ACS BFC 600 Guide

Blown Film Coolers 882.04341.00 • 08.09.2023 i
Blown Film Coolers
Part Number: 882.04341.00
Revision Date: 08.09.2023
Revision: A
OPERATION AND INSTRUCTION MANUAL
BFC 600, 1000, 1500, 2000, 3500, 5000

Blown Film Coolers 882.04341.00 • 08.09.2023 ii
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without
notice.
DCN No. ____________
© Copyright 2023 All rights reserved.

Blown Film Coolers 882.04341.00 • 08.09.2023 iii
Shipping Info
Inspecting Packaging and Equipment
Please inspect all packaging for any damage prior to unpacking. If you see any damage to
the packaging, please take pictures of the packaging prior to unpacking the equipment.
Once the pictures are taken of the packaging, take pictures of the equipment as well.
If the packaging is damaged, write Damaged Freight on the delivery receipt. If we find the
equipment is damaged, a claim can be filed.
Thoroughly check the equipment for any damage that might have occurred in transit, such
as broken or loose wiring and components, loose hardware and mounting screws, etc.
Please take pictures of the damage.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the freight claims are filed by
the terms below.
If the order is prepaid, ACS Group is responsible for the freight payment. ACS will file the
claim with the truck line. We need pictures of the damaged freight and a copy of the
delivery receipt marked Damaged Freight. ACS must be notified within 24 hours of any
damage. The driver should give you a claim number before they leave your facility.
If the order is collect or third party billing to a customer’s account, the customer is
responsible to file the claim with the truck line. You will need pictures of the damaged
freight and a copy of the delivery receipt marked Damaged Freight to file the claim. The
driver should give you a claim number before they leave your facility.
Advise customer service regarding your wish for assistance and to obtain an RMA (Return
Material Authorization) number. If you need assistance, contact the shipping supervisor at
262-641-8600.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization and,
you have received your RMA (Return Material Authorization) number from ACS.
A certified copy of our invoice is available upon request. The original Bill of Lading is
attached to our original invoice. If the shipment was prepaid and ACS is responsible for the
freight, we will submit the claim. You will need pictures of the freight, a copy of the delivery
receipt marked damaged freight and the claim number.

Blown Film Coolers 882.04341.00 • 08.09.2023 iv
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
Machine
Bill of lading
Packing list
Operating and Installation manual
Electrical schematic and panel layout drawings
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately.
Please call 262-641-8600. Have the order number and item number available.
Hold the items until you receive shipping instructions. Do not return any goods before
receiving your RMA (Return Material Authorization) number from ACS.
Returns
Do not return any goods before receiving your RMA (Return Material Authorization)
number and shipping instructions from ACS.

Blown Film Coolers 882.04341.00 • 08.09.2023 v
Table of Contents
CHAPTER 1: SAFETY................................................................ 1
1-1 How to Use This Manual............................................................................................................1
Safety Symbols Used in this Manual.......................................................................1
1-2 General Safety Regulations........................................................................................................2
1-3 Responsibility.............................................................................................................................2
1-4 Warnings and Precautions.........................................................................................................4
CHAPTER 2: FUNCTIONAL DESCRIPTION..............................5
2-1 Models Covered in This Manual................................................................................................ 5
Model Identification..................................................................................................5
2-2 General Description................................................................................................................... 5
2-3 Typical Features and Components.............................................................................................5
CHAPTER 3: INSTALLATION.................................................. 10
3-1 Uncrating the Equipment.........................................................................................................10
3-2 In the Event of Shipping Damages........................................................................................... 10
3-3 If Shipment is not Complete.................................................................................................... 10
3-4 Returns.....................................................................................................................................11
CHAPTER 4: INSTALLATION.................................................. 12
4-1 Selecting a Location................................................................................................................. 12
4-2 Installing Coil Assembly and Blower........................................................................................ 12
4-3 Power Supply and Wiring.........................................................................................................15
4-4 Piping....................................................................................................................................... 15
4-5 Condensate Drain Piping Considerations.................................................................................16
4-6 Installing Chilled Water Piping.................................................................................................16
4-7 Air Handling System Considerations........................................................................................18
4-8 Air Handling System Insulation Considerations.......................................................................19
CHAPTER 5: OPERATION....................................................... 20
5-1 Start-up.................................................................................................................................... 20
5-2 Starting the Cooler...................................................................................................................20
5-3 Adjusting the 3-Way Valve for Proper Temperature...............................................................21
Raising the Temperature...........................................................................................21
Lowering the Temperature........................................................................................21
CHAPTER 6: MAINTENANCE.................................................. 22
6-1 Servicing the Filter................................................................................................................... 22

