BAC Vertex VRC A-1012N Series Manual

Vertex™
Evaporative Condenser
OPERATION & MAINTENANCE MANUAL

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Table of Contents Page | 2
Vertex™ Evaporative Condenser
OPERATION & MAINTENANCE MANUAL
Contents
1. Recommended Maintenance Intervals.......................................................................................................................................................... 5
2. Warnings and Cautions................................................................................................................................................................................. 6
Safety Precautions........................................................................................................................................................................................ 6
Equipment Precautions................................................................................................................................................................................. 7
General Maintenance Information ................................................................................................................................................................ 8
3. Unit Operation and Storage .......................................................................................................................................................................... 9
Recommended Spare Parts ....................................................................................................................................................................... 11
Start-Up Procedure..................................................................................................................................................................................... 12
Considerations for Initial Start-Up........................................................................................................................................................... 12
General................................................................................................................................................................................................... 12
Cleaning ................................................................................................................................................................................................. 12
Inspection............................................................................................................................................................................................... 12
Start-Up.................................................................................................................................................................................................. 13
Extended Shutdown.................................................................................................................................................................................... 15
Prolonged Outdoor Storage........................................................................................................................................................................ 16
Storage Preparation ............................................................................................................................................................................... 16
Maintenance Requirements During Storage .......................................................................................................................................... 18
Start-Up Preparation After Prolonged Storage....................................................................................................................................... 18
4. Component Maintenance Procedures......................................................................................................................................................... 19
Basin........................................................................................................................................................................................................... 19
Water Levels .......................................................................................................................................................................................... 19
Inspection & Maintenance...................................................................................................................................................................... 20
EC Fan System........................................................................................................................................................................................... 20
Electronically Commutated (EC) Fan Motors ......................................................................................................................................... 20
Unit Mounted Electrical Panel ................................................................................................................................................................ 20
Alarm Signal........................................................................................................................................................................................... 20
Override Switch...................................................................................................................................................................................... 21
BALTIDRIVE®Power Train......................................................................................................................................................................... 21
Adjustable Motor Base ........................................................................................................................................................................... 24
Fan Motor Inspection & Maintenance..................................................................................................................................................... 24

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Table of Contents Page | 3
Fan Shaft Bearing Inspection & Maintenance ........................................................................................................................................ 24
Locking Collars....................................................................................................................................................................................... 25
Water Distribution System and Heat Transfer Section ............................................................................................................................... 26
Water Level Control.................................................................................................................................................................................... 27
Mechanical Make-up Valve Assembly.................................................................................................................................................... 27
Optional Electric Water Level Control Package...................................................................................................................................... 28
5. Corrosion Protection .................................................................................................................................................................................. 29
Water Treatment......................................................................................................................................................................................... 30
Corrosion and Scale Control....................................................................................................................................................................... 31
Gray Water and Reclaimed Water.............................................................................................................................................................. 32
Chemical Treatment Requirements............................................................................................................................................................ 32
Passivation ................................................................................................................................................................................................. 32
Biological Control........................................................................................................................................................................................ 33
Long Term Care of Stainless Steel............................................................................................................................................................. 33
BAC’s Manufacturing Process................................................................................................................................................................ 33
Jobsite Considerations ........................................................................................................................................................................... 33
Recommended Cleaning Procedure ...................................................................................................................................................... 33
System Cleaning......................................................................................................................................................................................... 34
Coil Cleaning.......................................................................................................................................................................................... 34
Weld Byproduct Cleaning....................................................................................................................................................................... 34
6. Bleed Rate .................................................................................................................................................................................................. 35
7. Cold Weather Operation ............................................................................................................................................................................. 36
Inspection & Maintenance .......................................................................................................................................................................... 36
Fan Section Icing Protection....................................................................................................................................................................... 36
Fan Control............................................................................................................................................................................................. 37
Dry Operation......................................................................................................................................................................................... 37
Basin Water and Internal Piping Freeze Protection.................................................................................................................................... 37
Basin Protection ..................................................................................................................................................................................... 37
Coil Freeze Protection ................................................................................................................................................................................ 38
Minimum Operation................................................................................................................................................................................ 38
8. Operation Considerations for ...................................................................................................................................................................... 39
Accessories..................................................................................................................................................................................................... 39
Basin Heater (Optional) .............................................................................................................................................................................. 39
Operation................................................................................................................................................................................................ 39
Stand Alone BAC Heater Control Panel (Optional)..................................................................................................................................... 40
Operation................................................................................................................................................................................................ 40
Vibration Cutout Switch (VCOS)................................................................................................................................................................. 42
Mechanical Vibration Cutout Switch (Optional) ...................................................................................................................................... 42

