BAC FXV-1212C-32Q-M/Q Manual

OPERATION & MAINTENANCE MANUAL
FXV and FXV3 Closed Circuit Cooling Tower
CXVB and CXVT Evaporative Condenser
Model FXV-1212C-32Q-M/Q

Inspect and clean as necessary: Start-Up Monthly Quarterly Annually Shutdown
Inspect general condition of the unit[2] and check unit for
unusual noise or vibration
Inspect cold water basin
Flush water distribution system/Inspect spray nozzles
Drain basin and piping
Inspect combined inlet shields and SunScreens (Single Air
Intake Units)/Inspect air intake louvers (Dual Air Intake Units)
Check and adjust water level in basins
Check operation of make-up valve
Check and adjust bleed rate
Inspect unit finish
Mechanical equipment system: Start-Up Monthly Quarterly Annually Shutdown
Check belt condition
Adjust belt tension[3]
Lubricate fan shaft bearings
Lubricate motor base adjusting screw
Check and lubricate optional gear drive See gear drive section for detailed instructions and schedule
Check drive alignment
Check motor voltage and current
Clean fan motor exterior
Check fan motor for proper rotation
Check general condition of the fan
Check and unplug fan drain holes (hollow blade fans)
Check fan for uniform pitch
Check fan for rotation without obstruction
Check and recoat steel shafts with RUST VETO®
Check basin heater and stand alone BAC heater control panel
Test vibration cutout switch
DANGER: Rotating equipment will cause severe
personal injury or death to persons who come
in contact. Do not perform any service on or
near the fans, motors, and drives, or inside the
unit without first ensuring that the fans and
pump motors are disconnected, locked out, and
tagged out.
NOTES:
1. Recommended service intervals are the minimum for typical installations.
Different environmental conditions may dictate more frequent servicing.
2. When operating in ambient temperatures below freezing, the unit should be
inspected more frequently. Refer to “Cold Weather Operation” on page 32 for
more details.
3. Tension on new belts must be readjusted after the first 24 hours of operation
and quarterly, thereafter.
Recommended Maintenance Intervals[1]

Table of Contents
Warnings and Cautions
2Safety Precautions
3Equipment Precautions
3General Maintenance Information
3Warranties
PART 1 Unit Operation & Storage
5Start-Up Procedure
7Extended Shutdown
7Prolonged Outdoor Storage
PART 2 Detailed Component Maintenance Procedures
10 Cold Water Basin
11 Fan
12 Fan Drive System
20 Fan Shaft Motors
21 Fan Shaft Bearings
22 Heat Transfer Section
22 Water Distribution System
23 Water Level Control
PART 3 Corrosion Protection
25 Water Treatment
26 Corrosion and Scale Control
26 Chemical Treatment Requirements
27 Passivation
27 Biological Control
28 Long Term Care of Stainless Steel
29 System Cleaning
PART 4 Bleed Rate
PART 5 Cold Weather Operation
32 Inspection and Maintenance
32 Fan Section Icing Protection
33 Basin Water and Internal Piping Freeze Protection
34 Coil Freeze Protection
PART 6 Operation Considerations for Accessories
38 Basin Heater
38 Stand Alone BAC Heater Control Panels
40 Vibration Cutout Switch (VCOS)
PART 7 Fan Control
41 Independent Fan Control
41 Variable Frequency Drive Operation
42 Resonant Speed Identification Procedure
PART 8 Installation Instructions for Field Connections
OPERATION & MAINTENANCE » FXV AND FXV3 CLOSED CIRCUIT
COOLING TOWER, CXVB AND CXVT EVAPORATIVE CONDENSER
1
WWW.BALTIMOREAIRCOIL.COM

2
WWW.BALTIMOREAIRCOIL.COM
WARNING
•WARNING: Check to ensure the controls for the fan motor are set to allow a maximum of six on-off cycles per hour to prevent
motor overload.
•WARNING: The top horizontal surface of the unit is not intended to be used as a walking surface or working platform. If access to the
top of the unit is desired, the purchaser/end-user is cautioned to use appropriate means complying with applicable safety standards of
governmental authorities.
•WARNING: SunScreens on FXV and CXVB units are not designed to support the weight of a person or to be used as a storage or work
surface for any equipment or tools. Use of these SunScreens as walking, working or storage surfaces may result in injury to personnel or
damage to equipment. Units with SunScreens should not be covered with a plastic tarpaulin.
•WARNING: When the fan speed of the unit is to be changed from the factory set speed, including changes achieved by the use of a
variable fan speed device, steps must be taken to avoid operation at or near the fan’s “critical speed” which could result in fan failure
and possible personal injury or damage. Contact your local BAC Representative regarding any such applications.
•WARNING: The recirculating water system may contain chemicals or biological contaminants, including Legionella, which could
be harmful if inhaled or ingested. Personnel exposed directly to the discharge airstream and the associated drift mists, generated
during operation of the water distribution system and/or fans, or mists produced by high pressure water jets or compressed air (if
used to clean components of the recirculating water system), must wear respiratory protection equipment approved for such use by
governmental occupational safety and health authorities.
•CAUTION: The operation, maintenance, and repair of this equipment shall be undertaken only by personnel authorized and qualified to
do so. All such personnel shall be thoroughly familiar with the equipment, the associated system and controls, and the procedures set
forth in this manual. 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.
•CAUTION: All electrical, mechanical, and rotating machinery are potential hazards, particularly for those not familiar with their design,
construction, and operation. Accordingly, use appropriate lockout procedures. Adequate safeguards (including the use of protective
enclosures where necessary) should be taken with this equipment both to safeguard the public from injury and to prevent damage to
the equipment, its associated system, and the premises.
•CAUTION: This equipment should never be operated without all fan screens, access panels, and access doors in place. For the
protection of authorized service and maintenance personnel, install a lockable disconnect switch located within sight of the unit on
each fan and pump motor associated with the equipment.
•CAUTION: Openings and/or submerged obstructions may exist in the bottom of the cold water basin. Use caution when walking inside
the equipment.
•DANGER: Rotating equipment will cause severe personal injury or death to persons who come in contact. Do not perform any service on
or near the fans, motors, and drives, or inside the unit without first ensuring that the fans and pump motors are disconnected, locked
out, and tagged out.
DANGER
CAUTION
Safety Precautions