Blown Film Coolers 882.04341.00 • 08.09.2023 vi
6-2 Servicing the 3-Way Valve....................................................................................................... 22
CHAPTER 7: TROUBLESHOOTING........................................ 25
CHAPTER 8: APPENDIX.......................................................... 27
8-1 Customer Satisfaction Warranty Program...............................................................................27
SafetyChapter 1:
How to Use This Manual1-1
Use this manual as a guide and reference for installing, operating, and maintaining your
machine. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the machine. We can also provide the assistance of a factory-trained technician to help train
your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the machine.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in addition
to information for operating the machine safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly
instructions for those areas of the equipment requiring service. Preventive maintenance sections
are included to ensure that your machine provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and available
options. A spare parts list with part numbers specific to your machine is provided with your
shipping paperwork package. Refer to this section for a listing of spare parts for purchase.
Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.

Blown Film Coolers 882.04341.00 • 08.09.2023 ii
DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
CAUTION! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property
damage.
General Safety Regulations1-2
These regulations should be read, understood and periodically reviewed by all personnel
involved in any way with this machine.
Never operate or remove any machine components that are secured by mechanical fasteners
unless the motor is electrically locked out and all moving parts are motionless.
Do not circumvent the safety interlocks.
Extreme care should be taken to see that all bolts are properly tightened at all times during the
operation of the machine.
Service personnel should observe PPE (Personal Protective Equipment) requirements for Arc
Flash per OSHA1910 and NEC70 standards.
Responsibility1-3
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Become familiar with materials, inspection, speed limitations, guard maintenance, and total
user responsibility while using or servicing the equipment.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. Any actual or potential
dangerous conditions must be reported to your immediate supervisor.

Blown Film Coolers 882.04341.00 • 08.09.2023 iii
Safety Tags and Warning Labels
Hazard Alert Symbol Description/Explanation
Electrical Ground Hazard
Mandatory Symbol Description/Explanation
Read operators Manual. This equipment must be operated
and maintained by properly trained personnel. The
information contained within this manual must be read and
understood prior to operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical
power. Therefore, when performing any maintenance
operations, we recommend following the local standards for
performing a lock-out/tag-out procedure. Lock out power
whenever worked on to prevent electrical shock.
Safety Gloves Required. Wear gloves to prevent injury when
performing maintenance work to avoid serious injury.
Eye & Ear protection required. This unit may produce loud
and continuous noise and may produce projectiles.
Do not reach into unit. Reaching into a unit is prohibited
while the unit is in operation and may cause serious injury.

Blown Film Coolers 882.04341.00 • 08.09.2023 iv
Do not step. Stepping on the unit is prohibited and may cause
serious injury.
Do not operate the unit without guards. Operating the unit
with guards removed is prohibited and may cause serious
injury.

