BAC PCT Cooling Tower User manual

www.BaltimoreAircoil.com.au
120 Wisemans Ferry Road, Somersby NSW 2250 › Telephone (Australia): 1300.134.622 › Telephone (New Zealand): 0800.225.842
RIGGING & ASSEMBLY INSTRUCTIONS
PCT Cooling Tower
PCT

PCT Cooling Towers should be rigged and assembled
as outlined in this manual.
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 ensure that all
necessary equipment will be available beforehand.
If outstanding circumstances require a departure from the
procedures outlined in this manual, contact your local BAC
Representative for guidance.
Be sure to have a copy of the submittal drawings available for reference.
If you do not have a copy of these drawings, or if you need additional
information about this unit, contact your local BAC Representative whose
name and telephone number are on the outside of the cold water basin. The
model number and serial number of the unit are also located in this area.

WWW.BALTIMOREAIRCOIL.COM.AU
1
MAR109-1
RIGGING & ASSEMBLY INSTRUCTIONS » PCT COOLING TOWER
1 Introduction
2 Safety
2 Shipping
2 Pre-Rigging Checks
3 Cold Weather Operation
3 Location
3 Warranties
3 Unit Operation
2 Unit Rigging & Assembly
4 Rigging
5 Section Assembly
6 Field Sealing of Basin to Casing Post Joint
7 Multi-Cell Unit Installation
9 Roof Deck Section Lifting
3 Optional Accessory & Loose Item Installation
10 Air Inlet Louvres
10 Float Valve
11 Fitting Tie Braces
12 Fitting of Wind Walls
13 Piping
13 Fan Speed
13 Bleed Line Installation
14 Basinless Unit Installation
15 Platform Installation
Table of Contents

WWW.BALTIMOREAIRCOIL.COM.AU
2
MAR109-1
1PCT COOLING TOWER
Introduction
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 listed 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 PCT Cooling Towers are factory assembled to ensure uniform
quality with minimum eld assembly. As standard, models ship in
two sections per cell (lower and upper). Optional shipment of three
sections per cell and optional containerized shipments are available.
Contact your local BAC Representative for more information. For the
dimensions and weights of a specic unit or section, refer to the
submittal 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:
WARNING: 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
qualied 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.
WARNING: Only personnel
qualied to do so should
undertake the installation,
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.
Sheaves and Belts
Bearings
Bearing Supports
Fan Motor(s)
Fan Guard(s)
Fan(s) and Fan Shaft(s)
Float Valve Assembly(s)
Fill
Water Distribution System
Cold Water Basin Accessories
Interior Surfaces
Exterior Surfaces
Louvres
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.

WWW.BALTIMOREAIRCOIL.COM.AU
3
MAR109-1
Introduction
Safety
Shipping
Pre-Rigging Checks
Unit Weights
Anchoring
Cold Weather Operation
Location
Warranties
Unit Operation
Unit Weights
Before rigging any unit, the weight of each section should be veried
from the unit submittal drawing. Unit print weights include the nal
assembled tower with all accessories.
Anchoring
Holes suited for M16 bolts are provided for bolting the unit to the
support beams. Refer to the suggested support 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.
Support beams must also be level. Each footing should be shimmed
with a rm material to ensure the weight of the tower is carried at all
points and that the basin ledges are level at all places. Shims may be
required either side of a joint. This is to be done before the basin is
lled with water. If vibration isolators are used, a supporting framework
must be provided between the unit and the vibration isolators to
provide continuous and rigid support. Anchor bolts, footings and beams
to be supplied by others.
Cold Weather Operation
These products must be protected by mechanical and operational
methods against damage and/or reduced effectiveness during sub-
freezing temperatures. Please 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 fans. When units are located
adjacent to walls or in enclosures, care must be taken to ensure the
warm, saturated, discharge air is not deected and recirculated back to
the air intakes.
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. For detailed
recommendation on BAC equipment layout, please contact your local
BAC 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 PCT Operation &
Maintenance Manual shipped with the unit.
ATTENTION: 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.