3
WWW.BALTIMOREAIRCOIL.COM
• The basin heater is not designed to prevent icing during unit operation.
• BAC units are typically installed immediately after shipment and many operate year round. However, if the unit is to be stored for a
prolonged period of time either before or after installation, certain precautions should be observed, as outlined in “Unit Operation and
Storage” on page 4.
• For fan motors controlled with VFDs, when reversing the direction of fan rotation, allow the fan to come to a complete stop before
restarting the motor.
• Do not use oils containing detergents for bearing lubrication. Detergent oils will remove the graphite in the bearing sleeve and cause
bearing failure. Also, do not disturb bearing alignment by tightening the bearing cap adjustment on a new unit as it is torque-adjusted
at the factory.
• Do not use steam or high pressure water to clean PVC eliminators or materials other than steel.
• Pressure greater than 10.0 psig may cause damage to the distribution system.
• Never use chloride or chlorine based solvents such as bleach or muriatic (hydrochloric) acid to clean stainless steel. It is important to
rinse the surface with warm water and wipe with a dry cloth after cleaning.
General Maintenance Information
Equipment Precautions
NOTICE
The services required to maintain a piece of evaporative cooling equipment are primarily a function of the quality of the air and water in the
locality of the installation:
• AIR: The unit should be located such that unusual quantities of industrial smoke, chemical fumes, salt, or heavy dust do not enter the
equipment. Such airborne impurities entering into the equipment and absorbed by the recirculating water, which can form a corrosive
solution.
• WATER: As water evaporates from the equipment, dissolved solids are left behind, which were originally contained in the make-up water.
These dissolved solids may be either alkaline or acidic and as they are concentrated in the circulating water, they can cause scaling or
accelerated corrosion.
The extent of impurities in the air and water determines the frequency of most maintenance services and also governs the extent of water
treatment which can vary from a simple continuous bleed and biological control to a sophisticated treatment system. Refer to “Water
Treatment” on page 25 and “Biological Control” on page 27 for more details.
Warranties
Please refer to the Limitation of Warranties in the submittal package applicable to and in effect at the time of the sale/purchase of these
products. Described in this manual are the recommended services for start-up, operation, and shutdown, and the approximate frequency
of each.

WWW.BALTIMOREAIRCOIL.COM
4
Fan Guard
Air Intake Louvers
BACross®Fill with Intergral
Drift Eliminators
Figure 1b. Dual Air Intake FXV3/CXVT
Coil Connection:
FXV3 Fluid In/
CXVT Refrigerant Out
Coil Connection:
FXV3 Fluid Out/
CXVT Refrigerant In
Spray Water
Distribution System
Access Door
Casing
Cold Water Basin
Removable Drift
Eliminators
BALTIDRIVE®
Power Train
Prime Surface
Coil
Suction
Strainer
Spray Riser Pipe
Bleed Valve
Spray Pump
Access Door
Spray Pump
Motor Make-up
Valve
Axial Fan(s)
Cold Water
Basin
Recirculating
Water Pump
Access Door
Figure 1. Single Side Air Intake FXV/CXVB
Coil Connection:
FXV Fluid In/
CXVB Refrigerant Out
Coil Connection:
FXV Fluid Out/
CXV Refrigerant In
BALTIDRIVE®
Power Train
Spray Water
Distribution System
SunScreens
(Option Not Shown)
FXV, FXV3, CXVB, AND CXVT UNITS
Unit Operation and Storage
1

WWW.BALTIMOREAIRCOIL.COM
5
WWW.BALTIMOREAIRCOIL.COM
5
Start-Up Procedure
Considerations for Initial Start-Up
•For units with independent fan control, see Page 41.
•For units with VFDs, see Page 15.
•For units with vibration cutout switches, see Page 40.
General
•If the unit is mounted on vibration isolators or isolation rails (by others), refer to the
vibration isolation manufacturer’s guidelines before loading/unloading weight from the
unit.
•Verify fan and unit pump motors are disconnected and locked out.
Cleaning
•Drain the cold water basin with the strainer in place.
•Remove all dirt and debris from the fan guard(s).
•Inspect and clean all spray nozzles.
•Clean all mechanical components, such as the fan and motor.
•Flush the cold water basin interior to remove any accumulated dirt and debris.
•Remove, clean, and replace the strainer.
Inspection
•Conduct external inspection of the equipment. Check for leaks, corrosion, and any
structural damage.
•Conduct internal inspection of the equipment. Check for anything unusual such as
structural or mechanical component damage.
•Inspect piping and connections.
•Thoroughly inspect the fan(s) for any mechanical or physical damage.
•At seasonal start-up or after prolonged shutdown, check the motor insulation with an
insulation tester prior to the motor start-up.
•For belt drive units, prior to seasonal start-up, check and adjust the belt tension. At
initial start-up, the belt tension may not require adjustment as the drive will be
properly tensioned at the factory prior to shipment.
•For gear drive units, verify adequate oil level and check all fittings to ensure there
are no visible leaks. Refer to “Gear Drive System” on Page 17 for initial start-up
instructions.
•For ENDURADRIVE®Fan System Units, Refer to Page 14 for initial start-up
instructions.
Unit Operation and
Storage
Start-Up Procedure
Considerations for Initial
Start-Up
General
Cleaning
Inspection
Start-Up
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service
on or near the fans, motors, and
drives, or inside the unit without
first ensuring that the fans and
pump motors are disconnected,
locked out, and tagged out.

