BAC 1500 Series User manual

RIGGING & ASSEMBLY INSTRUCTIONS
Series 1500 Cooling Tower
Series 1500

Series 1500 Cooling Towers should be rigged and
assembled as outlined in this bulletin.
These procedures should be thoroughly reviewed prior to the
actual rigging and assembly of the equipment to acquaint all
personnel with procedures to be followed and to assure that all
necessary equipment will be available beforehand.
Be sure to have a copy of the 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 your local BAC Representative whose name and
telephone number are on a label adjacent to the access door. The model
number and serial number of the unit are also located in this area.

Table of Contents
RIGGING & ASSEMBLY INSTRUCTIONS » SERIES 1500 COOLING TOWER
1 Introduction
2Safety
2Shipping
2Pre-Rigging Checks
3Unit Weights
3Anchoring
3Cold Weather Operation
3Location
3Warranties
4Unit Operation
2 Rigging & Assembly
4Rigging
5Single-Cell Installation
5Two Piece Section Assembly
6Multi-Cell Installation
6Multi-Cell Unit Assembly
6Flume Box Installation
8Positive Closure Plate Installation
8Motor Location and Conduit Installation
10 Fan Guard Installation
3 Optional Accessory Installation
11 Bottom Water Outlet/Equalizer/Bypasses
12 Access Door Platform and Ladder
13 Internal Service Platform
14 Internal Service Platform Ladder
15 Internal Ladder Only
16 External Access Platform
17 External Access Platform for Multi-cell Units
18 Ladder Safety Cage
19 Louver Face External Access Platform Ladder
20 Louver Face External Access Platform with End Ladder
21 Fan Deck Handrail
22 Hot Water Basin Handrail for Multi-cell Units
23 Hot Water Basin Handrail Ladder
24 Motor Removal System with Davit Arm
25 Fan Cowl Extensions
25 Basin Accessories
26 Heater Control Panel

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Safety
Adequate precautions appropriate for the installation and location of these products should
be taken to safeguard the equipment and the premises from damage and the public from
possible injury. The procedures in this manual must be thoroughly reviewed prior to rigging
and assembly. Read all warnings, cautions, and notes detailed in the margins.
When the fan speed of the unit is to be changed from the factory set speed, including the
use of a variable speed device, steps must be taken to avoid operating at or near the fan’s
“critical speed” which could result in fan failure and possible injury or damage. Consult
with your local BAC Representative on any such applications.
Shipping
BAC Cooling Towers are factory assembled to assure uniform quality and minimum field
assembly. Models S15E/XES15E-x-06x and S15E/XES15E-x-07x ship in a single piece.
All other models ship in two sections per cell. For the dimensions and weights of a specific
unit or section, refer to the certified drawings.
Pre-Rigging Checks
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:
Sheaves and Belts
Bearings
Bearing Supports
Fan Motor(s)
Fan(s) and Fan Shaft(s)
Float Valve Assembly(s)
Water Distribution System
Fill
Cold Water Basin Accessories
Interior Surfaces
Exterior Surfaces
Combined Inlet Shields
Mating Surfaces Between Sections /
Modules
Miscellaneous Items: All bolts, nuts,
washers, and sealer tape required to
assemble sections or component parts
are furnished by BAC and shipped
with the unit. A checklist inside
the envelope marked “Customer
Information Packet” indicates what
miscellaneous parts are included
with the shipment and where they are
packed. This envelope will be attached
to the side of the unit or located in a
box inside the unit.
SERIES 1500 COOLING TOWER
Introduction
1
WARNING: Failure to use lifting
provisions 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 a supplemental safety
sling may also be required if the
lift circumstances warrant its
use, as determined by the rigging
contractor.
CAUTION: Only personnel qualified
to do so should undertake
operation, maintenance and repair
of this equipment. Proper care,
procedures and tools must be used
in handling, lifting, installing,
operating, maintaining and
repairing this equipment to prevent
personal injury and/or property
damage.

