BAC PT2 Manual

OPERATION & MAINTENANCE MANUAL
PT2 Cooling Tower

Recommended Maintenance Intervals[1]
DANGER: Rotating equipment will cause
severe personal injury or death to persons who
come in contact. Do not perform any service,
maintenance or inspection on or near the fans,
motors, and drives, or inside the unit without
first ensuring that the fan and pump motors are
disconnected, locked out, and tagged out.
NOTES:
1. Recommended service intervals are the minimum for typical
installations. Different environmental conditions may dictate more
frequent servicing.
2. When operating in ambient temperatures below freezing, the unit
should be inspected more frequently. Refer to “Cold Weather Operation”
on page 24 for more details.
3. Tension on new belts must be readjusted after the first 24 hours of
operation and quarterly, thereafter.
Inspect and clean as necessary: Start-Up Monthly Quarterly Annually Shutdown
Inspect general condition of the tower[2] and check unit
for unusual noise or vibration
Inspect cold water basin
Flush water distribution system/Inspect spray nozzles
Drain basin and piping
Inspect combined inlet shields
Verify combined inlet retainers are compressed
Check and adjust water level in basin(s)
Check operation of make-up valve
Check and adjust bleed rate
Inspect tower finish
Mechanical equipment system: Start-Up Monthly Quarterly Annually Shutdown
Check belt condition
Adjust belt tension[3]
Lubricate fan shaft bearings
Lubricate motor base adjusting screw
Check drive alignment
Check motor voltage and current
Clean fan motor exterior
Check fan motor for proper rotation
Check general condition of the fan
Check and unplug fan drain holes (hollow blade fans)
Check fan for uniform pitch
Check fan for rotation without obstruction
Check and recoat steel shafts with RUST VETO®

Table of Contents
Safety and Equipment Precautions
2Safety Precautions
2Equipment Precautions
3General Maintenance Information
3Warranties
PART 1 Unit Operation and Storage
4Start-Up Procedure
6Extended Shutdown
7Prolonged Outdoor Storage
PART 2 Detailed Component Maintenance Procedures
10 Cold Water Basin
11 Fan
12 Fan Drive System
14 Fan Motors
15 Fan Shaft Bearings
16 Water Distribution and Heat Transfer Section
16 Water Level Control
PART 3 Corrosion Protection
18 Water Treatment
19 Corrosion and Scale Control
20 Chemical Treatment Requirements
20 Passivation
20 Biological Control
21 Long Term Care of Stainless Steel
PART 4 Bleed Rate
23 Bleed Rate
PART 5 Cold Weather Operation
24 Inspection & Maintenance
24 Fan Section Icing Protection
25 Basin Water and Internal Piping Freeze Protection
PART 6 Operation Considerations for Accessories
26 Basin Heater (Optional)
26 Stand Alone BAC Heater Control Panel (Optional)
28 Vibration Cutout Switch (VCOS)
Part 7 Fan Control
30 Independent Fan Control (Optional)
30 Variable Frequency Drive Operation
31 Resonant Speed Identification Procedure
PART 8 Installation Instructions for Field
Connections – TriArmor®Corrosion
Protection System Cold Water Basin
33 Installation Instructions
OPERATION & MAINTENANCE » PT2 COOLING TOWER
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DANGER
• DANGER: Rotating equipment will cause severe personal injury or death to persons who come in contact. Do not perform any service, maintenance
or inspection on or near the fans, motors, and drives, or inside the unit without first ensuring that the fan and pump motors are disconnected,
locked out, and tagged out.
• WARNING: The top horizontal surface of the unit is not intended to be used 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: 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 fan’s “critical speed” which could result in fan failure and possible personal
injury or damage. Contact your local BAC Representative regarding any such applications.
• 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.
• WARNING: All electrical, mechanical, and rotating machinery are potential hazards, particularly for those not familiar with their design,
construction, and operation. Accordingly, use appropriate lock out procedures. 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.
• WARNING: To prevent possible contamination of the make-up water supply, install a backflow prevention method in accordance with applicable
local and national codes.
• CAUTION: The operation, maintenance, and repair of this equipment shall be undertaken only by personnel authorized and qualified to do so. All
such personnel shall be thoroughly familiar with the equipment, the associated system and controls, and the procedures set forth in this manual.
Proper care, personal protective equipment, procedures, and tools must be used in handling, lifting, installing, operating, maintaining, and
repairing this equipment to prevent personal injury and/or property damage.
• CAUTION: This equipment should never be operated without all fan screens, access panels, and access doors in place.
• CAUTION: Openings and/or submerged obstructions may exist in the bottom of the cold water basin. Use caution when walking inside this
equipment.
• CAUTION: Do not use the plastic eliminators as a walking, working, or storage surface. Misuse can result in physical injury and/or equipment
damage. After ensuring that the fan and pump motors are locked and tagged out, lift and remove eliminators as necessary to perform
recommended maintenance and inspections. If access to the top of the fill is required, place a piece of plywood at least 1/2 inch thick on top
of the fill to protect the surface while performing the recommended maintenance. When finished, carefully remove the plywood and replace any
eliminators which were removed.
• CAUTION: Combined inlet shields can separate from the product during high winds. Fasten combined inlet shields in place using the retaining
system.
WARNING
CAUTION
Safety Precautions