WWW.BALTIMOREAIRCOIL.COM
6
Start-up
Prior to seasonal start-up, lubricate the motor
base adjusting screw (see Figure 2) and the
fan shaft bearings. At initial
start-up, no bearing lubrication is
required since the bearings are factory
lubricated prior to shipment.
•Apply RUST VETO®to steel shafts.
•Fill the cold water basin with fresh water
to the overflow level via the make-up
valve.
•Set the make-up valve float so the water shuts off at the operating level see Table 1 on
page 10).
•Execute one of the following biocide treatment programs while operating the
circulating pump and prior to operating the unit fan(s):
–Resume treatment with the biocide that was used prior to shutdown. Operate the
pump only while maintaining the maximum recommended biocide residual for a
sufficient duration (residual and time will vary with the biocide) as recommended
by the water treatment supplier. Start the fan only after this treatment period is
completed.
–Check the pH of the circulating water and, if necessary, adjust it to 7.0 - 7.6 pH.
Then, running the pump only, treat the system with sodium hypochlorite to maintain
a level of 4 to 5 mg/l (ppm) free chlorine (as Cl2) over a six hour period. Test kits for
measuring the free residual of chlorine are commercially available. Start the fan only
after this treatment period is completed.
•Start the unit pump and check for the proper rotation indicated by the arrow on the
pump cover.
•On installations where the unit pump was not furnished by BAC, a globe valve should
be installed in the pump discharge line and the pump flow rate adjusted to the correct
water flow and pressure (2 psig at spray header connection).
•Check that the float operated make-up valve is operating freely. Closely monitor water
level and adjust as necessary during the first 24 hours of operation.
•Inspect the nozzles and heat transfer section as described in “Water Distribution
System” on Page 22.
•Verify proper fan tip clearance. Refer to Fan “Inspection & Maintenance” on Page 11.
•Open the valve in the unit bleed line, and adjust the bleed by closing or opening the
valve until desired bleed rate is reached.
•For initial start-up, bump fan motor(s) and note the direction of rotation. Start the
fan motor(s) and check for proper fan rotation. The fan should rotate in the direction
indicated by the arrow on the fan cowl.
•Run the fan in manual mode for several minutes to check for any unusual noise or
vibrations.
•For the BALTIGUARD™ Fan System, BALTIGUARD PLUS™ Fan System or two speed
motors: check that the starter incorporates a 15 second time delay when switching
from high to low speed.
•Check the operation of the vibration cutout switch (see Page 40).
•Once the unit is operating, check the current and voltage of all three phases (legs)
of the fan motor with a heat load on the unit under warm ambient conditions. The
current must not exceed the nameplate ratings.
•For units with VFDs, see Page 15.
•For units with the optional Electric Water Level Control, see Page 24.
Figure 2. Adjustable Motor Base on Dual Air Intake FXV3/CXVT
NOTICE: Spray pressure greater
than 10.0 psig may cause damage
to the distribution system.
NOTICE: Check to ensure the
controls for the fan motor are set
to allow a maximum of six on-off
cycles per hour to prevent motor
overload.
After 24 hours of operation
under thermal load, perform the
following services:
9Check the unit for any unusual
noises or vibrations.
9Check the operating water
level in the cold water basins.
9Adjust the make-up valve if
necessary.
9Check the belt tension and
readjust if necessary.
9Inspect the spray nozzles and
heat transfer section.

WWW.BALTIMOREAIRCOIL.COM
7
WWW.BALTIMOREAIRCOIL.COM
7
Extended Shutdown
Perform the following services whenever the unit is shutdown in excess of three days:
•If the unit is mounted on vibration isolators or isolation rails (by others), refer to the
manufacturer’s guidelines before loading/unloading weight from the unit.
•Disconnect, lock-out, and tag-out all fans and pumps.
•Close the shut-off valve in the make-up water line (supplied by others) and drain all
exposed make-up water piping. Heat trace and insulate all exposed piping.
•Drain the cold water basin and all the piping (excluding the coils) that will be exposed
to freezing temperatures. Heat trace and insulate all exposed piping.
•To minimize the risk of biological contamination during shutdown, it is recommended
the entire system be drained, excluding the coil.
•Clean all debris, such as leaves and dirt, from the interior and exterior of the unit.
•Clean and flush the water distribution system and cold water basin with the basin
strainer in place.
•Leave the cold water basin drain open so rain and melting snow will drain from the
unit.
•Clean the basin strainer and re-install.
•Cover the fan discharge to keep out dirt and debris.
•Lubricate the fan shaft bearings, motor base, and motor base adjusting screw (if
applicable).
•Apply RUST VETO®to steel shafts.
•Inspect the protective finish on the unit. Clean and refinish as required. Refer to
“Corrosion Protection”on page 25 for more details.
•Lockout the fan motor starting device in the “OFF” position to ensure personal safety
in case of future inspection or service.
Prolonged Outdoor Storage Storage Preparation
•Conduct the “Extended Shutdown” procedure on page 7 if the unit is installed.
•Ensure the cold water basin is fully drained and the drain is open.
•For storage prior to installation, all components (ladders and platforms) and
accessories, which sometimes ship inside the unit and are not a permanent fixture in
the basin, should be removed and stored indoors.
•Remove the bottom drain plug to the spray pump(s). Put the plug(s) in a marked
plastic bag and attach to the spray pump(s) for future use.
•Remove and store fan belts (if supplied) indoors, keeping matched belts together. Tag
belts appropriately for future identification.
•For storage prior to installation, coils should be charged with nitrogen at 15 psi in the
factory. Units are available charged with nitrogen from BAC for a nominal fee.
•Installed units that have been piped but not filled do not require additional
precautions.
NOTICE: Covering the unit with
a clear plastic tarpaulin during
storage can trap heat inside the
unit and cause damage to the
PVC components. If units must be
covered during storage, an opaque,
reflective tarp should be used.
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service
on or near the fans, motors, and
drives, or inside the unit without
first ensuring that the fans and
pump motors are disconnected,
locked out, and tagged out.

