BAC Parts & Maintenance Guide

MAINTENAN
PARTS &
MAINTENANCE
GUIDE
ENERGY SAVINGS RETROFITS
REDUCTION IN WATER USAGE
DECREASED WATER LEAVING TEMPERATURES
INCREASED PERFORMANCE
SOUND REDUCTION OPTIONS
COMPLETE PART DESCRIPTIONS
LARGE PRODUCT PHOTOS
MAINTENANCE TIPS
TECH TIPS
CAUTION TIPS
PRODUCT RETROFIT OPPORTUNITIES
MAINTENANCE REFERENCE MATERIALS
PICTURE INDEX OF PARTS
Welcome to the BAC Parts & Maintenance Guide. We are pleased to provide you with
a combination of parts, maintenance reference materials, and technical information
for use on all your evaporative cooling products. We are committed to keeping all of
your equipment running at peak performance through the life of the unit by providing
you with energy efficient solutions and the most reliable parts in the industry.
this guide contains:
FANS & DRIVES / PAGES 2–11
WATER DISTRIBUTION / PAGES 12–17
CONTROLS / PAGES 18–20
RETROFITS / PAGES 21–35
SPOTLIGHTS / 11, 22, 26
ENDURADRIVE™ Fan System Retrofit Kit 11
Energy Saving Retrofits 22
VersaCross® Replacement Fill 26
REFERENCE / 36–52
Maintenance Checklist 36
Recommended Spare Parts 37
Troubleshooting Vibration Cutoff Switches 38–39
Fan Shaft Bearing Maintenance 40
Belt Tensioning and Sheave Alignment 41
Aluminum Fan and Bushing Installation 42
Aluminum and Cast Iron Sheave and Bushing
Installation Instructions 43
Fan Assembly Exploded View Drawings 44–46
Motor Orientation 47
Pump Selection 48-49
Water Quality Guidelines 50-51
Gear Drive Shaft Alignment Instructions 52
PICTURE INDEX (PIC DEX) / 53
CAUTION
LOOK FOR THESE
TIPS THROUGHOUT THE GUIDE: MAINTENANCE
PARTS &MAINTENANCE GUIDE
F I ND YOUR R EPRESENTATIVE: Visit Baltimore A ircoil.com/repfinder or Call: 800.896.8497
TECH
BAC OFFERS A FULL RANGE OF BAC PARTS FOR ALL EVAPORATIVE COOLING
MANUFACTURERS EQUIPMENT. LOOK FOR THIS SYMBOL THROUGHOUT THE GUIDE.
PARTS & MAINTENAN C E G UIDE 1
BAC MAINTENANCE TIP:
When installing centrifugal fan wheels on hollow shafts, remember to apply the adhesive under the fan tabs to prevent the fan wheel from
slipping on the shaft.
Axial Fans
› Standard fan is high-efficiency and low sound
› Rugged, aluminum construction for corrosion resistance and
extended life
› For further reduced sound levels, Low Sound Fans, Whisper
Quiet Fans, and sound attenuation are available
› Factory balanced for easy installation and vibration-free
operation
› Maintain thermal performance as originally certified by CTI
› Most fan kits include bushing and special length bolts
AVAILABILITY: Available in sizes from 24” to 156” diameter,
4 blades to 12 blades for economical and quiet operation.
Centrifugal Fans
› Centrifugal fans have inherently low sound characteristics
› Available in multiple materials of construction to meet
various operating conditions
› Engineered and rated by BAC for optimum performance
› Maintain thermal performance as originally certified by CTI
› Complete installation kit includes hardware, adhesive, and
clamps
AVAILABILITY: Available in 15”, 18”, 22”, and 30” diameters
for shafts 1-3/16” to 5” in diameter. Fits BAC and other
manufacturers’ products.
2 B A LT I M ORE A I R C O IL CO M P ANY
FANS &DRIVES
BAC CAUTION TIP:
Hub clamp bolts should be tightened gradually to a torque of 30 ft/lbs. Tighten bolts evenly around the clamp so that gaps are equal.