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Table of Contents Page | 4
Electronic Vibration Cutout Switch (Optional)......................................................................................................................................... 43
Redundant Pump System (Optional).......................................................................................................................................................... 44
Pump Switch Over:................................................................................................................................................................................. 45
Pump Removal:...................................................................................................................................................................................... 45
Pump Installation:................................................................................................................................................................................... 47
9. Fan Control ................................................................................................................................................................................................ 48
EC Fan System Fan Control....................................................................................................................................................................... 48
Sequence of Operation .......................................................................................................................................................................... 48
Fan Ramp Sequence ............................................................................................................................................................................. 48
VERTEX™ Fan Ramp-down.................................................................................................................................................................. 49
EC Fan System Troubleshooting................................................................................................................................................................ 49
Loss of Control Signal ............................................................................................................................................................................ 49
Refrigeration System Controller Power Outages.................................................................................................................................... 49
Single Fan Communication Loss............................................................................................................................................................ 49
All Fan Communication Loss.................................................................................................................................................................. 50
Power Outage ........................................................................................................................................................................................ 50
Single Fan Power Outage ...................................................................................................................................................................... 50
Unit Power Outage................................................................................................................................................................................. 51
Fan Alarm Codes ................................................................................................................................................................................... 51
BALTIDRIVE®Power Train......................................................................................................................................................................... 53
Independent Fan Control (Optional) ........................................................................................................................................................... 53
Variable Frequency Drive Operation .......................................................................................................................................................... 54
Resonant Speed Identification Procedure .................................................................................................................................................. 55
10. Installation Instructions for Field Connections.......................................................................................................................................... 57

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Recommended Maintenance Intervals Page | 5
1. Recommended Maintenance Intervals
1
Recommended service intervals are the minimum for typical installations. Harsh environmental conditions may dictate more frequent servicing
2
When operating in ambient temperatures below freezing, the unit should be inspected more frequently. Refer to section 7. Cold Weather Operation on
Page 30 for more details.
3
On units equipped with BALTIDRIVE®Power Train only.
4
Tension on new belts must be readjusted after the first 24 hours of operation and quarterly, thereafter.
Inspect and clean as necessary
[1]
:
Start-Up
Monthly
Quarterly
Annually
Shutdown
Inspect general condition of the unit [2] and check unit for unusual noise or vibration
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Inspect basin
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Flush water distribution system/Inspect spray nozzles
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Clean basin strainer
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Clean water guards
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Drain basin and piping
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Check and adjust water level in basin
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Check operation of make-up valve
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Inspect coil
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Check and adjust bleed rate
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Inspect unit finish
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Mechanical equipment system [1]:
Start-Up
Monthly
Quarterly
Annually
Shutdown
Check belt condition [3]
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Adjust belt tension [3],[4]
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Lubricate fan shaft bearings [3]
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Lubricate motor base adjusting screw [3]
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Check drive alignment [3]
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Check motor voltage and current
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Clean fan motor exterior
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Check fan motor for proper rotation
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Check general condition of the fan
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Check fan for uniform pitch [3]
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Check fan for rotation without obstruction
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Check and recoat steel shafts with RUST VETO® [3]
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Check optional basin heater and stand alone BAC heater control panel
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Test optional vibration cutout switch [3]
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Vertex™ Evaporative Condenser Operation & Maintenance Manual –Warnings and Cautions Page | 6
2. Warnings and Cautions
Safety Precautions
•: Rotating equipment will cause severe personal injury or death to persons who come in contact.
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.
•: Risk of electrocution which will cause severe personal injury or death. Use appropriate lockout
procedures. Do not perform any service on or near the unit without first ensuring the unit is de-energized.
•: 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 OSHA or other applicable safety standards of governmental authorities.
•: 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.
•: Before performing an adjustment or inspection of the VCOS, make certain that all power has
been disconnected and locked in the off position. Moisture inside the switch can lead to switch failure. Care must be taken
when replacing the cover on the vibration switch to ensure that the proper watertight seal is obtained.
•: 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.
•: A lockable disconnect switch should be located within sight of the unit for each fan motor
associated with this equipment. Before performing any type of service of inspection, make certain that all power has been
disconnected, and the switch is locked out in the “OFF” position.
•: 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.
•: This equipment should never be operated without all fan screens, access panels, and access
doors in place.
•: Openings and/or submerged obstructions may exist in the bottom of the basin. Use caution when
walking inside this equipment.