WWW.BALTIMOREAIRCOIL.COM
8
• Units (with coils) that have been installed and operated should remain filled. If the
unit is stored in a freezing climate, the coil must be protected from freezing. For
protection against coil freeze-up, BAC recommends the use of an inhibited glycol
solution. If protecting the coils with glycol is not possible, the galvanized steel coils
should be drained completely and capped once as much water and moisture is
removed from the coil as possible.
• For extended shutdown periods after start-up, coils should be charged with nitrogen at
15psi in the field and capped by adding a threaded connection or a welded cap. Upon
start-up, the coil connections will require cutting and bevelling.
• Coat steel sheaves (if supplied) with RUST VETO®. RUST VETO®can be removed with
mineral spirits and must be removed from the grooves of the sheaves before start-up.
• Apply a weather-resistant lubricant or heavy grease such as Anti-Seize (BAC part #
160069) to all exposed threaded or flanged connections and the adjustable motor
base threaded rod.
• Insert desiccant bags into the control panel (if supplied) to absorb moisture. Seal the
control panel for storage.
• Spray coat electrical component housings (if supplied) with a suitable protective
coating, such as Cosmoline®Weathershed, and individually cover them with plastic,
taking care to leave openings for free air circulation.
• Inspect the protective finish on the unit. Clean and refinish as required. Refer to
“Corrosion Protection” on page 25 for more details.
Motor Recommendations
BAC standard motors are designed for storage at ambient temperatures of -20ºF to 104ºF
(-28.9ºC to 40ºC). Prolonged periods of exposure above or below these specified conditions
could degrade components of the motor and cause malfunction or premature failure.
• Motors should be removed and stored inside whenever possible. When indoor storage
is not possible the motors must be covered with a loose fitting tarpaulin. Do not
use plastic/plastic film. This cover should extend below the motor and be secured;
however, it should not tightly wrap the motor. This will allow the captive air space to
breathe, minimizing formation of condensation.
• Care must also be taken to protect the motor from flooding or from harmful chemical
vapors.
• The storage area should be free from ambient vibration. Excessive vibration can cause
bearing damage. Motors that must be stored in areas with high ambient vibration,
such as from heavy construction equipment or other sources, must have the shaft
locked to prevent any movement.
• Precautions should be taken to prevent rodents, snakes, birds, or other small animals
from nesting inside the motors. In areas where they are prevalent, precautions must
also be taken to prevent insects from gaining access to the interior of the motor.
• If not stored indoors in a controlled environment, some form of heating must be
utilized to prevent condensation from accumulating in the motor. This heating
should maintain the winding temperature at a minimum of 9ºF (5ºC) above the
ambient temperature of the room, keeping it from dropping below the dew point
where condensation could form inside the motor. If space heaters are supplied, they
should be energized. If none are available, single phase or “trickle” heating may be
utilized by energizing one phase of the motor’s winding with a low voltage. Request
the required voltage and transformer capacity from your local BAC Representative. A
third option is to use an auxiliary heat source and keep the winding warm by either
convection or blowing warm air into the motor.
• Rotate the motor shaft monthly to redistribute bearing grease.
NOTICE: Draining the coil will not
completely protect the coil from
corrosion; some corrosion will still
occur.
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service
on or near the fans, motors, and
drives, or inside the unit without
first ensuring that the fans and
pump motors are disconnected,
locked out, and tagged out.

WWW.BALTIMOREAIRCOIL.COM
9
WWW.BALTIMOREAIRCOIL.COM
9
Instructions for Optional Gear Drive Units
Follow the procedures below when a gear drive will not be used for a prolonged period of
time.
•Drain all of the old oil from the gear drive and properly discard.
•Re-install drain plug.
•Remove the air breather from the gear drive.
•Completely fill the gear drive through the air breather port with a recommended
lubricant listed in the “Fan Drive System” section.
•After completely filling the gear with oil, plug the previously removed air breather port,
and all remaining open ports. Use steel plugs to plug the openings, and store the air
breather so that you can reuse it when the gear drive is put back in operation.
•Securely attach a “warning” tag to the gearbox and motor starter stating that it has
been “overfilled” to remind start-up personnel that they need to drain the gear oil
back to the proper level before using.
•To establish a positive moisture barrier, cover the drive with a tarpaulin or other
protective cover.
Maintenance Requirements
•Rotate all fans and motors shafts monthly by hand. Hand-turning will ensure that the
shafts and bearings are free and will redistribute grease within the bearings.
•Inspect the cold water basin monthly to ensure that the drain is open and remove any
leaves or debris that may have accumulated in the cold water basin.
•Inspect axial fans prior to start-up and at least once annually to ensure that the blades
are tight and that there is no obvious corrosion between the hub and the fan blade. Do
not energize the fans if there is obvious corrosion of fan components. Loose fan blades
could result in fan failure and possible injury or damage.
•Inspect the rust preventative coating on all motor external machined surfaces
including shaft extensions monthly. If necessary, re-coat the surfaces with RUST
VETO®.
Start-Up Preparation After Prolonged Storage
Keep in mind that start-up procedures after long periods of storage are just as important
as pre-shutdown procedures.
•Motor should be thoroughly inspected and cleaned to restore it to pre-storage
condition.
•Inspect axial fan(s) prior to start-up to ensure that the blades are tight and that there
is no obvious corrosion between the hub and the fan blade. Do not energize the fan(s)
if there is obvious corrosion of fan components. Loose fan blades could result in fan
failure and possible injury or damage.
•Reinstall all fan belts, motors, door gaskets, and drain plugs (as applicable), and
remove all protective coverings.
•For units stored prior to installation, conduct rigging procedures as directed in the
unit’s Rigging and Assembly Instructions, available on www.BaltimoreAircoil.com or
by contacting your local BAC Representative.
•Perform an insulation test of motor windings to ensure satisfactory insulation
resistance.
•Conduct full start-up procedure as stated in the “Start-Up Procedure” on page 5.
Be especially thorough for cleaning and inspection prior to start-up.
NOTICE: Upon start-up, the gearbox
must be drained back to the proper
level before operation to prevent
damage. The fan motor should be
locked and tagged out in order to
prevent operation until the oil level
is returned to normal.
Unit Operation and
Storage
Prolonged Outdoor Storage
Motor Recommendations
Maintenance Requirements
Start-Up Preparation After
Prolonged Storage