Shafts
› Specially selected tubing materials ensure strength and
durability
› BAC shafts are precision manufactured for vibration-free
operation
› Epoxy-coated for corrosion resistance
› Journals are ground and polished for an accurate fit and
easy bearing and drive component installation
› Long keyways for multiple drive combinations
› Grooved flats for positive, secure set-screw installation
AVAILABILITY: Sizes from 1” to 2-15/16” diameter and 18” to
148” long. Many available with nickel plating or in stainless
steel for added corrosion resistance.
Whisper Quiet Fans
› Ultimate low sound solution
› Available for Series 3000, 1500, PT2, FXV, and CXVB units
› Reduces sound levels generated from the unit with
minimal impact on thermal performance
PARTS & MAINTENAN C E G UIDE 3
FANS &
DRIVES
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
FANS &DRIVES
Automatic Bearing Greaser
› Compatible with all BAC bearings and other non BAC bearings
› Lithium batteries are standard
› Positive displacement pump allows installations up to 20 feet away from bearings when
using single and multiple greaser kits
› Variable output and user-settable based on number of bearings, size and type of service
› Significant labor savings through less maintenance
› Multi-Point Automatic Bearing Greasers are now available in 250cc and 500cc
› Replacement grease packs and batteries are available from stock
4 B A LT I M ORE A I R C O IL CO M P ANY
Don’t forget
to order
bearing greaser
refill packs!
Multi-Point Automatic Bearing Greaser
Forced Draft – Multiple Bearings per Greaser
Bearing
Quantity Size of Bearings Multi-Point Greaser Setting
2 1-11/16”
or smaller 250cc Multi-point kit 1 Year
4 1-11/16”
or smaller 500cc Multi-point kit 6 Month
2 Larger than
1-11/16”
250cc Multi-point kit
500cc Multi-point kit
6 Month
1 Year
Induced Draft – Multiple Bearings per Greaser
2 1-11/16”
or smaller 250cc Multi-point kit 1 Year
4 1-11/16”
or smaller 500cc Multi-point kit 6 Month
2
Larger than
1-11/16”
Smaller than 2-15/16”
250cc Multi-point kit
500cc Multi-point kit
6 Month
1 Year
4
Larger than
1-11/16”
Smaller than 2-15/16”
250cc Multi-point
500cc Multi-point
3 Month
6 Month
2 2-15/16” 500cc Multi-point 3 Month
Single Automatic Bearing Greaser
Forced Draft – One Greaser per Bearing
Bearing
Quantity
Size of
Bearings
Bearing
Greaser Setting
1 1-11/16”
or smaller 125cc 1 Year
1 Larger than
1-11/16”
125cc
250cc
6 Month
1 Year
Induced Draft – One Greaser per Bearing
1 1-11/16”
or smaller 125 cc 1 Year
1
Larger than
1-11/16”
Smaller than
2-15/16”
125cc
250cc
6 month
1 Year
1 2-15/16” 250cc 3 Month
FANS &
DRIVES
PARTS & MAINTENAN C E G UIDE 5
Induced Draft Bearings
› Rated with a minimum L10 of 80,000 or more operating hours
› Industrial grade pillow block castings for extended life
› Exclusive BAC slinger/locking collar keeps water off the
bearing seals
› Double-lip seal to keep moisture from contaminating the
grease
› Complete installation kit includes all hardware, shims, and
instructions
AVAILABILITY: Sizes from 1 7/16” to 2 15/16” for all vertical shaft cooling
tower applications.
Forced Draft Bearings
› Rated for an average life of 200,000 operating hours
› Pre-packed with water resistant grease for
easy maintenance
› Split sleeve design bearings are available for easy
replacement
AVAILABILITY: Sizes from 1” to 2 3/16” in flange mount, sleeve, split sleeve,
and pillow block ball bearing configurations.
BAC MAINTENANCE TIP:
If replacing only the top fan shaft bearing on vertical shafts, the locking collar on the bottom fan shaft bearing must be loosened and
then retightened after the installation of the new top bearing. This is critical because, by design, the top bearing is intended
to handle the thrust load.
6 B A LT I M ORE A I R C O IL CO M P ANY
FANS &DRIVES
Cast Iron Bushings and Sheaves
› Minimum 2.0 service factor
› Fine-grain, high-strength cast iron
› Factory balanced for smooth operation
› Bushing design minimizes fretting corrosion on the shaft,
which greatly eases removal when required
AVAILABILITY: Bushing styles for all standard drive components from 1” to 2
15/16” diameter. Cast iron sheaves for all drive combinations, 1 to 8 grooves.