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NOTICE
• 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. See “Prolonged Outdoor Storage” on
page 7 for more details..
• 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 “Cold Weather Operation” on page 24 for more details.
• The basin heater is not designed to prevent icing during unit operation.
• Ensure the controls for the fan motor are set to allow a maximum of six on-off cycles per hour to prevent motor overload.
• When reversing the direction of fan rotation, allow the fan to come to a complete stop before restarting the motor.
• Only lubricate the bearings with one of the compatible water resistant greases listed on page 15.
• Spray system pressure greater than 10.0 psig may cause damage to the distribution system.
• Never use chloride or chlorine based solvents such as bleach or muriatic (hydrochloric) acid to clean stainless steel. It is important to
rinse the surface with warm water and wipe with a dry cloth after cleaning.
• Do not use steam or high pressure water to clean PVC eliminators or materials other than steel.
The services required to maintain a piece of evaporative cooling equipment are primarily a function of the quality of the air and water in
the locality of the installation:
• 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 equipment and absorbed by the recirculating water to form a corrosive solution.
• WATER: The most harmful conditions develop as water evaporates from the equipment, 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. Refer to “Water
Treatment” on page 18 and “Biological Control” on page 20 for more details.
Please refer to the Limitation of Warranties in the submittal packet 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 shutdown, and the approximate frequency
of each.
General Maintenance Information
Warranties
Equipment Precautions

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Figure 1. PT2 Cooling Tower
PT2
Unit Operation and Storage
1
Start-Up Procedure
Considerations for Initial Start-Up
• For units with independent fan control, see page 30.
• For units with VFDs, see page 30.
• For units with vibration cutout switches, see page 28.
Access Door
Axial Fan
Fan Guard
Hot Water
Distribution
Fill
BALTIDRIVE®
Power Train
(Internal Motor Shown)
InterLok™
System
Water Outlet with Strainer
Cold Water Basin
Make-up Valve
Adjustment Float
Combined Inlet Shields
Drift Eliminators
Hot Water Inlet (Not Shown)
Basin Heater (Optional)
Motor Davit
(Optional)

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DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.
General
• If the unit is mounted on vibration isolators (by others), refer to the vibration isolation
manufacturer’s guidelines before loading/unloading weight from the unit.
• Verify the fan and the pump motors are disconnected, locked out, and tagged out.
Cleaning
• Drain the cold water basin with the strainer in place.
• Remove all dirt and debris from the fan guard(s) and combined inlet shields.
• Inspect and clean all spray nozzles.
• Clean all of the mechanical components, such as the fan and motor.
• Flush the cold water basin to remove any accumulated dirt and debris.
• Remove, clean, and replace the basin strainer.
Inspection
• Conduct external inspection of the equipment. Check for leaks, corrosion, and any
structural damage.
• Conduct internal inspection of the equipment. Check for anything unusual such as
structural or mechanical component damage.
• Inspect piping and connections.
• Thoroughly inspect the fan(s) for any mechanical or physical damage.
• At seasonal start-up or after prolonged shutdown, check the motor insulation with an
insulation tester prior to the motor start-up.
• Except for the PT2-0412, prior to seasonal start-up, check and adjust the belt
tension. Prior to the initial start-up, the belt tension may not require adjustment as the
drive will be properly tensioned at the factory prior to shipment. However, tension of
new belts must be adjusted after the first 24 hours of operation.
Start-Up
• Prior to seasonal start-up, lubricate the motor base adjusting screw, if applicable (see
page 14) and the fan shaft bearings (see page 15). At initial start-up, no bearing
lubrication is required since the bearings are factory lubricated prior to shipment.
• Apply RUST VETO®to steel shafts, and bushings.
• Fill the cold water basin with fresh water to the overflow level via the make-up valve.
• Set the make-up valve float so the water shuts off at the operating level (see Table 1
on page 10).
• Start the system pump.
• Adjust the system flow rate to the design rate. Open the supply valve slowly until the
design flow is reached.
• Check that the float operated make-up valve is operating freely. Closely monitor the
water level and adjust as necessary during the first 24 hours of operation.
• Inspect the nozzles and heat transfer section as described in “Water Distribution and
Heat Transfer Section” on page 16.
• For multicell arrangements, balance flow between the cells to obtain even water
distribution.
Unit Operation and
Storage
Start-Up Procedure
Considerations for Initial
Start-Up
General
Cleaning
Inspection
Start-Up
NOTICE: Spray system pressure
greater than 10.0 psig may cause
damage to the distribution system.

