BAC Ice Chiller TSC-95C Quick start guide

RIGGING AND
INSTALLATION INSTRUCTIONS
1
R_TSU-C/Dv00 EN
TSU-C/D for External Melt ICE CHILLER®Thermal Storage Unit
TSC-C/D for External Melt ICE CHILLER®Thermal Storage Coil only
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.
Table of Contents Page
General Information 2
Rigging 4
Inspection Prior to Start-up 8
Recommended Maintenance and
Monitoring Programme 12

2
GENERAL INFORMATION
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.
BAC cooling equipment is factory assembled to assure uniform
quality and minimum field assembly.
For the dimensions and weights of a specific unit or section, refer to
the certified drawing.
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
- Ice coils
- Sight tube and Ice Logic Ice Quantity controller (optional)
-Airpump
- Caulking material
The air pump and caulking material are shipped loose in a separate
crate.
If shipping damage has occurred, this should be clearly indicated on
the CMR.
Before rigging any BAC cooling equipment, the weight of each
section should be verified on the unit certified drawing.
Note: These weights are approximate only and should be confirmed by
weighing before lifting when available hoisting capacity provides little
margin for safety.
!
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.
About engineering and application
practices
Shipping
Inspection before Rigging
Unit Weights
Model
TSU-C/D Approx Shipping weight (kg)
TSU 95C
TSU 115C 2550 2780
TSU 120C
TSU 145C
TSU 170C
TSU 200C
TSU 225C
2860
3270
3670
4220
4630
TSU 185C
TSU 230C
TSU 270C
TSU 310C
TSU 350C
4040
4630
5170
5940
6490
Table 1: Approximate Shipping weights TSU-C/D
TSU 290C
TSU 340C
TSU 400C
TSU 450C
5440
6120
7080
7760
TSU 480C
TSU 590C
TSU 700C
TSU 800C
TSU 910C
TSU 1050C
8940
10340
11660
13610
14960
17190
TSU 790D
TSU 940D
TSU 1080D
TSU 1220D
TSU 1440D
13790
15470
17920
19550
22090
Model No° of Coils Approx. Shipping Weight
(kg)
TSC-95C
TSC-115C
TSC-120C
TSC-145C
TSC-170C
TSC-200C
TSC-225C
1
1
1
1
1
1
1
1065
1205
1315
1500
1635
1950
2135
TSC-185C
TSC-230C
TSC-270C
TSC-310C
TSC-350C
2
2
2
2
2
1065
1205
1340
1590
1725
TSC-290C
TSC-340C
TSC-400C
TSC-450C
2
2
2
2
1500
1635
1950
2135
TSC-480C
TSC-590C
TSC-700C
TSC-800C
TSC-910C
TSC-1050C
4
4
4
4
4
6
1365
1545
1680
2000
2180
1680
TSC-790D
TSC-940D
TSC-1080D
TSC-1220D
TSC-1440D
4
4
4
4
4
2065
2315
2720
2950
3310
Table 2: Approximate shipping weights TSC-C/D coil only
Model
TSU-C/D Approx Shipping weight (kg)
Table 1: Approximate Shipping weights TSU-C/D

GENERAL INFORMATION
3
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.
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.
All connections in the external pipework (installed by others) must
be leak free and tested accordingly. All piping external to BAC
cooling equipment must be supported separately.
Coils of ICE THERMAL STORAGE units are filled with a low inert gas
at the factory before shipping, to ensure an optimal internal
corrosion protection.
On site, the pressure needs to be released from the coil by opening
the pressure relieve valve and removing the pipe caps.
For NH3 coils cut the threaded pipe-end and bevel for welding on
site. Make sure to protect the unit against sparks from the cutting
process with a suitable material. Next connect the pipework to the
coil connections by welding.
The installer of BAC equipment must ensure proper system purging
of air prior to operation. Entrained air can obstruct the proper flow of
glycol solution, resulting in higher operating pressures than design
and reduced thermal storage capacity.
These products must be protected against damage and/or reduced
effectiveness due to possible uncontrolled 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.
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.
Air piping between air pump and TSU/TSC can have temperatures
above 40°C. Insulate the piping if necessary to prevent personal
injury.
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, 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, access cover panels and access doors in place.
For more information consult your local BAC Balticare
representative.
ELECTRICAL SAFETY
Each motor associated with this equipment should be installed with
a lockable disconnect switch located within the sight of the
equipment. No service work should be performed on or near the
motors or inside the equipment unless motors are electrically
isolated.
LIFTING
!
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.
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.
Please refer to the Limitation of Warranties applicable to and in
effect at the time of the sale/purchase of these products.
Leveling
Connecting Pipework
Welding Pipework
Purge Requirements
Freeze Protection
Safety Precautions Warranties