WWW.BALTIMOREAIRCOIL.COM.AU
4
MAR109-1
2PCT COOLING TOWER
Unit Rigging & Assembly
NOTE: For weight information,
refer to the submittal drawing
package.
NOTE: Any motors or
accessories shipped in the
cold water basin must be
removed prior to installation.
Rigging
To simplify shipping, rigging and installation all PCT Cooling Towers are
shipped in major sections consisting of a basin assembly(s) and one or
more casing/roof deck sections (see Table 1).
The proper rigging sequence for the PCT series is to lift the basin
section(s) into place rst. On multi-section basins lift each section into
place separately and then bolt sections together. Next, lift each casing
section into place and secure to the basin section. If motor(s) are
supplied loose t the motors. At the completion of this stage a crane is
no longer required.
Finally securely bolt the unit to supporting steel and on multi-section
basins seal the joint between sections.
Table 1 gives the recommended dimensions for rigging each section of
any PCT unit. With the information from the table and the additional
instructions on the following pages the rigging of a PCT Cooling Tower
can be quickly accomplished.
WARNING: Unless units ship
fully assembled, basin &
casing/roof deck sections
must be rigged separately.
Never assemble the unit
before lifting as the lifting
devices provided on the unit
are not designed to support
the weight of the entire
assembled unit.
THE USE OF SAFETY SLINGS IS
RECOMMENDED FOR
EXTENDED LIFTS OR
WHENEVER HAZARDS EXIST.
Table 1. Recommended Dimensions for Rigging
NOMINAL
BOX
SIZES
No. of NOMINAL
BOX
SIZES
No. of NOMINAL
BOX
SIZES
No. of H1 H2 L
Basin Casing Basin Casing Basin Casing (g 2a) (g 3) (g 3)
Sections Sections Sections (mm) (mm) (mm)
SINGLE FAN UNITS
5’ x 5’
1 each
DOUBLE FAN UNITS
-
2 each
TRIPLE FAN UNITS
-
3 each
1200 1700 1500
6’ x 6’ - - 1600 1900 1800
7’ x 7’ - - 1900 2200 2100
8’ x 8’ 8’ x 16’ 8’ x 24’ 2200 2500 2400
7’ x 10.5’ - - 2900 2200 3300
9’ x 9’ 9’ x 18’ 9’ x 27’ 2400 2700 2800
8’ x 12’ - - 3500 2500 3700
10’ x 10’ 10’ x 20’ 10’ x 30’ 2700 3000 3000
11’ x 11’ 11’ x 22’ 11’ x 33’ 2900 3300 3400
9’ x 13.5’ - - 4000 2700 4200
10’ x 15’ - - 4500 3000 4700
11’ x 16.5’ - - 5000 3300 5100
*** Casing Section Includes Roof Deck (Fan Assembly) ***

WWW.BALTIMOREAIRCOIL.COM.AU
5
MAR109-1
Section Assembly
1. Remove any motors or accessories shipped in the cold water basin.
2. Figures 1 and 2 show 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. Using basin to casing joining brackets, guide the upper section
onto the lower section. Match marks must line up.
4. Fasten the hardware between the upper casing and lower section
per Figure 3a and 3b.
5. Seal the joint between the upper section and lower section as
described on page 6.
Figure 1. Lifting basin section
H1
Figure 2. Lifting casing/roofdeck section
H2
L
Unit Rigging & Assembly
Rigging
Section Assembly
Figure 3a. Joining Casing to Basin section
Figure 3b. Joining Casing to Basin section
See g.3b
for detail
Casing Section being
lowered onto basin
Casing Section
lowered onto basin
Basin-to-Casing
Joining Bracket Insert & tighten
bolts with sealer
washer to “lock”
casing to basin
Basin “Louvre”
Post

WWW.BALTIMOREAIRCOIL.COM.AU
6
MAR109-1
Field Sealing of Basin to Casing Post Joint
Procedure:
1. Clean area for 30mm either side of the joint. Total width 60mm.
Use emery paper to rough up surface and remove sheen. Wipe with
acetone and allow to dry.
2. Wrap a layer of masking tape around post 30mm below joint and
a layer 30mm above the joint. This will assist in limiting spread of
excess sealer beyond sealing area.
3. Apply enough sealer on all faces of the square posts to give 2mm
thick coverage 30mm either side of the joint. Use a scraper to
spread this evenly over the surface. The sealer has a working time
of 30 minutes before skinning over.
4. Wrap berglass cloth over the joint and press into the sealer. Cloth
provided should wrap around the post approximately three times.
5. Apply and spread extra sealer if required to ensure berglass cloth
is coated with sealer.
6. Remove masking tape applied at step (2) and tidy up edges with
a scraper.
Figure 4. Sealing of Basin to Casing Post Joint
Basin Post
Easytape & Sealer
Casing Post
2 Min
60

WWW.BALTIMOREAIRCOIL.COM.AU
7
MAR109-1
Multi-Cell Unit Installation
Refer to the submittal drawing unit print for the proper orientation of
each cell. Multi-cell unit installations require eld sealing of the basin
where the two cells are joined. The following procedure should be
followed to join basin sections.
Figure 5. Installing Multi-section basin
1st basin
section installed on
supports
2nd (or subsequent) basin section being
lowered into position prior to joining to
basin section(s) already on supports
Unit Rigging & Assembly
Field Sealing of Basin to Casing
Post Joint
Multi-Cell Unit Installation