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After 24 hours of operation
under thermal load, perform the
following services:
9Check the unit for any unusual
noises or vibrations.
9Check the operating water
level in the cold water basins.
9Adjust the make-up valve if
necessary.
9Check the belt tension and
readjust if necessary.
9Inspect the spray nozzles and
heat transfer section.
• Execute one of the following biocide treatment programs while operating the
circulating pump and prior to operating the unit fan(s):
–Resume treatment with the biocide that was used prior to shutdown. Operate the
pump only while maintaining the maximum recommended biocide residual for a
sufficient duration (residual and time will vary with the biocide) as recommended
by the water treatment supplier. Start the fan only after this treatment period is
completed.
–Check the pH of the circulating water and, if necessary, adjust it to 7.0 - 7.6 pH.
Then, running the pump only, treat the system with sodium hypochlorite to maintain
a level of 4 to 5 mg/l (ppm) free chlorine (as Cl2) over a six hour period. Test kits for
measuring the free residual of chlorine are commercially available. Start the fan only
after this treatment period is completed.
• Verify proper fan tip clearance. Refer to Fan “Inspection & Maintenance” on page 11.
• Adjust the valve (supplied by others) in the unit bleed line until the desired bleed rate
is reached.
• For initial start-up, briefly energize the fan motor(s) and note the direction of rotation.
The fan should rotate in the direction indicated by the arrow on the fan cowl.
• Run the fan in manual mode for several minutes to check for any unusual noise or
vibrations.
• For a 2-speed motor, check to ensure the starter includes a minimum 15 second time
delay when switching from high speed to low speed.
• Check the operation of the optional vibration cutout switch if ordered. Refer to page
29 for more information.
• Once the cooling tower is operating, check the current and voltage of all three phases
(legs) of the fan motor with a heat load on the unit under warm ambient conditions.
The current must not exceed the motor nameplate rating.
• Verify combined inlet shield retainers are compressed to engage the combined inlet
shields (CIS). This will prevent the CIS from separating from the unit during high
winds.
Extended Shutdown
Perform the following services whenever the unit is shutdown in excess of three days:
• If the unit is mounted on vibration isolators (by others), refer to the manufacturer’s
guidelines before loading/unloading weight from the unit.
• Disconnect, lock out, and tag out the fan and pump motors.
• Close the shut-off valve in the make-up water line (supplied by others).
• Disconnect, lock out, and tag out power to the optional basin heater, if applicable,
before draining the cold water basin.
• Drain the cold water basin and all the piping that will be exposed to freezing
temperatures. Heat trace and insulate all exposed piping.
• Clean all debris, such as leaves and dirt, from the interior and exterior of the unit,
including the combined inlet shields.
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.
NOTICE: Ensure the controls for
the fan motor are set to allow a
maximum of six on-off cycles per
hour to prevent motor overload.

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• Clean and flush the cold water basin with the basin strainer in place.
• Leave the cold water basin drain open so rain and melting snow will drain from the
tower.
• Clean the basin strainer and re-install.
• Cover the fan discharge to keep out dirt and debris.
• Except for the PT2-0412, lubricate the fan shaft bearings, motor base, and motor
base adjusting screw.
• Apply RUST VETO®to steel shafts and bushings.
• Inspect the protective finish on the unit. Clean and refinish as required. Refer to
“Corrosion Protection” on page 18 for more details.
• Lock out the fan motor starting device in the “OFF” position to ensure personal safety
in case of future inspection or service.
• Verify combined inlet shield retainers are compressed to engage the combined inlet
shields (CIS). This will prevent the CIS from separating from the unit during high
winds.
Prolonged Outdoor Storage
Perform the following services whenever the unit will be shutdown and stored in excess
of three months. Conduct the “Extended Shutdown” procedure on page 6 if the unit is
installed.
Water Distribution System
• Ensure the cold water basin is fully drained and the drain is open to minimize
stagnant buildup in the basin.
Motors and Drives
BAC standard motors are designed for storage at ambient temperatures of -20ºF to 104ºF
(-28.9ºC to 40ºC). Prolonged periods of exposure above or below these specified conditions
could degrade components of the motor and cause malfunction or premature failure.
• Motors should be removed and stored inside whenever possible. When indoor storage
is not possible, the motors must be covered with a breathable tarp. Do not use plastic
or plastic film. This cover should extend below the motor and be secured; however,
it should not tightly wrap the motor. This will allow the captive air space to breathe,
minimizing formation of condensation.
• Care must also be taken to protect the motor from flooding or from harmful chemical
vapors.
• The storage area should be free from ambient vibration. Excessive vibration can cause
bearing damage.
• Precautions should be taken to prevent rodents, snakes, birds, or other small animals
from nesting inside the motors. In areas where they are prevalent, precautions must
Unit Operation and
Storage
Start-Up Procedure
Start-Up
Extended Shutdown
Prolonged Outdoor Storage
Water Distribution System
Motors and Drives
NOTICE: Covering the unit with
a clear plastic tarpaulin during
storage can trap heat inside the
unit and cause damage to the PVC
components.

