BAC SP2B series Quick start guide

SP Adiabatic Cooler
RIGGING AND INSTALLATION INSTRUCTIONS
RSPv07EN-SA

About Rigging and Installation
The BAC equipment should be rigged and installed as outlined in this bulletin.
These procedures should be thoroughly reviewed prior to the rigging and operation to acquaint all personnel with
the procedures to be followed and to assure that all necessary equipment will be available at the jobsite.
Be sure to have a copy of the unit certified drawing available for reference. If you do not have a copy of this drawing
or if you need additional information about this unit, contact the local BAC Balticare representative. His name and
phone number can be found on the BAC website: www.BaltimoreAircoil.eu or www.BaltimoreAircoil.co.za. The
model type and serial number of your equipment are indicated on the unit nameplate.
Recommended Maintenance and
Monitoring Programme
Checks and Adjustments Start-Up Every
Month
Every 3
Months
Every 6
Months
Every Start of Adiabatic
Season, Spring
Adiabatic Pre-Cooler water flow X X X
Tighten Electrical Connections X X X
Rotation of fan(s) X
Motor voltage and current X X X
Unusual noise and/or vibration X X X
Inspections and Monitoring Start-Up Every
Month
Every 3
Months
Every 6
Months
Every Start of Adiabatic
Season, Spring
General condition of the equipment X X X
Adiabatic pre-cooling pads X X X
Heat transfer coil X X
Water distribution pipe X X X
City water strainer X X X
Cleaning Procedures Start-Up Every
Month
Every 3
Months
Every 6
Months
Every Start of Adiabatic
Season, Spring
Adiabatic Pre-Cooling media X X X
Adiabatic gutter system X X
Auxiliary equipment integrated in the cooling system may require additions to the table above. Contact
suppliers for recommended actions and their required frequency.
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Table of Contents
RIGGING AND INSTALLATION INSTRUCTIONS
1 General Information 4
About Engineering and Application Practices 4
Shipping 4
Inspection Before Rigging 4
Unit Weights 4
Anchoring 5
Leveling 5
Connecting Pipework 5
Purge Requirements 5
Freeze Protection 5
Safety Precautions 5
Non-walking Surfaces 6
Modifications by others 7
Warranty 7
2 Rigging 8
General Notes 8
Rigging Method 9
3 Section Assembly 12
Installed Adiabatic Pre-Cooler 12
Installation of screw-on Flanges 13
4 Optional Accessories Assembly 14
5 Inspection Prior to Start-up 15
Start-up and Commissioning 15
SpartiumCooler with Factory installed Control Panel with Variable Frequency Drive 15
6 Further Assistance & Information 20
Balticare 20
More Information 20
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GENERAL INFORMATION
About Engineering and Application Practices
This bulletin only refers to the assembly of the unit. To ensure a proper operation, a correct integration of the unit in
the overall installation is mandatory. For good engineering and application practices on layout, levelling,
connecting pipework, etc., please refer to our website:
http://www.baltimoreaircoil.co.za/knowledge-center/application-information.
Shipping
BAC cooling equipment is factory assembled to assure uniform quality and minimum field assembly.
The adiabatic pre-cooler sections of the SpartiumCooler unit are factory installed.
Inspection Before Rigging
When the unit is delivered to the jobsite, it should be checked thoroughly to ensure all required items have been
received and are free of any shipping damage prior to signing the bill of lading.
The following parts should be inspected:
- Exterior panels and covers
- Fans
- Heat Exchanger
- Adiabatic Pre-Cooler Sections
The fluid temperature sensor/pressure sensor is shipped loose and stored inside the electrical cabinet for
installation on site.
Unit Weights
Before rigging any BAC equipment, the weight of each section should be verified on the unit certified drawing.
These weights are approximate and should be confirmed by weighing before lifting when available
hoisting capacity provides little margin for safety.
Caution
BEFORE AN ACTUAL LIFT IS UNDERTAKEN, ENSURE NO WATER, SNOW, ICE OR DEBRIS
HAS COLLECTED IN THE SUMP OR ELSEWHEREIN THE UNIT. SUCH ACCUMULATIONS WILL
ADD SUBSTANTIALLY TO THE EQUIPMENT’S LIFTING WEIGHT.
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1 General Information
1 General Information

