Baltimore Aircoil Company BCP2D User manual

BCP2D Automatic Dosing and Bleed Control
Package
INSTALLATION, OPERATING & MAINTENANCE
MBCP2Dv01EN

Table of contents
INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS
1 Construction Details 3
BCP2D 3
2 General information 4
Introduction 4
Safety precautions 4
Disposal requirements 5
Non-walking surfaces 5
Modifications by others 6
Warranty 6
3 Water Care 7
About water care 7
Biological control 8
Chemical treatment 9
Passivation 9
4 Receiving and Installation 10
Receiving Equipment 10
Piping Interface Connections 11
Design Criteria 11
Installation and Anchoring 11
Electrical Wiring 14
Dosing Pumps 15
5 Controller Settings 16
Default parameters and set points 16
Programming 21
6 Operating Conditions 22
Function Overview 22
Maintenance 32
Troubleshooting 34
7 Further Assistance & Information 37
More information 37
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1 Construction Details
1 Construction Details W W W . B A L T I M O R E A I R C O I L . E U
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CONSTRUCTION DETAILS
BCP2D
1. Fluid inlet coupling
2. Fluid outlet coupling
3. Bleed
4. Controller
5. Conductivity probe
6. Sampling point
7. Bleed valve
8. Insulation valve
9. Flow controller
10. Chemical injection
11. Pump oxidizing biocide
12. Pump scale/corrosion inhibitor
13. Chemical drum
14. Retention
15. Water meter
16. Suction tubing
17. Discharge tubing
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GENERAL INFORMATION
Introduction
Baltimore Aircoil Company is the right choice when it comes to having a more efficient, safe and effective
system.
The BCP2D automatic dosing and bleed control is a compact package that offers accurate, high quality, liquid
chemical based water treatment for evaporative cooling equipment.
The BCP2D control package provides for water meter controlled proportional dosing of a scale and corrosion
inhibitor, automatic conductivity based control of dissolved solids level in the recirculating water through blow
down, as well as automatic time based dosing of a biocide.
Together with the implementation of a monitoring program, this equipment will assist with the implementation of
optimum water quality treatment, with effective and safe control of the water quality and bacteriologic growth,
including Legionella Pneumophilia, and reducing operating costs, chemical usage, and maintenance.
Following the guidelines listed in this manual will help to ensure the safety of all personnel who maintain the unit
and related equipment. If there are any questions on the procedures or performance of the BCP, contact your
local BAC representative. Name, e-mail and phone number can be found on the website www.BACservice.eu
Safety precautions
All electrical, mechanical and rotating machinery constitutes a potential hazard, particularly for those not familiar
with its design, construction and operation. Accordingly, adequate safeguards (including use of protective
enclosures where necessary) should be taken with this equipment both to safeguard the public (including
minors) from injury and to prevent damage to the equipment, its associated system and the premises.
If there is doubt about safe and proper rigging, installation, operation or maintenance procedures, contact the
equipment manufacturer or his representative for advice.
When working on operating equipment, be aware that some parts may have an elevated temperature. Any
operations on elevated level have to be executed with extra care to prevent accidents.
AUTHORIZED PERSONNEL
The operation, maintenance and repair of this equipment should be undertaken only by personnel authorized
and qualified to do so. All such personnel should be thoroughly familiar with the equipment, the associated
systems and controls and the procedures set forth in this and other relevant manuals. Proper care, 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. Personnel must use personal
protective equipment where necessary (gloves, ear plugs, etc...)
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2 General information
2 General information

MECHANICAL SAFETY
Mechanical safety of the equipment is in accordance with the requirements of the EU machinery directive.
Depending upon site conditions it also may be necessary to install items such as bottom screens, ladders,
safety cages, stairways, access platforms, handrails and toe boards for the safety and convenience of the
authorized service and maintenance personnel.
For more information consult your local BAC Balticare representative.
ELECTRICAL SAFETY
All electrical components associated with this equipment should be installed with a lockable disconnect switch
located within sight of the equipment.
In the event of multiple components, these can be installed after a single disconnect switch but multiple switches
or a combination thereof are also allowed.
No service work should be performed on or near electrical components unless adequate safety measures are
taken. These include, but are not limited to the following:
• Isolate the component electrically
• Lock the isolation switch in order to prevent unintentional restart
• Measure that no electrical voltage is present anymore
• If parts of the installation remain energized, make sure to properly demarcate these in order to avoid
confusion
Fan motor terminals and connections may have residual voltage after unit shut-down. Wait five minutes after
disconnecting the voltage at all poles before opening the fan motor terminal box.
