Colortronic BFC Series Specification sheet

Operation and Installation Manual
BFC Series
Blown Film Coolers
Important! Read Carefully Before Attempting to Install or Operate Equipment
Part No. A0503599 Bulletin No. CW4-605.1
$30.
00

Page 2 BFC Series Blown Film Cooling Systems
Write down your blown film ________________ ________________
cooler serial numbers ________________ ________________
here for future reference ________________ ________________
________________ ________________
Performance figures stated in this manual are based on a standard atmosphere of 59°F
(15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 Hz power. Ambient air
temperature is an important consideration when specifying blown film coolers.
Colortronic can advise you on proper selection and sizing of systems for your operating
environment.
Colortronic is committed
to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
© Copyright Colortronic 2008
All rights reserved. Effective 4/30/08
Part No. A0503599 Bulletin No. CE4-605.1

BFC Series Blown Film Cooling Systems Page 3
Safety Considerations
Colortronic BFC Series blown film cooling systems are designed
to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety
codes.
To avoid possible personnel injury or equipment damage when
installing, operating or maintaining this equipment, use good
judgment and follow these safe practices:
;Follow all SAFETY CODES.
;Wear SAFETY GLASSES and WORK GLOVES.
;Use care when LOADING, UNLOADING, RIGGING or
MOVING this equipment.
;Operate this equipment within design specifications.
;OPEN, TAG, and LOCK ALL DISCONNECTS before
working on equipment. It is a good idea to remove the fuses
and carry them with you.
;Make sure that the blown film cooler is properly GROUNDED
before switching power on.
;When welding or brazing in or around this equipment, make
sure VENTILATION is ADEQUATE. PROTECT adjacent
materials from flame or sparks by shielding with sheet metal.
An approved FIRE EXTINGUISHER should be nearby and
ready for use if needed.
;Do not jump or bypass any electrical safety control.
;Do not restore power until all tools, test equipment etc. have
been removed and the panels replaced.
;Only PROPERLY TRAINED personnel familiar with the
information within this manual should work on this equipment.

Page 4 BFC Series Blown Film Cooling Systems
Table of Contents
1 Introduction...............................................................7
1-1 Introduction .....................................................................................7
1-2 Necessary Documents....................................................................7
1-3 Model Identification......................................................................... 7
1-4 Features..........................................................................................8
2 Shipping Information .............................................13
2-1 Unpacking and Inspection.............................................................13
2-2 In the Event of Shipping Damages................................................13
2-3 If the Shipment is Not Complete....................................................14
2-4 If the Shipment is Not Correct....................................................... 14
2-5 Returns .........................................................................................14
3 Installation...............................................................15
3-1 Placing the Blown Film Cooler at the Site.....................................15
3-2 Installing the Coil Assembly and Blower ....................................... 15
3-3 Power Supply and Wiring..............................................................17
3-4 Condensate Drain Piping Considerations ..................................... 18
3-5 Installing Chilled Water Piping....................................................... 18
3-6 Air Handling System Considerations............................................. 20
3-7 Air Handling System Insulation Considerations ............................21

BFC Series Blown Film Cooling Systems Page 5
Table of Contents
4 Operations...............................................................23
4-1 Making Water Chiller Systems Operational...................................23
4-2 Starting the Cooler........................................................................ 23
5 Maintenance............................................................27
5-1 Lubricating the Optional Blower ....................................................27
5-2 Servicing the Filter ........................................................................ 27
5-3 Servicing the 3-Way Valve............................................................27
6 Troubleshooting .....................................................31
I Index ........................................................................33

Page 6 BFC Series Blown Film Cooling Systems
Charts and Figures
1 BFC Series Technical Specifications 8
2 BFC Series Standard Components 9
3 BFC Standard Dimensions 10-11
4 Typical Electrical Schematic 16
5 Wiring Specifications:
16” (3.9 kPa) and 35” (8.7 kPa) Static Pressure 17
6 Typical Piping Schematic 18
7 Air Flow, Required Cooling, and Piping Specifications 19
8 Chilled Water Coil Pressure Drop Chart 19
9 Blower Performance Curves 20
10 Typical Four-Point Air Distribution System 21

