Professional Documents
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A Cost-Saving Opportunity
Owners and operators who have a working
knowledge of cooling tower preventive maintenance
and upgrade technology will get the most out of
their cooling towers. Their efforts can yield beneficial results, including:
keeping them running smoothly and reliably
increasing cooling tower life expectancy
maintaining and potentially improving
performance
This article will take a look at routine maintenance
and suggest ways to improve cooling tower
performance.
N2
Preventive Maintenance
Performing routine preventive maintenance is paramount for consistently achieving the desired temperature
and flow rate, and plays an important role in maximizing cooling tower operating life. Today, those
manufacturers conscious of the importance of maintenance offer many features which simplify these
procedures, saving time and money.
To perform properly, all tower components must be kept clean and free of obstructions. The following sections
describe standard maintenance procedures for optimized operation. These procedures can prevent loss of
efficiency in the heat transfer section by maintaining proper water and air flow, as well as preventing corrosion
in the cooling tower.
N3
Maintenance frequency will depend largely upon the condition of the circulating water, the cleanliness of the
ambient air used by the tower, and the environment in which the tower is operating. More detailed
information is provided by BACs Operating and Maintenance Manual.
Strainer
Fundamentally important to the performance of a cooling tower is a method to minimize contact between air
& water-borne debris and the system components. This is accomplished with strainers. Strainers in the
tower provide a means of keeping debris out of the condenser water loop. Strainers in the cold water basin
outlet prevent debris from reaching the pump. Some towers feature low-pressure drop pre-strainers
upstream of the hot water basin to prevent clogging of distribution nozzles. This added feature eliminates the
need to access the distribution nozzles. Both strainers should be routinely inspected and cleaned as
necessary. Some tower designs allow external access to the strainers, which enables maintenance to take
place without the need to turn off the unit.
Water Distribution
The water distribution system should evenly distribute water over the fill section or coil section via either a
gravity distribution system or a pressurized spray system. If the water distribution is found to be uneven, the
nozzles need to be checked. Clogged nozzles should be cleaned in accordance with the manufacturers
recommendations.
N4
In a gravity distribution system, the nozzles can be externally accessed, visually inspected and cleaned by
removing the hot water basin covers on the fan deck. Most pressurized spray distribution systems use
nozzles and branches held in place by snap-in rubber grommets, which allow easy removal to clean and
flush debris.
Make-up
Though most of the water in the system is recirculated, some water must be added to replace what is lost by
evaporation and bleed. Bleed is the defined as the water that is discharged to prevent the accumulation of
solids in the recirculated water. The make-up water system provides the means to replace the water via a
mechanical float ball and valve assembly or an electronic water level probe assembly (with solenoid valve),
which measures water depth in the cold water basin. The make-up water supply pressure should typically be
maintained between 15 psig and 50 psig to ensure proper valve shut-off and avoid chatter. If the supply
pressure is higher than 50 psig, install a pressure reducing valve.
N5
Bleed
To prevent the accumulation of solids in the recirculating water, the tower should be equipped with a bleed
line (including a metering connection and globe valve) connected to a nearby drain. In a closed circuit
cooling tower or evaporative condenser with a circulating pump, a metering valve to control the bleed rate
should be provided at the pump discharge. While a manually adjusted bleed valve is the simplest system,
getting the proper bleed rate can be a problem, as cooling tower loads vary throughout the day. A
conductivity meter connected to a solenoid valve solves this problem by maintaining the proper cycles of
concentration at all times. Also, it is recommended that a separate meter is installed to measure bleed
volume, since less water is discharged to drain than supplied to the cooling tower. This can reduce sewer
water charges.
The bleed rate should be adjusted to prevent an excessive build-up of impurities in the re-circulating water.
This is largely dependent upon the local water quality and the evaporation rate. Constant bleed and
replacement with fresh water will prevent the accumulation of impurities. To obtain specific
recommendations, contact a competent water treatment professional for your area.
N6
Gear drives provide reliable operation, when properly maintained. If a problem occurs, resolution may be
more involved if a gear box rebuild or replacement is required. Some manufacturers offer both systems to
meet user needs or preferences. To ensure proper operation of a belt drive system, tighten drive belts to
manufacturers specifications. In gear drive systems, the oil level and quality, as well as shaft alignment
should be checked regularly in accordance with the manufacturers recommendations.
When starting up a new unit, lubrication for the fan shaft bearings is typically not necessary, since most units
leave the factory already greased. However, for seasonal start-up, purge the fan shaft bearings with new
grease (per manufacturers recommendations). Fan shaft bearings should be lubricated after every 2,000
hours of operation or every three months (whichever occurs sooner). Motor bearings should be lubricated as
recommended by the manufacturers instructions. For maximum life, it is best to install motors with a cooling
tower duty rating.
N7
The cooling tower and surrounding area should be examined for air flow restrictions which may cause
blockage of the air inlets. Check for clogging or improper distribution of water across the tower fill and
check for proper operation of capacity control dampers in centrifugal fan towers to ensure proper air flow.
The dampers, airfoil blades located in the discharge of the fan housing, help achieve tight temperature
control and energy savings by matching cooling tower airflow to actual load requirements.