Aluminum Sheaves
› Designed for use with all induced draft cooling towers
› Corrosion resistant aluminum alloy for operation in the moist
cooling tower environment
› Less corrosion means less wear on sheave grooves and
extended belt life
› Available for both driver and driven shafts
AVAILABILITY: From 2 groove to 8 groove, 3 3/5” to 50” diameter for all
induced draft applications.
BAC MAINTENANCE TIP:
See bushing torque requirements for Cast Iron and Aluminum Sheaves in the reference section on page 43.
Always replace
bushings and
bearings
together to
reduce downtime!
PARTS & MAINTENAN C E G UIDE 7
FANS &
DRIVES
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
Belts and Powerbands
› Engineered for evaporative cooling operations
› Rated for 150% of unit horsepower
› Neoprene, backed with reinforced polyester, specifically
designed for extended life
AVAILABILITY: Up to 8 grooves and 195” long in A groove,
B groove, and cogged configurations.
ENDURADRIVE™ Fan System
Retrofit Kit
› Complete kit with matching motor, VFD, fan, bushing and
upgraded 2 beam mechanical support
› 90% reduction in maintenance costs
› Up to 10% energy reduction vs standard gear drive system
› 100% reliability with the elimination of a power transmission
system
› Industry best 7 year motor warranty and 5 year limited VFD
warranty
AVAILABILITY: Horsepower ratings from 20 to 125 horsepower with mounting
and shaft dimensions to fit the Series 3000 Cooling Tower.
8 B A LT I M ORE A I R C O IL CO M P ANY
FANS &DRIVES
BAC Gear Systems
› Meet AGMA and CTI standards to ensure reliability
› Constructed of high-strength cast iron for
low sound, vibration-free operation
› Gear drives are available for both BAC and other
manufacturers’ equipment (exact dimensional fit, no
modification required)
AVAILABILITY: Horsepower ratings from 7.5 to 100 horsepower with mounting
and shaft dimensions to fit virtually any make of cooling tower.
Gear Couplings
› No need for maintenance or lubrication
› Installation is quick and easy, and no special tools are needed
› Couplings absorb all types of misalignment caused by shock
or vibration
› Not affected by dirt or moisture
Composite Drive Shafts
› Composite shaft ships with 316 SST gear and motor
couplings and hardware
› Made from high-strength composite material that allows for
higher misalignment tolerance
› Corrosion resistant
› Lightweight, which reduces vibration and extends the life of
the shaft
BAC TECH TIP:
Prior to installing the couplings, it is important to clean the shaft of any lubricants or protective coatings, as well as remove any existing
burrs that may damage the coupling.
PARTS & MAINTENAN C E G UIDE 9
FANS &
DRIVES
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
Premium Efficient Motors
› Motors are engineered specifically for the rigors of cooling tower applications
› Made of high-grade FC-200 cast iron for maximum cooling and includes additional grounding plug
› Permanently sealed bearings never require lubrication and eliminate water contamination to the
bearing grease
› BAC Premium Efficiency Cooling Tower Duty Motors are covered by a 7 year warranty when the motor
space heater is wired according to the motor wiring diagram.
› IP55 rating for greater protection from water and particulate contaminants
Bearings – Permanently sealed
and lubricated bearings provide
maintenance free long life.
Umbrella Seal – Fits over V-ring slinger
to provide protection from water and other
contaminants.
Conduit Box – Fully
gasketed, cast iron conduit
box includes drain plugs, lead
separator gasket, and internal
epoxy coating.
Internal Epoxy Coating –
Entire interior of the motor is
coated with epoxy for maximum
moisture/corrosion resistance.
Drain Plugs – Located every 90 degrees and on
the face of each endshield. They are easy to open
and accommodate all mounting configurations.
THE ENDURADRIVETM FAN SYSTEM RETROFIT KIT
Includes Factory Authorized Start Up
10 B A LT I M ORE A I R C O IL CO M P ANY
FANS &DRIVES
Baltimore Aircoil Company’s ENDURADRIVE™ Fan System is the most
durable engineered solution for your Series 3000 Cooling Tower!