WWW.BALTIMOREAIRCOIL.COM
10
FXV, FXV3, CXVB, AND CXVT UNITS
Detailed Component
Maintenance Procedures
2
Cold Water Basin
The fluid (refrigerant) to be cooled (condensed) is circulated inside the tubes of the unit’s
heat exchanger. Heat flows from the process fluid through the coil to the spray water
outside which is cascading over the tubes. The spray water collects in the cold water
basin, passes through the suction strainer and is pumped back to the distribution system.
The cold water basin is constructed from one of the following materials of construction.
•Galvanized steel
•TriArmor®Corrosion Protection System
•Welded Type 304 stainless steel
Water Levels
Model Number At Overflow Level (in.) At Operating Level (in.)
FXV-08xx, CXVB-xxx-08xx 13 1/2” 8 1/4”
FXV-12xx, CXVB-xxx-12xx 14 1/2” 8”
FXV3-1224-xxx, FXV3-1426-xxx, CXVT-x-1224-x,
XECXVTx-1224-x,CXVT-x-2424-x, XECXVTx-2424-x 19 1/4" 16 1/4"
FXV3-1224-xxx, FXV3-1426-xxx, XECXVTx-1426-x,
CXVT-x-2826-x, XECXVTx-2826-x 19 1/4" 16 1/4"
•The operating water level in the cold water basin will vary with system thermal load
(evaporation rate), the bleed rate employed, and the make-up water supply pressure.
•The make-up valve controls the operating level, which is maintained at the levels
shown in Table 1.
•Check the operating water level monthly, and readjust the float when necessary to
maintain the recommended operating level.
•Consult “Water Level Control” on Page 23 for information on how to set and maintain
basin operating level.
Table 1. Cold Water Basin Water Levels (Measured from Inside the Cold Water Basin)

WWW.BALTIMOREAIRCOIL.COM
11
WWW.BALTIMOREAIRCOIL.COM
11
Inspection & Maintenance
•Inspect the cold water basin monthly. Remove trash or debris accumulated in the
basin or on the strainer.
•Quarterly or more often if necessary, drain, clean, and flush the entire cold water basin
with fresh water. This will remove sediment which can collect in the basin during
operation. If not removed, sediment can become corrosive and cause deterioration of
the protective finish of metallic basins.
–When flushing the basin, leave the strainer in place to prevent the sediment from
re-entering the system.
–Remove the strainer after the basin has been flushed.
–Clean and replace the strainer before refilling the basin with fresh water.
•Adjust the float to maintain the design operating level. See Table 1.
Fan
FXV, FXV3, CXVB, and CXVT units use axial fan(s). Thoroughly inspect the fan(s) for
damaged or deteriorated fan blades and replace the fan(s) as required.
Inspection & Maintenance
•If the unit is already in operation, while the fan is running, check for any unusual
noises or vibrations.
•With the fan off and the motor disconnected, locked out, and tagged out, check the
general condition of the fan:
–Inspect for any loose or missing bolts in the fan shaft bushing, the fan hub, and the
fan shaft bearing(s).
–Check the fan blades for looseness, first by twisting the blade by hand, and then by
moving the blade tip up and down. There should be no play or slippage.
–Inspect each blade for excessive scale build-up that could cause vibration.
–Check each blade in the area of the shank for any signs of cracking. If cracking is
found, the fan motor should be locked out immediately. Contact your local BAC
Representative for assistance.
•Tip Clearance: Check the clearance between the tip of the blade and the fan cowl.
The clearance should be within 5/16” to 1/2” for single air intake FXV/CXVB units and
within 3/8” to 3/4” for dual air intake FXVT/CXVT units.
•Drain Holes: On hollow blades, the drain hole in the blade tip should be unobstructed.
Tip: Use a piece of wire to probe the hole.
•Blade Pitch: Check to ensure that the blades are all at the same pitch. If uncertain,
measure the pitch with an inclinometer. All blades should be within -1/2° to 0°.
•Rotation: Turn the fan by hand to ensure that it moves freely with no rough spots,
binding or other malfunctions that could cause vibration or fan motor overload. While
rotating the fan, check the blade tracking. All blades should track within a 3/4” to 1”
band at any single point around the cowl.
•Direction of Rotation: On initial start-up, or if the fan motor has been rewired, bump
the fan motor and note the direction of rotation. It should rotate in the direction
indicated by the arrow on the fan cowl. On units with independent fan motors, check
the rotation of each fan.
•Operation: On initial start-up, run the fan in the manual position for several minutes
and check for any unusual noises or vibration.
CAUTION: Openings and/or
submerged obstructions may exist
in the bottom of the cold water
basin. Use caution when walking
inside this equipment.
NOTICE: Check to ensure the
controls for the fan motor are set
to allow a maximum of six on-off
cycles per hour to prevent motor
overload.
Detailed Component
Maintenance
Procedures
Cold Water Basin
Water Levels
Inspection & Maintenance
Fan
Inspection & Maintenance
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service
on or near the fans, motors, and
drives, or inside the unit without
first ensuring that the fans and
pump motors are disconnected,
locked out, and tagged out.