In the event of extended lifts or where hazards exist, the lifting devices should be used in conjunction with safety
slings placed under the unit.
Anchoring
The unit must be properly anchored in place.
Refer to the suggested support details on the certified drawing for locations of the mounting holes. Anchor bolts
must be provided by others.
Holes suitable for 19 mm bolts are provided in the bottom flange of the cooler support structure for bolting the unit
to the support beams.
Leveling
The unit must be level for proper operation and ease of piping.
Support beams must also be level as shims should not be used between pan and support beams to level the unit.
Connecting Pipework
All piping external to BAC cooling equipment must be supported separately.
In case the equipment is installed on vibration rails or springs, the piping must contain compensators to eliminate
vibrations carried through the external pipework.
Purge Requirements
The installer of BAC closed circuit cooling towers must ensure a proper air purging of the system prior to operation.
Entrained air can restrict the capacity of the cooler, resulting in higher process temperatures.
Freeze Protection
These products must be protected against damage and/or reduced effectiveness due to possible freeze-up by
mechanical and operational methods. Please refer to the BAC Product & Application Handbook or contact your
local BAC Balticare representative for recommended protection alternatives.
Safety Precautions
All electrical, mechanical and rotating machinery constitutes a potential hazard, particularly for those not familiar
with its design, construction and operation. Accordingly, adequate safeguards (including use of protective
enclosures where necessary) should be taken with this equipment both to safeguard the public (including minors)
from injury and to prevent damage to the equipment, its associated system and the premises.
If there is doubt about safe and proper rigging, installation, operation or maintenance procedures, contact the
equipment manufacturer or his representative for advice.
When working on operating equipment, be aware that some parts may have an elevated temperature. Any
operations on elevated level have to be executed with extra care to prevent accidents.
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1 General Information
1 General Information

AUTHORIZED PERSONNEL
The operation, maintenance and repair of this equipment should be undertaken only by personnel authorized and
qualified to do so. All such personnel should be thoroughly familiar with the equipment, the associated systems
and controls and the procedures set forth in this and other relevant manuals. 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. Personnel must use personal protective
equipment where necessary (gloves, ear plugs, etc...)
MECHANICAL SAFETY
Mechanical safety of the equipment is in accordance with the requirements of the EU machinery directive.
Depending upon site conditions it also may be necessary to install items such as bottom screens, ladders, safety
cages, stairways, access platforms, handrails and toe boards for the safety and convenience of the authorized
service and maintenance personnel.
At no time this equipment should be operated without all fan screens in place.
Since the equipment operates at variable speeds, steps must be taken to avoid operating at or near the
installation's "critical speed";
For more information consult your local BAC Balticare representative.
ELECTRICAL SAFETY
Each fan associated with this equipment should be installed with a lockable disconnect switch located within sight
of the equipment.No service work should be performed on or near the fans unless motors are electrically isolated.
LOCAL REGULATIONS
Installation and operation of cooling equipment may be subject to local regulations, such as establishment of risk
analysis. Ensure regulatory requirements are consistently met.
LIFTING
Caution
FAILURE TO USE DESIGNATED LIFTING POINTS CAN RESULT IN A DROPPED LOAD
CAUSING SEVERE INJURY, DEATH AND/OR PROPERTY DAMAGE. LIFTS MUST BE
PERFORMED BY QUALIFIED RIGGERS FOLLOWING BAC PUBLISHED RIGGING
INSTRUCTIONS AND GENERALLY ACCEPTED LIFTING PRACTICES. THE USE OF
SUPPLEMENTAL SAFETY SLINGS MAY ALSO BE REQUIRED IF THE LIFT CIRCUMSTANCES
WARRANT ITS USE, AS DETERMINED BY THE RIGGING CONTRACTOR.
Non-walking Surfaces
Access to and maintenance of any component needs to be performed in accordance with all local applicable laws
and regulations. If the proper and required access means are not present, temporary structures need to be
foreseen. Under no circumstance can one use parts of the unit, that are not designed as an access mean, unless
measures can be taken to mitigate any risks that might occur from doing so.
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Modifications by others
Whenever modifications or changes are made by others to the BAC equipment without written permission of BAC,
the party who has done the modification becomes responsible for all consequences of this change and BAC
declines all liability for the product.
Warranty
BAC will guarantee all products to be free from manufactured defects in materials and workmanship for a period of
12 months from the date of shipment. In the event of any such defect, BAC will repair or provide a replacement.
For more details, please refer to the Limitation of Warranties applicable to and in effect at the time of the
sale/purchase of these products. You can find these terms and conditions on the reverse side of your order
acknowledgement form and your invoice.
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1 General Information
1 General Information