Though you may encounter dampers in older existing units, todays towers tend to take advantage of
variable frequency drive technology (VFDs) to control capacity. VFDs help save energy, do a better job of
following the load, and help reduce wear and tear on the drive system.
N8
Check Ambient Conditions: Cooling towers are selected to produce the required leaving water temperature
at the design cooling load and entering wet-bulb temperature. Whenever the actual entering wet-bulb
temperature is higher than design conditions, the leaving water temperature will also be higher. The result
is decreased energy efficiency.
Drift occurs as air flows through the cooling tower and carries water droplets out of the tower. Drift eliminators
are installed in the discharge stream to remove water droplets from the air. In a properly maintained system,
efficient eliminators will reduce drift loss to a negligible percentage of the design flow rate.
Inspecting coil
Corrosion is always a concern with cooling towers because of their ability to wash the air of impurities. These
impurities cause scale, corrosion, and eventually damage to system components after long-term exposure.
If a constant bleed of the system is ineffective to combat scale or corrosion, chemical treatment may be
necessary. A successful chemical or water treatment program should satisfy the specific guidelines set by the
manufacturer, provide effective microbiological control, and be compatible with the systems materials of
construction as an integral part of the total water treatment program.
Potential airborne impurities and biological contamination (such as Legionella) should be controlled through
the use of biocides, and such treatment should be initiated at system start-up and continued regularly.
ASHRAE has taken proactive steps to understand and deal with Legionella through its popular publication,
ASHRAE Guideline 12 2000, entitled Minimizing the Risk of Legionellosis Associated with Building Water
Systems. Contact ASHRAE to secure a copy of this important document. To obtain specific
recommendations of water treatment programs, contact a competent water treatment supplier.
Performance Improvements
Older, structurally sound cooling towers can be retrofitted with upgrade kits to:
conserve energy
restore or improve performance
facilitate maintenance
To conserve energy, two-speed motors, variable frequency drives (VFDs) or the ENERGY MISER Fan
System can be added to the mechanical drive system. VFDs offer a wide range of speeds to closely parallel
operating requirements, and pony motors provide the added benefit of redundancy in the event of a motor
failure. A popular energy conservation approach employs a pony motor system with a VFD controlling the
lower horsepower motor.
If excess drift occurs, check drift eliminators for proper installation, spacing, and overall condition. Examine
the fill for even spacing, to insure there is no clogging or blockage, and check water and air flow as described
above. Repair or replace eliminators as necessary.
N9
Conclusion
Paying regular attention to the forgotten system component, the cooling tower, through a regular,
comprehensive maintenance program can save time, money and energy while increasing the towers life
expectancy. A well-maintained tower is a candidate for retrofit kits designed to enhance performance and
lengthen its life. Owners and operators save money through preventative maintenance technology. If you
are not regularly performing routine maintenance on your cooling tower, implement a comprehensive
maintenance program today.
For more information on how to get started, contact your local BAC Representative.
N10
Included in this manual are the recommended maintenance services for start-up, operation, and shutdown
and the approximate frequency for each. Note that the recommendations on frequency of service are
minimums and where operating conditions are severe, the services should be performed more often. For
each required service, follow the procedures outlined under the "Maintenance Procedures" section of this
manual. The cooling towers are illustrated in each appropriate section with the major points of inspection
and service identified.
If you need additional information about the operation or maintenance of this equipment that is not covered
in this manual, contact your local BAC Representative. Their name and telephone number are on a label
located adjacent to the access door. The model and serial number of the unit are also located in this area.
You can also visit our web site at www.BaltimoreAircoil.com or contact us at 800-896-8097.
Baltimore Aircoil Company Crossflow Cooling Towers have been designed to give long, trouble-free service
when properly installed, operated, and maintained. To obtain optimum performance and maximum service
life, it is important that a program of regular inspection and maintenance be developed and carried out. This
manual is published as a guide to establishing such a program
N11
Table of Contents.........................................................................................Page
Air:
The most harmful atmospheric conditions are those with unusual quantities of industrial smoke, chemical
fumes, salt or heavy dust. Such airborne impurities are carried into the cooling tower and absorbed by the
recirculating water to form a corrosive solution.
Water:
The most harmful conditions develop as water evaporates from the cooling tower, leaving behind the
dissolved solids originally contained in the make-up water. These dissolved solids may be either alkaline or
acidic and, as they are concentrated in the circulating water, can produce scaling or accelerated corrosion.
The extent of impurities in the air and water determines the frequency of most maintenance services and also
governs the extent of water treatment which can vary from a simple continuous bleed and biological control to
a sophisticated treatment system. (See sections on "Water Treatment and Biological Control.")
N12
Safety Precautions
WARNING: Before performing any maintenance or inspection, or performing service on or near fans,
drives, motors or inside the unit, make certain that all power has been disconnected and locked in the
off position.
WARNING: The top horizontal surface of the unit is not intended for use as a walking surface or
working platform. If access to the top of the unit is desired, the purchaser/end-user is cautioned to use
appropriate means complying with applicable safety standards of governmental authorities.
