating water may bedefined as the cycles of concentration. Specifically, cycles of concentration is the ratio of the concentrationof dissolved solids (for example - chlorides, sulfates, etc.) in the recirculating water to the concentration ofthe same material in the make-up water.

• In order to optimize heat transfer efficiency and maximize equipment life “bleed” or “blowdown” a smallamount of recirculating water from the system. This controls the cycles of concentration to maintain thequality of the recirculating water within the guidelines given in Table 2, on Page N105.

• Replenish the “bleed” water with fresh make-up water, thereby limiting the build-up of impurities.

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• Bleed/blowdown:o Accomplish the bleed automatically through a solenoid valve controlled by a conductivity meter. The

conductivity meter set point is the water conductivity at the desired cycles of concentration and shouldbe determined by a competent water treatment expert.Note: The solenoid valve and conductivity meter must be supplied by others.

o Alternatively, use a bleed line with a valve to continuously bleed from the system. In this arrangement,adjust the rate of bleed using the valve in the bleed line. Measure the rate of bleed by filling acontainer of known volume while noting the duration. Check the bleed rate and water qualityperiodically to ensure that adequate control of the water quality is being maintained.

Bleed Line Calculations: Bleed rate is determined by the following formula:

Where: B = Bleed Rate (GPM)E* = Evaporation Rate (GPM) = Q (GPM) x R (°F) x .001Q = Process Fluid Flow Rate (GPM)R = Rangen = Number of Cycles of Concentration = CR/CMCR = Concentration in Recirculating WaterCM = Concentration in Make-up Water

* NOTE: The evaporation rate (E) can be determined by any one of the following methods:1. The evaporation rate is approximately 2 GPM per 1 million BTUH of heat rejection.2. The evaporation rate is approximately 3 GPM per 100 tons of refrigeration.3. Evaporation Rate = Q (GPM) x R x .001 (as shown in the example above).

The following example illustrates a bleed rate calculation:

Given:• Closed Circuit Cooling Tower• Process Fluid Flow Rate = 800 GPM• Maximum Allowable Chloride Concentration = 250 ppm• Concentration of Chlorides in Make-up Water = 45 ppm• Range = 10°F

Find: Bleed Rate

Soluti on: So in this case,

Therefore, in this case we must bleed approximately 1.75 GPM to limit the concentration of impurities.

NOTE: This example focuses on a single parameter (chloride concentration) of water only. The bleed raterequired for a system (when evaluating more than one parameter) is the highest bleed rate required tokeep all parameters within recommended limits.

Bleed Rate = B = E = 8 GPM = 1.75 GPM(n-1) (5.55-1)

n = CR = 250 ppm = 5.55CM 45 ppm

E = Q x R x 0.001 = 800 x 10 x 0.001 = 8 GPM

Bleed Rate = B = E(n-1)

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Basin Heater and Stand Alone Heater Control Panel1

Basin HeaterThe cold water basin heater consists of one or more electricimmersion heaters. It is designed to prevent the cold water basinfrom freezing during shutdown or standby. The heaters are sizedfor the specific application. The heating element has an enclosurethat is suitable for outdoor use.

WARNING: The basin heater is not designed to prevent icingduring unit opera tion.

OperationEnsure that the heating element is completely submerged beforeenergizing the main disconnect. For installations that have a BACControls Enclosure, please contact your local BAC Representative.For installations that use a BAC Heater Control Panel, see below.

Stand Alone BAC Heater Control PanelThe heater control system consists of a heater control panel and a combination temperature/liquid levelsensor. The stainless steel 1/4” NPT sensor has an on/off relay output that de-energizes the heaters wheneverthe basin liquid temperature is above 45°F (7.2°C), or whenever the sensor probe is not fully submersed. Thecontrol panel has an enclosure that is suitable for outdoor use.

NOTE: The heater control panel temperature/low level control can only be used with the supplied combinationtemperature/liquid level sensor probe. Please contact your local BAC Representative for replacementparts.

The control system utilizes a 24V combination temperature/low liquid level control sensor, which is powered bya transformer in the control panel. When the sensor provides a 24V signal back to the control panel, the panelthen sends a 24V control voltage to the magnetic contactors. When energized, the magnetic contactors supplyline voltage to the heaters.

OperationEnsure that the heating element is completely submerged before energizing the main disconnect. Thecombination temperature/low level control is preset to energize the heater at 45°F (7.2°C), but will notenergize if the water level is too low or if the water temperature is above 45°F (7.2°C).

WARNING: Disc onnect the heater control panel and tag the circuit out before performing the followingsteps.

Testing heater when water temperature s are above 45°F (7.2°C):• Disconnect the heater control panel and tag out circuit.• Remove the heater control panel cover.• Remove the sensor wires connected to terminals T1 and T2 on the combination temperature/low level

control and isolate them.• Install the 1.5K ohm test resistor supplied with the heater control panel (in bag on outside of cover) across

terminals T1 and T2.• Install the heater control panel cover.• Energize the system. You should hear the contactors close, energizing the heater.• After operation, de-energize the circuit, remove the resistor and place it back in the storage bag. Check all

connections, reconnect sensor wires per the wiring diagram to terminals T1 and T2, replace the cover, andplace the system back in service.

WARNING: Do not oper ate the sy stem unattende d or for extende d periods of time during test mode(res is tor across terminals T1 and T2). Operation in water temperatures above 45°F (7.2°C)coul d damage the unit.

1. Reprinted with permission from INDEECO O&M #76-2000-83-5.

Figure 1 - Basin Heater

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Operation when sensor probe is encased in ice:• De-energize the heater control panel and tag circuit out.• Remove the heater control panel cover.• Install a jumper wire across terminals G1 and G2 on the combination temperature/low level control circuit

board.• Install the heater control panel cover.