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RIGGING
General Notes
1. The equipment arrives on site by truck.
A crane must always be used to unload the unit from the truck. Do not attempt to unload the unit using a forklift.
2. Spreader bars of the full width of the section must be used between the lifting cables to prevent damage to the
section.
3. For extended lifts or where hazards exist, it is recommended to use the lifting devices in conjunction with
safety slings placed under the unit.
4. For each unit, only one lift is required. Lifting ears are foreseen on each unit.
5. Attach the lifting devices to the unit as per rigging methods below. Do not use lifting hooks to lift the unit, use
shackles (max. Ø 39mm) as shown on below picture. Unload the unit from the truck.
Use shackles (max. Ø 39mm) to lift the unit
6. Install the unit in its final position and anchor to the support beams (supplied by others).
Caution
BEFORE AN ACTUAL LIFT IS UNDERTAKEN, ENSURE NO WATER, SNOW, ICE OR DEBRIS
HAS COLLECTED IN THE UNIT. SUCH ACCUMULATIONS WILL ADD SUBSTANTIALLY TO THE
EQUIPMENT'S LIFTING WEIGHT.
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2 Rigging
2 Rigging

Rigging Method
To avoid damage during hoisting, a spreader beam should be used and the angles shown in the diagrams below
must be observed.
End View
End view
Side View
All 2-fan units
3-fan units (A-models – Fan diameter 910 mm)
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2 Rigging
2 Rigging

3-fan units (B-models – Fan diameter 1250 mm)
4-fan units (A-models - Fan diameter 910mm)
All 5-fan units
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All 6-fan units
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2 Rigging
2 Rigging

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SECTION ASSEMBLY
Installed Adiabatic Pre-Cooler
CONNECTION OF DRAINS
The surplus of water distributed over the Adiabatic Pre-Cooling media during adiabatic operation is collected into a
gutter and drained to the sewer via one or two different drains per pre-cooler side.
Each Adiabatic pre-cooler section is equipped with a separate bottom drain guaranteeing full emptying and drying
of the gutter system after each adiabatic cycle.
Refer to the Table below for the number of Adiabatic Pre-Cooler Sections and number of drains per model.
Model Number & Size of Fans Number of Adiabatic Pre-
Cooling Sections/Unit
Number of Bottom
Drains/Unit
SP2B* 2 fans 1250 mm 2 2
SP3B* 3 fans 1250 mm 4 4
SP4B* 4 fans 1250 mm 4 4
SP5B* 5 fans 1250 mm 4 4
SP2A* 2 fans 910 mm 2 2
SP3A* 3 fans 910 mm 2 2
SP4A* 4 fans 910 mm 4 4
SP5A* 5 fans 910 mm 4 4
SP6A* 6 fans 910 mm 4 4
Number of Adiabatic Pre-Cooler Sections and Drains
Each pre-cooler section has a sloping pan, assuring complete water drainage and discharge of any floating solids
to the sewer. Larger debris will however accumulate and settle in the gutter system and may be too large to drain
via the bottom drain and finally may block the bottom drain.
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3 Section Assembly
3 Section Assembly

Draining System – inside
Draining System - outside
It is therefore necessary to regularly clean the Adiabatic Gutter system to remove all solids. Access for cleaning is
given to the inside of the gutter system after removal of the Pre-Cooling Media. For cleaning sequence see Table
"About Rigging and Installation" on page2
Installation of screw-on Flanges
Care must be taken when installing screw-on flanges on the fluid-connections of the unit to make sure no forces
are transferred from the flange to the copper header of the unit. These forces may damage the header and result in
coil leaks.
Apply the proper opposite force by means of a chain pipe wrench, as shown in the following picture to make sure
no force is put on the copper tubes.
Installing screw-on flange
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3 Section Assembly
3 Section Assembly

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OPTIONAL ACCESSORIES ASSEMBLY
All optional Accessories are factory installed.
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4 Optional Accessories Assembly
4 Optional Accessories Assembly