LOCATION
All cooling equipment should be located as far away as possible from occupied areas, open windows or air
intakes to buildings.
LOCAL REGULATIONS
Installation and operation of cooling equipment may be subject to local regulations, such as establishment of
risk analysis. Ensure regulatory requirements are consistently met.
Disposal requirements
Dismantling of the unit and treatment of refrigerants (if applicable), oil and other parts must be done with respect
to the environment whilst protecting workers from potential risks related to exposure to harmful substances.
National and regional legislation for material disposal and protection of workers should be taken into account
with regard to:
• Appropriate handling of construction and maintenance materials when dismantling the unit. In particular
when dealing with materials that contain harmful substances, such as asbestos or carcinogenic substances.
• Appropriate disposal of the construction and maintenance materials and components such as steel, plastics,
refrigerants and waste water according to local and national requirements for waste management, recycling
and disposal.
Non-walking surfaces
Access to and maintenance of any component needs to be performed in accordance with all local applicable
laws and regulations. If the proper and required access means are not present, temporary structures need to be
foreseen. Under no circumstance can one use parts of the unit, that are not designed as an access mean,
unless measures can be taken to mitigate any risks that might occur from doing so.
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2 General information
2 General information

Modifications by others
Whenever modifications or changes are made by others to the BAC equipment without written permission of
BAC, the party who has done the modification becomes responsible for all consequences of this change and
BAC declines all liability for the product.
Warranty
BAC will guarantee all products to be free from manufactured defects in materials and workmanship for a period
of 24 months from the date of shipment. In the event of any such defect, BAC will repair or provide a
replacement. For more details, please refer to the Limitation of Warranties applicable to and in effect at the time
of the sale/purchase of these products. You can find these terms and conditions on the reverse side of your
order acknowledgement form and your invoice.
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3 Water Care
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WATER CARE
About water care
In all cooling equipment, operating in evaporative mode, the cooling is accomplished by evaporating a small
portion of the re-circulating water as it flows through the equipment. When this water evaporates, the impurities
originally present in the water remain. Unless a small amount of water is drained from the system, known as
blow down, the concentration of dissolved solids will increase rapidly and lead to scale formation or corrosion or
both. Also, since water is being lost from the system through evaporation and blow down, this water needs to be
replenished.
The total amount of replenishment, known as make-up, is defined as:
Make-up = evaporation loss + blow down
In addition to the impurities present in the make-up water, any airborne impurities or biological matter are carried
into the equipment and drawn into the re-circulating water. Over and above the necessity to blow down a small
quantity of water, a water treatment programme specifically designed to address scale, corrosion and biological
control should be initiated when the system is first installed and maintained on a continuous base thereafter.
Moreover there must be an ongoing programme of monitoring in place to ensure the water treatment system is
maintaining the water quality within the control guidelines.
Check and adjustments of blow down depends on the blow down device actual in use.
To prevent excessive build-up of impurities in the circulating water, a small amount of water must be « bled »
from the system at a rate to be determined by the water treatment regime. The amount of blow down is
determined by the design cycles of concentration for the system. These cycles of concentration depend on the
quality of the make-up water and the design guidelines for the quality of the recirculating water given below.
Make-up water to the evaporative unit should have minimum 30 ppm hardness as CaCO3.
Where use of a softener is necessary to achieve this, the supply to the evaporative unit should not be totally
softened, but blended with the incoming unsoftened water to achieve the minimum hardness between 30 and
70 ppm as CaCO3.
Maintaining a minimum hardness in the make-up water offsets the corrosive properties of totally softened water
and reduces the reliance on corrosion inhibitors to protect the system.
To control corrosion and scale, the water chemistry of the circulated water has to be kept within the water quality
guidelines of the specific materials of construction used, as listed in the following table(s).
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Baltibond®Hybrid Coating and SST304L
pH 6.5 to 9.2
Total hardness (as CaCO3) 50 to 750 mg/l
Total alkalinity (as CaCO3) 600 mg/l max.
Total dissolved solids 2050 mg/l max.
Conductivity 3300 µS/cm
Chlorides 300 mg/l max.
Sulfates* 350 mg/l max.*
Total suspended solids 25 mg/l max.
Chlorination (as free chlorine / halogen): continuous 1.5 mg/l max.
Chlorination (as free chlorine / halogen): batch dosing for cleaning &
disinfection
5-15 mg/l max. for 6 hours max.
25 mg/l max. for 2 hours max.
