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BAC Trillium Series Operation & Maintenance Manual

Fluid cooler with ecoflex controls
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1 Cntact Information
TrilliumSeries
Fluid Cooler
TM
With ECOFLEX Controls
&
RIGGING, OPERATION
MAINTENANCE MANUAL
Page 1

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Summary of Contents for BAC Trillium Series

  • Page 1 1 Cntact Information TrilliumSeries Fluid Cooler With ECOFLEX Controls & RIGGING, OPERATION MAINTENANCE MANUAL Page 1...

  • Page 2: Table Of Contents

    Table of Contents OPERATIONS & MAINTENANCE » HEAT REJECTION SYSTEMS - TVFC SERIES Contents 1 Contact Information ..........................6 2 Principle of Operation ..........................7 2.1 Efficiency Control Bias ........................ 7 2.2 Water Quality Control Bias ......................7 3 Legislation, Codes of Practice and Guidance Notes ..................8 Part 2: Operation &...
  • Page 3 If the water temperatures returning from the TrilliumSeriesTM Fluid Cooler system are higher than normal ........................... 25 9 BAC Adiabatic Equipment Site Commissioning Checklist .............. 26 Pre - Commissioning Checklist: to be Completed by Customer ..........26 General Installation – Please confirm ..................26 Unit Switchboard –...
  • Page 5 Congratulations on the purchase of your new BAC heat rejection system. The system is designed for straightforward installation, operation and maintenance. This manual has been provided to help you install and operate your BAC system so that it gives you many years of efficient and trouble free service.

  • Page 6: Contact Information

    1 Contact Information For assistance with your BAC heat rejection unit please contact your local representative or agent. Additional contact information is also provided below. w w w . B a l t i m o r e A i r c o i l . c o m . a u 120 Wisemans Ferry Road, Somersby NSW 2250 Telephone (Australia): 1300.134.622...

  • Page 7: Principle Of Operation

    You should refer to local environmental regulations to When operated remotely, it is recommended BAC is determine the types of reuse that are allowed. consulted to ensure the system operates both within legislated and operational design guidelines.

  • Page 8: Legislation, Codes Of Practice And Guidance Notes

    6 metres from an air intake in accordance with “ AS1668.2 The use of ventilation and air For the purpose of installation guidance, your BAC conditioning in buildings - Ventilation design for TrilliumSeriesTM Fluid Cooler heat rejection indoor air contaminant control”.

  • Page 9: Installation Requirements

    The precooler pad represents the only potential flammable component of the TrilliumSeriesTM Fluid Cooler. The precooler pad will only ignite while an The BAC TrilliumSeriesTM Fluid Cooler system is external ignition source is applied. required to be installed by an appropriately...

  • Page 10: Location

    5 Water Distribution System 4.1.4 Location For optimum performance, the TrilliumSeriesTM Fluid Cooler system should be positioned to meet the following criteria: - Sufficient space on both air inlet sides of the unit (minimum distance 1.5m) to prevent restrictions to the air flow.

  • Page 11: Installation Requirements

    4 Installation Requirements 4.3 Location and Spacing Location and spacing guidelines for TrilliumSeriesTM Fluid Coolers are shown on the drawing below. For details on a specific unit, please contact BAC directly. Parapet wall is not restrictive provided Y is equal to or greater than 2X...

  • Page 12: General Arrangement

    5 Water Distribution System 4.4 General Arrangement 4.4.1 End View Figure 6...

  • Page 13: General Arrangement: Sump/Sump Pump And Controls

    4 Installation Requirements 4.4.2 General Arrangement: Sump/Sump Pump and Controls Figure 7 Sump and Pumps - 1 strainer removed for Clarity Water Make-up Solenoid Valve M A R 4 1 6 - 2 W W W . B A L T I M O R E A I R C O I L . C O M . A U 13 __ Page 13...

  • Page 14: General Arrangement: Switch Connections

    5 Water Distribution System 4.4.3 General Arrangement: Switch Connections Figure 8...

  • Page 15: Trilliumseriestm Fluid Cooler

    4 Installation Requirements A small valve or valves should be installed at the “TrilliumSeriesTM Fluid Cooler” highest point or points in the fluid piping to allow any trapped air to be purged. 4.5 Specific Instructions All fluid piping should be thoroughly flushed to free it This section details the specific installation from foreign material before the system is placed requirements for mounting, pipe work and...