BFC Series Blown Film Cooling Systems Page 7
1 Introduction
1-1 Introduction
A properly installed, operated, and maintained BFC Series blown
film cooling system provides you with many years of reliable
operation. To get the most satisfaction from your new blown film
cooler, read and follow the instructions in this manual.
1-2 Necessary Documents
These documents are necessary for the operation, installation, and
maintenance of Colortronic BFC Series blown film-cooling
systems. Additional copies are available from Colortronic Make
sure that the appropriate personnel are familiar with these
documents:
;This manual.
;The schematic and connection diagram in the information
packet.
;The Customer Parts List included in the information packet.
Contact Colortronic immediately if your copy of this manual was
damaged or lost. Do not attempt to operate blown film coolers
without access to this manual.
1-3 Model Identification
The serial tag label lists blown film cooler model numbers. A -Q
following the model number indicates a specially constructed unit;
not all information in this manual may apply. Make sure that you
know the model number, serial number, and operating voltage of
your cooler if you need to contact Colortronic
Model numbers describe the cooler model and rated airflow in
cubic feet per minute. For example, a BFC3500 Series blown film
cooler has a capacity airflow of 3,500 cubic feet per minute (5,946
cubic meters per hour).

Page 8 BFC Series Blown Film Cooling Systems
1-4 Features
•Bolt-on support legs
•Condensate trap
•Insulated heavy-gauge steel cabinet designed for up to 35”
(8.7 kPa) static pressure
•Dial thermometers for discharge air and chilled water
supply/return
•Air inlet and outlet adapters
•Copper tube aluminum fin chilled water cooling coil
•Insulated drip pan
•Permanent filter
•Choice of 230/3/60 or 460/3/60 operating voltages
•1-year warranty on parts and labor
Optional
•Pre-piped automatic 3-way chilled water control valves
•Pre-piped automatic 2-way chilled water control valves; for
use only with a distributed chilling system, not with a
dedicated chiller
•Electric blower starters for field mounting
•Blowers, with High or Low Static Pressure
Figure 1
BFC Series Technical Specifications
Optional blower motor Shipping weights
Die 16” (3.9 kPa) 35” (8.7 kPa) with blower
Air flow Max. static static Base 16” (3.9 kPa) 35” (8.7 kPa)
rated hp/kW dia. pressure pressure unit static pressure static pressure
Model no. cfm cmh in. cm hp kW hp kW lbs. Kg lbs. Kg lbs. Kg
BFC-600 600 1,019 5 12.7 3 2.24 7.5 5.60 440 205 570 265 1,030 478
BFC-1000 1,000 1,699 18 45.7 5 3.73 10 7.46 440 205 570 265 1,030 478
BFC-1500 1,500 2,548 30 76.2 7.5 5.60 15 11.19 690 321 890 413 1,325 615
BFC-2000 2,000 3,398 40 101.6 10 7.46 20 14.92 740 344 965 448 1,465 680
BFC-3500 3,500 5,946 60 152.4 20 14.92 40 29.84 1,260 585 1,710 794 2,365 1,098
BFC-5000 5,000 8,495 80 203.2 30 22.38 60 44.76 1,880 873 2,465 1,144 3,165 1,469
cEntering air @ 100ºF (38ºC) dry bulb, 80ºF (27ºC) wet bulb, 40ºF (4ºC) chilled water = 50ºF (10ºC) leaving air temperature.

BFC Series Blown Film Cooling Systems Page 9
Figure 2
BFC Series Standard Components
Note: Optional blower not shown. Contact the factory for more
information.
Chilled water inlet
Chilled water outlet
Air outlet
Optional 3-way regulating valve
Air outlet thermometer
Drain
Air inlet
Chilled water thermometers

Page 10 BFC Series Blown Film Cooling Systems
Figure 3
BFC Standard Dimensions
F
A
Front View
C
D
Top View
B
Right view
Inlet
(dia.)
H
J
G
Air
inlet
(dia.)
Drain
(dia.)
Outlet
(dia.)
3-way regulating
valve (diameter)
EE
Note: Allow a clearance of 48” (1.3 m) on each side of the blown
film cooler to permit access to the filter.