WWW.BALTIMOREAIRCOIL.COM.AU
8
MAR109-1
Procedure:
1. Use jigs or clamps to hold basin sections together temporarily.
When aligned, re-drill any holes that do not align properly.
2. Prepare the joint. Use Acetone and a scraper to clean the faces of
the joint to remove smears or deposits of berglass release agent,
loose paints or ller materials such as Plasticine. Abrade the
mating faces of the basin to at least 50mm from the corner.
Clean and abrade the corners. Clean and abrade 12mm of the
exposed edges of the basin adjacent to the joint (see Fig 6).
Note that the key area for sealing and gluing is regarded as the
50mm part of the joint closest to the water.
3. Wipe with acetone to remove dust.
4. Apply 5mm diameter beads of sealant around the perimeter of the
abraded prepared areas. Fill in the area with a 5mm bead in striped
or a serpentine pattern. Sealer is to be applied to both faces in this
manner.
5. Pull the basin sections close together so that beads of sealant
touch. Fit a bolt in each hole, with a nut & 2 washers, and do up
nger tight.
6. Smooth over the joint with spatula, removing excess sealant or
adding extra to ll hollows.
7. Do not disturb for 2 hours.
8. After 2 hours, bolts can be tightened further to put pressure on joint.
Figure 6. Abrading of basin halves
50
12

WWW.BALTIMOREAIRCOIL.COM.AU
9
MAR109-1
Roof Deck Section Lifting
In certain situations it may be required that the roof deck section be
shipped separate to the casing. In this situation lifting of the roof
deck section will be required on site to position it back on the casing.
Where units are shipped in this orientation, extra lifting ears are
added to the roof deck.
The sketch below shows the orientation of each lifting ear as it bolts
to the joining ange between segments. For direct drives one lifting
ear per roof deck ange joint will be tted. In the eld, for belt drives
the lifting will take place with one sling around the motor and three
slings to the lifting ears. For this reason, the lifting ears are only
tted to the three anges not covered by the motor and mechanical
equipment support. These lifting ears are for use when lifting the
roof deck section only. They should not be used for lifting the entire
casing section.
Figure 7a. Lifting Lugs for Roof Decks
Figure 7b. Lifting Roof Decks
WARNING: UNDER NO
CIRCUMSTANCES SHOULD THE
ROOF DECK LIFTING EARS BE
USED FOR LIFTING THE CASING
SECTION. THEY ARE ONLY
DESIGNED FOR LIFTING THE
ROOF DECK.
Unit Rigging & Assembly
Multi-Cell Unit Installation
Roof Deck Section Lifting

WWW.BALTIMOREAIRCOIL.COM.AU
10
MAR109-1
3
PCT COOLING TOWER
Optional Accessory & Loose
Item Installation
AIR INLET LOUVRES
Air inlet louvres are a lift and drop in design. They are to be installed
with utes facing downwards into basin. A shorter louvre is provided to t
over the quick ll/makeup.
FLOAT VALVE
If the unit has shipped without the oat arm/ball assembly attached this
should be installed as per Figure 8, before louvres are installed.
Figure 8. Attaching oat arm

WWW.BALTIMOREAIRCOIL.COM.AU
11
MAR109-1
Optional Accessory
& Loose Item Installation
Air Inlet Louvres
Float Valve
Fitting Tie Braces
FITTING TIE BRACES
Some PCT units are tted with tie braces on the basin legs to provide
structural stiffness to the unit. Where possible these are factory tted
although if they are shipped loose they will need to be tted in the
eld. The following procedure should be followed to t the tie braces:
1. Once the basin has been levelled out and shimmed, and prior
to the casing being tted, an inspection should be made to
ensure that all posts are reasonably vertical and that the basin is
supported in all nine places [or twelve places for rectangular units].
2. Fit the diagonal tie braces at their top end only picking up pre-
drilled holes in the post. Do not drill the bottom tie brace holes
in the posts yet. The tie braces have a bend to give stiffness. The
bent edges should be oriented so that they will deect water into
the basin.
3. Place the casing on top of the basin legs with the majority of the
weight being carried by the crane. DO NOT REMOVE THE CRANE
UNTIL ALL TIE BRACES ARE TIGHTENED.
4. Check that posts are vertical and aligned correctly. The weight
of the casing and the position of the crane can skew the posts
sideways and may need adjustment. Swing the tie braces so that
the lower hole is centred in the basin post. If the posts are parallel
and square, the holes should be an equal distance up from basin
ledge. Once the posts are square, tie braces should be pulled tight
and clamped. The bolt holes may now be drilled and bolts tted.
Now tighten all tie brace bolts. The crane can now be released.
Figure 9. Fitting Tie Braces
Section AA