50 mg/l max. for 1 hour max.
Circulated water quality guidelines for Baltibond® Hybrid Coating
*Note: Higher concentration of sulfates is allowed, provided the sum of chlorides + sulfates parameters does not exceed 650 mg/l for
Baltibond/SST304L.
For Ozone water treatment application:
• Stainless steel 316L execution is required.
• Ozone levels are to be maintained to 0.2 ppm ± 0.1 ppm for at least 90% of the time, with absolute maximum
peaks of 0.5 ppm
Cycles of concentration are the ratio of the dissolved solids concentration in the circulating water compared to
the dissolved solids concentration in the make-up water. The blow down rate can be calculated as follows:
Blow down = Evaporation loss / (Cycles of concentration – 1)
The evaporation loss is not only function of the heat load but also depends on climatic conditions, the type of
equipment used and the method of capacity control, which is applied. The evaporation loss at summer
conditions is approximately 0.431 l/ 1000 kJ heat rejection. This number should be used for blow down valve
sizing only and not for the calculation of annual water consumption.
Biological control
The growth of algae, slimes and other micro-organisms, if uncontrolled, will reduce system efficiency and may
contribute to the growth of potentially harmful micro-organisms, such as Legionella, in the recirculating water
system.
Accordingly a treatment programme specifically designed to address biological control should be initiated when
the system is first filled with water and administered on a regular base thereafter in accordance with any
regulations (national, regional) that may exist or in accordance with accepted codes of good practice, such as
EUROVENT 9-5/6, VDMA Detailsheet 24649 etc.
It is strongly recommended to monitor the bacteriological contamination of the recirculating water on a regular
base (for example, TAB test with dip slides on a weekly base) and record all results.
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Certain products used for water treatment, particular some dispersant and bio-dispersant additives, might
change the properties of the water (such as the surface tension), which can cause excessive drift loss (water
passing through the eliminators). In such case we recommend to review the water treatment (product type,
dosage) with your water treatment expert.
In case of doubt, a short test can be performed, after cleaning & disinfection, using fresh water without addition
of the concerned chemical (within the limits of the local legislation).
Chemical treatment
1. Water treatment chemicals or non-chemical systems need to be compatible with the materials of
construction used in the cooling system including the evaporative cooling equipment itself.
2. In case of chemical water treatment, chemicals should be added to the recirculating water by an automatic
feed system. This will prevent localised high concentrations of chemicals, which may cause corrosion.
Preferably the water treatment chemicals should be fed into the cooling system at the discharge of the
recirculation pump. The chemicals should not be fed in concentrated form, nor batch fed directly into the cold
water sump of the evaporative cooling equipment.
3. BAC specifically discourages acid dosing as mean of scale control (unless under certain strict circumstances
for open circuit cooling towers with very large system volume and remote sump, or constructed from
stainless steel).
4. A competent water treatment company should be consulted for the specific water treatment programme to
be applied. Next to the supply of dosing and control equipment and chemicals, the programme should
include regular monthly monitoring of the circulating and make up water quality.
5. If it is proposed to operate a treatment programme outside the BAC Water Quality Control Guidelines, the
BAC factory warranty may be invalidated if the water quality is persistently outside the Control Guidelines,
unless specific prior written BAC approval. (Some parameters may be exceeded under certain strict
circumstances.)
It is strongly recommended to check the key parameters of the circulating water quality on a monthly base. See
table: "Circulated water quality guidelines". All test results need to be recorded.
Passivation
When new systems are first commissioned, special measures should be taken to ensure that galvanized steel
surfaces are properly passivated to provide maximum protection from corrosion. Passivation is the formation of
a protective, passive, oxide layer on galvanized steel surfaces.
To ensure that galvanized steel surfaces are passivated, the pH of circulating water should be kept between 7.0
and 8.2 and calcium hardness between 100 and 300 ppm (as CaCO3) for four to eight weeks after start-up, or
until new zinc surfaces turn dull grey in colour. If white deposits form on galvanized steel surfaces after the pH is
returned to normal service levels, it may be necessary to repeat the passivation process.
Full stainless steel units and units protected by the Baltibond® hybrid coating do not require passivation.
An exception to this are units with a galvanized steel coil bundle which do still require the proper
passivation procedure as described here in this section.
In case you can't keep the pH below 8.2, a secondary approach is to conduct a chemical passivation using
inorganic phosphate or film-forming passivation agents. Consult your water treatment specialist for specific
recommendation.