WARNING: The recirculating water system may contain chemicals or biological contaminants, including
Legionella, which could be harmful if inhaled or ingested. Personnel exposed directly to the discharge
airstream and the associated drift mists, generated during operation of the water distribution system
and/or fans, or mists produced by high pressure water jets or compressed air (if used to clean
components of the recirculating water system), must wear respiratory protection equipment approved
for such use by governmental occupational safety and health authorities.
Safety Precautions
Only qualified personnel may operate, maintain, and repair this equipment. All such personnel must be
thoroughly familiar with the equipment, the associated system and controls, and procedures in this manual.
Use proper care, procedure, and tools when handling, lifting, installing, operating, maintaining, and repairing
this equipment to prevent personal injury and/or property damage.
CAUTION: Storage
BAC units are typically installed immediately after shipment, and many operate year round. However, if the
unit is to be stored for a prolonged period of time either before or after installation, certain precautions
should be observed. For instance, covering the unit with a clear plastic tarpaulin during storage can trap
heat inside the unit, potentially causing damage to the fill and other plastic components. If units must be
covered during storage, an opaque, reflective tarp should be used. Consult with your local BAC
Representative for additional recommendations on long-term storage. For normal seasonal shutdowns, refer
to the applicable section in this manual.
CAUTION: All electrical, mechanical, and rotating machinery are potential hazards, particularly for those
not familiar with there design, construction and operation. Accordingly, use appropriate lockout procedures
and adequate safeguards (including the use of protective enclosures where necessary) should be taken with
this equipment both to safeguard the public from injury and to prevent damage to the equipment, its
associated system, and the premises.
CAUTION: This equipment should never be operated without all fan screens, access panels, and
access doors in place. For the protection of authorized service and maintenance personnel, install a
lockable disconnect switch located within sight of the unit on each fan and pump motor associated with this
equipment.
Freeze Protection: Mechanical and operational methods must be employed to protect these products
against damage and/or reduced effectiveness due to possible freeze-up. Please refer to the product catalog
or contact the local BAC Representative for recommended protection alternatives.
Warranties: Please refer to the Limitation of Warranties applicable to and in effect at the time of the
sale/purchase of these products. Described in this manual are the recommended services for start-up,
operation, and shut down and the approximate frequency for each of BACs Crossflow Cooling Towers.
WARNING: When the fan speed of the unit is to be changed from the factory set speed, including
changes achieved by the use of a variable fan speed device, steps must be taken to avoid operation at
or near the fans critical speed which could result in fan failure and possible personal injury or
damage. Consult with your local BAC Representative on any such applications.
N13
Figure 1a
BALTIDRIVE Power Train
Fan System
Fan Guard
Fan Deck
Top Water
Inlet
Casing
Hot Water
Basin & Cover
Air Inlet
Louvers
Make-up Valve
Adjustable Float
Cold Water
Basin
Water Outlet
Connection
Suction
Strainer
BACross Fill
with Integral Drift
Eliminators
Figure 1b
N14
Figure 2b
Make-up Valve
Adjustable Float and
Suction Strainer
Figure 2a
N15
Figure 3a
Plastic Metering
Orifices
Hot Water
Distribution Basin
Hot Water Inlet
Drives
Motor
Access Door
Air Inlet
Cylinder
Fan Shaft
And Bearings
Water Make-Up
Valve Assembly
Adjustable
Float
Axial Fan
Strainer
Figure 3b
Water Outlet
Connection
N16
(2)
and check
Start-Up
Monthly
Quarterly
Annually
Shutdown
(3)
X
X
x
x
X
X
N17
Prior to initial start-up or after a shut-down period, the cooling tower must be thoroughly inspected and
cleaned:
1. Clean all debris, such as leaves and dirt, from inside the tower, the air inlets and the hot water basins.
2. Remove, clean and install the inlet pre-strainer on Series 1500, and the inlet strainer on Series 3000
Cooling Towers provided with the optional BALANCE CLEAN Chamber.
3. Drain the cold water basin (with basin strainers in place) and flush to remove accumulated dirt.
4. Remove the suction strainer, clean and reinstall.
5. Turn the fan(s) by hand to insure rotation without obstruction.
6. Bump the fan motor(s) and check for proper fan rotation.
7. At seasonal start-up, check and adjust the belt tension on the fan drive system. Note, during initial
start-up, the belt tension may not require adjustment since the drive has been properly tensioned at the
factory prior to shipment.
8. Check float operated make-up valve to be sure it is operating freely.
9. Lubricate the fan shaft bearings prior to seasonal start-up.
10. At start-up, when the cold water basin is completely drained, fill the cold water basin with fresh water to
the overflow level. For new installations, initiate the biocide water treatment program at this time (See
section on "Biological Control"). At seasonal start-up, and following a shutdown period of more than 3
days, resume the biocide treatment program or administer a shock treatment of appropriate biocides prior
to operating the cooling tower fans to eliminate accumulated biological contaminants (See section on
"Biological Control").
11. Set the float on the make-up valve to close the valve when the float is approximately 1/2" below the
overflow level.