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SERIES 1500 COOLING TOWER
Introduction
Unit Weights
Before rigging any unit, the weight of each section should be verified from the unit
certified drawing. Some accessories add additional weight as shown on the respective
accessory drawings.
Anchoring
Seven-eighths (7/8”) diameter holes are provided in the bottom flange of the basin section
for bolting the unit to the support beams. Refer to the suggested support location drawing
included in the submittal for location and quantity of the mounting holes. The unit must
be level for proper operation. Anchor bolts must be provided by others.
Cold Weather Operation
These products must be protected by mechanical and operational methods against damage
and/or reduced effectiveness due to possible freeze-up. Please refer to the Series 1500
Operation and Maintenance Manual on www.BaltimoreAircoil.com, or contact your local
BAC Representative for recommended cold weather operation strategies.
Location
All evaporative cooling equipment must be located to ensure an adequate supply of fresh
air to the unit air intakes. When units are located adjacent to walls or in enclosures,
care must be taken to ensure the warm, saturated, discharge air is not deflected and
recirculated back to the air intakes.
Each unit should be located and positioned to prevent the introduction of discharge
air into the ventilation system of any building. For detailed recommendations on BAC
equipment layout, see our website at www.BaltimoreAircoil.com or contact your local
Representative.
Warranties
Please refer to the Limitation of Warranties (located in the submittal package) applicable
to and in effect at the time of the sale/purchase of these products.
Unit Operation
Prior to start-up and unit operation, refer to the Series 1500 Operation & Maintenance
Manual shipped with the unit and also available at www.BaltimoreAircoil.com.
NOTE: Each unit must be located
and positioned to prevent the
introduction of discharge air
into the ventilation systems of
the building on which the unit is
located and of adjacent buildings.
WARNING: Before an actual lift
is undertaken, ensure no water,
snow, ice, or debris has collected
in the basin or elsewhere in the
unit. Such accumulations will add
substantially to the equipment’s
lifting weight.
Introduction
Safety
Shipping
Pre-Rigging Checks
Unit Weights
Anchoring
Cold Weather Operation
Location
Warranties
Unit Operation

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Rigging
Refer to Table 1 and Figures 1 and 2 for the required minimum spreader bar and the
recommended vertical dimension “H” from the lifting device at the base of each unit or
section to the spreader bar. Figure 1 shows the proper rigging of a Series 1500 that ships
in one-section. Figure 2 shows the proper rigging of a two-section unit.
Figure 1. Single Piece Lift
Table 1. Minimum Vertical Dimension and Spreader Bar Length
2
NOTE: Models S15E/XES15E-x-06x
and S15E/XES15E-x-07x ship in a
single piece. All other models ship
in two sections per cell.
Figure 2. Two-Section Cells
Model Number
Min.
W1
(ft)
Single Piece Lower Section Upper Section
Min. H (ft) Min. W2 (ft) Min. H (ft) Min. W2 (ft) Min. H (ft) Min. W2 (ft)
S15E/XES15E-1285-06x 12 11 6 — — — —
S15E/XES15E-1285-07x 12 12 6 — — — —
S15E/XES15E-1285-09x 12 15 6 7 5.5 9 6
S15E/XES15E-1285-10x 12 16 6 8 5.5 9 6
S15E/XES15E-1212-07x 12 12 6 — — — —
S15E/XES15E-1212-09x 12 15 6 7 5.5 9 6
S15E/XES15E-1212-10x 12 16 6 8 5.5 9 6
S15E/XES15E-1212-11x 12 17 6 9 5.5 9 6
S15E/XES15E-1212-12x 12 19 6 11 5.5 9 6
S15E/XES15E-1218-07x 12 12 6 — — — —
S15E/XES15E-1218-09x 12 15 6 7 5.5 9 6
S15E/XES15E-1218-10x 12 17 6 9 5.5 9 6
S15E/XES15E-1218-11x 12 18 6 10 5.5 9 6
S15E/XES15E-1218-12x 12 19 6 11 5.5 9 6
WARNING: Failure to use lifting
provisions 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 a supplemental safety
sling may also be required if the
lift circumstances warrant its
use, as determined by the rigging
contractor.
Upper Section
Lower Section
1/2”
Flat
Washer