BAC’s new ENDURADRIVE™ Fan
System retrofit kit gives you:
9 100% reliability on transmission components
versus a traditional gear drive system
9 90% reduction in maintenance costs
9 All while providing you the opportunity to increase
your energy savings by 10%
Please contact your local Representative for more
information at www.BaltimoreAircoil.com/repfinder
or by calling 410.799.6200.
This system is available for retrofit on Series 3000
units manufactured between 1991 through today!
includes
KIT
THE ENDURADRIVETM FAN SYSTEM RETROFIT KIT
Includes Factory Authorized Start Up
MOTOR AND
MATCHING VFD
FAN AND BUSHING
NEW 2-BEAM
ENDURADRIVE ME SUPPORT
WITH MOTOR BASE
SPOTLIGHT
PARTS & MAINTENAN C E G UIDE 11
Spray Branches
› Constructed of corrosion resistant PVC
› Grommeted construction allows spray branches and nozzles
to be easily removed
Water Distribution Nozzles
› BAC 360™ Spray Nozzle, A, AA, and Pyramid Nozzles are
grommeted for easy inspection and removal
› XF nozzles are gravity flow and can easily be inspected and
replaced while unit is in operation
› Kits are available to install 360™ Spray Nozzles in other
manufacturers coil products
› Patented design for pressurized or gravity-feed systems
guarantees optimum thermal performance
› Large orifice means non-clogging performance for effective
wetting of the heat-transfer surface
› Multiple sizes are available to accommodate
all system flow rates
AVAILABILITY: 1/4” through 1 1/8” orifice for properly
metered flow.
A or AA Counterflow Nozzle
used on open cooling towers
BAC 360™ Spray Nozzle
used on closed circuit
cooling towers and
evaporative condensers
XF Crossflow Nozzle used
on open cooling towers
BAC MAINTENANCE TIP:
Always check spray nozzles when inspecting evaporative cooling equipment as poor spray patterns will negatively effect unit performance.
BAC’s Pyramid nozzles
are used in IPC, IMT, and
other manufacturers’ field
erected units
12 B A LT I M ORE A I R C O IL CO M P ANY
WATER DISTRIBUTION
Spray Pumps
› Cast iron, bronze-fitted construction with mechanical seal
means pumps are industrial quality for a long, trouble-free
life
› Impeller and trims have been selected for difficult high-flow,
low-head requirements, assuring complete coil wetting to
reduce scale and provide maximum thermal capacity
› Supplied with vented seal housing to prevent air binding and
to provide a sump bleed connection
› Mechanical seal is constructed with a carbon rotating
element and a ceramic stationary element with stainless
steel hardware for a long, leak-free life
AVAILABILITY: High efficiency, high flow/low head pumps 1/3 through 10
horsepower and 1 1/2” through 4” discharge.
Pump Seal Kits
› Replacement TEFC pump motors are designed for outdoor
application
› Complete seal kits available from stock
› Shaft sleeves are available for pumps 1.5 hp and larger
BAC TECH TIP:
The pump is supplied with a bleed line and valve connected to the seal vent. This valve can be set to provide the proper bleed rate to
minimize impurities in the basin water.
Even if the basin bleed is accomplished by other methods, always leave the valve slightly cracked to prevent air binding in the pump.
PARTS & MAINTENAN C E G UIDE 13
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
WATER
DISTRIBUTION
Float Valves
› Rubber seal disc assures a positive shut-off to prevent
water waste
› Reliable stainless steel linkage in all kits
AVAILABILITY: 1/2” to 2” valves for all applications.
Float Balls
› Heavy-duty polypropylene construction resists cracking
› Foam-filled for structural rigidity and additional buoyancy
› Available in many sizes and configurations to ensure
positive shutoff
AVAILABILITY: 4 1/2” to 8” diameter and 10” pancake style
for all applications.
BAC CAUTION TIP:
Many commercially available float balls are hollow with no foam filling and are not suitable for the rigors of evaporative cooling
equipment. While operating, the inside of your equipment can resemble a hurricane with high winds and extreme temperature swings.