12. Balance flow to the hot water basin(s) by adjusting the flow balancing valves (provided by others or
optionally supplied by BAC) on Series 3000, Series 1500 and FXT Cooling Towers. This is not required
on Series 3000 Cooling Towers equipped with the optional EASY CONNECT Piping Arrangement with
the BALANCE CLEAN Chamber. However, multi-cell arrangements will require flow balancing between
cells to obtain even water distribution.
13. Open the valve in the tower bleed line and adjust bleed.
14. Check the voltage and current of all three legs of the fan motor. The current should not exceed the
nameplate rating. Note: Current should be measured during warm ambient conditions and with a heat
load on the tower. After prolonged shutdowns, the motor insulation should be checked with an insulation
tester prior to restarting the motor.
WARNING: No service work should be performed on or near the fans, motors, and drives or inside the
unit without first ensuring the fan and pump motors have been disconnected and locked out.
CAUTION: Rapid on-off cycling can cause the fan motor to overheat. It is recommended that the controls be
set to allow a maximum of 6 on-off cycles per hour. When using a 2-speed motor, the starter should include a
15-second time delay when switching from high speed to low speed.
Inverter duty fan motors, furnished in accordance with NEMA Standard MG.1 Part 31, are required for
applications using variable frequency drives for fan motor control.
AFTER 24 HOURS: After 24 hours of operation under thermal load, the following services should be
performed:
1. Check the tower for any unusual noise or vibration.
2. Check the operating water level in the hot and cold water basins and adjust balancing valves.
N18
Operation:
During operation, the tower should be inspected, cleaned, and lubricated on a regular basis. The required
services and the minimum recommended frequency for each are summarized in Table 1 on page N16 of this
bulletin.
Seasonal Shutdown:
1. Drain the cold water basin and all piping that will be exposed to freezing temperatures.
2. Clean and flush the hot and cold water basins with the basin strainers in place. Leave the cold water
basin drain open so rain and melting snow will drain from the tower. For Series 3000 Cooling Towers with
the optional BALANCE CLEAN Chamber, clean and flush the inlet strainer.
3. Clean the basin strainers and reinstall.
4. Cover the fan discharge opening to keep out dirt and debris on Series 3000 and Series 1500 Cooling
Towers.
5. Lubricate the fan shaft bearings and motor base adjusting screw.
6. Close the shut-off valve in the make-up water line (supplied by others) and drain all exposed make-up
water piping.
7. Inspect the integrity of the corrosion protection system on the steel portion of the tower. (See section on
"Corrosion Protection").
8. On Series 1500 Cooling Towers, inspect the anti-skid tape on the internal walkway and replace as
necessary if deterioration or lifting is observed.
9. Secure the fan motor starting device in the off position. If inspection or repair requires service personnel
to work around either the fan or drives during shutdown, a personal safety hazard exists if this precaution
is not taken.
WARNING: No service work should be performed on or near the fans, motors, and drives or inside
the unit without first ensuring the fan and pump motors have been disconnected and locked out.
The following services should be performed whenever the cooling tower is to be shutdown for more than
3 days:
N19
The water to be cooled enters the tower through a single connection and passes through the BALANCE
CLEAN Chamber. This device is equipped with an internal strainer. The bottom of the BALANCE CLEAN
Chamber is a capped cleanout connection. This can be used to periodically purge the BALANCE CLEAN
Chamber of dirt and debris as indicated in the Recommended Maintenance Schedule. This is accomplished
by un-bolting and temporarily removing the chamber bottom plate and inspecting the strainer for dirt and
debris, see Figure 5.
Height of Water in
the Cold Water
Basin (in.)
8 3/4
9 3/4
Series 1500
Model Number
Height of Water in
the Cold Water
Basin (in.)
All Models
FXT
Model Number
6 - 11
16 - 33
38 - 536
Height of Water in
the Cold Water
Basin (in.)
4 1/2
5
6
The entire cold water basin should be drained, cleaned, and flushed quarterly, or more often if necessary,
with fresh water to remove the silt and sediment which normally collects in the basin.
N20
It is important to note that the same maintenance applies to galvanized steel basins, basins protected by the
BALTIBOND Corrosion Protection System, and stainless steel basins. If not removed periodically, sediment
can become corrosive and cause deterioration of the protective finish of metallic basins. When flushing the
basin, the strainers should be left in place to prevent the sediment from re-entering the tower system. After
the basin has been flushed, the strainers should be removed, cleaned, and replaced before refilling the
basin with fresh water.
Make-Up Valve:
A float-operated mechanical water make-up assembly is furnished as standard equipment on the cooling
tower (unless the unit has been ordered with the optional electric water level control package or is equipped
for remote sump application). The mechanical make-up assembly is located within easy reach from the
access door at the connection end of the unit on FXT and Series 3000 Cooling Tower. The mechanical
make-up valve is easily accessible from the louver face of the Series 1500 Cooling Tower. The standard
make-up assembly consists of a bronze make-up valve connected to a float arm assembly and is actuated
by a large diameter polystyrene-filled plastic float. The float is mounted on an all-thread rod held in place by
wing nuts. The operating water level in the cold water basin can be adjusted by repositioning the float and
all-thread rod using the wing nuts provided.