WARNING: Do not oper ate the system unattende d or for extende d periods of time with G1-G2jumpere d. A low liquid level condition could occur and the sys tem will not shut off which

coul d resul t in damage to the heater and unit.

• Energize the system and listen for the contactor closing.• Operate the system until the ice is melted around the probe.• After operation, de-energize the circuit, remove the jumper, check all connections, replace the cover, and

place the system back in service.

Electronic Vibration Cutout Switch2

GeneralThe PMC/BETA electronic switches utilize a solid state crystalaccelerometer which provides an electrical output when it isdeformed by the vibration forces. The output is electronicallyconverted to a signal proportional to velocity. This signal iscompared with a preset limit and triggers a solid state relay ifthe limit is exceeded. There are no moving parts in the 440vibration switches except when configured with mechanicalrelays.

An important feature of the PMC/BETA switches is the built intime delay. This prevents triggering of the alarm or shutdownfunctions from transient increases in vibration levels. It alsoavoids shutdown due to transitory vibrations occurring duringstart-up. 3 second alarm trip delay is standard, however timedelays are independently adjustable in the field over a range of2 to 15 seconds.

Operation

Testing“Test” position on the shutdown dial sets a minimum set point so that any vibration will cause trip condition.Light will come on immediately, and trip will occur after duration of the time delay, proving that the completesystem is operational. If test position is maintained for less than the duration of the time delay, trip will notoccur, thus permitting system test without shutdown.

Remote ResetConnection between terminals 5 and 6 latches triac output in the alarm state after setpoint is exceeded.Operating the connection will reset the output to non-alarm state.

2. Reprinted with permission from METRIX Instrument Company documentation for “Electronic Vibration Switch PMC/BETA 440 and 450”.

Figure 2 - Electronic Vibration Cutout Switch

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Instructions for Installing Field Connections(Equalizer/Bypass/Outlet) on a ColdWater Basin with theTriArmor® Corrosion Protection SystemBAC recommends adding a flange connection for field installed equalizers, bypass and outlet connections. Pleaseorder the following supplied prior to unit shutdown.

Table 3: Supplies for Installing Field Connections

1. Use the BAC template provided with the accessory to layout and mark the hole pattern on the exterior of thecold water basin.

2. Drill a pilot hole from the outside of the cold water basin to the inside of the cold water basin.3. On the inside of the cold water basin:

a. For connections 3” or less, score the TriArmor® Corrosion Protection System with a hole saw as shown inFigure 3.

b. For connections 3” or greater, proceed to step 4 and 4b.

4. Cut the hole from the outside of the cold water basin.a. Use a hole saw or a step drill bit for smaller

connections 3” or less as shown in Figure 4.b. Use a reciprocating saw or a Sawzall® for larger

connections 3” or greater.5. Position the BAC supplied stainless steel backing ring,

gasket to the inside of the cold water basin.6. Position the flange to the outside of the cold water basin.7. Bolt the flange and the stainless steel backing plate

together using stainless steel bolts.8. Seal any exposed galvanized steel of the connection

inside the cold water basin with Vulkem® caulk as shownin Figure 5.

Figure 3 - Scored TriArmor® Figure 4 - Remove Material

Supplies Provided by BAC Recommended Supplies Provided by Others

Template for the connection with bolt holes Stainless Steel threaded shoulder bolts

Type 304 stainless steel backing ring with gasket 150 lb flange – please weld any piping to the flange prior to installation

Vulkem® caulk Gasket for the outside of the cold water basin

Figure 5 - Caulk Exposed Galvanized Steel

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Factory Authorized Parts• Baltimore Aircoil Company maintains a stock of common replacement parts at all times.• Many BAC Representatives also have BAC replacement parts stocked in their warehouses.• These parts are designed and built specifically for BAC units and assure BAC’s customers of:

o Guaranteed performanceo Immediate availability in most caseso Original equipment qualityo Local assistance with service problems

• All factory-authorized parts are guaranteed for 1 year and their use will ensure continued maximumperformance from your BAC equipment.

• Parts shipment is normally made within 3 business days after receipt of an order.• In emergency situations, shipment can usually be made within 24 hours.• To order factory authorized parts, contact your local BAC Representative. You can locate your local BAC

Representative by the label next to the unit nameplate, by calling (800) 896-8497, or via the Internet atwww.BaltimoreAircoil.com/repfinder. Be sure to include the unit serial number when ordering any parts.

• To facilitate service of your BAC unit, it is suggested that some of the following spare parts be kept onhand:o Make-Up Float Ball – large diametero Valve Seat for Make-up Valve – elastomer seat for positive shut offo Fan Shaft Bearings – grease-lubricated ball bearings with special moisture proof seals and integral

slinger rings designed specifically for evaporative cooler applications.o Fan Belt – solid backed, multi groove, specially compounded, neoprene polyester drive band.o Spray Nozzle and Grommet Kit – large diameter plastic metering nozzles engineered for optimum

water distributiono Access Door Gasketo In addition to the repair parts, BAC also offers many retrofit kits designed to enhance safety and

access, ease of maintenance/operational flexibility and provide additional capacity and capacitycontrol.

• Finally, your local BAC Representative usually stocks common wear items for immediate delivery, and isavailable to inspect your unit to ensure it is in proper operating condition.

• Please record your unitʼs model number and serial number (as they appear on the unit nameplate) on thefront and back cover. This will help ensure the quickest, most accurate response to your inquiries.

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