Without the added structural rigidity from the foam filling, the float ball may easily crack, allowing the float to fill with water, which
will cause the system to run improperly. Do not exceed 50 psi inlet water pressure to the float valve.
BAC TECH TIP:
Upon start-up, fill the tower to approximately 1/2” below the overflow level before starting the unit. This will provide enough water to
fill the rest of the system without draining the tower on start-up. After the system is running, adjust the water level as shown in your
Operation and Maintenance Manual. Monitor the operating level for the first 24 hours of operation to make sure it is set properly.
PVC Float Valve
Brass Float Valve
14 B A LT I M ORE A I R C O IL CO M P ANY
WATER DISTRIBUTION
14 B A LT I M ORE A I R C O IL CO M P ANY
Electric Water Level Control
› Universal mounting system fits any tower
› Completely sealed and waterproof
› Located inside the tower so no heat tracing is required
› 6 second time delay prevents short-cycling
› Plastic sheath on probes and stilling chamber prevents
false-cycling
› Requires 110 volt solenoid valve for operation
› Equipped with trouble shooting LED to diagnose water and
probe conditions
AVAILABILITY: 3-probe through 6-probe models for on/off, low water cut-out,
low water alarm, high water cut-out, and/or high water alarm.
Solenoid Valves
› Forged brass body for durability and high-pressure
applications
› Watertight electrical enclosure for outdoor use
› Slow-closing feature minimizes water-hammer on shut-off
› Valves are sized for a water pressure between 15 and 50 psig
at the valve inlet
AVAILABILITY: 3/8” to 2” with 110 volt normally closed holding coil.
BAC TECH TIP:
LED error codes can be found in the Universal Electric Water Level Control Installation, Operation & Maintenance Manual on BAC’s
website, www.BaltimoreAircoil.com.
PARTS & MAINTENAN C E G UIDE 15
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
WATER
DISTRIBUTION
Inlet Strainers
› Single point inlet provides automatic flow-balancing to both
hot water basins
› Inlet strainer protects water distribution nozzles from debris,
eliminating the need for a separate system strainer
› Large free-area inlet strainer minimizes pumping head
› Inlet strainer is easy to remove and clean
Series 3000 Cooling Towers built in 1991 through 2007 were equipped
with inlet strainers located in the BALANCE CLEAN® Chamber. The
BALANCE CLEAN® Chamber provides a single-point piping connection and
automatically balances the flow to both hot water basins. Contact your local
BAC Representative for replacement inlet strainers and options, such as winter
operation bleed down valves, that prevent freeze-up when the tower is shut
down.
Suction Strainers
› 3/16” strainer perforations help keep the system clean
› Strainer perforations are spaced to provide maximum strainer
free area for low pump suction losses
› Anti-cavitation design prevents air from reaching the system
pump
BAC offers many styles of suction strainers and suction hoods for just about
any application. Proper strainer design is critical to the total system operation.
It provides protection for the pump and keeps debris out of the condenser water
loop. BAC strainers are designed to offer optimum system protection while still
providing a full 50% free area to allow efficient system pump operation. Also
important, the anti-cavitation design is built into all BAC strainers. This keeps
air from entering the piping that would cause pump cavitation.
Inlet strainer
inspection for
Series 1500
Inlet strainer
inspection for
Series 3000
16 B A LT I M ORE A I R C O IL CO M P ANY
WATER DISTRIBUTION
Combined Inlet Shields
› Available for the Series 3000E, Series 1500E, PT2, PF2, PFi,
PC2, PCC, FXV, FXV3, CXVT and CXVB units
› Prevent algae growth in the cold water basin
› Eliminate water splash out
› Prevent debris from entering the cold water basin
› Inlet shield is easy to remove and clean
› Separate from the fill and removable to allow easy access for
inspection of the air/water interface at the air inlet side of the
equipment
› Also available on the FXV and CXVB for installation above the
spray distribution system
Air Intake Louvers
› Wide spaced louvers reduce the potential for scale build-up
and damaging ice formations at the air/water interface by
providing an easy visual inspection from the outside of the
unit into the fill
› Standard air intake louvers are constructed of corrosion and
UV-resistant fiberglass reinforced polyester (FRP)
› Galvanized and stainless steel are available
PARTS & MAINTENAN C E G UIDE 17
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
WATER
DISTRIBUTION
Basin Heaters
› UL and CSA rated
› Durable copper heating elements for long life
› 2” MPT connection is easy to retrofit into any cooling tower
AVAILABILITY: 2 – 24 kW ratings, 50 watts/in2
watt density
200, 230, 460, and 575 volt.