5 Inspection Prior to Start-up
5 Inspection Prior to Start-up W W W . B A L T I M O R E A I R C O I L . C O . Z A
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INSPECTION PRIOR TO START-UP
Start-up and Commissioning
ROTATION OF FANS
Fans must rotate without obstruction in the direction indicated by arrows on the equipment.
MOTOR VOLTAGE AND CURRENT
Check the voltage and the current of all three legs of the fan motors. The current should not exceed the nameplate
rating. After prolonged shutdown the motor insulation should be checked with a Megger insulation tester prior to
restarting.
The voltage must not fluctuate more than +/-10% and the imbalance between phases must not be greater
than+/-2%.
UNUSUAL NOISE AND VIBRATIONS
Unusual noise and/or vibration are the result of malfunctioning of mechanical components or operational problems
(e.g. unwanted ice formation). If this occurs, a thorough inspection of the entire unit followed by immediate
corrective action is needed. If required, consult your local BAC Balticare representative for assistance.
PURGE REQUIREMENTS
The installer of BAC closed circuit cooling towers must ensure a proper air purging of the system prior to operation.
Entrained air can restrict the capacity of the cooler, resulting in higher process temperatures.
For water quality guidelines and for calculation of Practical Scaling Index, refer to the Operating and Maintenance
Instructions, section Water Care.
SpartiumCooler with Factory installed Control Panel
with Variable Frequency Drive
ELECTRICAL PANEL
All units are equipped with an electrical panel with variable frequency drive.
When operating above nominal speed, be aware of the potential risk for overload or mechanical damages.
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Control Panel with Variable Frequency Drive
The fan speed is controlled on the basis of the actual process fluid temperature at the exit of the unit and the design
leaving temperature, ensuring a minimum in electrical consumption and noise levels.
The adiabatic pre-cooling will be activated and stopped on the basis of a pre-programmed logical combination of
the fan speed and the ambient temperature (release set-point). Default settings will not activate adiabatic pre-
cooling unless all fans are running at maximum permissible speed and the dry-to-adiabatic release set-point is
reached.
The adiabatic control logic is pre-programmed and is ready for operation.
Depending on the actual size of the installation, the controller pre-programmed parameters may need to be
adjusted.
ELECTRICAL FIELD WIRING
Caution
ALL OPERATIONS DESCRIBED BELOW MUST BE PERFORMED BY A LICENSED
ELECTRICAL TECHNICIAN AND MUST COMPLY WITH LOCAL REGULATIONS.
The equipment is standard provided with a door interlocked main power switch (Q0), which is factory fitted.
Connect electrical power to the power switch through a 3-pole cable, with ground, of adequate cross section for the
main fuse rating.
The power tension must not fluctuate more than ±10%. The imbalance between the phases must not be
greater than ±2%.
Connect the immersion sensor to the terminal strip as indicated in the wiring diagram.
PRE-COMMISSIONING
1. With main power switch open, check all electrical connections in electrical panel to be sure that they are tight
and provide good electrical contact. Although connections were tightened at the factory, they may have
loosened enough in shipment to cause a malfunction.
2. Check and inspect all water piping. Make sure flow direction is correct in counterflow, as shown by the arrows
on the connectors.
3. Check that the immersion sensor is properly located in the main cold water pipe so that the water is well mixed
where the temperature is measured.
4. The immersion sensor needs to be installed in such a way that any risk of water ingress is minimised.
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Mounting Positions:
Permitted Positions for mounting VFD sensor
Not Permitted positions for mounting VFD sensor
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5 Inspection Prior to Start-up
5 Inspection Prior to Start-up

