Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for BAC 3000 Series
Summary of Contents for BAC 3000 Series
- Page 1 Series 3000 Cooling Tower OPERATION & MAINTENANCE MANUAL w w w . B a l t i m o r e A i r c o i l . c o m 7600 Dorsey Run Road, Jessup, MD 20794 › Telephone: (410) 799-6200 › Fax: (410) 799-6416 ©...
- Page 2 Recommended Maintenance Service Inspect and clean as necessary: Start-Up Monthly Quarterly Annually Shutdown Inspect general condition of the unit and check unit for unusual noise or vibration Inspect cold and hot water basins Flush water distribution system/Inspect spray nozzles Drain basin and piping Inspect air intake louvers/Combined inlet shields Check and adjust water level in cold water basin Check operation of make-up valve...
-
Page 3: Table Of Contents
Warranties PART 6 Operation Considerations for Accessories PART 1 Unit Operation and Storage Basin Heater (Optional) Start-Up Procedure Stand Alone BAC Heater Control Panel (Optional) Extended Shutdown Vibration Cutout Switch (VCOS) Prolonged Outdoor Storage Part 7 Fan Control PART 2... -
Page 4: Safety And Equipment Precautions
• CAUTION: BAC does not recommend field application of aftermarket coatings in the cold water basins of products equipped with electric immersion heaters. The coating material may create an increased risk of fire if the heaters remain energized for any reason without sufficient water in the cold water basin. -
Page 5: Notice
Please contact your local BAC Representative for replacement parts. • For the stand alone BAC heater control panel, do not operate the system unattended or for extended periods of time during test mode (resistor across terminals T1 and T2). Operation in water temperatures above 45°F (7.2°C) could damage the unit. -
Page 6: Unit Operation And Storage
SERIES 3000 COOLING TOWER Unit Operation and Storage Fan Guard BALTIDRIVE ® Top Water Inlet Power Train Fan Deck Hot Water Basin and Cover Casing Air Intake Louvers Make-up Valve Adjustable Float Water Outlet Cold Water Connection Basin BACross Fill with ®... - Page 7 • For the top inlets only, adjust the flow balancing valves to equalize flow to the hot water basin(s). This valve may be provided by others or optionally supplied by BAC. • Series 3000 Cooling Towers equipped with the optional EASY CONNECT Piping ®...
-
Page 8: Extended Shutdown
• Adjust the valve (supplied by others) in the tower bleed line to achieve the desired bleed rate by closing or opening the valve. NOTICE: Ensure the controls for • Inspect the nozzles and heat transfer section as described in “Water Distribution the fan motor are set to allow a System”... -
Page 9: Prolonged Outdoor Storage
• Remove and store fan belts (if supplied) at room temperature. Tag belts appropriately for future identification. • Apply a weather-resistant lubricant or heavy grease such as Anti-Seize (BAC Part # 160069) to all exposed threaded or flanged connections and adjustable motor base threaded rod. - Page 10 Request the required voltage and transformer capacity from your local BAC Representative. A third option is to use an auxiliary heat source and keep the winding warm by either convection or blowing warm air into the motor.
-
Page 11: Cold Water Basin
If the connection size is 20 1/8 9 3/4 custom, contact your local BAC Table 1. Cold Water Basin Water Levels (Measured From Inside the Cold Water Basin) representative. • The operating water level in the cold water basin will vary with system thermal load (evaporation rate), the bleed rate employed, and the make-up water supply pressure. -
Page 12: Fan
– Check each blade for any cracks. If cracks are found, the fan motor should be reason, the fan guard must be locked out until the fan is replaced. Contact your local BAC Representative for reinstalled properly in accordance assistance. -
Page 13: Fan Drive System
– Tip Clearance: Check the clearance between the tip of the blade and the fan cowl. The clearance should be sufficient to prevent the fan blades from contacting the fan cowl during operation. Contact your local BAC Representative if there are any Cold Water Basin concerns. - Page 14 • Belt tension check: – Place a straight edge along the belt from sheave to sheave as shown in Figure 3a, or NOTE: If belts are properly use a tape measure as shown in Figure 3b to measure belt deflection. tensioned, there should be no –...
- Page 15 Detailed Component Optional ENDURADRIVE Fan System ® Maintenance The ENDURADRIVE Fan System is an option for select Series 3000 Cooling Towers and it is Procedures ® standard on S3E-1424-14U and S3E-1424-14W models. The ENDURADRIVE® Fan System includes a direct drive motor and variable frequency drive (VFD) designed specifically for Fan Drive System the motor.