BFC Series Blown Film Cooling Systems Page 11
Figure 3
BFC Standard Dimensions Cont’d.
Dimensions
Model A B C D E F G H J
number in. cm in. cm in. cm in. cm in. cm in. cm in. cm in. cm in. cm
BFC600 48” 122 38” 97 49” 125 45” 115 38” 97 29” 74 58” 148 44” 112 32” 82
BFC1000 48” 122 38” 97 49” 125 44” 112 38” 97 29” 74 58” 148 44” 112 32” 82
BFC1500 47” 120 38” 97 42” 107 46” 117 33” 84 20” 51 57” 145 42” 107 24” 61
BFC2000 59” 150 38” 97 48” 122 46” 117 39” 99 20” 51 66” 168 54” 137 24” 61
BFC3500 69” 176 47” 120 61” 155 62” 158 44” 112 20” 51 78” 199 63” 160 24” 61
BFC5000 89” 226 51” 130 70” 178 63” 160 45” 115 13” 33 89” 226 73” 186 17” 43
Dimensions
Model Air inlet/outlet dia. 3-way regulating valve Water outlet dia. Water inlet dia. Drain dia.
number in. mm dia. inches NPT inches NPT cinches NPT inches NPT
BFC600 10” 254 mm 3/4” 1” 1” 0.75”
BFC1000 10” 254 mm 1” 1.25” 1.25” 0.75”
BFC1500 14” 356 mm 1.25” 1.5” 1.5” 0.75”
BFC2000 14” 356 mm 1.5” 2” 2” 0.75”
BFC3500 16” 407 mm 2” 2.5” 2.5” 0.75”
BFC5000 18” 457 mm 2” 2.5” 2.5” 0.75”
cCustomer is responsible to convert measurements to metric. Multiply inches by 25.4 to convert to mm.
Note: Allow a clearance of 48” (1.3 m) on each side of the blown
film cooler to permit access to the filter.

Page 12 BFC Series Blown Film Cooling Systems
- Notes -

BFC Series Blown Film Cooling Systems Page 13
2 Shipping Information
2-1 Unpacking and Inspection
Remove the crate from the skid base. You should inspect your
Colortronic BFC Series blown film-cooling system for possible
shipping damage. If the crate, skid, and packing materials are in re-
usable condition, save them for reshipment if necessary.
Thoroughly check the equipment for any damage that might have
occurred in transit, such as broken or loose components, loose
hardware and mounting screws, etc. In case of breakage, damage,
shortage, or incorrect shipment, refer to the following sections.
2-2 In the Event of Shipping Damages
Important!
According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of shipment.
;Notify the transportation company’s local agent if you discover
damage.
;Hold the damaged goods and packing material for the
examining agent’s inspection. Do not return any goods to
Colortronic before the transportation company inspection
and authorization.
;File a claim against the transportation company. Substantiate
the claim by referring to the agent’s report. A certified copy of
our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was
prepaid, write us for a receipted transportation bill.
;Advise Colortronic regarding your request for assistance and to
obtain an RMA (return material authorization) number.

Page 14 BFC Series Blown Film Cooling Systems
2-3 If the Shipment is Not Complete
Check the packing list. The apparent shortage may be intentional.
Back-ordered items are noted on the packing list. You should have:
;BFC Series blown film cooling system.
;Bill of Lading.
;Packing list.
;Operating and Installation packet.
;Component instruction manuals.
Re-inspect the container and packing material to see if you missed
any smaller items during unpacking. Determine that the item was
not inadvertently taken from the area before you checked in the
shipment. Notify Colortronic immediately of the shortage.
2-4 If the Shipment is Not Correct
If the shipment is not what you ordered, contact the parts and
service department immediately at [810] 720-7300. Have the
order number and item number available. Hold the items until you
receive shipping instructions.
2-5 Returns
Important!
Do not return any damaged or incorrect items
until you receive shipping instructions from Colortronic

BFC Series Blown Film Cooling Systems Page 15
3 Installation
3-1 Placing the Blown Film Cooler at the Site
Selecting a Site
For conventional applications, you should place the blown film
cooling system in close proximity to film processing areas. Make
sure that you allow adequate clearance for installing the connec-
ting ducts, access to the filter, and the flexible tubing of the air
handling system. The length of the tubing to each inlet of the air
ring should be approximately equal and as short as possible for
proper air distribution. See Figure 10 on Page 21 for more
information.
3-2 Installing the Coil Assembly and Blower
Bolt the blown film cooling system firmly to the floor, being
careful to provide proper alignment of the blower and air
handling piping. The optional blower is shipped separately from
the cooling assembly. The blower is supplied with a flexible
connection. Clamp the other end of the flexible connection to the
inlet of the cooling assembly.
Note: When placing the blown film cooling system, make sure
that you allow for sufficient clearance for servicing the
blown film cooler filter.