LEGEND
Q0Main Power Switch
FINV Inverter's Fuses
FA1Auxiliary Fuses - Transformer T1
FA2Auxiliary Fuses - 230 V supply
FA3Auxiliary Fuses - 24 V supply
T1Transformer 400/ 0 – 230 - 24 V
F1, F2, F3, etc. Circuit Breakers
DVW Pad Maintenance Switch
DINV Control Operation Switch
TH Electrical Panel Ventilation Thermostat
MF Electrical Panel Ventilator
Q1, Q2, Q3etc. Thermal Overload Relay
K1, K2, K3etc. Fan Contactor Relay
INV Inverter
VH1City Water Solenoid Valve
VD1Drain Solenoid Valve
QAC Ambient Air Sensor
QAE Fluid Temperature Sensor
S0Emergency Stop Switch
S01 Power Failure Reset
C01 Power Failure Relay
H0Indicating Lamp
QBO Power Invertor By-pass Switch (optional)
F0Main Fuses (with optional Inverter By-pass Switch)
Legend for Electrical Panel with Variable Frequency Drive
START-UP
1. Turn the main power switch Q0, main fuses FINV and auxiliary control circuit fuses FA1, FA2, FA3 to the “off”
position. Put the Circuit Breakers F1, F2, F3 etc. in the “off” position. Measure the mains voltage.
2. Turn the main power switch Q0 and FINV "on" and push Power Failure Reset Button S01 to power the inverter;
its LCP (Local Control Panel) is energised. Place the main fuses FA1, FA2, FA3, to the "on" position. The
amber indicating lamp on the front panel lights up. Put the Circuit Breakers F1, F2, F3 etc. in the “on” position.
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3. MANUAL INVERTER OPERATION: by pressing "HAND ON" on the inverter's LCP, the fans start at the
minimum rpm at which the inverter was programmed. By pressing arrow key up "↑" on the LCP, the maximum
programmed rpm can be reached and by pressing arrow key down "↓" the rpm can be reduced to the minimum
programmed rpm. At this stage the fans' rmp are not regulated by any control device. Check the fan rotation (all
fans are factory wired to run in the same direction). Change phases if necessary to obtain correct fan rotation,
as shown by arrow on the fan cowl.
4. By pressing key "OFF" the inverter stops the fan operation.
5. AUTOMATIC OPERATION: the "Remote Start" must be wired to the remote operation via terminals Y2:1 and
Y2:2 and the control operation switch DINV on the front panel to the A-position (automatic operation) before the
inverter is operated through the "AUTO-ON" key. Once the inverter starts, it will now be controlled ty the input
feed of the immersion temperature sensor, regulating the fan rpm accordingly.
6. The unit will now operate according to the load demand. When the inverter reaches the maximum speed, the
controller will activate the adiabatic system by energising/de-energising the appropriate solenoïd valves.
7. A set of clean contacts (1,2,3) from the inverter are wired to the Y6 location of the terminal strip, for remote
observation of the inverter status.
EMERGENCY STOP
A red mushroom switch S0S1on the front panel is provided to allow the unit emergency stop in case of
malfunction. The unit can be re-started by rotating the
S0S1emergency switch, as shown by its arrow and then following the starting procedure of the unit.
WEEK-END OR TEMPORARY SHUTDOWN
The unit must shut down by the inverter's "OFF-STOP" key, or by the "Remote Start" off command, or by the
control operation switch DINV on the front panel, so that the drain valve VD1 will remain open and the city valve
VH1 closed.
If the unit is shut down by the main power switch, all the valves will close, risking stagnant water in the
copper tubes.
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5 Inspection Prior to Start-up
5 Inspection Prior to Start-up

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FURTHER ASSISTANCE & INFORMATION
Balticare
BAC has established a specialized independent total care company called Balticare. The BAC Balticare offering
involves all elements required to ensure a safe and efficient operation of your evaporative cooling products. From a
full range of risk assessment to selective water treatment, training, testing, record keeping and annual system
overview.
For more details, contact your local BAC representative for further information and specific assistance
www.BaltimoreAircoil.co.za.
More Information
REFERENCE LITERATURE
• Eurovent 9-5 (6) Recommended Code of Practice to keep your Cooling System efficient and safe.
Eurovent/Cecomaf, 2002, 30p.
• Guide des Bonnes Pratiques, Legionella et Tours Aéroréfrigérantes. Ministères de l'Emploi et de la Solidarité,
Ministère de l'Economie des Finances et de l'Industrie, Ministère de l'Environnement, Juin 2001, 54p.
• Voorkom Legionellose. Minsterie van de Vlaamse Gemeenschap. December 2002, 77p.
• Legionnaires' Disease. The Control of Legionella Bacteria in Water Systems. Health & Safety Commission.
2000, 62p.
• Hygienische Anforderungen an raumlufttechnische Anlagen. VDI 6022.
INTERESTING WEB SITES
• www.BaltimoreAircoil.co.za
• www.BaltimoreAircoil.eu
• www.Balticare.com
• www.eurovent-certification.com
• www.ewgli.org
• www.ashrae.org
• www.uniclima.org
• www.aicvf.org
• www.hse.gov.uk
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6 Further Assistance & Information
6 Further Assistance & Information