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also be taken to prevent insects from gaining access to the interior of the motor.
• If not stored indoors in a controlled environment, some form of heating must be
utilized to prevent condensation from accumulating in the motor. This heating should
maintain the winding temperature at a minimum of 9ºF (5ºC) above the ambient
temperature of the surrounding environment, keeping it from dropping below the dew
point where condensation could form inside the motor. If space heaters are supplied,
they should be energized. Request the required voltage and transformer capacity from
your local BAC Representative. A third option is to use an auxiliary heat source and
keep the winding warm by either convection or blowing warm air into the motor.
• Lubricate the fan shaft bearings at shutdown. Rotate the motor shaft monthly to
redistribute bearing grease.
• Remove and store fan belts at room temperature, keeping matched belts together. Tag
belts appropriately for future identification. Failure to remove the belts from the unit
for storage can result in severe degradation of the belt life.
• Coat steel sheaves with RUST VETO®, especially where the belt rides, to protect the
sheaves from corrosion. RUST VETO® can be removed with mineral spirits and must
be removed from the grooves of the sheaves before start-up.
Controls (If Ordered)
• Insert desiccant bags into the control panel to absorb moisture. Seal the control panel
for storage.
• Spray coat electrical component housings with a suitable protective coating such as
Cosmoline® Weathershed, and individually cover them with plastic, taking care to
leave openings for free air circulation.
Miscellaneous
• Apply a weather-resistant lubricant or heavy grease such as Anti-Seize (BAC part #
160069) to all exposed threaded or flanged connections as well as the sliding motor
base and motor base adjusting screws if applicable.
• For storage prior to installation, all components and accessories which are not
permanent fixtures in the basin but are shipped inside the unit, should be removed
and stored indoors to protect the components from exposure during storage.
• Verify combined inlet shield retainers are compressed to engage the combined inlet
shields (CIS). This will prevent the CIS from separating from the unit during high
winds.
• Inspect the protective finish on the unit. Clean and refinish as required. Refer to
“Corrosion Protection” on page 18 for more details.
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.

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Maintenance Requirements
• Rotate all fans and motor shafts monthly by hand. Hand-turning will ensure that the
shafts and bearings are free and will redistribute grease within the bearings. Keep
hands away from pinch points such as belts and sheaves.
• Inspect the cold water basin monthly to ensure that the drain is open, and remove any
leaves or debris that may have accumulated in the cold water basin.
• Inspect axial fans prior to start-up and at least once annually to ensure that the blades
are tight and that there is no obvious corrosion between the hub and the fan blade.
• Inspect the rust preventative coating on all motor shafts, fan shafts, and bushings
monthly. If necessary, re-coat the surfaces with RUST VETO.
Start-Up Preparation After Prolonged Storage
Keep in mind that start-up procedures after long periods of storage are just as important
as pre-shutdown procedures.
• Motors should be thoroughly inspected and cleaned and restored to pre-storage
condition.
• Inspect the axial fan(s) prior to start-up to ensure that the blades are tight and that
there is no obvious corrosion between the hub and the fan blades. Do not energize the
fan if there is obvious corrosion of fan components. Loose fan blades could result in
fan failure and possible injury or damage.
• Reinstall all fan belts and motors, and remove all protective coverings.
• For units stored prior to installation, conduct rigging procedures as directed in the
unit’s Rigging and Assembly Instructions, available on www.BaltimoreAircoil.com or by
contacting your local BAC Representative.
• Perform an insulation test of motor windings to ensure satisfactory insulation
resistance.
• Conduct full start-up procedure as stated in the “Start-Up Procedure” on page 4. Be
especially thorough for cleaning and inspection prior to start-up.
Unit Operation and
Storage
Prolonged Outdoor Storage
Motors and Drives
Controls
Miscellaneous
Maintenance Requirements
Start-up Preparation After
Prolonged Storage
Motor Recommendations
Maintenance Requirements
Start-Up Preparation After
Prolonged Storage
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.