The make-up assembly should be inspected monthly and adjusted as necessary. The valve itself should be
inspected annually for leakage and the valve seat replaced if necessary. The make-up water supply
pressure should be maintained between 15 and 50 psig for proper operation of the valve.
To set the initial basin water level, adjust the wing nuts so that the make-up valve is completely closed when
the water level in the cold water basin is 1/2" below the overflow connection. Under design thermal load and
with average water pressure (15 to 50 psig) at the valve, this setting should produce the operating water
levels stated in Table 2.
Note that if the thermal load is less than the design load at the time of unit start-up, the procedure may
produce operating levels greater than these shown in table 2. It may be necessary to re-adjust the float in
order to attain the recommended operating level. The unit cold water basin should be closely monitored and
water level adjusted as necessary during the first 24 hours of operation.
As 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 cold water basin. These electrodes should be periodically cleaned to prevent accumulations of scale,
corrosion, sludge or biological growth which could interfere with the electrical circuit.
WARNING: Openings and/or submerged obstructions may exist in the bottom of the cold water basin.
Use caution when walking inside this equipment.
N21
With the electric water level control package, the water level is maintained at the recommended operating
level regardless of the system thermal load. Therefore, it is not necessary, nor is it recommended, that the
operating level be adjusted. During the start-up of units equipped with the electric water level control package,
the control unit should be bypassed in order to fill the unit 1/2" below the overflow connection.
Operation at the recommended water level will ensure that the unit basin contains sufficient water volume to
prevent air entrainment in the circulating pump during system start-up and to provide sufficient excess basin
capacity to accept the total system pull-down volume. ("Pull-down volume" is defined as that quantity of water
suspended in the tower during operation plus that contained in the hot water basin, fill, external piping, and
any heat exchangers which could drain to the tower cold water basin when the circulating pump is shut down.)
Fan Motors:
The standard fan motors used on BAC Cooling Towers are Cooling Tower Duty Motors, either a TEAO (Totally
Enclosed, Air Over), or a TEFC (Totally Enclosed, Fan Cooled) configuration, with permanently lubricated ball
bearings and special moisture protection on the bearings, shaft, and windings. The only servicing required
during operation is to clean the outside surface of the motor at least quarterly to ensure proper motor cooling.
Additionally, after prolonged shutdowns, the motor insulation should be checked with an insulation tester prior
to restarting the motor.
Series 1500 & Series 3000: The fan motor(s) is totally enclosed, air-over (TEAO), single-speed, single-winding, reversible "squirrel cage", ball bearing type, designed specifically for evaporative heat rejection service.
Series 3000 (Option): The fan motor(s) is totally enclosed, fan-cooled (TEFC) ball bearing type,
single-speed, single-winding, and suitable for outdoor service. A TEFC motor(s) is standard when the cooling
tower is provided with gear drive and externally mounted motor(s).
FXT: The fan motor(s) is totally enclosed, fan-cooled (TEFC), single-speed, single-winding, suitable for
outdoor service.
WARNING: When the fan speed of the cooling tower is changed from the factory-set speed, including
changes achieved by the use of a variable fan speed control device, steps must be taken to avoid
operating at or near the fans "critical speed", which could result in fan failure and possible injury or
damage. On most fan drive systems, it is not uncommon for one or more resonant speeds to exist.
Consult with your local BAC Representative on any such applications.
N22
Amoco - Rycon Premium #3
Mobil - Mobil #28
Shell - Alvania 3
Texaco - Regal AFB 2
Chevron - SRI
Mobil - SHC 32
Shell - Dolium "R"
Figure 6
Figure 7
N23
NOTE: There should be no "chirp" or "squeal" when the fan motor is started.
The position of the fan motor can easily be changed by adjusting the rod which extends from the frame to the
motor base. Loosen the locknut on top of the frame and rotate the nut under the frame with a wrench as
necessary. Then retighten the locknut (see Fig. 12 and 13).
NOTE: Direct drive units (FXT-6 thru FXT-20) do not employ fan shaft bearings, adjustable motor bases, fan
drives or belts. The fans are driven directly by the motor and there is never a need for any adjustment.
Figure 13 FXT
fan belt adjustment
N24
To check the belt tension, place a straight edge along the belt from sheave to sheave as shown in Figure
15a or use a tape measure as shown in Figure 15b to measure belt deflection. Apply a moderate force by
hand (approximately 40 lbs) evenly across the width of the belt in the center of the span between the
sheaves. If the belt deflects between 1/4" and 3/8" as shown in Figures 15a and 15b, the belt is adequately
tensioned.
If belt tensioning is required, proceed as follows:
NOTE: There should be no "chirp" or "squeal" when the fan motor is started.
Figure 15a
Figure 15b
Belt Tension
The drive alignment should be checked annually to ensure maximum belt life. This can be done by placing a
straight edge across the driver and driven sheaves as shown in Figure 16a for standard drives and in Figure
16b for ENERGY-MISER Fan System drives. When the drives are properly aligned, the straight edge will
contact all four points as indicated. There should be no more than 1/16" deviation from four points of
contact. If realignment is necessary, loosen the motor sheave and align it with the fan sheave. Allow
approximately 1/4" for draw-up as the bushing screw is retightened.