Blown Film Coolers 882.04341.00 • 08.09.2023 v
Warnings and Precautions1-4
Our machines are designed to provide safe and reliable operation when installed and operated
within design specifications, and follow national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this machine, use good judgment and follow these safe practices:
LEARN AND OBEY your company’s safety policy regarding mechanical and electrical 
equipment.
Follow all SAFETY CODES.
Wear SAFETY GLASSES and WORK GLOVES.
Use care when LOADING, UNLOADING, RIGGING or MOVING this equipment.
Operate this equipment within design specifications.
OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. It is a good 
idea to remove the fuses and carry them with you.
Make sure that the blown film cooler is properly GROUNDED before switching power 
on.
When welding or brazing in or around this equipment, make sure VENTILATION is 
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet
metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if
needed.
Do not jump or bypass any electrical safety control.
Do not restore power until all tools, test equipment etc. have been removed and the 
panels replaced.
Only PROPERLY TRAINED personnel familiar with the information within this manual 
should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide by
the foregoing recommendations in order to make operator safety a reality.
Functional DescriptionChapter 2:
Models Covered in This Manual2-1
BFC600, BFC1000, BFC1500, BFC2000, BFC3500, and BFC5000
Model Identification
The serial tag label lists blown film cooler model numbers. When contacting the
manufacturer, provide the model number, serial number, and operating voltage of the
cooler.

Blown Film Coolers 882.04341.00 • 08.09.2023 vi
Model numbers describe the cooler model and rated air flow in cubic feet per minute. For
example, a BFC3500 Series blown film cooler has a capacity air flow of 3,500 cubic feet per
minute (5,946 cubic meters per hour).
General Description2-2
The Blown Film Cooler (BFC) eliminates production variables in the air ring supply, including
air temperature, pressure, and volume. The BFC units use a modulated chilled water supply
to provide a constant leaving air temperature to the process. The air inlet adapter assures
that the air stream covers the full face of the cooling coil to provide optimum cooling
efficiency.
Typical Features and Components2-3
• Bolt-on support legs.
• Condensate trap.
• Insulated heavy-gauge steel cabinet designed for up to 35 IWC (1.26 PSI) (8.7 kPa) static
pressure.
• Dial thermometers for discharge air and chilled water supply/return.
• Air inlet and outlet adapters.
• Copper tube aluminum fin chilled water-cooling coil.
• Insulated drip pan.
• Permanent filter.
• Choice of 230/3/60 or 460/3/60 operating voltages if equipped with blower.
• 1-year warranty on parts.
Optional
• Pre-piped automatic 3-way chilled water control valves
• Pre-piped automatic 2-way chilled water control valves; for use only with a distributed
chilling system, not with a dedicated chiller
• Electric blower starters for field mounting
BFC Series Standard Components

Blown Film Coolers 882.04341.00 • 08.09.2023 vii
Figure 1
Note: Optional blower not shown. Contact the manufacturer for more information.
Figure 2 BFC Standard Dimensions
Chilled water
inlet
Chilled water
outlet
Air
outlet
Optional 3-way
regulating valve
Air outlet
thermometer
Dr
ain
Air
inlet
Chilled water
thermometers

Blown Film Coolers 882.04341.00 • 08.09.2023 viii
F
A
Front View
C
D
Top View
B
Right view
Inlet
(dia.)
H
J
G
Air
inlet
(dia.)
Drain
(dia.)
Outlet
(dia.)
3-way regulating
valve (diameter)
EE
Note: Allow a clearance of 48” (1.3 m) on each side of the blown film cooler to permit access to the
filter.
BFC Standard Dimensions

Blown Film Coolers 882.04341.00 • 08.09.2023 ix
Table 1
Model
Number
Dimensions
A B C D E F G H J
in.
(
cm
)
in.
(
cm
)
in.
(cm)
in.
(
cm
)
in.
(
cm
)
in.
(c
m
)
in.
(
cm
)
in.
(
cm
)
in.
(
cm
)
BFC600
50 (127)
38
(
97
)
36 (91)
43 (109)
40 (102)
30 (
7
6)
58
(
148
)
4
2 (107)
25 (64)
BFC1000 50 (127) 38 (97) 46 (117) 45 (114) 40 (102) 30 (76) 60 (152) 46 (117) 28 (71)
BFC1500 55 (140) 38 (97) 48 (122) 44 (112) 40 (102) 27 (69) 65 (165) 50 (127) 32 (81)
BFC2000
70 (178)
38
(
97
)
55 (
1
40)
44 (
11
2)
50 (127)
30 (76)
80 (203)
65 (165)
35 (89)
BFC3500 76 (193) 47 (120) 61 (155) 53 (135) 50 (127) 25 (64) 83 (211) 68 (173) 30 (76)
BFC5000 83 (211) 53 (135) 70 (178) 65 (165) 50 (127) 15 (38) 92 (234) 76 (193) 20 (51)
Table 2
Dimensions
Model
Number
Air inlet/outlet
dia.
3-way regulating
valve
Water
inlet
and outlet dia.
Drain dia.
in.
(
c
m
)
dia. inches NPT
inches NPT