WWW.BALTIMOREAIRCOIL.COM
12
Fan Drive System
BALTIDRIVE®Power Train, Independent Fan, BALTIGUARD™
and BALTIGUARD™Plus Fan System
The BALTIDRIVE®Power Train consists of a solid-
backed, multi-groove, neoprene/polyester belt rated
for cooling tower service, and corrosion resistant
sheaves. These components provide high reliability
with low maintenance requirements.
The independent fan option consists of one fan motor
and drive assembly for each fan to allow independent
operation, adding redundancy and an additional step
of fan cycling and capacity control to models with
more than one fan.
The BALTIGUARD™ Fan System consists of two standard single-speed fan motors and
drive assemblies. One drive assembly is sized for full speed and load, and the other is
sized for approximately 2/3 speed and consumes only 1/3 the design horsepower.
The BALTIGUARD PLUS™ Fan System builds on the advantages of the BALTIGUARD™
Fan System by adding a VFD to one of the motors.
Inspection & Maintenance
These drives require a periodic check of the belt condition and, when necessary, tension
adjustment. The recommended service intervals are as follows:
•Initial Start-up: Servicing is not required prior to initial unit start-up. The drive has
been tensioned and aligned at the factory.
•Seasonal Start-up: Readjust the belt tension (if required).
•Operation: After the first 24 hours of operation, readjust the belt tension on a new unit
start-up or installation of a new belt. Thereafter, check the belt condition monthly, and
adjust tension as necessary. Readjust tension at least once every three months.
NOTE: There should be no “chirp”
or “squeal” when the fan motor is
started.
Figure 4a. Belt Tension with a Straight Edge Figure 4b. Belt Tension with a Tape Measure
Figure 3. BALTIGUARD™ Fan System
DANGER: Rotating equipment
will cause severe personal injury
or death to persons who come in
contact. Do not perform any service
on or near the fans, motors, and
drives, or inside the unit without
first ensuring that the fans and
pump motors are disconnected,
locked out, and tagged out.

WWW.BALTIMOREAIRCOIL.COM
13
WWW.BALTIMOREAIRCOIL.COM
13
Detailed Component
Maintenance
Procedures
Fan Drive System
BALTIDRIVE®Power Train,
Independent Fan and
BALTIGUARD™ Fan System
Inspection & Maintenance
•Belt tension check:
–Place a straight edge along the belt from sheave to sheave as shown in Figure 4a, or
use a tape measure as shown in Figure 4b, to measure belt deflection.
–Apply a moderate force by hand (approximately 40 lbs/275 kPa) evenly across the
width of the belt in the center of the span between the sheaves.
–There is adequate belt tension if the belt deflects between 1/4” and 3/8” as shown
in Figures 4a and 4b.
•Belt tension adjustment (if required):
–Loosen the lock nut on the motor base adjusting screw.
–Turn the motor base adjusting screw clockwise to tension the belt, or
counterclockwise to relieve belt tension. During adjustment of belt tension, rotate
the drives several times by hand to evenly distribute the tension throughout the belt.
–When the belt is properly tensioned, retighten the locking nut on the motor base
adjusting screw.
•Drive alignment check and adjustment:
–Check the drive alignment annually to ensure maximum belt life.
–Place a straight edge across the driver and the driven sheaves as shown in Figure
NOTICE: Check to ensure the
controls for the fan motor are set
to allow a maximum of six on-off
cycles per hour to prevent motor
overload.
Figure 5a. Standard Drive Alignment
Figure 5b. BALTIGUARD™/BALTIGARD PLUS™ Fan System Drive Alignment
5a for standard drives and in Figure 5b for the
BALTIGUARD™ Fan System or the BALTIGUARD
PLUS™ Fan System.
–The straight edge should contact all four points as
shown in Figure 5a and 5b indicating proper drive
alignment.
–There should be no more than 1/16” deviation from
four points of contact.
–In case of realignment, loosen the motor sheave and
align it with the fan sheave. Allow 1/4” for draw-up
as the bushing screw is retightened.

WWW.BALTIMOREAIRCOIL.COM
14
Optional ENDURADRIVE®Fan System
The ENDURADRIVE®Fan System is an option for select FXV3 Closed Circuit Cooling
Towers and CXVT Evaporative Condensers. The ENDURADRIVE® Fan System includes a
direct drive motor and variable frequency drive (VFD) designed specifically for the motor.
DANGER FOR THE OPTIONAL ENDURADRIVE® FAN SYSTEM
•DANGER: Rotating equipment will cause severe personal injury or death to persons who come into contact. Do not perform any service on or near
the fans, motors, and drives, or inside the unit without first ensuring that the fans and pumps are disconnected, locked out, and tagged out.
WARNING FOR THE OPTIONAL ENDURADRIVE FAN SYSTEM
•WARNING: Do not disassemble the motor, because it contains strong permanent magnets that can cause severe personal injury or death.
•WARNING: ENDURADRIVE®Fan System motors can induce voltage and current in the motor leads by rotating the motor shaft, even when the
motor is completely disconnected from the power source. Electrical shock can cause severe personal injury or death. Therefore, mechanically lock
or tie down the fan until all wiring has been completed and before servicing the drive system, or when performing any motor maintenance
procedure. Only qualified personnel should attempt the installation, operation and maintenance of this equipment.
•WARNING: Pacemaker danger − Magnetic and electromagnetic fields in the vicinity of current carrying conductors and ENDURADRIVE®Fan
System motors can result in a serious health hazard to persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk,
stay away from the area surrounding a ENDURADRIVE®Fan System motor.
•WARNING: The variable frequency drive may apply hazardous voltages to the motor leads after power to the controller has been turned off. Verify
that the controller is incapable of delivering hazardous voltages and that the voltage at the motor leads is zero before proceeding. Failure to
comply with this warning may result in severe personal injury or death.
•WARNING: The surfaces of motor enclosures may reach temperatures that are high enough to cause discomfort or injury to personnel coming into
contact with them. Protection should be used to prevent accidental contact with hot surfaces. Failure to observe this precaution could result in
personal injury.
NOTICES FOR THE OPTIONAL ENDURADRIVE®FAN SYSTEM
•VFD must be powered on at all times so that moisture can be removed from motor automatically.
•Do not bypass VFD. The motor can only be operated by VFD, and bypassing the VFD by wiring the motor directly across-the-line will result in motor failure.
•Incorrect motor rotation direction for extended periods can cause equipment damage. Be sure to verify motor rotation direction before operating the
unit. When reversing the direction of rotation, allow the fan to come to a complete stop before restarting the motor. Fan reversal should be used only
after the other methods of fan control fail. If utilized, the fans should be run in reverse for no longer than 20 minutes at no more than 50% speed,
and the cooling tower should be observed during this time. Before returning to normal operation, visually inspect the fan blades for ice formation.
•Use only a shielded motor power cable with a complete circumferential braided or copper film/tape ground jacket around the power leads.
This ground should be secured to the motor frame from within the motor terminal box and must return without interruption to the drive ground.
•To prevent equipment damage, be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on
the rating plate.
•To prevent equipment damage, do not exceed the RPM listed on the motor nameplate.
•If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure in
NEMA MG1 and MG2 standards to avoid equipment damage.
®