  • Page 16: (B) Dump Valve

    5 Water Distribution System (b) Dump Valve • Dump valve has been opened manually to prevent damage to pump prior to final site commissioning. If frequent flush mode has been selected then the dump valve should be left as is and the unit commissioned.

  • Page 17: (E) Celpad Water Make-Up

    4 Installation Requirements (e) Celpad Water Make-up 4.5.5 Water Probe • Connect main water supply via appropriate The water probe has been temporarily connected isolation valve and anti back flow device to sump for factory testing. water makeup connection. Please mount probe in the “water out” pipe work, •...

  • Page 18: Water Level Control

    5 Water Distribution System 5.1 Water Level Control 5.3 Water Sump The TrilliumSeriesTM Fluid Cooler evaporative system’s Water draining off the evaporative pads is captured in water levels in the Celpad basins are controlled by a stainless steel sump and recirculated. water float switch.

  • Page 19: Water Treatment Considerations For The Open Loop Water

    6.1.1 Potential for Scale • Circulate for 5 minutes then dump the water The novel design of the BAC TrilliumSeriesTM Fluid to remove any residual chlorine. Cooler systems and the use of evaporator pads ensure scale on the heat exchanger is avoided •...

  • Page 20: Water Treatment Considerations For The Closed Loop Water

    6 Water Treatment Considerations 6.2 Water Treatment Considerations for the Closed Loop Water Information Damage to, or failure of the heat exchanger due to inadequate water treatment of the closed loop water system is not covered by the product warranty. Installation and operational issues should be considered at the time of design and installation.

  • Page 21: System Controller

    6 Water Treatment Considerations 7.1 System Controller 7.2 Switchboard Maintenance A BAC supplied programmed logic controller has The switchboard should be periodically checked and been provided as standard. The PLC is used for cleaned as necessary. capacity control and for regulating the evaporative pre-cooling system.

  • Page 22: Routine Cleaning

    7 Operation and Maintenance 7.3 Routine Cleaning During cleaning it is advisable to inspect the pre-cooler The TrilliumSeriesTM Fluid Cooler system should be pumps and associated pipe fittings to ensure all are in cleaned periodically (say quarterly) depending on a sound operating condition. It is also prudent to check operational and environmental factors.

  • Page 23: Operation And Maintenance

    Re- Control System carries out ‘bleed off’ automatically. epoxy coil coat if required. Avoid hosing directly on to This is determined by BAC at the time of the fan motors or electrical components. commissioning and servicing. Bleed off should be Avoid hosing directly on to the fan motors or inspected at cleaning.

  • Page 24: Bac Annual Maintenance Program

    7 Operation and Maintenance 7.8 BAC ANNUAL MAINTENANCE PROGRAM ANNUAL BI-ANNUAL QUARTERLY MOTORS AND IMPELLERS Check fan impeller operation – noise, vibration, stress cracks etc Check motor operation – electrical connections, bearings, vibration & general condition Check fans for guard obstructions WATER DISTRIBUTION Check operation &...

  • Page 25: Trouble Shooting Guide

    Is the water level satisfactory? If the answer to all of the above is “yes”, please contact BAC Australia Pty Ltd Support Services on 1300.134.622 w w w . B a l t i m o r e A i r c o i l . c o m . a u 120 Wisemans Ferry Road, Somersby NSW 2250 Telephone (Australia): 1300.134.622...

  • Page 26: Bac Adiabatic Equipment Site Commissioning Checklist

    Additional Items/Special requirements/ Access restrictions Please Note: If upon the commissioning day the above items are found to cause delays due to non compliance, and BAC are required to attend, the extra time or return travel to site to place the unit into operation will be CHARGABLE.

  • Page 27: Site Commissioning

    9 Site Commissioning 10 Celldeck Commissioning Procedure Carried out on site by installer 1. Confirm mains pressure water is connected to make up solenoid valve. 2. Initiate pre-cooling cycle in “Technician-Manual Control” using the control display on the electrical panel face. Fans should also be set to run at 100%.

  • Page 28: Tvfc Control Switchboard

    10 Celldeck Commissioning Procedure 11. TVFC Control Switchboard 11.1 Standard Fully Automatic Switchboard The Control system supplied with the TVFC unit should be fully operational when delivered to site. Connection to a suitable 3 phase and Neutral power supply can be made directly to the isolation switch located on the left side of mounted on the end of the unit between the coil connections.