inches NPT
BFC600
10
(
25
.
4
)
¾
1
¾
BFC1000 10 (25.4) 1 1¼ ¾
BFC1500 14 (35.6) 1¼ 1½ ¾
BFC2000
14
(
35
.
6
)
1½
2
¾
BFC3500 16 (40.6) 2 2½ ¾
BFC5000 18 (45.7) 2 2½ ¾
 The customer is responsible to convert measurements to metric. Multiply inches by 25.4 to convert
to mm.

Blown Film Coolers 882.04341.00 • 08.09.2023 x
BFC Series Technical Specifications
Table 3
Optional blower motor Shipping weights
Model
Number
16
IWC
(3.9 kPa)
35
IWC
(8.7 kPa)
W
ith blower
Air flow
Die
S
tatic
S
tatic
Base
16
(
3.9 kPa
)
35
(
8.7 kPa
)
at
rated
hp/kW
maximum
dia.
pressure
pressure
unit
S
tatic
pressure
S
tatic
pressure
c
fm
(
cmh
)
in.
(
cm
)
Hp
(
kW
)
Hp
(
kW
)
lbs.
(k
g
)
lbs.
(k
g
)
lbs.
(k
g
)
BFC600 600 (1,019) 5 (12.7) 3 (2.24) 7½ (5.6) 440 (205) 570 (265) 1,030 (478)
BFC1000 1,000 (1,699) 18 (45.7) 5 (3.73) 10 (7.5) 440 (205) 570 (265) 1,030 (478)
BFC1500
1,500
(
2,548
)
30
(
76.2
)
7½
(
5.60
)
15
(
11.
2)
690
(
321
)
890
(
413
)
1,325
(
615
)
BFC2000
2,000
(
3,398
)
40
(
101.6
)
10
(
7.46
)
20
(
14.9
)
740
(
344
)
965
(
448
)
1,465
(
680
)
BFC3500 3,500 (5,946) 60 (152.4) 20 (14.92) 40 (29.8) 1,260 (585) 1,710 (794) 2,365 (1,098)
BFC5000
5,000 (8,495) 80 (203.2) 30 (22.38) 60 (44.8) 1,880 (873)
2,465
(1,144) 3,165 (1,469)
Entering air @ 110°F (43°C) dry bulb, 83.5°F (29°C) wet bulb, 30°F (-1°C) chilled water = 50°F (10°C)
leaving air temperature.

Blown Film Coolers 882.04341.00 • 08.09.2023 xi
InstallationChapter 3:
Uncrating the Equipment3-1
Remove the crate from the skid base. You should inspect your BFC Series blown film cooling
system for possible shipping damage. If the crate, skid, and packing materials are in re-
usable condition, save them for reshipment if necessary.
Thoroughly check the equipment for any damage that might have occurred in transit, such
as broken or loose components, loose hardware, and mounting screws, etc. In case of
breakage, damage, shortage, or incorrect shipment, refer to the following sections.
In the Event of Shipping Damages3-2
Important: According to contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s 
inspection. Do not return any goods to the manufacturer before the
transportation company inspection and authorization.
File a claim against the transportation company. Substantiate the claim by referring 
to the agent’s report. A certified copy of our invoice is available upon request. The
original Bill of Lading is attached to our original invoice. If the shipment was prepaid,
write us for a receipted transportation bill.
Advise the manufacturer regarding your wish for assistance and to obtain an RMA 
(return material authorization) number.
If Shipment is not Complete3-3
Check the packing list. Back-ordered items are noted on the packing list. You should have:
BFC Series blown film cooling system.
Bill of Lading.
Packing list.
Operating and Installation packet.
Component instruction manuals.
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking. Determine that the item was not inadvertently taken from the area before you
checked in the shipment. Notify the manufacturer immediately of the shortage.

