Baltimore S3000E User manual

S3000E Open Cooling Towers
XES3000E Open Cooling Tower
RIGGING AND INSTALLATION INSTRUCTIONS
RS3000Ev02EN

About Rigging and Installation
The BAC equipment should be rigged and installed as outlined in this bulletin.
These procedures should be thoroughly reviewed prior to the rigging and operation to acquaint all personnel with
the procedures to be followed and to assure that all necessary equipment will be available at the jobsite.
Be sure to have a copy of the unit certified drawing available for reference. If you do not have a copy of this drawing
or if you need additional information about this unit, contact the local BAC Balticare representative. His name and
phone number can be found on the BAC website: www.BaltimoreAircoil.eu. The model type and serial number of
your equipment are indicated on the unit nameplate.
Recommended Maintenance and
Monitoring Programme
Checks and Adjustments Start-Up Weekly Monthly Quarterly Every 6
Months
Annually Shutdown
Hot water basin X X
Nozzles X X
Cold Water Basin and Basin Strainers X X
Operating level and make-up X X
Blow down X X
Sump heater Package X X
Belt tension X X
Drive alignment X X
Locking Collar X
Rotation of fan(s) and pump(s) X
Drive Train X X
Gear Drive X X
Variable Frequency Drive X
Motor voltage and current X X
Unusual noise and/or vibration X X
Inspections and Monitoring Start-
Up
Weekly Monthly Quarterly Every 6
Months
Annually Shutdown
General condition X X
Heat transfer section and drift eliminators X X
Combined Inlet Shields X X
Hot Water Basin X X
Spray Nozzles X X
Fan shaft & Axial Fan X X
Fan Motor X X
Electric Water Level Control Package (option) X X
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Inspections and Monitoring Start-
Up
Weekly Monthly Quarterly Every 6
Months
Annually Shutdown
TAB test (dip slides) X X
Circulating water quality X X
System overview X X
Recordkeeping as per event
Lubrication Start-Up Weekly Monthly Quarterly Every 6
Months
Annually Shutdown
Fan shaft bearings X X X
Motor bearings* X X
Adjustable motor base X X X
Gear Drive X X
* only for motors with grease fittings with typical frame size > 200L (>30 kW)
Cleaning procedures Start-Up Weekly Monthly Quarterly Every 6
Months
Annually Shutdown
Mechanical cleaning X X X
Disinfection** (X) (X) (X)
** depends on applied code of practice
Notes
1. Water Treatment and auxiliary equipment integrated in the cooling system may require additions to the table
above. Contact suppliers for recommended actions and their required frequency.
2. Recommended service intervals are for typical installations. Different environmental conditions may dictate
more frequent servicing.
3. When operating in ambient temperatures below freezing, the unit should be inspected more frequently (see
Cold Weather Operations in the appropriate Operating and Maintenance Instructions).
4. For units with Belt Drive, tension on new belts must be readjusted after the first 24 hours of operation and
monthly thereafter.
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Table of Contents
RIGGING AND INSTALLATION INSTRUCTIONS
1 General Information 5
About Engineering and Application Practices 5
Shipping 5
Inspection Before Rigging 5
Unit Weights 6
Anchoring 7
Leveling 7
Connecting Pipework 7
Freeze Protection 7
Bleed Line Installation 7
Safety Precautions 8
Non-walking Surfaces 9
Modifications by others 9
Warranty 9
2 Rigging 10
General Notes 10
Rigging Information 11
Rigging Method for Upper Section 12
Rigging Method for Lower Section 13
3 Section Assembly 14
Method 14
Assembly of Multiple-Cell Units 18
Installation of Fan Cowl 18
Installation of Whisper Quiet Fans 19
4 Optional Accessories Assembly 20
General 20
Clean Out Port 20
Optional Bottom Connection 22
Optional Flanges on Side-Outlets 22
5 Inspection Prior to Start-up 23
General 23
6 Further Assistance & Information 24
Balticare 24
More Information 24
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1 General Information
1 General Information W W W . B A L T I M O R E A I R C O I L . E U
5
GENERAL INFORMATION
About Engineering and Application Practices
This bulletin only refers to the assembly of the unit. To ensure a proper operation, a correct integration of the unit in
the overall installation is mandatory. For good engineering and application practices on layout, levelling,
connecting pipework, etc., please refer to our website:
http://www.baltimoreaircoil.eu/knowledge-center/application-information.
Shipping
BAC cooling equipment is factory assembled to assure uniform quality and minimum field assembly.
The unit models S3E/XES3E-1222-10x through S3E/XES3E-1424-14x are shipped in 2 sections (upper and lower)
due to shipping height restrictions.
For the dimensions and weights of a specific unit or section, refer to the certified drawing.
Caution
DO NOT COVER UNITS WITH PVC ELIMINATORS OR FILL WITH A PLASTIC TARPAULIN.
TEMPERATURE INCREASE DUE TO SUN RADIATION COULD DEFORM THE FILL OR
ELIMINATORS.
Inspection Before Rigging
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:
• Sheaves and belts
• Gearbox
• Bearings
• Bearing supports
• Fan motor(s)
• Fan(s) and fan shaft(s)
• Wet Deck Surface with integral drift eleminators
• Water distribution system
• Strainers
• Float valve assembly
• Combined Inlet Shields
• Interior / exterior surfaces
• Miscellaneous items
S3000E
XES3000E
1