  • Page 29: Operating Sequences

    11. TVFC Control Switchboard 11.2 Operating sequences Pre Cool Mode is called if the following occur. The unit when first turned on will operate in Dry The ambient temperature Mode. This is shown on the LCD screen on the • Exceeds Set point for 30 secs in Default Mode Outside of the Switchboard Panel.

  • Page 30: Electrical Schematics

    11. TVFC Control Switchboard 11.3 Electrical Schematics – Ziehl Abegg 3 and 6 fan units...

  • Page 31: Ziehl Abegg 8, 10, 12 And 14 Fan Units

    11. TVFC Control Switchboard Ziehl Abegg 8, 10, 12 and 14 fan units Page 31...

  • Page 32: Ebm Papst 3 And 6 Fan Units

    11. TVFC Control Switchboard EBM PAPST 3 and 6 fan units...

  • Page 33: Ebm Papst 8, 10, 12 And 14 Fan Units

    11. TVFC Control Switchboard EBM PAPST 8, 10, 12 and 14 Fan units Page 33...

  • Page 34: Operating Status Information And Diagnostics

    11. TVFC Control Switchboard 11.4 Operating Status Information and Diagnostics The control system has diagnostic and operating information that is accessible via the LCD screen on the front of the electrical panel. If a fault occurs in the unit the LCD panel can be used to diagnose and assist in corrective action. Also Note some faults are regarded as critical and if detected the unit will automatically run all fans at full speed until the fault is corrected and the fault is reset.
  • Page 35 11. TVFC Control Switchboard The third screen shows individual fan speed, temperature, power consumption and current. There is one screen for every fan on each unit. This screen shows the Fan Number and the Fan Address. Ref Section 14 for further details. The next screen shows the total unit power consumption These screens can be used to access and change operating parameters.
  • Page 36 11. TVFC Control Switchboard 11.4.2 Technician and Diagnostics Menu Screen For purposes of maintenance, system operation adjustment and troubleshooting the unit control system has a diagnostics menu that can be accessed on the LCD screen on the front door of the electrical panel enclosure. To access the diagnostics menu - Ensure the screen is at the top level status screen by pressing the Esc key several times.
  • Page 37 11. TVFC Control Switchboard 11.4.3 Technician and Diagnostics Screens After Accessing the Technician Menu Highlight the b.Diagnostic menu item, press enter to display the following status screen. Use the arrow keys to scroll through all available screens as necessary. Some screens can be entered to change operating parameters via additional sub menus.
  • Page 38 11. TVFC Control Switchboard The screen to the right is a status screen Bank 1 Fan Speed (0 - 100 %) is the speed of the fans on the unit. Fan Request is the fan speed signal sent by a remote BMS if enabled (not used at this point) Dump Valve is the status of that valve Makeup Valve is the status of that valve...
  • Page 39 11. TVFC Control Switchboard The screen to the right shows the parameters for operation and fault detection on unit components. The values contained here should not be adjusted with out prior consultation with BACA HO. Page 39...
  • Page 40 11. TVFC Control Switchboard The first part of the screen (top half) to the right shows parameters set for the unit operating as a condenser. These values are redundant for a fluid cooler. The lower half of the screen shows the Anti Freeze Setpoint protection for the unit.

  • Page 41: Rigging

    12. Rigging 12 Rigging 12.1 Lifting Points All units are fitted with approved lifting ears as shown in the Fig 32. Units with 8 fans or less use 4 lifting ears only. Units with 10 fans or more use 8 lifting ears. Figure 32 Lifting Ears Centre lift ears only...

  • Page 42: Rigging

    12. Rigging 12.2 Rigging For shipping weights refer to unit submittal drawing. Slings are to be set at a hook height not less than 1.5 m (1500mm) above lifting ear. As per side elevation view, slings should be vertical. The unit can be placed safely down on hard flat ground 1500 mm End Elevation Side Elevation...

  • Page 43: Fan Numbering, Addressing, Grouping

    13. Fan Numbering, Addressing, Grouping 13. Fan Numbering, Addressing, Grouping The TVFC units have multiple fans For purposes of maintenance, diagnostics and fan replacement the following information has been provided. The TVFC fans are uniquely numbered for discrimination at the circuit breakers and on the electrical schematic.