N25
Fan Assembly:
1. If the unit is already in operation, check while the fan is running for any unusual noise or vibration.
2. With the fan off and the motor locked out and tagged, check the general condition of the fan:
a. Inspect for any loose or missing bolts in the fan shaft bushing, the fan hub and the fan shaft
bearings.
b. Check the fan blades for looseness, first by twisting the blade by hand and then by moving the
blade tip up and down.There should be no play or slippage whatsoever.
c. Inspect along each blade for excessive scale build-up that could cause vibration
d. Check each blade, in the area of the shank, for any signs of cracking. If cracking is
found, the fan should be locked out immediately. Contact you local BAC Representative for
assistance.
3. Tip Clearance Check the clearance between the tip of the blade and the fan cowl. This should be
between 3/8 and 1-1/8.
4. Drain Holes On hollow blades, the drain hole in the blade tip should be unobstructed. (Hint: Use a
piece of wire to probe the hole).
5. Blade Pitch Check to ensure that the blades are all at the same pitch. If uncertain, measure the pitch
with an inclinometer. All blades should be within +/- 1/2.
6. Rotation Turn the fan by hand to ensure that it moves freely with no rough spots, binding or other
malfunctions that could cause vibration or fan motor overload. While rotating the fan, check the blade
tracking. All blades should track within a 1" band at any single point around the cowl.
7. Direction of Rotation On initial start up, or if the fan motor has been rewired for some reason, bump
the fan motor and note the direction of rotation. It should rotate in the direction indicated by the arrow
on the fan cowl.
8. Operation On initial start up, run the fan in the manual position for several minutes and check for any
unusual noises or vibration.
Name Plate
Breather Plug
Gear drive units with internally mounted motors are properly installed and aligned at the factory. All fasteners
are factory tightened, but should be checked after installation. For units supplied with externally mounted
motors, install and align the motor and driveshaft in accordance with the customer assembly instructions
included with the unit. It is recommended that alignment and all external fasteners be rechecked after two
weeks of operation.
N26
Operation: No special break-in procedures, other than rechecking alignment and external fasteners, are
necessary except as noted under the Lubrication section.
Excessive noise or vibration at initial operation is an indication of one or more of the following:
1.
2.
3.
4.
Misalignment
Imbalance of the fan or other rotating parts
Improperly adjusted fan blades
Operation at mechanical equipment resonant speed
On installations with two speed motors, when slowing from high speed, allow a minimum 15 second time
delay for 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 before restarting the motor.
Variable Frequency Drive Operation:
CAUTION: On installations with variable speed motors, do not operate standard gear drives below 450 RPM
motor speed (gear input speed). Modifications to the lubrication system or special gear oil pumps are
required for operation at input speeds lower that 450 RPM.
CAUTION: Continued operation at a resonant speed condition will result in torsional vibrations within the
gear which can be damaging to all components of the system. The most common indicator of torsional
vibrations is an unusual rumbling or grinding noise from the gear drive at a sharply defined speed. The
noise will disappear when the speed is increased or decreased. This noise is not indicative of a defect but
results when the vibratory torque exceeds the drive torque causing the gear teeth to separate and clash
together very rapidly. On variable speed applications, operation close to a resonant speed should be
avoided and transition through a resonant speed range should be swift.
At start-up, the variable frequency drive should be increased through the range from 0 RPM to maximum
motor speed. As the speed is increased, the gear drive system should be observed to note the onset of
any unusual rumbling or grinding at specific speeds. These resonant speeds (+/- 10%) should be "locked
out" by the variable speed drive. Please refer to the variable frequency drive manufacturers
recommended start-up procedure for further information.
Lubrication: Use only rust and oxidation inhibited gear oils in accordance with AGMA (American Gear
Manufacturers Association), Standard 9005-D94. For general operating conditions, AGMA lubricant number
and corresponding ISO Grade should be as shown in Table 3 for mineral oils and Table 4 for synthetic
lubricants (reference the cooling tower nameplate to determine if synthetic lubricant was furnished). For
operation under extremely hot or cold ambient conditions, contact your local BAC Representative for specific
recommendations.
Start-up at an ambient temperature less than 20F (-7C ) requires either the use of lube oil heaters (for
mineral oils) or synthetic oil (ambient temperature to -20F (-29C)). Each unit has provisions for an internal
oil reservoir heater. Heaters and synthetic oil are extra cost accessories and can be 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 not
required.
WARNING: If noise or vibration persists, shut the unit down and correct the cause before further
operation.
N27
Duro 220
Machine Oil A W 220
Citgo Pacemaker 220
Hydroclear Multipurpose R & O Oil 220
Teresstic 220
Harmony 220
DTE Oil BB
Pennzbell R & O 220
Magnus 220
Morlina 220
Sunvis 999
Regal 220 R & O, Code 1531
Carter 220
** List of brand names is for purpose of identifying types and is not to be construed as exclusive
recommendations.