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Warnings and Cautions Page | 7
•: Do not use the plastic drift eliminators as a walking, working, or storage surface. Stepping on or
placing weight on an eliminator can result in physical injury and/or equipment damage. After ensuring that the fan and
pump motors are locked and tagged out, lift and remove eliminators as necessary to perform recommended maintenance
and inspections. If access to the top of the coil is required, place a piece of plywood at least 1/2 inch thick on top of the
coil to protect the surface while performing the recommended maintenance. When finished, carefully remove the plywood
and re-install any eliminators which were removed.
•: Drift eliminators can separate from the product during high winds. Fasten drift eliminators in place
using the retaining system.
Equipment Precautions
NOTICE
•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 either before or after installation, certain precautions should be observed, as outlined in
section Prolonged Outdoor Storage on Page 16.
•Spray system pressure greater than 10.0 psig may cause damage to the distribution system.
•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.
•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 with vents should be used.
•Do not use steam or high-pressure water to clean PVC eliminators or materials other than steel.
•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.
•Mechanical and operational methods must be employed to protect these products against damage and/or reduced
effectiveness due to possible freeze-up. Please refer to BaltimoreAircoil.com or contact your local BAC Representative for
recommended protection alternatives.
•The basin heater is not designed to prevent icing during unit operation.
•The stand alone BAC heater control panel temperature/low level control can only be used with the supplied combination
temperature/liquid level sensor probe.
•For the stand alone BAC heater control panel, Do not operate the system unattended or for extended periods of time
during test mode (resistor across terminals T1 and T2). Operation in water temperatures above 45°F (7.2°C) could
damage the unit.
•For the stand alone BAC heater control panel, do not operate the system unattended or for extended periods of time with
terminals G1-G2 jumpered. A low liquid level condition could occur, and the system will not shut off which could result in
damage to the heater and unit.
•For a unit with a VFD, with a switching frequency of 2.5 kHz, the line lead length cannot exceed 100 feet. If the switching
frequency is higher than 2.5 kHz and/or the line lead length exceeds 100 feet, a dV/dT output filter is recommended to
protect the motor. Since the switching frequency and maximum line length requirements vary between VFD and motor
suppliers, contact your local BAC Representative to determine if a dV/dT filter is required. 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.
•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.

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Warnings and Cautions Page | 8
General Maintenance Information
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 from the make-up water are left behind. 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 governs the extent of
water treatment which can vary from a simple continuous bleed and biological control to a sophisticated treatment system.
Refer to section Water Treatment on Page 30 and section Biological Control on Page 33 for more details.
Please refer to the Limitation of Warranties in the submittal packet 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.

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Unit Operation and Storage Page | 9
3. Unit Operation and Storage
Figure 1. Vertex™Evaporative Condenser with EC Fan System
Upper Casing Section
Basin Section
1
Factory Pre-Assembled Platforms with Perimeter Handrails
5
Access Door with Safety Handle and Step
2
Drift Eliminators
6
Internal Walkway
3
BranchLok™ Removal System
7
Fan Cover
3A
Feed Box Assembly
8
Water Guards
3B
Spray Branch
9
Pump
3C
Nozzles
10
Pump Riser Piping
4
Coil
11
Make-Up Valve Assembly
12
Float Ball
13
Strainer Assembly
14
EC Direct Drive Fan System Assembly
15
Terminal Box
Table 1. Vertex™ Evaporative Condenser with EC Fan System Parts List

Vertex™ Evaporative Condenser Operation & Maintenance Manual –Unit Operation and Storage Page | 10
Figure 2. Vertex™ Evaporative Condenser with Baltidrive®Power Train
Upper Casing Section
Basin Section
Baltidrive®Power Train
1
Factory Pre-Assembled Platforms
with Perimeter Handrails
5
Access Door with Safety
Handle and Step
A
Belt Set
2
Drift Eliminators
6
Internal Walkway
B
Fan Sheave
3
BranchLok™ Removal System
7
Partition Doors
C
Fan Sheave Bushing
3A
Feed Box Assembly
8
Pump
D
Fan Bushing
3B
Spray Branch
9
Pump Riser Piping
E
Axial Fan Assembly
3C
Nozzles
10
Make-Up Valve Assembly
F
Fan Shaft
4
Coil
11
Float Ball
G
Bearing Kit
12
Strainer Assembly
H
Mechanical Equipment Support
13
Air Intake Screens
I
Fan Cowl Assembly
14
Baltidrive®Power Train
J
Motor
K
Motor Sheave
L
Motor Sheave Bushing
M
Motor Base and Adjustment Rod Kit Assembly
Table 2. Vertex™ Evaporative Condenser with Baltidrive®Power Train Parts List