  • Page 44: Unit Fan Configuration

    14. Unit Fan Configuration 14. Unit Fan Configuration 14 fan unit Bank1 Bank 2 Address Address SW Ver 1.04 SW Ver 1.05 SW Ver 1.04 SW Ver 1.05 Fan # Group Fan # Group a nd below a nd a bove a nd below a nd a bove Fan #...
  • Page 45 14. Unit Fan Configuration 10 fan unit Bank1 Bank 2 Address Address SW Ver 1.04 SW Ver 1.05 SW Ver 1.04 SW Ver 1.05 Fan # Group Fan # Group a nd below a nd a bove a nd below a nd a bove Fan # Electrical Panel...

  • Page 46: A1. Modbus And Bacnet Option

    A1. MODBUS and BACnet Option (if applicable) A1. MODBUS and BACnet Option The TVFC range can be supplied with communications modules for Modbus or BACnet protocols to enable information to be sent to a BMS or similar central collection point. The communication module is a plug in device to the pCO5 Controller as shown below.

  • Page 47: Ethernet Serial Card (Modbus Or Bacnet)

    A1. MODBUS and BACnet Option (if Applicable) Ethernet Serial Card (MODBUS or BACnet) This module is shown to right. Communication is made using an RJ45 LAN Ethernet Cable. This connection should be made directly and the ethernet cable run back to the main communication point or switch without intermediate join.

  • Page 48: Supervisor Variables

    A1 – BMS Variables For Modbus and BACnet (if Applicable) TVFC Supervisor Parameter Table Analogue Variables BMS Side BMS  Read/ Modbus  Modbus  Address Description UOM Range Write Variable Name TCP/IP BACNet 1 Pressure sensor signal pressure_disp_1 30002 30002 AV1 2 Outside air temperature NTC Deg C oa_t_disp 30003 30003 AV2 3 Customer fan speed signal fan_speed_1 30004 30004 AV1...
  • Page 49 A2. Conductivity Sensor (if Applicable) TVFC Supervisor Parameter Table Integer Variables BMS Side BMS  Read/ Modbus  Modbus  Description Range Variable Name BACNet Address Write TCP/IP 1 Fan kW total ‐ move decimal left two spaces power_total_ZA 30210 30210 AV1001 2 Unit kW total ‐ move decimal left two spaces power_total_unit 30211 30211 AV1002 3 Current day current_day 30212 30212 AV1003 4 Current hour current_hour 30213 30213 AV1004 5 Current minute...
  • Page 50 A1 – BMS Variables For Modbus and BACnet (if Applicable) TVFC Supervisor Parameter Table Digital Variables BMS Side BMS  State  Read/ Modbus  Modbus  Address Description Descriptions Write Variable Name TCP/IP BACNet 1 An alarm is present for the Ziehl‐Abegg fan 1 A1_present‐ZA 10002 10002 BV1 2 An alarm is present for the Ziehl‐Abegg fan 2 A1_present‐ZA2 10003 10003 BV2 3 An alarm is present for the Ziehl‐Abegg fan 3 A1_present‐ZA3 10004 10004 BV3 4 An alarm is present for the Ziehl‐Abegg fan 4...
  • Page 51 A1 – BMS Variables For Modbus and BACnet (if Applicable) TVFC Supervisor Parameter Table Digital Variables BMS Side BMS  State  Read/ Modbus  Modbus  Address Description Descriptions Write Variable Name TCP/IP BACNet 40 An alarm is present for the Ziehl‐Abegg fan a1_present_ZA13 10041 10041 BV40 41 An alarm is present for the Ziehl‐Abegg fan a1_present_ZA14 10042 10042 BV41 42 An alarm is present for the Ziehl‐Abegg fan a1_present_ZA15 10043 10043 BV42 43 An alarm is present for the Ziehl‐Abegg fan...

  • Page 52: A2. Conductivity Sensor (If Installed)

    A2. Conductivity Sensor (if installed) A2. Conductivity Sensor (if installed) The TVFC unit can be supplied with a conductivity sensor and controller that samples the water quality (Electrolyte concentration) of the pre cool sump water. This feature is an optional extra and delivered ex-factory. A conductivity sensor is installed in the discharge line from the pump(s) and samples the conductivity of the water being delivered to the pre cool pads.
  • Page 53 COOLING TOWERS CLOSED CIRCUIT COOLING TOWERS ICE THERMAL STORAGE EVAPORATIVE CONDENSERS HYBRID PRODUCTS PARTS & SERVICES w w w . B a l t i m o r e A i r c o i l . c o m . a u 120 Wisemans Ferry Road, Somersby NSW 2250 ›...

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