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RECEIVING AND INSTALLATION
Receiving Equipment
Before accepting the BCP2D equipment and prior to signing the bill of lading, all equipment should be checked
thoroughly for any shipping damage. Make sure that all required equipment noted on the bill of lading is
received. Check the model and serial number against the packing list.
Receiving / Inspection check list
• (1) BCP2D panel
• (2) chemical drums
• (1) water meter
• (1) set of 2 suction strainers and suction tubes
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Piping Interface Connections
The BCP2D should be installed using the following guidelines:
1. Proper installation of the interconnecting piping is critical to the BCP2D system effectiveness.
2. BCP2D inlet, outlet and drain connection are standard glued on PVC connections.
3. Do not reduce the pipe size on the connections to and from the BCP2D or of the drain line. Increasing the
pipe size is acceptable.
4. Refer to recommended installation schematics provided with the submittal packages for the various system
configuration options:
• (1) BCP2D for use with closed circuit evaporative equipment
• (1) BCP2D for use with closed circuit evaporative equipment with a separate booster pump
• (1) BCP2D for use with single open circuit evaporative equipment
• (1) BCP2D for use with multiple open circuit evaporative equipment in parallel
Design Criteria
The BAC standard BCP2D water treatment system is designed for use with evaporative cooling equipment. The
number and sizing of BCP2D is function of the cooling system design load conditions, expected operating cycle
of concentration (hence water usage), and application for open and closed circuit evaporative cooling
equipment. Determination of these aspects is made by a qualified BAC representative. Changes in system load
which increase the bleed rate may require an increase in the size of each BCP2D .
Installation and Anchoring
The BCP2D should be located as close a s possible to the sump or system interface piping: maximum 7 m
distance.
For longer distance, it is recommended to install a separate booster pump (by others).
The BCP2D is designed to receive water flow at the inlet from pressurized sources, such as the pressure side of
the spray pump or condenser water lines. The pressure at the inlet of the BCP2D should not exceed 60 kPa.
The discharge water from the BCP2D should be returned on a non-pressurized point, preferably the cooling
water sump or the suction side of the system circulating pump (for open cooling towers).
The drain should be connected directly to a drain collecting point.
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The BCP2D can be mounted and supported to the cooling tower panel, to a wall or support structure using a
variety of anchoring methods. When installed outside it is recommended to install the BCP2D above the cooling
tower water level to allow free piping drainage when idle.
The water meter should be installed in the make up line to the cooling tower. Adapters supplied by other.
The BCP2D is equipped with valves at the inlet, discharge and drain.
1. The inlet and drain valve should be kept fully open during normal operation.
2. The return outlet valve might be throttle to reduce water flow during measuring cycle
3. Note: The drain valve might be throttled slightly to reduce bleed water flow if the flow controller switch off
during bleed cycle. Make sure however sufficient bleed rate can be guaranteed at nominal operation load.
4. The BCP2D is designed to handle a maximum water pressure of 60 kPa at 55°C.
DRUMS AND BUNDS
The drums and bunds should be positioned directly below panel as per sketch below.
Example of installation
CONNECTION BETWEEN DRUMS AND DOSING PUMPS
Install suction strainer into the drum and using the plastic tubing connect each drum to the respective dosing
pumps. Make sure that the suction strainer stands vertically in the drum. See more details below.
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Tubing and suction head with strainer.
Mounting of tubing on suction head.
Suction head to be installed inside drum.
Suction head should be installed vertically.
Adjust tubing length accordingly.
Mounting detail tubing on pump head.
Overview pump tubing connection to drum.
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WATER METER
The water meter should be installed in the make up line to the cooling towers
• Adapters supplied by others. It is recommended to install insulating valve for easier maintenance.
• Position the water meter with the arrow in the water flow direction
• Flush the piping before installation, to prevent dirt to enter the water meter. Water meter should be protected
from freezing (protected room or insulation and tracing)
• Make sure the water meter screen can be viewed and read at any time
Prestrainer should be cleaned on a yearly basis.
Water meter reading information
1. 1 rotation = 1L; 1 graduation = 0,1 L
2. 1 rotation = 10L; 1 graduation = 1 L
3. 1 rotation = 1m³; 1 graduation = 100 L
4. 1 rotation = 100L; 1 graduation = 10 L
Electrical Wiring
Refer to the wiring diagram of the submittal package.
The BCP2D is suitable for connection to networks of 110V - 230V and 50 - 60 Hz (AC POWER).
The BCP2D panel is pre-wired and only requires a main power supply to the controller BACT 100 .
A general alarm output is also available as indicated on the wiring.