BAC stocks a complete line of immersion heaters to prevent cold water basin
freeze-up during winter weather. These heaters are selected for cooling tower
duty and are constructed with copper heating elements rated at 50 watt/in2
with a 2” MPT brass connection and conduit box rated NEMA 4. Heaters are
suitable for use in all makes of evaporative cooling equipment.
Basin Heater Controls
› UL and CSA rated
› BAC thermostats and low water cutouts are designed to
ensure long life and proper operation
› Individual components or complete kits available
› Standard heater control panel consists of:
– Single probe to sense both water
temperature and water level
– Contactor(s)
– 24 Volt control circuit transformer
– NEMA 4 Enclosure
– UL Listed
18 B A LT I M ORE A I R C O IL CO M P ANY
CONTROLS
Float Switch
› Single-pole, double throw, liquid level float switch
› Designed to maintain a liquid level in the cold water basin
› When liquid level rises above or falls below a certain point,
the switch will close one circuit and open a second
Mechanical
Vibration
Cutout Switch
Electronic
Vibration
Cutout Switch
Vibration Cutout Switches
› Protect your tower from damage resulting from excessive
vibration
› Mechanical or electronic switches are available with multiple
options for alarms and reset
› Electronic switches are compatible with building
management systems
BAC MAINTENANCE TIP:
Test vibration switches during seasonal start-ups to ensure proper operation.
See pages 38 & 39 in the Reference Section for Basic Operation and Troubleshooting of the Vibration Cutout Switches or contact your local
BAC Representative for more information.
PARTS & MAINTENAN C E G UIDE 19
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
CONTROLS
› VFD Only: Includes a single VFD in a
weather-resistant enclosure sized to control
all fan motors on the unit
› Total Controls Package: Includes the
VFD Only PLUS sequencing and accessory
contactors
Benefits of BAC
Refrigeration Controls:
› Controls specifically designed for
industrial refrigeration applications
› Single point wiring (optional)
› UL/cUL listed
› All panel enclosures are NEMA 3R as standard
› Easy installation
› Total controls package
[1]Communication Protocols limited to Modbus, Lonworks, Johnson N2, BACNet, and Siemens APOGEE.
Fan Starter(s)
Spray Pump Starter
Basin Heater(s)
Vibration Cutout Switch Interface(s)
Electric Water Level Control Contactor(s)
Communication Card[1]
Sequencing Logic
Weather-Resistant Enclosure
Start-Up (Option)
Pressure Controller
9
9
9
9
9
9
9
9
9
9
9
VFD VFD
OPTIONAL OPTIONAL
VFD ONLY TOTAL CONTROLS
PACKAGE
Modbus-standard Modbus-standard
CONTROLS
BAC Refrigeration Controls
20 B A LT I M ORE A I R C O IL CO M P ANY
Performance
› Increase performance
and efficiency
› Restore lost performance
Ease of Maintenance
› Safety and access items
› Serviceability upgrades
Operational Items
› Capacity control and redundancy
› Controls
Sound
› Reduced sound levels
Retrofit and Rejuvenate Your Equipment
BAC offers a variety of retrofit kits and accessories to rejuvenate or maximize the performance
of your evaporative cooling equipment. Whether your unit appears to be on its last leg or brand
new, BAC parts and retrofit kits are available to bring it back to life or add features to meet the
needs of your projects.
RETROFITS
[1]Communication Protocols limited to Modbus, Lonworks, Johnson N2, BACNet, and Siemens APOGEE.