4
RIGGING
1. To simplify rigging and installation, units are shipped in one
piece, so only one lift is required. It is important to follow the
guidelines listed below when rigging these units.
2. Lifting devices have been provided for short lifts and final
positioning. The table “Approximate shipping weights” on page 7
shows the location of the lifting devices for each tank size. For
safety, it is recommended that for extended lifts or whenever
hazards exist, safety slings are used in addition to the spreader
beams.
3. Lifting and transportation of the equipment by means of lift
trucks is not permitted, as this may result in serious damage of
the tank bottom and the ice coils.
4. Spreader bars of the full width of the section must be used
between the lifting cables to prevent damage to the section.
For extended lifts or where hazards exist, it is recommended to
use the lifting devices in conjunction with safety slings placed
under the unit.
ON A LEVEL CONCRETE PAD
The unit should be continuously supported on a level concrete pad.
After the unit is set into final position, the tank bottom should be
sealed airtight all around to prevent condensation formation (see
figure). The sealer is shipped loose with the unit, together with the
air pump.
1. Seal around base of tank
ON 3 I-BEAMS
If continuous support is not possible, an alternative recommended
support arrangement consists of 3 parallel I-beams extending the
full length of the unit: 2 supporting beams should be located along
the unit length and 1 beam should be located on the centreline of
the unit. (see figure)
Each beam should be sized for 65% of the total operating weight. If
a unit is installed on I-beams additional insulation of the tank
bottom is necessary to avoid the formation of condensation.
ON A ROOF
For installation of the unit on a roof, additional field insulation
between tank bottom and the roof is required to prevent
condensation formation on the ceiling of the floor below (see
figure). Recommended insulation material is a vapour tight cork
layer.
1. Cork layer
General Notes
Support requirements
Figure 1: Unit continuously supported on a level concrete pad
Figure 2: Installation on 3 I-beams
Figure 3: Installation on the roof