Wiring of the water meter to the controller BACT 100 (by others).
Optional when specified at order: Analogic output 4-20 mA for conductivity.
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Conduit wiring
1. Digital inputs & analog outputs
2. Power switch
3. Relay outputs
4. Optional pH/ORP Sensor BNC
5. Sensor
6. AC Power
Dosing Pumps
Dosing pumps are premounted on BCP panel and prewired to the controller.
Refer to specific dosing pumps operating manual supplied with the submittal package for specific
questions regarding dosing pumps.
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CONTROLLER SETTINGS
Default parameters and set points
The BACT 100 controller has been preprogrammed specifically for use with BAC evaporative cooling
equipment.
MENU INPUT
S1 - Conductivity
LoLo Alarm (Very low alarm) 200 µS/cm
Low Alarm 200 µS/cm
High Alarm 3500 µS/cm
HiHi Alarm (Very high alarm) 3500 µS/cm
Deadband 25 µS/cm
Alarm suppression none
Reset Calibration values
Cal Req'd Alarm 365 days
Smoothing factor 0 %
Cell Const 1,000 1/cm
Cable length 6,10 m
Gauge 22 awg/0,35mm²
Default temp 25 °C
Temp Comp NaCl
Units µS/cm
Name (change with language, default is English) Conduct
Type Contacting Cond
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S2 - Temperature
LoLo Alarm (Very low alarm) 1,0 °C
Low Alarm 1,0 °C
High Alarm 50,0 °C
HiHi Alarm (Very high alarm) 50,0 °C
Deadband 1,0 °C
Reset Calibration values
Cal Req'd Alarm 0 days
Alarm suppression none
Smoothing factor 0 %
Name (change with language, default is English) Temp
Type 10K Therm
D1 - Flow detector
Open Msg (change with language - default is English) No Flow
Closed Msg (change with language - default is English) Flow
Interlock When open
Alarm When open
Total time When closed
Reset time N/A
Name (change with language - default is English) Flow switch
Type DI State
D2 - Water meter
Totalizer Alarm 0
Reset flow total
Scheduled reset Disabled
Volume/Contact 1 I
Flow units I
Name (change with language - default is English) Water meter
Type Contacting FM
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5 Controller Settings
5 Controller Settings

MENU OUTPUT
R1 - Bleed
HOA Setting Auto
Setpoint 1200 µS/cm
Deadband 25 µS/cm
Duty Cycle Period 0:00
Duty Cycle 100,0 %
Output Time Limit 3:00:00
Reset Output Timeout
Interlock Channels D1
Activate with Channels None
Min Relay Cycle 0 sec
Hand Time Limit 0:10:00
Input Conduct (S1)
Direction Force Lower
Name (change with language, default is English) Bleed
Mode On/Off
R2 - Inhibitor dosing based in water meter
HOA Setting Auto
Feed duration 00:02:00
Accum Volume 200 l
Reset timer
Output Time Limit 1:00:00
Reste Output Timeout
Interlock channels D1
Activate with channels None
Min Relay Cycle 0 sec
Hand Time Limit 0:10:00
Input Watermeter (D2)
Name (change with language - default is English) Inhib
Mode Flow Timer
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R3 - Timer dosing of biocide
HOA Setting Auto
Event 1 Repetition: 1 week
Day: Monday
Start time: 8:00:00
Duration: 0:15:00
Event 2 Repetition: 1 week
Day: Wednesday
Start time: 8:00:00
Duration: 0:15:00
Event 3 Repetition: 1 week
Day: Friday
Start time: 8:00:00
Duration: 0:15:00
Event 4...10 Inactive
Bleed Bleed (R1)
Prebleed time 0:00:00
Prebleed to 1150 µS/cm
Cond Input Conduct (S1)
Bleed lockout 1:00:00
Interlock channels D1
Activate with channels None
Min Relay Cycle 0 sec
Hand time limit 0:10:00
Name (change with language - default is English) Bio Timer
Mode Biocide Timer
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5 Controller Settings
5 Controller Settings

MENU CONFIGURATION
Global Settings
Date
Time
Global Units Metric
Temp Units °C
Alarm Delay 0:00
HVAC Modes Enabled
Language (change with language, default is English) English
Security Settings
Controller Log Out
Security Disabled
Local Password Default is 5555
Display Settings
Home 1 Conduct (S1)
Home 2 Temp (S2)
Adjust Display
Key Beep Disabled
Display Settings
File Utilities
Not applicable
Controller Details
Not applicable
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