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Baltimore Aircoil Company BCP3D Installation, Operating, Maintenance

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MBCP3Dv01EN
Automatic Dosing and Bleed Control
BCP3D
Package
INSTALLATION, OPERATING & MAINTENANCE

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Summary of Contents for Baltimore Aircoil Company BCP3D

  • Page 1 MBCP3Dv01EN Automatic Dosing and Bleed Control BCP3D Package INSTALLATION, OPERATING & MAINTENANCE...

  • Page 2: Table Of Contents

    Table of contents INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS Construction Details BCP3D General information Introduction Safety precautions Disposal requirements Non-walking surfaces Modifications by others Warranty Water Care About water care Biological control Chemical treatment Passivation Receiving and Installation Receiving Equipment Piping Interface Connections...

  • Page 3: Construction Details

    BCP3D CONSTRUCTION DETAILS BCP3D Fluid inlet coupling Pump oxidizing biocide Fluid outlet coupling Pump scale/corrosion inhibitor Bleed Pump secondary biocide Controller BACT 600 Redox sensor Conductivity probe Chemical drum Sampling point Retention Bleed valve Water meter Insulation valve Suction tubing...

  • Page 4: General Information

    BCP3D GENERAL INFORMATION Introduction Baltimore Aircoil Company is the right choice when it comes to having a more efficient, safe and effective system. The BCP3D automatic dosing and bleed control is a compact package that offers accurate, high quality, liquid chemical based water treatment for evaporative cooling equipment.

  • Page 5: Disposal Requirements

    MECHANICAL SAFETY Mechanical safety of the equipment is in accordance with the requirements of the EU machinery directive. Depending upon site conditions it also may be necessary to install items such as bottom screens, ladders, safety cages, stairways, access platforms, handrails and toe boards for the safety and convenience of the authorized service and maintenance personnel.

  • Page 6: Modifications By Others

    Modifications by others Whenever modifications or changes are made by others to the BAC equipment without written permission of BAC, the party who has done the modification becomes responsible for all consequences of this change and BAC declines all liability for the product. Warranty BAC will guarantee all products to be free from manufactured defects in materials and workmanship for a period of 24 months from the date of shipment.

  • Page 7: Water Care

    BCP3D WATER CARE About water care In all cooling equipment, operating in evaporative mode, the cooling is accomplished by evaporating a small portion of the re-circulating water as it flows through the equipment. When this water evaporates, the impurities originally present in the water remain. Unless a small amount of water is drained from the system, known as blow down, the concentration of dissolved solids will increase rapidly and lead to scale formation or corrosion or both.

  • Page 8: Biological Control

    ® Baltibond Hybrid Coating and SST304L 6.5 to 9.2 Total hardness (as CaCO 50 to 750 mg/l Total alkalinity (as CaCO 600 mg/l max. Total dissolved solids 2050 mg/l max. Conductivity 3300 µS/cm Chlorides 300 mg/l max. Sulfates* 350 mg/l max.* Total suspended solids 25 mg/l max.

  • Page 9: Chemical Treatment

    Certain products used for water treatment, particular some dispersant and bio-dispersant additives, might change the properties of the water (such as the surface tension), which can cause excessive drift loss (water passing through the eliminators). In such case we recommend to review the water treatment (product type, dosage) with your water treatment expert.

  • Page 10: Receiving And Installation

    RECEIVING AND INSTALLATION Receiving Equipment Before accepting the BCP3D equipment and prior to signing the bill of lading, all equipment should be checked thoroughly for any shipping damage. Make sure that all required equipment noted on the bill of lading is received.

  • Page 11: Piping Interface Connections

    1. Proper installation of the interconnecting piping is critical to the BCP3D system effectiveness. 2. BCP3D inlet, outlet and drain connection are standard glued on PVC connections. 3. Do not reduce the pipe size on the connections to and from the BCP3D or of the drain line. Increasing the pipe size is acceptable.
  • Page 12 3. Note: The drain valve might be throttled slightly to reduce bleed water flow if the flow controller switch off during bleed cycle. Make sure however sufficient bleed rate can be guaranteed at nominal operation load. 4. The BCP3D is designed to handle a maximum water pressure of 60 kPa at 55°C. DRUMS AND BUNDS The drums and bunds should be positioned directly below panel as per sketch below.
  • Page 13 Tubing and suction head with strainer. Mounting of tubing on suction head. Suction head to be installed inside drum. Suction head should be installed vertically. Adjust tubing length accordingly. Mounting detail tubing on pump head. Overview pump tubing connection to drum. 4 Receiving and Installation 4 Receiving and Installation W W W .

  • Page 14: Electrical Wiring

    Refer to the wiring diagram of the submittal package. The BCP3D is suitable for connection to networks of 110V - 230V and 50 - 60 Hz (AC POWER). The BCP3D panel is pre-wired and only requires a main power supply to the controller BACT 600.