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PT2
Detailed Component
Maintenance Procedures
2
Cold Water Basin
As water flows through the cooling tower it is cooled and flows into the cold water
basin then passes through the suction strainer into the system. The cold water basin
is constructed from one of the materials of construction listed below. The following
maintenance instructions apply to all basin materials of construction.
• Galvanized steel
• TriArmor®Corrosion Protection System
• Welded Type 304 stainless steel
Water Levels
Model Number At Overow Level (in.) At Operating Level (in.)
PT2-0412, PT2-0709, PT2-O809, PT2-1009,
PT2-1012, and PT2-1212 10 1/2” 6 5/8”
PT2-0814 and PT2-1214 11” 6 5/8”
PT2-1218 12 1/4” 8 1/2”
• The operating water level in the cold water basin will vary with system thermal load
(evaporation rate), the bleed rate employed, and the make-up water supply pressure.
• The make-up valve controls the operating level, which should be maintained at the
levels shown in Table 1.
• Check the operating water level monthly, and readjust the float when necessary to
maintain the recommended operating level.
• Consult “Water Level Control” on page 16 for information on how to set and maintain
the basin operating level.
Inspection & Maintenance
• Inspect the cold water basin regularly, according to the recommended maintenance
schedule. Remove trash or debris that may have accumulated in the basin or on the
strainer.
Table 1. Cold Water Basin Water Levels (Measured From Inside the Cold Water Basin)

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CAUTION: Openings and/or
submerged obstructions may exist
in the bottom of the cold water
basin. Use caution when walking
inside this equipment.
• Quarterly, or more often if necessary, drain, clean, and flush the entire cold water basin
with fresh water. This will remove the sediment, which can collect in the basin during
operation. If not removed, sediment can become corrosive and cause deterioration of
the protective finish of metallic basins.
–When flushing the basin, leave the strainer in place to prevent the sediment from re-
entering the spray pump.
–Remove the strainer after the basin has been flushed.
–Clean and replace the strainer before refilling the basin with fresh water.
• Adjust the float to maintain the design operating level. See Table 1.
• Verify combined inlet shield retainers are compressed to engage the combined inlet
shields (CIS). This will prevent the CIS from separating from the unit during high winds.
Fan
The PT2 Cooling Tower uses axial fan(s). Thoroughly inspect the fan(s) for damaged or
deteriorated fan blades and replace the fan(s) as required.
Inspection & Maintenance
• If the unit is already in operation, while the fan is running, check for any unusual noises
or vibrations from a safe distance.
• With the fan off and the fan motor disconnected, locked out, and tagged out, check the
general condition of the fan:
–Inspect for any loose or missing bolts in the fan shaft bushing, the fan hub, and the
fan shaft bearing(s).
–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.
–Inspect each blade for excessive scale build-up that could cause vibration.
–Check each blade for any cracks. If cracks are found, the fan motor should be locked
out until the fan is replaced. Contact your local BAC Representative for assistance.
• Tip Clearance: Check the clearance between the tip of the blade and the fan cowl. The
clearance should be between 1/8” and 1/2”.
• Drain Holes: On hollow blades, the drain hole in the blade tip should be unobstructed.
Tip: Use a piece of wire to probe the hole.
• 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° of each other.
• 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 1/2” band at
any single point around the cowl.
• Direction of Rotation: On initial start-up, or if the fan motor has been rewired, briefly
energize the fan motor and note the direction of rotation. It should rotate in the
direction indicated by the arrow on the fan cowl. On units with independent fan motors,
check the rotation of each fan.
• Operation: On initial start-up, run the fan in the manual mode for several minutes, and
check for any unusual noises or vibrations from a safe distance.
Detailed Component
Maintenance
Procedures
Cold Water Basin
Water Levels
Inspection & Maintenance
Fan
Inspection & Maintenance
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.
NOTICE: Ensure the controls for
the fan motor are set to allow a
maximum of six on-off cycles per
hour to prevent motor overload.