- Page 16 See wiring details in your submittal, and address details can be found in the ENDURADRIVE Fan System ACS880 Start Up Guide. For additional ® WWW. B A LT IM ORE A IRCOIL.COM protocols, contact your local BAC Sales Representative.
- Page 17 Inspection & Maintenance Detailed Component • Inspect the motor at regular intervals, approximately every 500 hours of operation or Maintenance every 3 months, whichever occurs first. Procedures • The following steps should be performed at each inspection: – Turn off the fan motor, and follow the required lockout/tagout procedure. Fan Drive System –...
- Page 18 • BAC ships all gear drives filled with oil. The initial oil level should be at or near the middle of the oil level sight gauge.
- Page 19 • Check to ensure that all bolts and external fasteners are tight. Fan Drive System • BAC recommends daily visual inspections and observation for oil leaks and unusual Optional Gear Drive System noises and vibrations. If any of these occur, shutdown the unit until the cause is found and corrected.
- Page 20 Contact • When the ambient temperature exceeds 180°F (82°C) or the gear drive is started at your local BAC Representative prior an ambient temperature less than 20°F (-7°C), a synthetic lubricant is recommended. to using any synthetic lubricant not When mineral oils are used in operation at ambient temperature less than 20°F (-7°C)
- Page 21 Optional Gear Drive System 8518-06H 1222-12Q 8518-06J 1222-12R 8518-06K 1222-12S NOTE: For projects with whisper 8518-06L 1222-13M quiet fans, please contact your local 8518-06M 1222-13N 8518-06N 1222-13O BAC Representative. 8518-06O 1222-13P 8518-07H 1222-13Q 8518-07J 1222-13R 8518-07K 1222-13S 8518-07L 1222-14M 8518-07M 1222-14N 8518-07N 1222-14O...
-
Page 22: Fan Guard Installation
Fan Guard Installation Fan Guard Installation If the fan guard is removed or if the fan guard installation is altered for any reason, the fan guard must be reinstalled properly in accordance with the instructions below. Never step If the fan guard is removed or if the fan guard installation is altered for any reason, the fan DANGER: Fan guard must be or walk on the fan guard. - Page 23 Two-Piece Fan Guard Detailed Component Two-Piece Fan Guard Maintenance • Using six U-bolt assemblies, fasten the two halves of the fan guard together as Detailed Component illustrated in Figure 7, Detail B. Locate the U-bolt assemblies along the seam between Procedures •...
- Page 24 Four-Piece Fan Guard Four-Piece Fan Guard • Assemble fan guard supports as illustrated in Figure 8, Detail A. • Assemble fan guard supports as illustrated in Figure 8, Detail A. • Secure fan guard pieces to fan guard supports as shown in Figure 8, Detail B. •...
-
Page 25: Fan Motors
• Only lubricate the bearings with a manual grease gun or BAC’s optional Automatic out, and tagged out. Bearing Greaser. Do not use high-pressure grease guns since they may rupture the bearing seals. -
Page 26: Heat Transfer Section
• Lubricate the bearings as follows: – Initial Start-up: Normally, no lubrication is required since the bearings have been lubricated at the factory prior to shipment. However, if the cooling tower has been stored at the job site or more than three months, both bearings should be lubricated with new grease before initial operation. -
Page 27: Water Level Control
Operating Level Detailed Component At design flow, the operating level should not be less than 2 inches or greater than 6 Maintenance inches deep. Procedures Fan Shaft Bearings Inspection and Maintenance Inspection & Maintenance • Quarterly, or more often as required, remove any dirt or debris which may clog the Heat Transfer System nozzles. - Page 28 • 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. BAC recommends a pressure regulator valve (provided by others) for pressures over 50 psig.
- Page 29 L.E.D. Status Codes Detailed Component • L.E.D. on steady: Indicates normal operation. Maintenance • Steady one second flashing: Indicates dirty probes, reading in the capacitance mode. Procedures The unit will still operate but will give the following status code of 1 second on, 1 second off (steady 1 second flashing).
-
Page 30: Corrosion Protection
SERIES 3000 COOLING TOWER Corrosion Protection BAC products are constructed of corrosion-resistant materials. The fill is made of a polyvinyl chloride (PVC), which is not susceptible to rot, decay, rust or biological attack. Other materials listed below are used in the equipment construction: •... -
Page 31: Corrosion And Scale Control
In evaporative cooling products, cooling is accomplished by evaporating a small portion of Corrosion Protection the recirculating water as it flows through the unit. As the water evaporates, the dissolved solids originally present in the water remain behind and if not controlled, the concentration Water Treatment of dissolved solids will increase rapidly. -
Page 32: Chemical Treatment Requirements
(pipe, heat exchanger, etc.). same unit. • BAC discourages acid dosing as means of scale control except for open circuit cooling 6. Water chemistry will change towers with remote sump applications or towers constructed from stainless steel. This with operating temperatures. -
Page 33: Passivation
Passivation Corrosion Protection Water Treatment When new systems are first commissioned, special measures should be taken to ensure that galvanized steel surfaces are properly passivated to provide maximum protection from Corrosion and Scale Control corrosion. Passivation is the formation of a protective, passive, oxide layer on galvanized Chemical Treatment steel surfaces. - Page 34 NOTICE: Never use chloride or cleaning may be required. BAC uses commercially available equipment for electro- chlorine based solvents such as chemical cleaning in the field. Contact your local BAC Representative for more bleach or muriatic (hydrochloric) information or to arrange a service call.