  • Page 15: Dosing Pumps

    1. Ethernet 2. 4-20 mA outputs 3. Sensor 1 4. Power in 5. Power switch 6. Relays 7. Relays 8. Sensor 2 9. Digital inputs Dosing Pumps Dosing pumps are premounted on BCP panel and prewired to the controller. Refer to specific dosing pumps operating manual supplied with the submittal package for specific questions regarding dosing pumps.

  • Page 16: Controller Settings

    BCP3D CONTROLLER SETTINGS Default parameters and set points The BACT 600 controller has been preprogrammed specifically for use with BAC evaporative cooling equipment. MENU INPUT S11 - Conductivity LoLo Alarm (Very low alarm) 200 µS/cm Low Alarm 200 µS/cm High Alarm 3500 µS/cm...
  • Page 17 S12 - Temperature LoLo Alarm (Very low alarm) 1,0 °C Low Alarm 1,0 °C High Alarm 50,0 °C HiHi Alarm (Very high alarm) 50,0 °C Deadband 1,0 °C Reset Calibration values Cal Req'd Alarm 0 days Alarm suppression none Smoothing factor Name (change with language, default is English) Temp Type...
  • Page 18 D1 - Flow detector Open Msg (change with language - default is English) No Flow Closed Msg (change with language - default is English) Flow Interlock When open Alarm When open Total time When closed Reset time Name (change with language - default is English) Flow switch Type DI State...
  • Page 19 MENU OUTPUT R1 - Bleed HOA Setting Auto Setpoint 1200 µS/cm Deadband 25 µS/cm Duty Cycle Period 0:00 Duty Cycle 100,0 % Output Time Limit 3:00:00 Reset Output Timeout Interlock Channels Activate with Channels None Min Relay Cycle 0 sec Hand Time Limit 0:10:00 Input...
  • Page 20 R3 - Timer dosing of biocide HOA Setting Auto Event 1 Repetition: 1 week Day: Monday Start time: 8:00:00 Duration: 0:15:00 Event 2 Repetition: 1 week Day: Wednesday Start time: 8:00:00 Duration: 0:15:00 Event 3 Repetition: 1 week Day: Friday Start time: 8:00:00 Duration: 0:15:00 Event 4...10...
  • Page 21 R4 - Redox based dosing of biocide HOA Setting Auto Setpoint 200,0 mV Proportional Band 100,0 mV Sample period 0:02:00 Duty Cycle 100,0 % Output Time Limit 0:00:00 Reset Output Timeout Interlock channels Activate with channels None Min Relay Cycle 0 sec Hand Time Limit 0:10:00...
  • Page 22 MENU CONFIGURATION Global Settings Date Time Global Units Metric Temp Units °C Alarm Delay 0:00 HVAC Modes Enabled Language (change with language, default is English) English Security Settings Controller Log Out Security Disabled Local Password Default is 5555 Display Settings Home 1 Conduct (S11) Home 2...

  • Page 23: Programming

    Programming The effective bleed set point should be defined by the owner or by its representative (contractor, water treatment specialist,...) in function of the following parameters: • Make Up water quality parameters • Materials of construction: refer to the "Water Care" on page 7 and the submittal information of the BAC equipment •...

  • Page 24: Operating Conditions

    BCP3D OPERATING CONDITIONS Function Overview FRONT PANEL DISPLAY - TOUCH SCREEN A Home screen is displayed while the controller is on. This display shows a user-defined list of input readings or status of outputs. Touching any of the items on the Home screen will bring up the item's Details screen, where you can access calibration and settings menus.
  • Page 25 ICONS The Main menu icon brings you to the list of menu options listed below. The following icons appear on the Home screen. Press the key below the icon to get to the Main Menu selection. Alarm Menu Inputs Menu Outputs Menu Configuration/Settings Menu HOA Menu...
  • Page 26 Calibration key appears in sensor Inputs Menu and brings up the Calibration Menu Cancel key cancels any entry The Page Down icon scrolls down to a new page in a list of options The Page Up icon scrolls up to a new page in a list of options The Confirm icon accepts a choice and advances to the next calibration step The Back/Return icon return the display to the previous screen The Make Character Higher key is used when making an alphanumeric entry...
  • Page 27 Overview of the use of keys Changing numeric values • To change a number, use the Character Delete icon on the digit to be changed. • If the new number will be negative, start wtih touching the minus sign, the use the numeric touchpad and decimal point to type the number.
  • Page 28 Settings menu Choose language Touch the Configurations Setting icon. Tough Global Settings. Touch the Scroll Down icon until the English word "language" is displayed and then touch it. Touch the Scroll Down icon until your language is displayed and touch it. Touch the Confirm icon to change all menus to your language.
  • Page 29 D1 Flow switch Preprogrammed by BAC, no action required D2 Water meter Note the K value of the water (L/impulse) and enter as alter value as required. Default preprogrammed value is 1 liter / impulse • Select input screen • Select water meter (D2) •...
  • Page 30 R1: Bleed valve Preprogrammed with default values by BAC, see "Default parameters and set points" on page 16 Enter the correct bleed set point with following procedure: Select bleed (R1) Touch the Settings icon Touch the Scroll Down icon until the Setpoint is highlighted Use the screen key pad to change value if required (default is 1200).
  • Page 31 R2: Scale and Corrosion Inhibitor Dosing Preprogrammed with default values by BAC, see "Default parameters and set points" on page 16 Enter the correct values with following procedure • The Inhib R2 relay output will be highlighted • Program the setting for the scale and corrosion inhibitor dosing •...
  • Page 32 R3: Bio Timer Preprogrammed with default values by BAC, see "Default parameters and set points" on page 16 Enter the correct values with following procedures: The Bio Timer R3 relay output will be highlighted • Touch the Settings icon • Touch the Scroll Down icon until the "Event 1"...
  • Page 33 • Repetition Daily / 1 week (every week), 2 weeks (every 2 weeks), 4 weeks (every 4 weeks) • Edit also in the same way: Day (Default is Monday, Wednesday and Friday dosing), Start Time and Duration of each dosage •...
  • Page 34 Enter the correct values with following procedures: Select the Bio2 ORP R4 relay when highlighted • Program the setting for the oxidizing biocide dosing • Touch the Settings icon • Touch the Scroll Down icon until the "Set point" is highlighted (default is 200 mV) •...
  • Page 35 FILE UTILITIES Allows you to export event logs to a USB stick, export the configuration and settings (for later back-up or program additional controllers in the same way). File Transfer Displays the status of the last attempt to export a file. Status Export Event Log Save the event log file to a USB stick.
  • Page 36 Repeat operation with BIO 2 ORP R4 Push the "START" button on the relevant dosing pump to allow the pump to operate • The BCP is now ready to control and dose. SHUT DOWN To shut down the controller, simply turn off the power. Programming remains in memory. For more details on controller functionality, refer to the BACT 100 controller manuals as per submittal package.