RIGGING
5
RECOMMENDED LIFTING METHOD TSU C/D
The recommended method of rigging the unit is shown in the figure.
1. Safety slings
TSU 95C - TSU 1050C: H= 2160 mm
TSU 790D – TSU 1440D: H= 2415 mm
!
The lifting cables must be vertical in both planes as shown.
!
When lifting units as shown, some tank covers must be removed
to provide access to the lifting ears. Ensure that the lifting cables
do not damage the remaining covers.
Three lifting beams are required. The lifting ears and tank are not
designed to support the loads resulting from lifts employing less
than 3 lifting beams as shown in hereunder.
ROLLING INTO POSITION TSU C/D
As an alternative to lifting, the unit can be rolled into position. If
rollers are used they should be placed under the unit and must
exceed the unit width. The span between the rollers should not
exceed 1 m.
RECOMMENDED LIFTING METHOD TSC COILS ONLY
When lifting the coils, use the U-bolts provided on each corner.
Hoisting cables should be at a minimum of 45° up to maximum
vertically with the horizontal top line of the coil..
Rigging method
Figure 4: Recommended lifting method
Figure 5: Lifting methods not permitted
Model
TSU C/D L x W Dimensions
Approx
Shipping
weight (kg)
A
(mm) B (mm) C (mm)
TSU 95C
TSU 115C 3073 x 1308 3683 x 1308 2550 2780 1597 2403 738 640 1124 1124
TSU 120C
TSU 145C
TSU 170C
TSU 200C
TSU 225C
3073 x 1600
3683 x 1600
4293 x 1600
4877 x 1600
5486 x 1600
2860
3270
3670
4220
4630
1597
2403
2899
3371
3276
738
640
702
753
1105
1416
1416
1416
1416
1416
TSU 185C
TSU 230C
TSU 270C
TSU 310C
TSU 350C
3073 x 2400
3683 x 2400
4293 x 2400
4877 x 2400
5486 x 2400
4040
4630
5170
5940
6490
1597
2403
2889
3371
3276
738
640
702
753
1105
2216
2216
2216
2216
2216
TSU 290C
TSU 340C
TSU 400C
TSU 450C
3683 x 2981
4293 x 2981
4877 x 2981
5486 x 2981
5440
6120
7080
7760
2403
2889
3371
3276
640
702
753
1105
2797
2797
2797
2797
TSU 480C
TSU 590C
TSU 700C
TSU 800C
TSU 910C
TSU 1050C
6096 x 2981
7290 x 2981
85 x 29081
9703 x 2981
10922 x 2981
12725 x 2981
8940
10340
11660
13610
14960
17190
3430
4618
5889
5941
6300
6899
1333
1336
1310
1881
2311
2913
2797
2797
2797
2797
2797
2797
TSU 790D
TSU 940D
TSU 1080D
TSU 1220D
TSU 1440D
7290 x 3581
8509 x 3581
9703 x 3581
10922 x 3581
12725 x 3581
13790
15470
17920
19550
22090
4618
5889
5941
6300
6899
1336
1310
1881
2311
2913
3397
3397
3397
3397
3397
Table 3: Approximate Shipping weights TSU-C/D
Figure 6: Lifting Method for TSC coil only

6
RIGGING
WATER CONNECTIONS
Balancing valves must be installed on all water inlet connections to
adjust the flow through each connection.
COIL CONNECTIONS
Coils of ICE THERMAL STORAGE units are filled with a low inert gas
at the factory before shipping, to ensure an optimal internal
corrosion protection.
On site, the pressure needs to be released from the coil by opening
the pressure relieve valve and removing the pipe caps.
For NH3 coils cut the threaded pipe-end and bevel for welding on
site. Make sure to protect the unit against sparks from the cutting
process with a suitable material. Next connect the pipework to the
coil connections by welding.
1. If coils are supplied filled with nitrogen, the nitrogen pressure
should be relieved through the supplied relief valve before
removing the cap.
2. If units remain on site for a long period without being installed,
coils must be kept closed to avoid condensation and corrosion.
REFRIGERANT CONNECTIONS ON SITE
All connections in the external pipework (installed by others) must
be leak free and tested accordingly. All piping external to BAC
cooling equipment must be supported separately.
PURGE REQUIREMENTS
The installer of BAC equipment must ensure proper system purging
of air prior to operation. Entrained air can obstruct the proper flowof
glycol solution, resulting in higher operating pressures than design
and reduced thermal storage capacity.
Figure 7: Rigging Dimensions for TSC coil only
Model L
(mm) W (mm) H (mm) H1 (mm)
TSC-95C
TSC-115C
TSC-120C
TSC-145C
TSC-170C
TSC-200C
TSC-225C
2654
3258
2654
3258
3861
4464
5070
1055
1055
1350
1350
1350
1350
1350
1912 2260
TSC-185C
TSC-230C
TSC-270C
TSC-310C
TSC-350C
2654
3258
3861
4464
5070
1055 1912 2260
TSC-290C
TSC-340C
TSC-400C
TSC-450C
3258
3861
4464
5070
1350 1912 2260
TSC-480C
TSC-590C
TSC-700C
TSC-800C
TSC-910C
TSC-1050C
2721
3327
3928
4534
5137
4030
1350 1912 2260
TSC-790D
TSC-940D
TSC-1080D
TSC-1220D
TSC-1440D
3327
3931
4534
5140
6045
1645 2102 2448
Table 4: Approximate Dimensions TSC-C and TSC-D
TSU-C/D piping

