BAC DCV Series Quick start guide

DCV Dry Condenser
DCV-AD TrilliumSeries Condenser
RIGGING AND INSTALLATION INSTRUCTIONS
RDCVv04EN

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. 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
Freeze Protection 5
Safety Precautions 6
Warranties 7
2 Construction Details 8
3 Rigging 10
Unloading of Equipment 10
Rigging Method 11
4 Installation Adiabatic Pre-Cooler 13
1. Removal of Crating 13
2. Removal of Pre-Cooler Media 14
3. Attachment of Pre-Cooler Frame 15
4. Gutter System Connection 17
5. Interconnection of Pre Cooler sections 17
6. Re-Installation of the Pre-Cooler Media 18
7. Connection of Water Inlet 19
8. Connection of Drains 19
5 Start-up and Commissioning 21
DCV Condensers - General 21
TrilliumSeries Condensers - General 22
TrilliumSeries Condensers with Factory installed Control Panel with Variable Frequency Drive 22
6 Further Assistance & Information 26
Balticare 26
More Information 26
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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.eu/knowledge-
center/application-information.
Shipping
BAC 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
DCV-S9122-* 4 2
DCV-S9123-* 6 2
DCV-S9124-* 8 4
DCV-S9125-* 10 4
DCV-S9126-* 12 4
Number of Fans and Pre-Cooler Sections per model
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
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DCV
DCV-AD
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1 General Information
1 General Information

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.
The water immersion 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 only 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 UNIT. SUCH ACCUMULATIONS WILL ADD SUBSTANTIALLY TO THE
EQUIPMENT'S LIFTING WEIGHT.
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.
Support beams must also be level as shims should not be used between pan and support beams to level the unit.
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.
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1 General Information
1 General Information

Safety Precautions
All electrical, mechanical and rotating machinery constitute 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 advise.
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, procedures and tools
must be used in handling, lifting, installing, operating and repairing this equipment to prevent personal injury and/or
property damage.
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 screens, ladders, bottom
screens, 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 avid 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 of 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.
Warranties
Please refer to the Limitation of Warranties applicable to and in effect at the time of the sale/purchase of these
products.
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1 General Information
1 General Information

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CONSTRUCTION DETAILS
DCV V-Type Dry Condenser DCV-AD TrilliumSeries Condenser
1. Heat exchanger (not shown)
2. Coil Headers (not shown)
3. Casing
4. Fans
5. Pre-cooler Media
6. Pre-Cooler Solenoid Valve and Water Filter
7. Pre-Cooler Drains
8. Pre-Cooler flow Valve/Meter
9. Pre-Cooler Water Distribution Header
10. Pre-Cooler Water Distribution Pads
11. Ambient Temperature Sensor
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DCV
DCV-AD
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2 Construction Details
2 Construction Details

Details
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2 Construction Details
2 Construction Details

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RIGGING
Unloading of Equipment
1. The equipment arrives on site by truck.
It is recommended to unload the unit with a crane. 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 at the four corners as per rigging methods below. Do not use lifting hooks to
lift the unit, use shackles as shown on below picture. Unload the unit from the truck.
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.
Use shackles to lift the unit
6. Install the unit in its final position and anchor to the support beams (supplied by others).
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DCV
DCV-AD
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3 Rigging
3 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
4-fan unit
6-fan unit
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3 Rigging
3 Rigging

8-fan unit
10-fan unit
12-fan unit
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4 Installation Adiabatic Pre-Cooler
4 Installation Adiabatic Pre-Cooler 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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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
DCV
DCV-AD
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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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4 Installation Adiabatic Pre-Cooler
4 Installation Adiabatic Pre-Cooler

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. Gutter System Connection
Interconnect gutter system of side-by side pre-cooler sections using the threaded PVC fittings with counter ring.
Gutter with interconnecting PVC fitting - side 1
Gutter with interconnecting PVC fitting - side 2
5. Interconnection of Pre Cooler sections
Interconnect pre-cooler sections with the stainless steel connection plates.
Empty Pre-Cooler frame attached.
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4 Installation Adiabatic Pre-Cooler
4 Installation Adiabatic Pre-Cooler

Side-by-side pre-cooler frames connected with stainless steel connection plates.
6. 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 Medium
Caution
THE PRE-COOLING MEDIA HAS A FRONT SIDE AND A BACK SIDE AND NEEDS 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 COLORED SIDE NEEDS TO
BE AT THE OUTSIDE.
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Continue with installation of Pre-Cooler Media
Re-installation of Top Plate.
7. Connection of Water Inlet
At water inlet side, connect the flexible water hose to the copper water distribution piping pre-installed on the unit.
Connection of Pre-Cooler water inlet to the pre-installed copper water distribution piping.
8. Connection of Drains
Connect bottom water drains of all Pre-Cooler sections at both sides of the unit to evacuate excess water.
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4 Installation Adiabatic Pre-Cooler
4 Installation Adiabatic Pre-Cooler

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
DCV-S9122-* 4 2 2
DCV-S9123-* 6 2 2
DCV-S9124-* 8 4 4
DCV-S9125-* 10 4 4
DCV-S9126-* 12 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.
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.
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