  • Page 37: Maintenance

    Maintenance The controller itself requires very little maintenance. Wipe with a damp cloth. Do not spray down the controller unless the enclosure door is closed and latched. CONDUCTIVITY SENSOR CLEANING The controller must be recalibrated after cleaning the sensor. Frequency The sensor should be cleaned periodically.
  • Page 38 FLOW SWITCH CLEANING Frequency The flow switch should be checked periodically. This to make sure it is free and the chamber is free from any debris that would prevent its proper operation. The frequency required will vary by installation. Check the conductivity monthly with a handheld device and compare with the value indicated on the controller. After cleaning, if the value deviates from the reading on the handheld device, see calibration procedure below.
  • Page 39 CALIBRATE THE ORP SENSOR To calibrate the sensor, from the home page return to the list of inputs Highlight ORP sensor (S21) and select Calibration Press the calibration key to calibrate the sensor Select the calibration to perform (3 possibilities) •...
  • Page 40 Example one point buffer During the stabilization steps, when the signal from the sensor is stable, the controller will automatically move to the next step. If it doesn't stabilize, you may manually go to the next step by pressing the Confirm key.

  • Page 41: Troubleshooting

    Troubleshooting CAUTION Disconnect power to the controller before opening the front panel. Troubleshooting and repair of malfunctioning controller should only be attempted by qualified personnel using caution to ensure safety and limit unnecessary further damage. Contact the factory. CALIBRATION FAILURE The calibration will fail if the adjustment to the gain is outside a certain range.
  • Page 42 Possible cause Corrective action Improper wiring of valve or controller Correct wiring Conductivity rose over alarm limit while biocide lockout Allow normal bleed to occur occured Clogged bleed line Clean Faulty bleed relay Replace Low or Low-Low Alarm Occurs if the conductivity drops below the low conductivity alarm set points. If your unit is programmed for an alarm relay output, the relay alarm will activate.
  • Page 43 Range Alarm It indicates that the conductivity signal from the sensor is out of the normal range of 0-30,000. This error condition will stop conductivity control. This prevents controlling based upon a false conductivity reading. If the temperature goes into range alarm (outside -5 to 90 °C for tower, -5 to 220 °C for boiler), then the controller will go into manual temperature compensation using the default temperature setting.

  • Page 44: Further Assistance & Information

    BCP3D FURTHER ASSISTANCE & INFORMATION More information REFERENCE LITERATURE • Eurovent 9-5 (6) Recommended Code of Practice to keep your Cooling System efficient and safe. Eurovent/Cecomaf, 2002, 30p. • Guide des Bonnes Pratiques, Legionella et Tours Aéroréfrigérantes. Ministères de l'Emploi et de la Solidarité, Ministère de l'Economie des Finances et de l'Industrie, Ministère de l'Environnement, Juin 2001,...
  • Page 45 W W W . B A L T I M O R E A I R C O I L . E U...
  • Page 46 COOLING TOWERS CLOSED CIRCUIT COOLING TOWERS ICE THERMAL STORAGE EVAPORATIVE CONDENSERS HYBRID PRODUCTS PARTS, EQUIPMENTS & SERVICES www.BaltimoreAircoil.eu info@BaltimoreAircoil.eu Please refer to our website for local contact details. Industriepark - Zone A, B-2220 Heist-op-den-Berg, Belgium © Baltimore Aircoil International nv...

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