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Rigging & Assembly
Rigging
Single-Cell Installation
Two Piece Section Assembly
Single-Cell Installation
All single cell 1500 Cooling Towers are designed to be lifted in one assembled piece as
shown in Figure 1. A two piece lift is shown in Figures 2 and 3.
Two Piece Section Assembly
1. Remove any accessories shipped in the cold water basin.
2. Figures 2 and 3show the proper rigging of the sections for units that ship in two
sections. Position the lower section on the steel support and bolt in place.
3. Wipe any moisture and dirt from the perimeter mating flanges of the lower section.
4. Install flat butyl sealer tape (BAC part # 554000) supplied with the unit, as illustrated
in Figure 3, on the mating flanges of the lower section in a continuous line. At each
corner, allow 1” overlap.
5. Before lowering the upper section onto the lower section, be sure to line up the bolt
holes using drift pins as illustrated in Figure 4, no fewer than one hole at each edge.
Guide the upper section onto the lower section starting with a bolt hole at one corner
and following down the flange.
6. Section assembly guides must line up as shown in Figure 3.
7. Secure the upper section in place as shown in Figure 3 to ensure leak-free operation.
Figure 4. Drift Pin Alignment
Figure 3. Upper and Lower Assembly for Series 1500 Cooling Towers
Section Assembly
Guide
Flat Butyl
Sealer
Tape
Flat Washer,
Lock Washer,
and Nut
1/2” Bolt
1/2”
Flat
Washer

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Multi-Cell Installation
Refer to the submittal drawings for the proper orientation of each cell. The number and
“face” are stenciled on the outer basin wall. Multi-cell cooling tower installations may
employ flume boxes to equalize the water level in the basin of each cell. Follow directions
in “Flume Box Installation” for details on their installation.
Multi-Cell Unit Assembly
1. First, attach the first cell’s lower section to the support and then fasten the first cell’s
upper section onto the first cell’s secured bottom section. For units shipped in two
sections per cell, follow the instructions on page 5 for “Single-Cell Installation” for
installation of the first cell.
2. Each subsequent cell should be assembled just adjacent to its final location, and then
properly positioned next the previous cell. Ensure spacing between the cells at the
bottom flange is 2 1/2”.
3. Some units come furnished with a flume box. If they do, use the flume box assembly
procedure outlined below to connect multi-cell units.
Flume Box Installation
4. Position Cell #1 on the unit support and bolt in place. Cell #1 will have a factory
installed flume box bolted onto Face B.
5. Wipe down the mating surface on the outer, protruding end of the flume box and apply
a layer of flat butyl sealer tape (BAC Part #554000) around the face of the flange over
the centerline of the holes. Do not overlap or stretch the butyl sealer tape too thinly at
the corners. When it is necessary to splice the butyl sealer tape, be sure to press the
two ends together to form a smooth, continuous strip. See Figure 5.
6. Apply a second layer of butyl sealer tape over the first layer following the same
procedure.
7. Assemble Cell #2 just adjacent to its final location. Wipe down the mating surface
adjacent to the flume box opening to remove any dirt or moisture.
8. Position Cell #2 on unit supports. Using drift pins to ensure alignment, draw Cell #2
tight against the flume box, ensuring that the spacing between the cells at the bottom
basin flange is 2 1/2”.
9. As illustrated in Figure 6, insert 3/8” x 1 1/4” thread cutting screws in each hole
from the flume box into the basin wall and tighten. For basins with TriArmor®
Corrosion Protection System and stainless steel basins, bolt strips are provided in
lieu of individual thread cutting screws. For TriArmor® basins only, a backing plate is
provided and must be installed inside of Cell #2, as seen in Figure 7. Secure using
the provided hardware.
NOTE: Flume boxes furnished
with units constructed with
TriArmor®Corrosion Protection
System or stainless steel basins
are assembled with stainless
steel bolts, washers and nuts
in lieu of self tapping screws.
Before installing the nuts, apply a
lubricant to the bolts to reduce the
potential for seizing.
NOTE: If the unit is provided with
a positive closure plate requiring
installation, go to “Positive Closure
Plate Installation” on page 8 prior
to installing flat washers and wing
nuts.
ATTENTION: If the backing plate is
not properly installed, the TriArmor®
Corrosion Protection System
warranty will be void.