PARTS & MAINTENAN C E G UIDE 21
ENERGY SAVING RETROFITS
22 B A LT I M ORE A I R C O IL CO M P ANY
Retrofit Opportunities
Water Distribution
Mechanical Drive Components
Fill
BAC VFD (Variable Frequency Drive)
1
2
3
4
A 2°F Decrease in Leaving Water Temperature Saves 6% in Electricity Costs
On average the HVAC system uses 25% of a building’s electricity. The slightest increase in
cooling tower leaving water temperature will result in significantly higher energy costs.1
Annual Cooling Tower Efficiency Savings2
$5,306
$10,612
$15,918
1˚F 2˚F 3˚F
Cooling Tower Leaving Water Temperature Decrease
› Note 1: U.S. Energy Information Administration (EIA)
› Note 2: Savings are based on the energy costs for a 500 ton centrifugal chiller, 0.68 kW/ton chiller efficiency at full load, $0.12/kWh energy cost, $25/kW per
month, 80% ratchet demand charge, and 2,000 equivalent full load hours of operation.
SPOTLIGHT
ENERGY SAVING RETROFITS
Replace Nozzles
Broken or clogged nozzles cause uneven water distribution
over the fill, scale build-up, and decreased capacity.
Upgrade or Replace Drive Components
For increased building heat loads, BAC’s drive upgrade kits
will increase the capacity of your cooling tower.
To maintain the peak performance of your cooling tower,
replace your motors, drive sheaves, drive bushings and belts
with BAC Factory Authorized Parts.
Install New Fill
Replace scaled or clogged fill with BAC’s replacement fill
kits that are designed with state-of-the-art fill technology to
restore or increase the capacity of your cooling tower.
Install a VFD
Adding a Variable Frequency Drive will provide a more efficient
method of operating your cooling tower while extending the life
of the motor and mechanical drive system.
Contact your local BAC Representative for a free unit inspection
and consultation on Energy Saving Retrofits.
1
2
3
4
2% to 3% Energy Savings
3% to 7% Energy Savings
7% to 10% Energy Savings
30% to 40% Energy Savings
1o
F Decrease in Leaving
Water Temperature
1-2o
F Decrease in Leaving
Water Temperature
2o
F Decrease in Leaving
Water Temperature
Pay Back Period: Less Than 1 Year
Pay Back Period: Less Than 1 Year
Pay Back Period: Less Than 1 Year
Pay Back Period: 2-3 Years
PARTS & MAINTENAN C E G UIDE 23
SPOTLIGHT
BACross® Replacement Fill Kits
For FXT, Series 1500, Series 3000, FXV, FXV3,
CXV and CXVB
› Maintains thermal performance as originally certified by CTI
› Available in standard PVC for normal temperature
applications or CPVC for high temperature applications
VersaCross® Replacement
Fill Kits
› Outstanding thermal performance will meet or exceed the
performance of any OEM fill
› Fits most crossflow towers
› Quick and easy field installation saves labor
› Nested shipment requires smallest fill staging area and low
shipping costs
› Model-specific kits contain everything needed for an efficient
installation, including detailed instructions, supports,
hardware, and fill
› 2-week standard lead time
BAC TECH TIP:
Block fill is not recommended for use in BAC’s crossflow cooling products and may decrease the thermal capacity of the unit by 10%.
24 B A LT I M ORE A I R C O IL CO M P ANY
RETROFITS
PROJECT SPOTLIGHT
BACount® Replacement
Fill Kits
For Series V Counterflow products
› Maintains the thermal performance as originally certified by
CTI
› Single-source responsibility, providing quality materials and
a guaranteed fit
› Available in standard PVC or CPVC for high temperature
applications
› Maintains 3/4” spacing to minimize fouling
BAC Pak™ Replacement
Fill Kits
For PT2 Counterflow products
› For use in counterflow and induced draft counterflow cooling
towers
› Pre-engineered kits to fit specific counterflow, and induced
draft counterflow cooling towers
› Easy to install
› All hardware and supports included
› Available in standard PVC or HPVC for high temperature
applications
BAC MAINTENANCE TIP:
Maintain or increase thermal capacity in all BAC counterflow cooling towers with BACount® Fill Kits. They offer the same
efficient heat transfer surface as currently supplied in new BAC towers, in an easy-to-install bundled configuration.
PARTS & MAINTENAN C E G UIDE 25
RETROFITS
VersaCross® Replacement Fill improves thermal performance of the original
fill by an average of 7.3% and 10% on other Manufacturers’ block fill.