Synthetic Lubricants: Synthetic lubricants offer advantages such as extended service life, a broader
operational temperature range, reduced friction, and the ability to maintain a higher film strength which can
extend the service life of the gear drive. For general operating conditions, AGMA lubricant number and
corresponding ISO Grade should be as shown in Table 4. Synthetic lubricants can be made of various base
stocks which are incompatible with certain gear drive components; therefore, any synthetic lubricant not listed
in this manual should not be used without first consulting your local BAC representative.
Change Interval: The original oil should be replaced after 500 hours or four weeks of operation, whichever
comes first. It is recommended that the oil be drained through the drain plug when it is at operating
temperature. Refill the drive through the air breather port with the recommended type (Tables 3 & 4) and
amount of lubricant (Table 5). See Figure 17 for locations of the gear drive fittings.
Maintenance: Check oil level weekly with the unit idle. Add oil if level is below oil level indicator. Normal operating oil capacity of each gear drive is given in Table 5. Specific gear model number for each unit can also be
found in Table 6, or on the gear drive nameplate. Daily visual inspections and observation for oil leaks and
unusual noises and vibrations are recommended. If any of these occur, the unit should be shut down and the
cause found and corrected.
Periodic checks should be made to ensure the proper alignment of all system components and that all bolts
and external fasteners are tight.
Special precautions are necessary during periods of inactivity. When the internal parts are not continually
bathed by the lubricant as during operation, the gear drive is susceptible to corrosion. For best results, let the
drive cool for approximately four hours after shutdown, start the fan and let run for approximately five minutes.
This will coat the internal parts of the drive with cool oil. Thereafter run the fan for five minutes once a week
throughout the shutdown period to maintain the oil film on the internal parts of the gear drive.
On seasonal shut down, it is recommended that the drive unit be completely filled with oil. This can be
accomplished by filling through the air breather port. Cover the drive with a tarpaulin or other protective covering.
N28
CAUTION: Drain the excess oil before returning the gear drive to service.
By following the above procedures, each BAC gear drive system will provide years of useful service.
Liters
65
0.5
85
110
135
11
155
19
175
5.5
21
Gear Model
Gear Model
3272A
65
3781A
110
3240A
3299A
3333A
3333A (20)
3358A
3379A
3412 A
3436A
3455A
3482A
65
85
65
85
85
3728A
3828A
3872A
3923A
110
110
110
110
3970A
135
85
31056A
135
85
3618A
110
85
85
85
3985A
3583A
3676A
110
110
3527A
110
3501A
85
31132A (50)
135
3604A
110
31213A
135
3672A
110
3473A
3552A
3648A
85
85
110
3725A
110
31132A
31132A (75)
31213A (75)
31301A
110
110
155
155
175
Corrosion Protection
BAC cooling towers are constructed of corrosion-resistant materials. The fill is made of an inert synthetic
material, which requires no protection against rot, decay, rust or biological attack. Other materials used in
construction of the equipment, which are listed below, should be inspected regularly.
Galvanized Steel Components
Galvanized steel components should be inspected for blemishes or corrosion. Affected areas should be wire
brushed and recoated with a cold galvanizing compound such as Zinc Rich Compound (ZRC).
BALTIBOND Corrosion Protection System Components
Galvanized steel components protected with the BALTIBOND Corrosion Protection System may develop
scratches, scrapes or blemishes. These may be touched up with a repair kit (BAC Part No. 16-133P). In the
unlikely event that the damage is more extensive than simple scratches or minor blemishes, contact your local
BAC Representative.
Stainless Steel Components
Stainless steel components should be inspected for signs of blemishes or corrosion and cleaned with
stainless steel wool as necessary. If more extensive corrosion is prevalent, contact your local BAC
Representative.
Fiberglass Reinforced Polyester (FRP) Components
Series 3000 Cooling Towers are provided with FRP casing panels as standard. These components should be
inspected for accumulation of dirt and cleaned with soap and water as necessary.
Gear Model
N29
Winter Operation
BAC cooling towers can be operated at ambient temperatures below freezing provided proper operating
methods are established and diligently followed.
Precautions that must be taken to ensure satisfactory operation include:
Freeze protection of the water in the cold water basin and elimination of water in the optional BALANCE
CLEAN Chamber (Series 3000) and in all internal piping when the tower is idle.
Freeze protection must be provided for the cold water basin during shutdown since ice formation in the
basin can severely damage the cooling tower. A remote sump located indoors in a heated space is an ideal
method since the water in the tower and connecting piping will drain by gravity whenever the circulating
pump is stopped. Where a remote sump arrangement is impractical, the cold water basin heat must be
provided in the tower itself. Electric immersion heaters, steam injectors, or steam coils, controlled by a
thermostat in the cold water basin, may be used. Consult your BAC Representative for details. Additionally,
all exposed make-up lines and water piping that does not drain at shutdown should be traced with electric
heater tape and insulated.