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Rigging & Assembly
Multi-Cell Installation
Multi-Cell Unit Assembly
Flume Box Installation
Install
Backing
Plate Here
Figure 7. Backing Plate Installation
3/8” x 1 1/4”
Thread Cutting
Screw
Figure 6. Thread Cutting Screw Pattern for Flume Box
Detail A
Figure 5. Flume Box Butyl Sealer Tape Application
2 1/2”

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Positive Closure Plate Installation (Figure 8)
The optional positive closure plate and gasket can be furnished on multi-cell units to allow
individual cells to be isolated for cleaning and routine maintenance. For Series 1500
Cooling Towers, the plate ships loose inside the basin. To install the positive closure plate
and gasket, follow the steps below.
1. If installed, remove flat washers and wing nuts from the flume box on the interior of
Cell #2.
2. Position the neoprene gasket and positive closure plate over the flume box hardware
and fasten in place with 3/8” flat washers and wing nuts.
Figure 8. Positive Closure Plate Assembly
Detail A
1”
Motor Location and Conduit Installation
Use the following when installing electrical conduit for Series 1500 Cooling Towers.
Installation Notes:
1. All conduit must be water tight and pitched downward to allow condensation to drain
away from motor conduit box. Therefore, do not run the conduit through the fan deck.
2. All wiring must conform to local and national electrical codes. Junction box/safety
switch and all conduit from fan motor conduit box to be sized, provided, and installed
by others.
3. Rigid conduit outside casing panel must turn down to junction box.
4. On multi-cell units, use separate conduit lines for each fan motor. Run conduit
through adjacent cells to junction box and or disconnect switch on front/rear cell.
Adjustable
Motor
Base
Standard Motor
Location
Conduit
Box
Flexible Conduit (Allow
Sufficient Slack for
Belt Tensioning)
Rigid Conduit Outside
Tower Turned Down to
Junction Box or Safety
Switch
Disconnect/Safety Switch
in Weatherproof Enclosure
Must be Rated for Proper
Voltage and Horsepower
of Fan Motor
A
A
Optional
BALTIGUARD™
Fan System Motor
Standard Motor
Location
Plan View
Hole in casing panel should be
large enough to accommodate conduit.
Seal hole with waterproof sealant.
B
B
Optional
BALTIGUARD™
Fan System Motor
Side View
Figure 9. S15E/XES15E-1285 -x Standard Motor and Optional
BALTIGUARD™ Fan System Location
Standard
Motor
Optional
BALTIGUARD™
Fan System
Motor
Figure 10. Motor for 15E/XES15E-1285 -x

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Rigging & Assembly
Multi-Cell Installation
Positive Closure Plate
Installation
Motor Location and Conduit
Installation
Optional Accessories and
Equipment
Figure 12. S15E/XES15E-1212-x Dual Drive Motor Location (Optional)
Figure 11. S15E/XES15E-1212-x Independent Drive Motor Location
Figure 14. S15E/XES15E-1218-x Dual Drive Motor Location (Optional)
Figure 13. S15E/XES15E-1218-x Independent Drive Motor Location
Adjustable
Motor
Base
Standard Motor
Location
Conduit
Box
Flexible Conduit (Allow
Sufficient Slack for
Belt Tensioning)
Rigid Conduit Outside
Tower Turned Down to
Junction Box or Safety
Switch
Disconnect/Safety Switch
in Weatherproof Enclosure
Must be Rated for Proper
Voltage and Horsepower
of Fan Motor
A
A
Optional
BALTIGUARD™
Fan System Motor
Standard Motor
Location
Plan View
Hole in casing panel should be
large enough to accommodate conduit.
Seal hole with waterproof sealant.
B
B
Optional
BALTIGUARD™
Fan System Motor
Side View
Figure 15. Independent Drive Motor
A
A
Optional
BALTIGUARD™
Fan System
Motor
Standard
Motor
Location
Hole in casing panel should be
large enough to accommodate conduit.
Seal hole with waterproof sealant.
Adjustable Motor Base
BStandard
Motor
Location
Conduit
Box
Flexible
Conduit (Allow
Sufficient
Slack for
Belt
Tensioning)
Rigid Conduit Outside
Tower Turned Down to
Junction Box or Safety
Switch
Disconnect/Safety Switch
in Weatherproof Enclosure Must
be Rated for Proper Voltage and
Horsepower of Fan Motor
Adjustable Motor Base
Optional
BALTIGUARD™
Fan System Motor
Plan View
Side View
Figure 16. Dual Drive Motor