An envelope with check-list is stored in a wooden no nail crate or a plastic container which is placed in the lower
section. For safety reasons, access doors / panels may be sealed with bolts. The following table specifies which
wrench is required to open them.
Wrench to open access door
17 mm
Required wrenches to open access door
The wooden no nail crate / plastic container also contains miscellaneous parts such as gasket, hardware and
accessory items.
At temperatures below -10°C the butyl sealer tape might loose it's flexibility. We recommend to store the sealer
tape in a heated room before using it during rigging at freezing temperatures.
Caution
BE SURE TO REMOVE ALL MISCELLANEOUS ITEMS FROM THE PAN BEFORE THE UNIT IS
ASSEMBLED.
The wooden box with the hardware is placed inside the unit or in the lower section of the unit. This box is fixed with
straps to the internal walkway of the unit.
Hardware Location
Unit Weights
Before rigging any BAC equipment, the weight of each section should be verified on the unit certified drawing.
These weights are approximate and should be confirmed by weighing before lifting when available
hoisting capacity provides little margin for safety.
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Caution
BEFORE AN ACTUAL LIFT IS UNDERTAKEN, ENSURE NO WATER, SNOW, ICE OR DEBRIS
HAS COLLECTED IN THE SUMP OR ELSEWHEREIN THE UNIT. SUCH ACCUMULATIONS WILL
ADD SUBSTANTIALLY TO THE EQUIPMENT’S LIFTING WEIGHT.
In the event of extended lifts or where hazards exist, the lifting devices should be used in conjunction with safety
slings placed under the unit.
Anchoring
The unit must be properly anchored in place.
Refer to the suggested support details on the certified drawing for locations of the mounting holes. Anchor bolts
must be provided by others.
Holes suitable for 20 mm bolts are provided in the bottom flange of the lower section for bolting the unit to the
support beams.
Leveling
The unit must be level for proper operation and ease of piping.
Support beams must also be level as shims should not be used between pan and support beams to level the unit.
Connecting Pipework
All piping external to BAC cooling equipment must be supported separately.
In case the equipment is installed on vibration rails or springs, the piping must contain compensators to eliminate
vibrations carried through the external pipework.
Suction pipe sizing should be done according to good practice, which may for larger flows require larger pipe
diameters than the outlet connection. In such cases adapter pieces need to be installed.
Freeze Protection
These products must be protected against damage and/or reduced effectiveness due to possible freeze-up by
mechanical and operational methods. Please refer to the BAC Product & Application Handbook or contact your
local BAC Balticare representative for recommended protection alternatives.
Bleed Line Installation
On all open cooling towers, 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.
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.
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1 General Information
1 General Information

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...)
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.
At no time this equipment should be operated without all fan screens, access panels and access doors in place.
When the equipment is operated with a variable fan speed control device, steps must be taken to avoid operating
at or near to the fan's «critical speed».
For more information consult your local BAC Balticare representative.
ELECTRICAL SAFETY
Each motor associated with this equipment should be installed with a lockable disconnect switch located within
sight of the equipment. No service work should be performed on or near the fans, motor, drives or inside the
equipment unless motors, heaters etc. are electrically isolated.
Each fan associated with this equipment should be installed with a lockable disconnect switch located within sight
of the equipment.No service work should be performed on or near the fans unless motors are electrically isolated.
LIFTING
Caution
FAILURE TO USE DESIGNATED LIFTING POINTS CAN RESULT IN A DROPPED LOAD
CAUSING SEVERE INJURY, DEATH AND/OR PROPERTY DAMAGE. LIFTS MUST BE
PERFORMED BY QUALIFIED RIGGERS FOLLOWING BAC PUBLISHED RIGGING
INSTRUCTIONS AND GENERALLY ACCEPTED LIFTING PRACTICES. THE USE OF
SUPPLEMENTAL SAFETY SLINGS MAY ALSO BE REQUIRED IF THE LIFT CIRCUMSTANCES
WARRANT ITS USE, AS DETERMINED BY THE RIGGING CONTRACTOR.
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LOCATION
All cooling equipment should be located as far away as possible from occupied areas, open windows or air intakes
to buildings.
Caution
EACH UNIT SHOULD BE LOCATED AND POSITIONED TO PREVENT THE INTRODUCTION
OF DISCHARGE AIR INTO THE VENTILATION SYSTEMS OF THE BUILDING ON WHICH THE
UNIT IS LOCATED OR THOSE OF ADJACENT BUILDINGS.
For detailed recommendations on BAC equipment layout, please see the BAC Application Handbook EU-
Edition, the BAC website: www.baltimoreaircoil.eu or contact your local BAC-Balticare Representative.
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.
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.
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
12 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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1 General Information
1 General Information