-
Page 35: Part 4 Bleed Rate
Evaporation is proportional to the load and will vary seasonally. BAC recommends the use of a conductivity meter to maximize water conservation. W WW.BALTIMOREAIR C OIL.C O M... -
Page 36: Bleed Rate
NOTE: Evaporation is proportional E = Q * R * 0.001 = 800 * 10 * 0.001 = 8 USGPM to the load and will vary seasonally. BAC recommends the use of a = 250 ppm = 5.55 conductivity meter to maximize 45 ppm water conservation. -
Page 37: Cold Weather Operation
SERIES 3000 COOLING TOWER Cold Weather Operation Inspection & Maintenance BAC products can be operated at subfreezing ambient temperatures provided proper operating methods are established and diligently followed. • Carry out frequent visual inspections and routine maintenance services during operation in subfreezing weather. -
Page 38: Basin Water And Internal Piping Freeze Protection
The two-position, slow closing solenoid valve provided with the BAC electric cooling tower and the remote sump. water level control package also minimizes valve freezing problems (see page 26). - Page 39 Freeze Protection for the Optional EASY CONNECT Piping Arrangement ® Cold Weather Operation • Eliminate all water in the optional EASY CONNECT Piping Arrangement and in all ® internal piping when the tower is idle. Fan Section Icing Protection Fan Control Basin Water and Internal Piping Freeze Protection Cold Water Basin Protection...
-
Page 40: Operation Considerations For Accessories
NOTICE: The basin heater is not submerged before energizing the main disconnect. designed to prevent icing during For installations that have a BAC Controls Enclosure, unit operation. please consult the submittal package provided with the unit and contact your local BAC Representative for support. -
Page 41: Stand Alone Bac Heater Control Panel (Optional)
Operation Considerations Stand Alone BAC Heater Control Panel (Optional) for Accessories Basin Heater The heater control system consists of a heater control panel and a combination Operation temperature/water level sensor. The stainless steel sensor probe with 1/2” NPT mounting Stand Alone BAC Heater... -
Page 42: Vibration Cutout Switch (Vcos)
Control Panel (If Required) Immersion Heaters Figure 12. Example Wiring Diagram for Stand Alone BAC Heater Control Panel (Refer to Submittal Drawing for Specific Wiring Diagram) NOTE: Figure 12 is superseded by any drawing supplied with the panel by the manufacturer. - Page 43 WARNING: Before performing an adjustment or inspection of the VCOS, make certain that all power has been disconnected and locked in the off position. Moisture inside the switch your local BAC Representative for can lead to switch failure. Care must be taken when replacing the cover on the vibration replacement parts.
-
Page 44: Fan Control
• Please refer to the manufacturer’s variable frequency drive recommended start-up recommended to protect the motor. procedure for further information or consult with your local BAC Representative for any Since the switching frequency and VFD applications. For projects with BAC controls, visit www.BaltimoreAircoil.com. -
Page 45: Resonant Speed Identification Procedure
Resonant Speed Identification Procedure Fan Control Variable Frequency Drive Operation There are several characteristic frequencies at which vibration levels may resonate with Optional Gear Drive Units unit structural components. These include fan speed, motor speed, bearing frequency, and with VFDs blade pass frequency. - Page 46 • As stated previously, when adjusting the VFD speed, proceed slowly while monitoring the vibration levels. If the vibration value approaches 0.35 ips (0-peak), slowly “zero in” on the speed where the value equals 0.35 ips, and record the speed at which this occurs as the lower end of the lockout range.
-
Page 47: New Field Connections For Triarmor
Table 9. Supplies for Installing Field Connections NOTE: BAC recommends adding a 1. Use the BAC template provided with the accessory to layout and mark the hole pattern flange connection for field installed on the exterior of the cold water basin. - Page 48 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 7600 Dorsey Run Road, Jessup, MD 20794 ›...
Need help?
Do you have a question about the 3000 Series and is the answer not in the manual?
Questions and answers