WWW.BALTIMOREAIRCOIL.COM.AU
12
MAR109-1
FITTING OF WIND WALLS
1. Prior to tting ashing, the following steps in installation should
have taken place: (a) Basin(s) placed in position and shimmed to
make level and carry weight evenly. (b) Casing lowered onto basin
legs and the leg joiners bolted together.
2. With the casing bolted to the basin, seal the joints between the posts.
3. There are two ashing pieces provided for each side of the unit.
Each ashing piece rests on the berglass ledge of the basin
wind wall. The wind wall is not fully glued to the post and can
be temporarily pulled away from the post to slide the ashing in.
Each ashing piece has a folded end to prevent water falling out.
When the ashing is in the correct place, this folded end is sealing
against the outside face of the corner post. The ashing pieces
overlap by approximately 30mm. They are not designed to be
bolted together.
4. To x the ashing in position, screw the Z-section brackets to
the ashing pieces so as to pull the ashing against the upper
berglass panel. Sealer is applied to the fastener as it is tted to
prevent water migration through the fastening points.
5. When the ashing is in place, there is a cavity created behind the
corner posts and sealing is required within this area. (a) Use the
sealer provided to seal the bottom horizontal corners behind the
post. (b) Seal the vertical joint between the post and ashing ends.
6. Seal the vertical joint where ashing pieces overlap each other.
7. It is not envisaged that sealing is needed on any of the other
horizontal joints such as where ashing overlaps berglass panels.
Figure 10. Fitting of Wind Walls

WWW.BALTIMOREAIRCOIL.COM.AU
13
MAR109-1
Optional Accessory
& Loose Item Installation
Fitting of Wind Walls
Piping
Fan Speed
Bleed Line Installation
PIPING
All piping must be supported external to the tower and restraint provided
to ensure no vertical or horizontal movement of the piping. All piping
and supports are to be furnished by others.
FAN SPEED
When the fan speed of this product is to be changed from the factory
set speed, including the use of a variable fan speed control 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.
BLEED LINE INSTALLATION
On all PCT units install a bleed line with valve between the system
circulating pump discharge riser and a convenient drain. Locate the bleed
line in a portion of the riser piping that drains when the pump is off.
WARNING: The bleed valve
should always be open when
the unit is in operation,
unless the bleed rate is
automatically controlled by
a water treatment system.
Recommended bleed rates
may be found in the Operating
and Maintenance Manual or by
consulting a competent water
treatment specialist.

WWW.BALTIMOREAIRCOIL.COM.AU
14
MAR109-1
BASINLESS UNIT INSTALLATION
Units supplied without a basin come in one of two arrangements, “A” or “B”.
Arrangement “A” - This is where the unit is supplied with the casing, roof
deck and mechanical equipment only. This arrangement does not include
any louvres, legs, strainer, suction, drain, quick-ll or make-up. The casing
section sits directly onto supporting piers or beams supplied by others. Since
the unit is essentially now only a casing/roof deck section, the unit is rigged
as per Figure 2.
Arrangement “B” -With this arrangement the unit is supplied the same as
above but also includes louvres and a louvre support frame consisting of
legs channels and tie braces. This support frame is shipped unassembled to
minimise transport costs and must rst be assembled in place.
See Figure 11 below demonstrating this assembly. See also “FITTING TIE
BRACES” on page 11 for correct installation of the tie braces. Once the
frame is assembled the casing section can then be lifted on and fastened
using the basin to casing joining bracket shown in Figure 3b.
Figure 11

WWW.BALTIMOREAIRCOIL.COM.AU
15
MAR109-1
PLATFORM INSTALLATION
Factory Fitted Platforms
Where a platform is supplied with the unit it is normally tted to the casing
section at the factory. In this case only the ladder, stiles and landing need
to be tted on site. See gure 12a below demonstrating this.
Pre-Assembled Platforms Shipped Loose
In some instances due to transport limitations it is necessary to ship the
platform separate from the unit. In this case the platform must rst be
lifted up and xed to the platform support beam. See gure 12b below
demonstrating this. Once the platform is tted to the support beam the
ladder, stiles and landing can be tted as above.
Knock Down Platforms
Platforms may be shipped as a knock down kit for assembly on site if
required. If this is the case the platform must rst be assembled on the
oor before being lifted into place. Figure 12c below shows an exploded
view of a typical platform.
Optional Accessory
& Loose Item Installation
Basinless Unit Installation
Platform Installation
Figure 12c.
Figure 12a.
Figure 12b.

COOLING TOWERS
CLOSED CIRCUIT COOLING TOWERS
ICE THERMAL STORAGE
EVAPORATIVE CONDENSERS
HYBRID PRODUCTS
PARTS & SERVICES
www.BaltimoreAircoil.com.au
120 Wisemans Ferry Road, Somersby NSW 2250 › Telephone (Australia): 1300.134.622 › Telephone (New Zealand): 0800.225.842