W W W . B A L T I M O R E A I R C O I L . E U
RIGGING
General Notes
1. Unless unit ships fully assembled, unit must be rigged one section at a time.
2. If the delivery consists of separate sections, do not assemble before lifting, as the lifting devices provided are
not designed to support the weight of the entire assembly.
3. Spreader bars of the full width of the section must be used between the lifting cables to prevent damage to the
section.
4. For extended lifts or where hazards exist, it is recommended to use the lifting devices in conjunction with
safety slings placed under the unit.
5. Refer to the following Table and Figures for the recommended minimum size of the spreader bar (dimension
"A") and the recommended vertical dimension "H" from the lifting device at the base of each unit or section to
the spreader bar. The lifting devices can be moved to the alternative lifting device location shown in the
following figures for final positioning of multi-cell units. Bolt holes have been provided to accommodate the
lifting devices at this alternative location.
6. Units equipped with intake sound attenuation are installed as an integral part of the unit. The use of the
alternative lifting device location requires the removal of the intake sound attenuation from the unit section.
7. Lifting devices have been provided on all sections. The tables below give the preferred method for rigging each
section of a unit.
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S3000E
XES3000E
2
2 Rigging
2 Rigging

Rigging Information
Unit Sections
1. Lower Section
2. Upper Section
Model Unit Sections N°
Sections
Rigging
Method
Min.
"H"
(mm)
Min.
"W"
(mm)
S3E/XES3E-8518-xxx FULLY
ASSEMBLED 1 A 4580 2590
S3E/XES3E-1020-xxx FULLY
ASSEMBLED 1 A 5180 3050
S3E/XES3E-1222-06x,
S3E/XES3E-1222-07x
FULLY
ASSEMBLED 1 A 5490 3660
S3E/XES3E-1424-07x FULLY
ASSEMBLED 1 A 6100 4270
S3E/XES3E-1222-10x
through
S3E/XES3E-1222-14x
Upper Section 1 A 5490 3660
Lower Section 1 B 5490 3660
S3E/XES3E-1424-12x
through
S3E/XES3E-1424-14
Upper Section 1 A 6100 4270
Lower Section 1 B 6100 4270
Rigging Method
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2 Rigging
2 Rigging

Rigging Method for Upper Section
Rigging Method A
One-Section Cell or Upper Section for Two-Section Cells
1. Spreader Bar
2. Lifting Cable
3. Lifting Device for this Section only
Above Figure shows the proper rigging of either a S3000E that ships in one section or the top section of a
S3000E that ships in two sections.
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Rigging Method for Lower Section
Rigging Method B
Bottom Section of Two-Section Cells
1. Spreader Bar
2. Lifting Cable
3. Lifting Device for this Section only. DO NOT USE for final positioning of assembled cell
4. Lifting Device Location. MUST BE USED for final positioning of multi-cells
The above figure shows the proper rigging of the lower section of a two-section unit, in addition to the
location of bolt holes, which accommodate the lifting devices at alternative locations. It is necessary to
move the lifting devices to these alternative locations for final positioning of multi-cell units.
Caution
FOR MULTI-CELL EXECUTIONS REMOVE SECURING BOLTS OF BOTH ACCESS DOORS OF
THE UNIT BEFORE RIGGING
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2 Rigging
2 Rigging

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SECTION ASSEMBLY
Method
On the lower section are 4 locations to position the upper section on the typical rigging guide/bracket
1. Rigging guide/bracket of upper section
2. Rigging guide/bracket of lower section
Secure the upper section to the lower section utilizing typical bolting technique as shown in figure below, using the
internal rigging guide/brackets with bolt holes.
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S3000E
XES3000E
3
3 Section Assembly
3 Section Assembly