Blown Film Coolers 882.04341.00 • 08.09.2023 xii
Returns3-4
Important: Do not return any damaged or incorrect items until you receive shipping
instructions from the manufacturer.

Blown Film Coolers 882.04341.00 • 08.09.2023 xiii
InstallationChapter 4:
Selecting a Location4-1
For conventional applications, you should place the blown film cooling system near film
processing areas. Make sure that you allow adequate clearance for installing the connecting
ducts, access to the filter, and the flexible tubing of the air handling system. The length of
the tubing to each inlet of the air ring should be approximately equal and as short as
possible for proper air distribution. See Figure 7 on Page 18 for more information.
Installing Coil Assembly and Blower4-2
Bolt the blown film cooling system firmly to the floor, being careful to provide proper
alignment of the blower and air handling piping. The optional blower is shipped separately
from the cooling assembly. The blower is supplied with a flexible connection. Clamp the
other end of the flexible connection to the inlet of the cooling assembly.
Note: When placing the blown film cooling system, make sure that you allow for sufficient
clearance for servicing the blown film cooler filter.

Blown Film Coolers 882.04341.00 • 08.09.2023 xiv
Figure 3 Typical Electrical Schematic

Blown Film Coolers 882.04341.00 • 08.09.2023 xv
Wiring Specifications: 16” (3.9 kPa) Static Pressure
Table 4
Model
Number Optional blower
motor
Disconnect size Fuse size Full load
amps
(blower)
Starter size
(blower)
hp
kW
Voltage
amps
amps

BFC600
3
2.2
230/3/60
30 A
12.0
7.9
0
460/3/60
30 A
6.0
3.9
0
BFC1000 5 3.7 230/3/60 30 A 23.0 15.2 1
460/3/60
30 A
11.5
7.6
0
BFC1500 7½ 5.6 230/3/60 60 A 33.0 22.0 1
460/3/60
30 A
16.5
11.0
1
BFC2000
10
7.
5
230/3/60
60 A
42.0
28.0
2
460/3/60
30 A
21.0
14.0
1
BFC3500 20 14.9 230/3/60 100 A 81.0 54.0 3
460/3/60
60 A
40.5
27.0
2
BFC5000 30 22.4 230/3/60 200 A 120.0 80.0 3
460/3/60
60 A
60.0
40.0
3
Fuse size based on Type J fuses, calculated at 1.5 times full load amps.
Wiring Specifications: 35” (8.7 kPa) Static Pressure
Table 5
Model
Number
Optional blower
motor
Disconnect size Fuse size Full load
amps
(blower)
Starter size
(blower)
hp
kW
Voltage
amps
amps

BFC600
7½
5.6
230/3/60
60 A
33.0
22.0
1
460/3/60
30 A
16.5
11.0
1
BFC1000 10 7.5 230/3/60 60 A 42.0 28.0 2
460/3/60
30 A
21.0
14.0
1
BFC1500
15
11.
2
230/3/60
100 A
63.0
42.0
2
460/3/60
60 A
31.5
21.0
2
BFC2000
20
14.9
230/3/60
100 A
81.0
54.0
3
460/3/60
60 A
40.5
27.0
2
BFC3500 40 29.8 230/3/60 200 A 156.0 104.0 4
460/3/60
100 A
78.0
52.0
3
BFC5000 60 44.8 230/3/60 400 A 231.0 154.0 5
460/3/60
200 A
115.5
77.0
4
 Fuse size based on Type J fuses, calculated at 1.5 times full load amps.