Customer Benefits
› Only replacement hanging fill on the market
› Designed to meet or exceed original performance specifications
› Lower shipping costs versus block fill
› Nested shipments require smaller staging areas
› Fill fits in most Class A freight elevators
› Shorter lead time than block fill
Integrated Custom Features
› Includes integral louvers and drift eliminators to eliminate splashout and drift
› Formed from 15 mil self-extinguishing PVC
› Fits most BAC crossflow towers
› Suitable for maximum entering water temperature of 130˚F
Custom Installation Kit
s Hanging PVC VersaCross®
Fill
s Fill hangers and supports
s Detailed instructions
s Complete Hardware
26 B A LT I M ORE A I R C O IL CO M P ANY
VERSACROSS® REPLACEMENT FILL
SPOTLIGHT
Internal and External Service Platforms,
Catwalks, and Walkways
› OSHA compliant
› Simplify maintenance
› Available in complete engineered kits
› Keep feet dry
› External service platforms allow for easy access to hot water basins or spray
distribution systems
› Internal walkways and internal platforms and ladders provide easy access to
drive components
BAC MAINTENANCE TIP:
Newer unit designs do not require routine maintenance on the fan deck. Louver face platforms allow easy access and
inspection of the water distribution area while the unit is in operation.
VERSACROSS® REPLACEMENT FILL
PARTS & MAINTENAN C E G UIDE 27
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
FANS &
DRIVES RETROFITS FANS &
DRIVES RETROFITS
BAC MAINTENANCE TIP:
Ladders and handrails are available for access to the top of the equipment. If the end-user elects to use this alternative, the
addition to the installation will make routine maintenance easier, and improve overall performance and unit life expectancy.
All BAC safety and access retrofit packages meet OSHA requirements.
Pre-assembled Platforms
› OSHA compliant
› Increases the ease of maintenance
› Available on Series 3000, Series 1500, PC2, PT2, FXV, FXV3, PF2, CXVB, CXVT and VCA models
› Ships in modules for quick and easy installation
› Three configurations available for the VCA (flush, offset, and full perimeter)
28 B A LT I M ORE A I R C O IL CO M P ANY
RETROFITS
Add Redundancy and Capacity Control
› ENERGY-MISER®/BALTIGUARD™ Fan System maximizes up-time
› Saves energy
› Maintains required performance for approximately 85% of the year, using only 1/3 of the full-load HP
› Utilizes standard, cooling tower duty motors for easy replacement: no need for two-speed or special
motors required
Redundancy – A simple solution to add redundancy is the ENERGY-MISER®/BALTIGUARD™ Fan System. This option adds a second
fan motor to the drive system. This second motor is usually sized at approximately 1/3 of the main motor horsepower. This allows the
smaller motor to operate around 85% of the year, while the larger main motor is only required on the hottest of days. Unlike a twospeed motor, this causes less wear and tear on the fan motors and provides redundancy in case of a motor failure. In addition, the
single-speed motors are available “off the shelf” from BAC.
Capacity Control – The ENERGY-MISER®/BALTIGUARD™Fan System also provides capacity control similar to a two-speed motor.
Another capacity control option is adding a VFD to control the motor speed. If you are thinking of converting to a VFD system, BAC can
supply the VFD and a fan motor built for that application; see page 20.
BAC TECH TIP:
The ENERGY-MISER®/BALTIGUARD™ Fan System utilizes the control and switch-gear of a two-speed, two-winding motor while
providing the security and economy of a redundant motor. You always have a motor, even if one motor fails.
PARTS & MAINTENAN C E G UIDE 29
FIND YOUR REPRESENTATIVE:
BaltimoreAircoil.com/repfinder
Or Call: 800.896.8497
FANS &
DRIVES RETROFITS FANS &
DRIVES RETROFITS
Aluminum Sheave
and Bushing Kits
› Complete with bushing and special bushing bolts
› Special torque requirements and installation techniques
included with kit instructions
› Corrosion resistant aluminum allows for operation in the
moist cooling tower environment
› Available exclusively from BAC
› Designed for the specific power transmission required by the
motor and fan application
Aluminum Fan
and Bushing Kits
› Complete with bushing and special bushing bolts
› Special torque requirements and installation techniques
included wi

Parts & Maintenance Guide