Typical Bolting Technique
1. Bolt
2. Flatwasher
3. Lockwasher
4. Nut
Models S3E/XES3E-1222-10x to S3E/XES3E-1222-14 and S3E/XES3E-1424-12x to S3E/XES3E-1424-14x
S3000 Section Assembly
1. Factory installed Foam Sealer Tape
2. 12 mm Bolt & Flatwasher
First, position the lower section on the unit supports and bolt in place. Wipe down the upper flanges to remove
dust, dirt or moisture that may have accumulated during shipment and storage. Install foam sealer supplied with
the unit, as illustrated in the fugures below.
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3 Section Assembly
3 Section Assembly

Installation of Foam Sealer around top of section
1. Apply foam sealer tape around the periphery of the section
Installation of Tape Sealer for S3000 Units
1. Foam Sealer Tape.
2. 12 mm Bolt & Flatwasher
3. Sealing Washer & Nut
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2. Remove the skid from the middle section. Lift the middle section and position it over the lower section so that
the flanges of the section are about 50 mm above the lower section. Dot not let the section swing and damage
the sealer.
Use at least four drift pins (see figure) in the fastening holes located on the long sides of the sections to align
the top section to the bottom section. To avoid incorrect alignment, refer to the below drawing for the position of
the fastening holes to be used. Use additional drift pins in the middle of the unit if required, to align long panels.
(See Figure "Usage of drift pin to align the screw holes")
Make sure all holes from upper section and lower section are properly aligned before lowering the top section
completely to the bottom section.
Position of the fastening holes to be used.
1. Fastening hole
2. Drift pin position
3. The distance between the fastening hole in which the drift pin is inserted and the corner should be at least 30cm
4. Usage of additional drift pin for long sides
Caution
WHEN LOWERING A SECTION, ENSURE NOTHING CAN BE TRAPPED BETWEEN THE
UPPER AND LOWER FLANGES.
Usage of drift pin to align the screw holes
3. Match marks must line up as shown in above Figure.
4. Bolt in place as illustrated in above Figure, using a sealing washer under each nut to prevent water leakage.
There are eight (8) bolts (four on each side) that are used to attach the top and bottom sections.
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3 Section Assembly
3 Section Assembly

5. On multi-cell installations, it is suggested that cells subsequent to the first, have the top and bottom sections
assembled on the support foundation, adjacent to the final mounting location. This will allow space for securing
the top and bottom sections and removal of the lifting cables. The subsequent cell(s) may then be moved to its
final position using the lifting devices in their alternate locations. Refer to the section "Assembly of Multi-Cell
Towers" hereafter for details.
6. All multi-cell units have the cell number on each section as well as match marks to show how the cells should
be mated.
Assembly of Multiple-Cell Units
Assembly of Multiple-Cell Units with Equalizing Connections
Multiple cell installations usually employ equalizing connections to equalize the water level in the sump of each
cell.
Assembly of Multiple Cells with Equalizing Connections
1. Cell 1
2. Cell 2
3. Equalizing Connection in bottom
Installation of Fan Cowl
Due to height limitations on truck shipments, the fan cowl with fan guards installed, may ship unmounted. The fan
cowl must be placed and installed as shown in the Figure below. The procedure is as follows:
1. Lift fan cowl by means of the 2 lifting ears and place on unit.
2. Bolt fan cowl together with unit, using 9 mm flatwashers and locknuts.
3. The minimum height must be 2200 mm.
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Install Fan Cowl on Unit
Caution
ENSURE THAT THE FAN COWL IS PROPERLY INSTALLED PRIOR TO COMMENCING
OPERATION!
Installation of Whisper Quiet Fans
To limit the shipping dimensions of some models with Whisper Quiet fans (recognizable in the nomenclature by
the'/WH' at the end), the fan motor assembly is lowered into the casing. This assembly must be raised to its
operating position after installing the fan cowl. The raising instructions are supplied with the unit
Caution
ENSURE THAT THE FAN MOTOR ASSEMBLY IS PROPERLY INSTALLED PRIOR TO
COMMENCING OPERATION!
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3 Section Assembly
3 Section Assembly

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OPTIONAL ACCESSORIES ASSEMBLY
General
1. All required installation instructions for optional accessories are stored in the wooden no nail crate / plastic
container which is placed in the lower section. See "Inspection Before Rigging" on page5- picture "Hardware
Location".
2. Optional intake and/or discharge sound attenuators can be fitted.
3. The platform, ladder and railing is packed on a separate skid. The assembly hardware is packed in a plastic
container and strapped to the platform, ladder or railing itself.
Hardware Location for platform, ladder & railing
Clean Out Port
Due to transport width limits, the cover flanges of the clean out port are mounted with flanges towards the inside
(1). On site, the cover can be placed with flanges to the outside for easy access to hardware (2).
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S3000E
XES3000E
4
4 Optional Accessories Assembly
4 Optional Accessories Assembly