WWW.BALTIMOREAIRCOIL.COM
15
WWW.BALTIMOREAIRCOIL.COM
15
Initial Start-Up
Motor
•Be sure that all power to motor is off, follow the required lockout/tagout procedure, and
mechanically secure the fan to prevent rotation.
•Inspect all electrical connections for proper termination, clearance, mechanical
strength and electrical continuity.
•Install the motor conduit box cover and all covers and panels that were removed during
installation.
•Remove the mechanical lock or tie down from the fan to allow the fan to turn freely.
•Rotate the fan by hand to be sure there are no obstructions to free rotation. Ensure that
no contact is made with electrical connections while rotating the fan.
•A motor that has been in storage for some time should be tested for moisture
(dielectric withstand insulation test) and relubricated (regreasable type) prior to being
put into service.
•During operation, observe motor performance. It should run smoothly with little noise.
The bearings should not overheat and should reach a normal operating temperature.
Any undue noise, overheating, or erratic performance should be investigated and
corrective action taken immediately to prevent serious damage. All ENDURADRIVE®
Fan System motors are lubricated before shipment and will operate for a long period
before regreasing is required. The period will vary depending on environmental and
service conditions. Refer to Maintenance section of this manual for regreasing intervals.
Variable Frequency Drive (VFD)
•The ENDURADRIVE®Fan System includes a VFD for each motor, which is required to
operate the motor, and only this VFD may be used to operate the motor. This VFD has
been designed and programmed for use with this fan system and has been
preprogrammed with parameters specific to your cooling tower.
•Startup must be performed by a service provider that is authorized to startup the
ENDURADRIVE®Fan System motor and VFD; contact your sales representative for
details regarding startup. For technical details about the drive, see the ENDURADRIVE®
Fan System ACS880 Start Up Guide.
•The motor can be controlled by sending the VFD either a 4-20mA (default) or a 0 -10V
(optional) signal. See the submittal drawing for wiring details and dip switch settings.
•The ENDURADRIVE®Fan System may be operated at any speed below the nameplate
RPM; there is no required minimum operating speed.
•The VFD must remain powered at all times, even when the motor is not operating. When
the run enable (DI1) opens, a trickle current protects the motor from moisture ingress.
Refer to the ENDURADRIVE® Fan System ACS880 Start Up Guide for set up and
wattage information.
•An optional vibration cutout switch should be wired to the VFD as shown in the
submittal. The vibration cutout switch is part of that safety circuit and can be wired in
series with other safety measures. See submittal drawings for additional information.
Before wiring the vibration cutout switch to the VFD, remove the appropriate factory
installed jumper per the submittal drawing.
•All VFDs include Modbus® communication protocol as the standard communication
method with your building automation system. BACnet communication protocol is
optional using a gateway adapter that includes BACnet MS/TP and BACnet/IP.
Depending on the NEMA VFD enclosure rating, the gateway will be field-installed or
factory-installed. See wiring details in your submittal, and address details can be found
in the ENDURADRIVE®Fan System ACS880 Start Up Guide. For additional protocols,
contact your local BAC Sales Representative.

WWW.BALTIMOREAIRCOIL.COM
16
Inspection & Maintenance
•Inspect the motor at regular intervals, approximately every 500 hours of operation or
every 3 months, whichever occurs first.
•The following steps should be performed at each inspection:
–Turn off the fan motor, and follow the required lockout/tagout procedure.
–Check that the motor is clean. Check that the exterior fins of the motor are free of
dirt, oil, grease, etc. If the motor is not properly ventilated, overheating can occur
and cause early motor failure.
–Perform a dielectric withstand insulation test periodically to ensure that the integrity
of the winding insulation has been maintained. Record the readings. Immediately
investigate any significant decrease in insulation resistance.
–Check all electrical connections to be sure that they are tight.
Relubrication & Bearings
•Bearing grease will lose its lubricating ability over time, not suddenly.
•The lubricating ability of a grease (over time) depends primarily on the type of grease,
the size of the bearing, the speed at which the bearing operates and the severity of the
operating conditions.
•Good results can be obtained if the following recommendations are followed in your
maintenance program.
Lubrication Procedure
•Relubrication is recommended with the shaft stationary and a warm motor.
•Wipe all dirt from the outside of the grease fills and drains.
•Locate the grease inlet at the top of the bearing hub, clean the area and replace the
1/8” pipe plug with a grease fitting if the motor is not equipped with grease fitting.
•Remove grease drain plug located opposite the grease inlet.
•Using a manual grease gun, pump in the recommended grease in the amount shown
in Table 2. This amount of grease will provide an ample supply of lubricant between
lubrication intervals. Use only clean, fresh grease from clean containers and handle
so as to keep it clean. In general, mixing of greases is not recommended. If an
incompatible grease is used, the lube system must be repacked completely with the
new grease.
•Wipe away any excess grease at the grease drain or relief and replace drain plugs.
•Follow the relubrication interval given in Table 2 (or sooner) unless otherwise specified
on the motor lubrication nameplate.
•Lubrication interval is based upon maximum ambient temperature of 40°C and a
minimum air flow of 750ft/min over the motor.
•Motors are shipped from the factory with full grease cavities and ready for operation.
Table 2. Type of Grease, Relubrication Amount, and Interval
Motor Frame
Size Grease Type
Vol. in Cubic in3
(cm3) Weight oz (g)
Relubrication
Interval (hrs)
FL320Y Mobilith SHC460 2 (32) 1.0 (28)
17,500
FL360Y Mobilith SHC460 2.5 (40) 1.25 (35)
FL400Y Mobilith SHC460 2.5 (40) 1.25 (35)
17,500
17,500