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Fan Drive System
Model Specic Fan Drive System Descriptions
Direct Drive Motor [Model PT2-0412]: Factory mounted direct drive system with premium
efficiency totally enclosed motors (Figure 2a).
Externally Mounted Motor [Models PT2-0709, PT2-0809, PT2-0812, and PT2-0814]:
A BALTIDRIVE®Power Train belt drive system with a premium efficiency totally enclosed
motor mounted outside the airstream is provided on these units (Figure 2b).
Internally Mounted Motor [Models PT2-1009, PT2-1012,PT2-1212, PT2-1214, and
PT2-1218]: A BALTIDRIVE®Power Train belt drive system with a premium efficiency
totally enclosed motor mounted inside the airstream is provided on these units (Figure 2c).
Inspection & Maintenance
Direct Drive System
Periodically check the rotation of the fan and motor assembly. No adjustments are
necessary.
BALTIDRIVE® Power Train
BALTIDRIVE® Power Train requires a periodic check of the belt condition and, when
necessary, tension adjustment. The recommended service intervals are as follows:
• Initial Start-up:
–Externally Mounted Motor: The motor base assembly has been pre-aligned at the
factory. Mount the motor base assembly to the unit and verify alignment. Install the
belt and follow the belt tensioning directions on page 13 [PT2-0709, PT2-0809,
PT2-0812, and PT2-0814].
–Internally Mounted Motor: The drive has been tensioned and aligned at the factory.
However prior to initial startup, check belt tension [PT2-1009, PT2-1012,
PT2-1212, PT2-1214, and PT2-1218].
• Seasonal Start-Up: Readjust the belt tension (if required).
• Operation: After the first 24 hours of operation, readjust the belt tension on a new unit
start-up or installation of a new belt. Thereafter, check the belt condition monthly, and
adjust tension as necessary. Readjust tension at least once every three months.
Figure 2b. Externally Mounted Motor Figure 2c. Internally Mounted MotorFigure 2a. Direct Drive Motor

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Detailed Component
Maintenance
Procedures
Fan Drive System
Model Specific Fan Drive
System Descriptions
Inspection & Maintenance
• Belt tension check:
–Place a straight edge along the belt from sheave to sheave as shown in Figure 3a, or
use a tape measure as shown in Figure 3b to measure belt deflection.
–Apply a moderate force by hand (approximately 40 lbs/178 N) evenly across the
width of the belt in the center of the span between the sheaves.
–There is adequate belt tension if the belt deflects between 1/4” and 3/8” as shown
in Figures 3a and 3b.
NOTE: If belts are properly
tensioned, there should be no
“chirp” or “squeal” when the fan
motor is started.
Motor Adjusting Screws
Figure 4a. External Motor Figure 4b. Internal Motor
Motor Adjusting Screw
• Belt tension adjustment (if required):
–Remove the locking wrench (wrench attached to casing near motor/door) by
loosening the plastic thumbscrew.
–Using the supplied locking wrench, wrench, or impact gun, turn the motor
base adjusting screw (Figures 4a and 4b) clockwise to tension the belt or
counterclockwise to relieve belt tension. During adjustment of the belt tension,
rotate the drives several times by hand to evenly distribute the tension throughout
the belt. Keep hands away from pinch points such as where belts engage sheaves.
–When the belt is properly tensioned, align the adjustment bolt to facilitate
replacement of the locking wrench. Replace the locking wrench and tighten the
plastic thumbscrew to secure.
Figure 3a. Belt Tension with a Straight Edge Figure 3b. Belt Tension with a Tape Measure
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.

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14
Fan Motors
Inspection & Maintenance
• Clean the outside of the motor at least quarterly to ensure proper motor cooling.
• After prolonged shutdowns, check the motor insulation with an insulation tester prior
to restarting the motor.
• Check the motor voltage and current following start-up and every three months while in
operation.
Adjustable Motor Base (BALTIDRIVE®Power Train Only)
Coat the motor base slides and adjusting screws (refer to Figures 4a and 4b on page 13)
prior to start-up, every three months while in operation, and following shutdown. Use good
quality, corrosion inhibiting grease such as one of those recommended for lubricating the
fan shaft bearings on page 15, or Anti-Seize (BAC part # 160069).
• Drive alignment check and adjustment:
–Check the drive alignment annually to ensure maximum belt life.
–Place a straight edge across the driver and the driven sheaves as shown in Figure 5.
–There should be no more than 1/16” deviation from the four points of contact with
the straight edge, as shown in Figure 5.
–In case of realignment, loosen the driver sheave, and align it with the driven sheave.
Allow 1/4” for draw-up as the bushing screws are retightened.
Figure 5. Drive Alignment
NOTICE: Ensure the controls for
the fan motor are set to allow a
maximum of six on-off cycles per
hour to prevent motor overload.
NOTE: See page 12 for fan motor
types.
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.