RIGGING
7
The standard BAC delivery consists of a centrifugal air pump (with
an inlet air filter), a threaded adaptor and a flexible discharge sleeve
to be connected to the customer provided air piping. A non-return
valve is shipped loose with the air pump for field installation.
After the unit has been rigged into position, the air pump can be
installed. The recommended air piping is shown in the figure: the air
supply is taken from the ambient air. The air pump is to be mounted
on a clean, dry and vibration free surface which is flat and will
support the unit. Special pads are not required.
The mounting surface should be levelled and the pumps must be
securely bolted in place. It is recommended that, in case of outdoor
installation, the air pump is installed under a shelter. The air pump
should be located within 6 meters of the air distribution inlet piping.
If a more remote location of the air pump is required, consult your
local BAC representative.
1. Non-return valve
2. Steel pipe for initial 3m; then PVC for remainder of air supply (by others)
3. Filter
4. Air pump
Whenever TSC coils are to be installed in a concrete tank the
following components are provided together with the coils:
- The Ice Logic ice thickness controller: sensors are installed on
the coil, control box is shipped loose, wiring to be done on site.
- The air pump: shipped loose
- Air piping: mounted underneath the coils
- Coil supports: with sufficient height to elevate the coils above
the tank bottom in order to provide space underneath for
water distribution piping supplied by other
- Hold down channels and covers are required to prevent the
coils from floating when completely loaded with ice. These
channels and covers on top of a concrete tank are not part of
BAC’s standard supply.
Contact your BAC representative if assistance is required for the
design of these components.
1. Concrete Tank
2. Ice Chiller Thermal Storage Coils
Air pump installation
Installation for TSC coils only
Figure 8: Recommended air pump piping arrangement
Figure 9: Ice Chiller Thermal Storage coils only - TSC C/D

8
INSPECTION PRIOR TO START-UP
Prior to start-up, the following services, which are described in detail
in the Operating and Maintenance Manual (see Table
Recommended Maintenance and Monitoring Schedule- Start-up)
must be performed.
Proper start-up procedures and scheduled periodic maintenance
will prolong the life of the equipment and ensure trouble-free
performance for which the unit is designed.
General

NOTES
9

10
NOTES

NOTES
11

RECOMMENDED MAINTENANCE AND MONITORING PROGRAMME
www.BaltimoreAircoil.com
[email protected]
www.balticare.com
[email protected]
Baltimore Aircoil Int. nv
Industriepark - Zone A,
B-2220 Heist-op-den-Berg,
Belgium
Please refer to our website
www.BaltimoreAircoil.com
for local contact details
©Baltimore Aircoil International nv
Model: ........................................................................................... Serialnumber: .................................................................................
Notes:
1. Water Treatment and auxiliary equipment integrated in the cooling system may require additions to the table above. Contact suppliers for
recommended actions and their required frequency.
2. Recommended service intervals are for typical installations. Different environmental conditions may dictate more frequent servicing.
3. When operating in ambient temperatures below freezing, the unit should be inspected more frequently.
Schedule
Type of Action Action Start-Up Monthly Every Six Months Annually Shutdown
Inspections and
Monitoring General condition X X
ICE CHILLER® Tank XX
ICE CHILLER®Water (1)
- Quality
- Level X
XX X
Ice Thickness X X
Coil X
ICE LOGIC TM Ice Quantity
controller :
- condition of sensor
- conductivity of tank water X
X
X
Air Pump
- Air Filter Replacement XX X
Refrigerant:
- Glycol quality
- NH3purge oil X
X
Air Distribution Piping X
Cleaning procedures Mechanical cleaning
- Air filter XXXX
Disinfection X X X
Table 5: Recommended Maintenance & Monitoring Schedule