BAC TrilliumSeries DFCV Series Quick start guide

DFCV Dry Cooler
DFCV-AD Adiabatic Cooler
RIGGING AND INSTALLATION INSTRUCTIONS
RDFCV-ADv15EN

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 job site.
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 www.BaltimoreAircoil.eu. 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
Adiabatic controller set-point 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 5
Anchoring 5
Leveling 5
Connecting pipework 5
Purge requirements 5
Freeze protection 6
Safety precautions 6
Non-walking surfaces 7
Modifications by others 7
Warranty 7
2 Rigging 8
General notes 8
Rigging method 9
3 Section Assembly 11
Installation adiabatic pre-cooler 11
Installation of screw-on flanges 18
4 Optional Accessories Assembly 20
5 Inspection Prior to Start-up 21
Start-up and Commissioning 21
TrilliumSeries Coolers with factory installed control panel with Variable Frequency Drive 21
6 Further Assistance & Information 25
Assistance 25
More information 25
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W W W . B A L T I M O R E A I R C O I L . E U
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.eu/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 TrilliumSeries equipment are shipped separately. Refer to below table for
number of adiabatic pre-cooler sections per model.
Model Number of fans Number of adiabatic
pre-cooler sections
DFCV/S9122-* 4 2
DFCV/S9123-* 6 2
DFCV/S9124-* 8 4
DFCV/S9125-* 10 4
DFCV/S9126-* 12 4
Number of fans and pre-cooler sections per model
Inspection before rigging
When the unit is delivered to the job site, 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
Pre-cooler sections are shipped loose and packed separately in a wooden crate. Gasket for assembly is already
applied on these sections. SST bolts and nuts are packed in a small cardboard box and stored inside the wooden
crate of the pre-cooler sections.
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1 General information
1 General information

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 or on the unit. Such accumulations will add substantially to the equipment’s lifting
weight.
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 13 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.
The unit should be level to 0,5 mm/m over the unit length and width.
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.
The equipment outlet piping must be installed under the operating level of the equipment to prevent air suction and
pump cavitation.
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.
All connections (installed by others) must be leak free and tested accordingly.
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1 General information
1 General information

Freeze protection
These products must be protected against damage and/or reduced effectiveness due to possible freeze-up by
mechanical and operational methods. Please 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.
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
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.
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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.
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
24 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.
It is recommended to unload the unit with a crane. If the adiabatic pre-cooling sections for the TrilliumSeries are
crated separately, a forklift should be used for unloading of the crate with adiabatic pre-coolers.
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 39 mm) as shown on below picture. Unload the unit from the truck.
Use shackles (max. Ø 39 mm) to lift the unit
6. Install the unit in its final position and anchor to the support beams (supplied by others).
When the unit is installed, all metal parts created by drilling, fastening self tapping screws, grinding, welding or
other mechanical works must be removed from the unit.If they remain on the unit (typically on the double break
flanges) this could lead to corrosion and eventually coating damage.
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2 Rigging
2 Rigging

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.
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
4-fan unit
6-fan unit
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2 Rigging
2 Rigging

8-fan unit
10-fan unit
12-fan unit
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3 Section Assembly
3 Section Assembly W W W . B A L T I M O R E A I R C O I L . E U
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SECTION ASSEMBLY
Installation adiabatic pre-cooler
1. REMOVAL OF CRATING
Remove crating of pre-cooling sections of the TrilliumSeries Coolers.
Crate with adiabatic pre-cooling sections
Front view after crate removal
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Side view after crate removal
2. REMOVAL OF PRE-COOLER MEDIA
The pre-cooler media have been placed inside the stainless steel frames for shipment and need to be removed
before installation of the empty pre-cooling frames on the dry cooler. Remove the pre-cooler media as follows:
Removal of top plate
Removal of green water distribution pads
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Removal of pre-cooler media
Empty pre-cooler frame
3. ATTACHMENT OF PRE-COOLER FRAME
Attach the empty pre-cooler frames to the dry unit, using the stainless steel hardware supplied. Place the different
pre-cooler frames such that the water distribution piping between sections can be connected, and the copper water
piping installed on the unit connects to the water flow meter of the pre-cooling sections.
Installation of empty pre-cooler frame at dry unit.
The pre-cooler sections are marked with the letters A, B, C and D to indicate their position on the V-type dry unit.
The dry unit is marked with the corresponding letters.
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3 Section Assembly
3 Section Assembly

Attaching pre-cooler frame to dry unit with stainless steel hardware.
Stainless steel bolts and nuts connecting pre-cooler frame to dry unit flanges.
Water distribution piping of pre-cooler sections interconnection.
Rubber sleeve used to connect with water distribution header of next section.
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4. INTERCONNECTION OF PRE-COOLER SECTIONS
Interconnect pre-cooler sections with the stainless steel connection plates.
Empty pre-cooler frame attached.
Side-by-side pre-cooler frames connected with stainless steel connection plates.
5. RE-INSTALLATION OF THE PRE-COOLER MEDIA
Re-install the pre-cooler medium (2) and the water distribution pads (1) placed on top of the pre-cooler medium. Re-
install the top plate covering the water distribution section.
Installation of pre-cooler media
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3 Section Assembly
3 Section Assembly

CAUTION
The pre-cooling media have a front side and a back side and need to be (re)installed in the correct
position to ensure full wetting over the depth of the media and to ensure maximum efficiency. The
blue coloured side needs to be at the outside.
Continue with installation of pre-cooler media
Re-installation of top plate.
6. CONNECTION OF WATER INLET
At water inlet side, connect the flexible water hose to the copper water distribution piping pre-installed on the unit.
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Connection of pre-cooler water inlet to the pre-installed copper water distribution piping.
7. CONNECTION OF DRAINS
Connect bottom water drains of all pre-cooler sections at both sides of the unit to evacuate excess water.
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.
8-fan, 10-fan and 12-fan coolers are equipped with 4 separately shipped adiabatic pre-cooling sections, 2 per 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 of
fans
Number of adiabatic
pre-cooling
sections/cooler
Number of bottom
drains/cooler
DFCV-S9122-* 4 2 2
DFCV-S9123-* 6 2 2
DFCV-S9124-* 8 4 4
DFCV-S9125-* 10 4 4
DFCV-S9126-* 12 4 4
Model Number of
fans
Number of adiabatic pre-cooling
sections/cooler
Number of bottom
drains/cooler
DFCV-EC9122-* 4 2 2
DFCV-EC9123-* 6 2 2
DFCV-EC9124-* 8 4 4
DFCV-EC9125-* 10 4 4
DFCV-EC9126-* 12 4 4
DFCV-EC9127-* 14 4 4
Number of adiabatic pre-cooler sections and drains
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3 Section Assembly
3 Section Assembly

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.
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.
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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