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Fan Guard Installation
As standard, the fan guard ships installed on all Series 1500 units except units with
the optional Whisper Quiet Fan and units with fan cowl extensions. However, due to
height limitations on specific truck shipments, the fan guard for other models may ship
unmounted.
One-Piece Fan Guard
Mount the fan guard to the unit as illustrated in Figure 17, Detail A.
DANGER: Fan guard must be
securely in place before the cooling
tower is placed in operation. Never
step or walk on fan guard. Failure to
follow these instructions may result
in serious injury or death.
Figure 17. One-Piece Fan Guard Assembly
Detail A
3/8” Bolt
3/8” Locknut
3/8” Flatwasher
Fan Guard Clip

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SERIES 1500 COOLING TOWER
Optional Accessory Installation 3
Bottom Water Outlet/Equalizer/Bypasses (Optional)
1. The bottom connection seal, Figure 18, is typical for all bottom outlets, equalizers,
and bypasses. Flange mounting hardware and gasket to be supplied by others.
2. Bottom connection seal kit(s) ship in plastic tubs.
Sump Suction
Strainer
(For Bottom Water
Outlets with Pump
Suction)
Cold
Water
Basin
Figure 18. Bottom Water Outlet
Detail A
2 1/4” OD Gasket
Backup Ring
Hardware
Provided by
Others
Gasket Provided by
Others

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Access Door Platform and Ladder (Optional)
The door access platform is shipped fully assembled. Some disassembly is required
for installation.
1. Secure the platform support brackets underneath the access door using 3/8” bolts
provided. See Figures 19 and 20, Details A, B and C.
2. Lift the platform module into place and secure the platform frame to the brackets using
3/8” bolts provided. See Detail D.
3. Secure the support channels to the platform and support brackets using 3/8” bolts
provided. See Detail D. If an access door platform ladder was ordered in addition to the
access door platform, continue to steps 4-5.
4. Secure the ladder using 3/8” bolts provided. See Detail E.
5. Attach the ladder flair using 5/16” X 5” bolts and spacers provided. See Details F and G.
6. Ladder with extensions below the unit must be secured at the bottom (by others).
Detail A Detail B Detail C Detail D
Detail E Detail F Detail G
Figure 19. Access Door Platform Figure 20. Access Door Platform with Ladder
Detail D
Detail B
Detail C
Details F
and G
Detail E
Detail A
PAP
PAN
PAN
PGG
NOTE: One gusset not shown for
clarity in Detail D.

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Figure 21a. S15E/X15E-1285-x (BALTIGUARD™ Fan System
Independent Drive) andS15E/X15E-1212-x (Independent Drive)
Details F
and G
Internal Service Platform (Optional)
1. The platform base is factory installed. The handrail system requires field installation.
2. The welded handrail assemblies drop into pre-installed sockets in a specific configuration
depending on the size of the unit and the type of drive system. See Figure 20 below for
configuration types.
3. Secure the vertical handrail posts in each socket using the 3/8” bolts provided. See
Figure 21, Detail A.
4. Connect the vertical handrail posts to each other using the 5/16” bolts provided. See
Detail B. Only two bolts are required per pair of posts, one on top and one on the bottom.
5. For dual drive units, attach the inside handrails to the blank off wall channels using the
5/16” bolts provided. Dee Detail E.
6. Attach the toe boards using 5/16” tappers provided. See Detail C and Detail F for
dual drive units.
7. Attach the safety gate at the ladder opening using 5/16” bolts provided. See Detail D.
Detail A
Figure 21b. S15E/X15E-1212-x Dual Drive
Figure 21d. S15E/X15E-1218-x Dual Drive
Figure 21c. S15E/X15E-1218-x Independent Drive
Optional Accessory
Installation
Access Door Platform and
Ladder
Internal Service Platform
Detail B
Detail D
Detail C
Detail FDetail E
Detail E
Detail F
PCK
PAI
PCR
PAD
PCP
PCK
PAI
PCK
PCJ
PAD
PCT
PAC PCT PAD
PAJ
PCK
PCJ
PCQ
PCQ
PCK
PCU
PAD
PCU
PCO
PCU
PCK
PCJ