EASY CONNECT Piping Arrangement with BALANCE CLEAN CHAMBER (Optional Series 3000):
Draining the water from the BALANCE CLEAN Chamber and internal piping is essential whenever the
potential for freezing temperatures exist. This can be accomplished by utilizing the 1/2" NPT drain port
located on the inboard side of the BALANCE CLEAN Chamber. There are 3 recommended methods for
draining the piping:
1. The preferred approach is to install a normally open 1/2" solenoid valve on the 1/2" drain connection of
the BALANCE CLEAN Chamber. This valve should be wired in the pump circuit such that it closes
when the pump is energized. The solenoid valve must be selected to operate with a minimum pressure
differential of zero PSI. The zero pressure differential valve is required due to the limited static head
imposed on the valve from the water column.
2. A 1/2" manual valve can be installed on the 1/2" drain connection of the BALANCE CLEAN Chamber.
The valve should be opened during cold weather operation. CAUTION: The valve must be closed
during warm weather to obtain full thermal performance.
3. Remove the 1/2" plug from the 1/2" drain connection of the BALANCE CLEAN Chamber during cold
weather operation. CAUTION: The plug must be reinstalled during warm weather to obtain full thermal
performance.
When operating at subfreezing ambient temperatures, the cooling tower will normally produce leaving water
temperatures appreciably below design. However, low leaving water temperatures tend to promote ice
formation. Therefore, when operating in subfreezing ambient temperatures, the leaving water temperatures
should be maintained as high as possible. The recommended minimum water temperature in the cold water
basin is 43F (6.1C). Additionally, frequent visual inspections should be performed to detect potential icing
problems.
The first step in maintaining a high leaving water temperature is to ensure the tower operates with the
maximum possible heat load. Next, reduce the tower capacity by cycling fans, which modulates the air flow
through the tower. Modulating the water flow rate to the tower is not recommended as a method for cooling
tower capacity control. (CAUTION: Rapid on-off cycling can cause the fan motor to overheat. It is
recommended that controls be set to allow a maximum of 6 on-off cycles per hour.) If the tower is equipped
with two-speed motors or VFD, operation at a lower speed may be sufficient to prevent icing.
Note: When two speed motors are used, the motor starter should include a minimum 15 second time
delay when switching from high to low speed.
N30
However, it may also be necessary to cycle fans off periodically to prevent ice formation and/or to melt ice
that accumulates on the intake louvers and face of the fill of the Series 3000 and Series 1500 Cooling
Towers. Under severe conditions where fan cycling is insufficient to prevent icing, it may be necessary to
operate the fan(s) in reverse for short periods of time to remove any ice accumulation by forcing warm air
through the fill.
WARNING: DO NOT operate the fans in reverse any longer than is necessary since extended reverse
operation may cause ice to form on the fan blades, fan cowl, or eliminators and damage the tower.
1. Ensure all controls for capacity and freeze protection are set properly and functioning normally.
2. Prevent excessively high water levels and possible overflow of the cold water basin due to over
pumping clogged strainers, or make-up valve malfunction.
3. Discover any icing conditions that may develop before they reach the point where the tower or
supports are damaged or system performance is impaired.
For more detailed information on winter operation and for recommended operating procedures on specific
installation, contact your local BAC Representative.
Water Treatment
A proper water treatment program, administered under the supervision of a competent water treatment
specialist, is an essential part of routine maintenance to ensure the safe operation and longevity of evaporative cooling equipment, as well as other system components.
In evaporative cooling products, cooling is accomplished by evaporating a small portion of the recirculating
water as it flows through the unit. As this water evaporates, the impurities originally present in the water
remain behind and, if not controlled, the concentration of dissolved solids will increase rapidly. This can lead
to corrosion, scale or biological fouling which may negatively affect heat transfer as well as the longevity of
the unit and other system components.
Corrosion 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 may lead to under
deposit corrosion.
Biological Fouling Slime and algae formations may reduce heat transfer, promote corrosion, and
harbor pathogens such as Legionella.
Each of these aspects of water quality is discussed in greater detail below. Since the quality of the ambient
air and make-up water varies significantly from job site to job site, BAC strongly 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, the cooling equipment
should never be operated without adequate biological control.
Because of this possibility, cooling towers using reverse fan operation for ice removal should be equipped
with a vibration cutout switch and the duration of reverse operation should be limited to a maximum of 30
minutes. A time delay of approximately 40 seconds between forward and reverse direction should be
incorporated into the motor controls. Lastly, the importance of performing frequent visual inspections and
routine maintenance services during operation in subfreezing weather cannot be overemphasized. These
must be carried out on a routine basis to:
N31
Recommended Level
Hardness as CaCO3
30 to 750 ppm2
pH
Alkalinity as CaCO3
6.5 to 9.0*
N32
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 can
reduce heat transfer, promote corrosion, and promote the growth of potentially harmful organisms such as
Legionella. To avoid biological contamination and minimize the risk of Legionella, initiate the biocide
treatment program at start-up and continue on a regular basis thereafter in accordance with the treatment
suppliers instructions. Bleed/blowdown or chemical treatment used for corrosion and scale control alone is
not adequate for control of biological contamination.
Solid or granular biocides should be introduced through a chemical "pot" feeder installed in parallel with the
system circulating pump(s). Dilute 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.