WWW.BALTIMOREAIRCOIL.COM
17
WWW.BALTIMOREAIRCOIL.COM
17
Optional Gear Drive System
Gear drive systems are optional for dual air intake FXV3/CXVT units only.
Initial Startup
•If the unit is equipped with the extended oil fill option, make sure the ball valve
located at the gear box is open prior to start-up.
•BAC ships all gear drives filled with oil. The initial oil level should be at or near the
middle of the oil level sight glass.
•Internally mounted gear drives are factory installed, aligned, and tightened. Double
check all gear drive fasteners after the unit has been installed.
•On units with externally mounted motors, install and align the motor and drive shaft
in accordance with BAC’s installation instructions. Recheck the alignment and all
external fasteners after two weeks of operation.
•On installations with variable frequency drives, do not operate the standard gear drives
below 450 RPM motor speed (gear input speed). For speeds less than 450 RPM, a
low speed option gear drive must be supplied.
•Prior to the start-up, check all fittings on the gear drive to ensure that there are no
visible leaks. Refer Figure 6 for locations of the gear drive fittings.
Air Breather Plug
Oil Level
Sight Gauge
Oil Drain Plug
Oil Fill Elbow
Name Plate
Figure 6. Single Reduction Gear Drive
Change Interval
•Initial oil change: Replace the original oil after 500 hours or four weeks of operation,
whichever comes first.
•After the initial oil change, change the oil every 2,500 hours or six months, whichever
comes first.
•Drain the oil at the operating temperature through the drain plug.
•Refill the gear drive through the oil fill elbow with the recommended type and amount
of lubricant (Table 3). Refer to Figure 6 for locations of these components.
NOTICE: Gear drives should not be
used with Wye-Delta (Y-) motors.
NOTE: Continued operation at a
speed which resonates with the
gear drive system may result in
torsional vibrations which can
damage system components. The
most common indicator of torsional
vibration is an unusual rumbling or
grinding noise from the gear drive
at a narrow speed range. The noise
will decrease to normal levels when
the speed is increased or decreased
away from the offending speed
range. This noise is not indicative
of a defect, but results when the
vibratory torque exceeds the drive
torque, causing the gear teeth to
separate and clash together very
rapidly. On variable frequency
applications, avoid operation near
this resonance speed by locking out
the resonance speed range.

WWW.BALTIMOREAIRCOIL.COM
18
Inspection and Maintenance
• Maintain the oil level at or near the middle of the oil level sight gauge. The oil level
should always be visible in the sight gauge window when the unit is not operating/
energized, and the oil is at ambient temperature.
• Check oil level weekly with the unit idle. On units supplied with an external sight
gauge, check the oil level of the external sight gauge and the sight gauge on the gear
drive to ensure that the proper amount of oil is in the gear drive.
• Add oil through the oil fill elbow if level is below the oil level sight gauge.
• The standard oil provided is mineral oil. Synthetic lubricants are also available as an
option (see Fan Drive System “Lubrication” on Page 19).
• Refer to Table 3 on Page 19 for normal operating oil capacity of each gear drive.
• Refer to Table 4on Page 20 or the gear drive nameplate for specific gear model
number for each unit.
• Quarterly check to ensure proper alignment of all system components.
• Check to ensure that all bolts and external fasteners are tight.
• BAC recommends daily visual inspections and observation for oil leaks and unusual
noises and vibrations. If any of these occur, shutdown the unit until the cause is found
and corrected.
• If equipped with an external oil line and site glass, check weekly to make sure the
breather hole at the top of the sight glass is open.
Routine Maintenance During Operation
• Periodically recheck the alignment and tighten external fasteners as necessary. No
special break-in procedures are required.
• Excessive noise or vibration at initial operation is an indication of one or more of the
following:
–Misalignment
–Imbalance of the fan or other rotating parts
–Improperly adjusted fan blades
–Operation at the mechanical equipment resonant frequency
• Installations with 2-speed motors: When slowing from high speed, allow a minimum
15-second time delay for the fan to slow down before energizing the low-speed
winding.
• During periods of inactivity, the lubricant does not constantly lubricate the internal
parts of the gear drive, leaving the gear drive susceptible to corrosion. Therefore, the
following special precautions are necessary during periods of inactivity:
–For best results, let the gear drive cool for approximately four hours after shutdown.
–Start the fan and let it run for approximately five minutes. This will coat the internal
parts of the gear drive with cool oil.
–Thereafter, run the fan for five minutes once a week, throughout the shutdown
period to maintain the oil film on the internal parts of the gear drives.
• Clean the outside of the gear drive at least quarterly.
• For start-up after prolonged shutdown, the gear box must be fully drained, then refilled
with new oil at or near the middle of the oil level sight gauge to prevent damage.
Re-install the air breather which was removed prior to the prolonged shutdown. Then,
follow the steps in “Initial Start-up” on page 15.
NOTICE: If noise or vibration
persists, shut the unit down and
correct the cause before continuing
operation.
NOTICE: When reversing the
direction of rotation, allow the fan
to come to a complete stop before
restarting the motor.
NOTICE: For installations with
2-speed motors when slowing
from high speed, allow a minimum
15-second time delay for the fan
to slow down before energizing the
low-speed winding.
NOTICE: Upon start-up, the gear box
must be drained back to the proper
level before operation to prevent
damage. The fan motor should be
locked and tagged out in order to
prevent operation until the oil level
is returned to normal.