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15
Fan Shaft Bearings
Two pillow block ball bearings support the fan shaft and are provided with extended lube
lines as standard. Each bearing is equipped with a lubrication fitting and a slinger/locking
collar to keep out moisture.
Inspection & Maintenance
• Only lubricate the bearings with a manual grease gun or BAC’s optional Automatic
Bearing Greaser. Do not use high-pressure grease guns because they may rupture the
bearing seals.
• Only lubricate the bearings with one of the following compatible water resistant
greases, which are suitable for ambient temperatures ranging from -65ºF (-53.9ºC) to
+250ºF (121.1ºC).
–Amoco - Rycon Premium #3
–Chevron - SRI
–Citgo - Polyurea MP2™
–Conoco - Polyurea 2™
–Exxon - Polyrex®EM
–Exxon - Unirex N™
–MobilGrease®- AW2
–Shell - Gadus S2 V100 3
–Shell - Gadus S3 T100 2
–SKF - LGHP2™
–Unocal 76 - Unilife Grease™
• Lubricate the bearings as follows:
–Initial Start-Up: Normally, no lubrication is required since the bearings have been
lubricated at the factory prior to shipment. However, if the unit has been stored at
the job site for more than three months, both bearings should be lubricated with
new grease before initial operation. When lubricating, purge the old grease from the
bearing by gradually adding grease until a bead of new grease appears at the seal on
the underside of the bearing.
–Seasonal Start-Up: Purge the bearings with new grease prior to start-up.
–Operation: Purge the bearings with new grease every three months while in
operation.
–Extended Shutdown: Purge the bearings with new grease prior to any prolonged
storage or downtime.
Detailed Component
Maintenance
Procedures
Fan Drive System
Inspection & Maintenance
Fan Motors
Inspection & Maintenance
Adjustable Motor Base
Fan Shaft Bearings
Inspection & Maintenance

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16
Water Distribution System and Heat Transfer Section
The hot water is distributed through a corrosion resistant polyvinyl chloride (PVC) spray
distribution system. The fill and drift eliminators are also made of PVC, which requires no
protection against rot, decay, rust, or biological attack.
The inspection procedure is as follows:
• Shut off the fan and system pump. Lock out and tag out the fan and pump motors.
• Remove drift eliminators to allow a clear view of the spray distribution system and
nozzle patterns.
• Start the system pump. Make sure the fan motor is locked out and tagged out. Check
to see if the nozzles are all spraying consistently and producing the spray pattern
shown in Figure 6.
• Quarterly or more often as required, turn off the fan and pump, and flush any dirt
or debris from the water distribution system to prevent clogged nozzles. Clean any
nozzles that are clogged. If necessary, the nozzle and rubber grommet may be
removed for cleaning. To remove, grasp the nozzle and pull while twisting. Replace any
damaged nozzles. If additional cleaning is necessary the branch may be removed for
cleaning. With the BranchLok™System, tools are not required to remove eliminator
support channels or branches.
With electrical heater tape, heat trace and insulate all exposed water piping, including
pump piping below the overflow level and make-up water lines.
Water Level Control
There are two types of water level controls used on BAC Cooling Towers:
• Mechanical make-up valve assembly
• Optional electric water level control package
Mechanical Make-up Valve Assembly
A float-operated mechanical water make-up assembly is furnished as standard equipment
on the unit. The standard make-up assembly consists of a corrosion resistant make-up
valve connected to a float arm assembly actuated by a polystyrene-filled plastic float. The
float is mounted on an all-thread rod held in place by wing nuts. The cold water basin
operating water level can be adjusted by repositioning the float and all-thread rod using
the wing nuts provided.
• Inspect the make-up valve assembly monthly and adjust if necessary.
• Inspect the valve annually for leakage. Replace the valve seat if necessary.
• Maintain the make-up water supply pressure between 15 psig and 50 psig for proper
operation. BAC recommends a pressure regulator valve (provided by others) for
pressures over 50 psig.
• Set the initial basin water level by adjusting the wing nuts so that the make-up valve is
completely closed when the water level in the cold water basin is at the operating level
as stated in Table 1 on page 10.
Figure 6. Nozzle Spray Pattern
NOTE: If the unit has been ordered
with the optional electric water
level control package or is intended
for remote sump application, a
mechanical water make-up valve
will not be provided.
CAUTION: Drift eliminators are not
designed to support the weight of a
person or to be used as a storage or
work surface for any equipment or
tools. Misuse can result in physical
injury and/or equipment damage.
NOTICE: Do not use steam or
high pressure water to clean PVC
eliminators, fill or materials other
than steel.
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service,
maintenance or inspection on or
near the fans, motors, and drives,
or inside the unit without first
ensuring that the fan and pump
motors are disconnected, locked
out, and tagged out.