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Internal Service Platform Ladder (Optional)
1. Attach ladder bracket to the access platform using 3/8” bolts provided. See Figure 22,
Detail A.
2. Attach the ladder to the lower walkway using 5/16” tappers provided. See Detail B.
3. Secure the ladder flair to the platform railing posts using 5/16” bolts provided. See
Detail C.
Figure 22. Internal Service Platform Ladder
Detail A Detail B Detail C

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Internal Ladder Only (Optional)
Lift the ladder guiding the bottom posts into the slots in the walkway as you are dropping
the pre-welded bolts at the top into the mounting holes in the upper support channel. No
further fastening is required. See Figures 23a and 23b.
Figure 23a. Internal Ladder (Top)
Optional Accessory
Installation
Internal Service Platform
Ladder
Internal Ladder Only
Figure 23b. Internal Ladder (Bottom)

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External Access Platform (Optional)
1. For S15E/XES15E-1218-x units only, lift the platform module into place and secure the
platform frame to the pre-mounted brackets using 3/8” bolts provided See Figure 24,
Detail A.
2. Secure the support channels to the platform and the unit casing using 1/2” bolts
provided. See Detail B, C, and D. For models S15E/XES15E-1285 and
S15E/XES15E-1212 there are 2 channels and for S15E/XES15E-1218 there are 4
channels.
3. Secure the ends of the platform frame to the unit structure using 1/2” bolts provided
and the toe board for the handrail system using 3/8” bolts provided. See Detail E.
4. Secure the handrail edges to the unit structure using 3/8” bolts provided. See Detail F.
Detail A Detail B Detail C
Detail E
Detail F
Figure 24. External Access Platform
Detail A
Detail F
Detail Band C
Detail E
Detail D
Detail D
PBT PBU PBS

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Optional Accessory
Installation
External Access Platform
External Access Platform for
Multi-cell Units
External Access Platform for Multi-cell Units (Optional)
1. Follow the instructions for the External Access Platform on page 16.
2. Fasten the top gap cover bracket using 3/8” bolts provided. See Figure 25, Detail A.
3. Fasten the vertical gap cover using 5/16” tappers provided. See Detail B.
4. Secure the toe board gap plate using 5/16” tappers provided. See Detail C.
5. Secure the platform plates to the platform base using 5/16” tappers and 1/4” x 2” self
tapping screws provided. See Detail D.
Detail A Detail B Detail C
Detail D
Figure 25. External Access Platform
5/16” Tappers
1/4” x 2” Self
Tapping Screw
1/4” x 2” Self
Tapping Screw
Detail A
Detail D
Detail B
Detail C
PCY
PCZ
PCE
PCC

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Ladder Safety Cage (Optional)
1. If the safety cage is shipped in multiple pieces, reassemble the safety cage.
2. Bolt the safety cage to the ladder using flatwashers and locknuts. Orient all fasteners
with bolt heads inside safety cage. See Figure 26, Detail A through Dand refer to
Table 3 for the quantity of bolting locations for different safety cage heights.
Share two lower
fasteners on
upper ladder
bracket
Upper ladder
bracket
Hoop
Detail D
Figure 26. Safety Cage
Detail A
Detail B
Detail C
Cage
Height (ft)
Bolting Location Cage
Height (ft)
Bolting Location Cage
Height (ft)
Bolting Location
A B C D A B C D A B C D
41 – – 1 12 1121 20 1141
51 1 – 1 13 1121 21 1141
61 1 – 1 14 1121 22 1141
71 1 – 1 15 1121 23 1141
81 1 – 1 16 1121 24 1141
91111 17 1131 25 1151
10 1111 18 1131 27 1151
11 1111 19 1 1 3 1
Table 3. Ladder Safety Cage Bolting Location and Quantities
NOTE: Safety gates are provided
for all handrail openings, and all
components are designed to meet
OSHA requirements.