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17
• With the design thermal load and the average water pressure (15 to 50 psig) at the
valve, the above setting will produce operating water levels as stated in Table 1 on
page 10.
• 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 those shown in Table 1. If
operating levels are higher than specified, readjust the float in order to attain the
recommended operating level.
• Closely monitor the water level in the cold water basin and adjust the level if necessary
during the first 24 hours of operation.
• Operating 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 provides sufficient excess basin capacity to accept the total
system pull-down volume.
Optional Electric Water Level Control Package
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. For more information,
refer to the Electric Water Level Control Operation & Maintenance Manual available at
www.BaltimoreAircoil.com.
• Clean the stainless steel electrodes periodically to prevent accumulations of scale,
corrosion, sludge, or biological growth, which could interfere with the electrical circuit.
• The water level is maintained at the recommended operating level regardless of the
system thermal load. Therefore, it is not recommended that the operating level be
adjusted.
• During the start-up of units equipped with the electric water level control package,
bypass the control unit in order to fill the unit to the overflow connection.
L.E.D. Status Codes
• L.E.D. on steady: Indicates normal operation.
• Steady one second flashing: Indicates dirty probes, reading in the capacitance mode.
The unit will still operate but will give the following status code of 1 second on, 1
second off (steady 1 second flashing). This status code continue until the probes are
cleaned and the power has been reset. Note: No other status codes will be displayed
until the dirty probes are cleaned.
• Two flashes and off for 5 seconds: Indicates make-up valve ran for more than 1 hour.
The unit will continue to fill, with the following status code of 1 second on, 1 second
off, 1 second on and then off for 5 seconds before repeating. This status will continue
until power has been reset. Possible causes: leaking tank, obstructed fill / defective
valve or reduced flow rate.
• Three flashes and off for 5 seconds: Indicates shorted probes or highly conductive
water. The unit will continue to operate but will give the following status code of 1
second on, 1 second off, 1 second on, 1 second off, 1 second on and then off for 5
seconds before repeating. This status will continue until the water is diluted or the
short is removed from the probes and power is reset.
• Four flashes and off for 5 seconds: Indicates black probe (P6) reads covered, but
white probe (P5) does not read covered (white should also be covered because it is
longer than the black). This will cause the fill solenoid valve to short cycle and lead to
premature failure of the fill valve. The unit will short cycle and give the status code of
1 second on, 1 second off, 1 second on, 1 second off, 1 second on, 1 second off, 1
second on and then off for 5 seconds before repeating. The unit will continue to short
cycle until the condition has been corrected (clean white probe) and the power reset.
• L.E.D. does not come on after power up or resetting power: Indicates unit inoperative.
Detailed Component
Maintenance
Procedures
Water Distribution and Heat
Transfer Section
Water Level Control
Mechanical Make-up Valve
Assembly
Optional Electric Water Level
Control Package

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18
PT2
Corrosion Protection
3
NOTE: 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 water
treatment specialist prior to the
initial start-up of the evaporative
cooling equipment. Additionally,
to protect against the risk of
Legionella contamination, never
operate the cooling equipment
without adequate biological control.
BAC products are constructed of corrosion-resistant materials. Materials listed below
may be used in the equipment construction, depending on which optional materials of
construction were ordered:
• Galvanized Steel Components: Inspect the galvanized steel components for blemishes
or corrosion. Wire brush and recoat the affected areas with a cold galvanizing
compound such as zinc rich compound (ZRC).
• Thermosetting Hybrid Polymer Components: Inspect components protected with
the thermosetting hybrid polymer for scratches, scrapes or blemishes. To touch up
these areas use a repair kit (BAC Part # 160133) available from your local BAC
Representative.
• Stainless Steel Components: Inspect stainless steel components for signs of blemishes
or corrosion. See “Long Term Care of Stainless Steel” on page 21 for cleaning and
care instructions.
• TriArmor®Corrosion Protection System: Inspect components protected with the
TriArmor®Corrosion Protection System for signs of deep scratches or blemishes,
especially in areas with field penetrations. Touch these up with 3M™ Windo-Weld™
Super Fast Urethane which is available through your local BAC Representative (BAC
Part # RK1015).
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 the water evaporates, the
dissolved solids 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
system components, as described below.
• Corrosion – Red rust on steel components and white rust on galvanized surfaces may
affect the longevity of system components.