Page 16 BFC Series Blown Film Cooling Systems
Figure 4
Typical Electrical Schematic

BFC Series Blown Film Cooling Systems Page 17
Figure 5
Wiring Specifications: 16” (3.9 kPa) Static Pressure
Model Optional blower motor Disconnect size Fuse size Full load
number hp kW Voltage amps amps camps (blower)
230/3/60 30 A 12.0 7.9
BFC600 3 2.24 460/3/60 30 A 6.0 3.9
230/3/60 30 A 23.0 15.2
BFC1000 5 3.73 460/3/60 30 A 11.5 7.6
230/3/60 60 A 33.0 22.0
BFC1500 7.5 5.60 460/3/60 30 A 16.5 11.0
230/3/60 60 A 42.0 28.0
BFC2000 10 7.46 460/3/60 30 A 21.0 14.0
230/3/60 100 A 81.0 54.0
BFC3500 20 14.92 460/3/60 60 A 40.5 27.0
230/3/60 200 A 120.0 80.0
BFC5000 30 22.38 460/3/60 60 A 60.0 40.0
cFuse size based on Type J fuses, calculated at 1.5 times full load amps.
Wiring Specifications: 35” (8.7 kPa) Static Pressure
Model Optional blower motor Disconnect size Fuse size Full load
number hp kW Voltage amps amps camps (blower)
230/3/60 60 A 33.0 22.0
BFC600 7.5 5.60 460/3/60 30 A 16.5 11.0
230/3/60 60 A 42.0 28.0
BFC1000 10 7.46 460/3/60 30 A 21.0 14.0
230/3/60 100 A 63.0 42.0
BFC1500 15 11.19 460/3/60 60 A 31.5 21.0
230/3/60 100 A 81.0 54.0
BFC2000 20 14.92 460/3/60 60 A 40.5 27.0
230/3/60 200 A 156.0 104.0
BFC3500 40 29.84 460/3/60 100 A 78.0 52.0
230/3/60 400 A 231.0 154.0
BFC5000 60 44.76 460/3/60 200 A 115.5 77.0
cFuse size based on Type J fuses, calculated at 1.5 times full load amps.
3-3 Power Supply and Wiring
Cooling coil assemblies with air handling systems are standard
230/- and 460/3/60 voltage. Optional voltages are available. You
must know the electrical power of the proper voltage, phase and
cycle to match the electrical data listed on the blower motor
nameplate. Voltage must be within 10% of the motor nameplate
voltage during operation.
Note: Check blower rotation for proper direction.

Page 18 BFC Series Blown Film Cooling Systems
Figure 6
Typical Piping Schematic
3-4 Condensate Drain Piping Considerations
You must make provisions to properly handle cooling coil
condensation. Your cooler features an
inverted bucket-style trap that must be
primed before startup. To prime the trap,
carefully remove and retain the top screw,
and fill the trap to the top with water.
Reinstall the screw and tighten.
Make sure that you connect the trap to the
nearest drain, using pipe sizes specified in Figure 7 on the
following page.
3-5 Installing Chilled Water Piping
Chilled water may be supplied to the cooling coil assembly by
individual portable chillers or central chilling and recovery
systems. Make sure that you run all chilled water supply and return
connections full size from the cooling coil assembly, as
recommended in Figure 7 on the following page.
Top screw

BFC Series Blown Film Cooling Systems Page 19
Figure 7
Air Flow, Required Cooling, and Piping Specifications
Air flow Nominal cooling Water 3-way regulating Condensation
Model rated hp / kW required ccapacity Pipe size valve size drain size
no. cfm cmh tons Kcal/hr gpm lpm in. NPT approx. mm in. NPT approx. mm in. NPT approx. mm
BFC-600 600 1,019 7.3 22,075 21 79.5 1” 25.4 mm 0.75” 19.0 mm 0.75” 19.0 mm
BFC-1000 1,000 1,699 12.1 36,590 34 128.7 1.25” 31.7 mm 1” 25.4 mm 0.75” 19.0 mm
BFC-1500 1,500 2,548 18.2 55,037 52 196.8 1.5” 38.1 mm 1.25” 31.7 mm 0.75” 19.0 mm
BFC-2000 2,000 3,398 24.2 73,181 69 261.2 2” 50.8 mm 1.5” 38.1 mm 0.75” 19.0 mm
BFC-3500 3,500 5,946 42.4 128,217 100 378.5 2.5” 63.5 mm 2” 50.8 mm 0.75” 19.0 mm
BFC-5000 5,000 8,495 60.5 182,952 145 548.8 2.5” 63.5 mm 2” 50.8 mm 0.75” 19.0 mm
cEntering air @ 100ºF (38ºC) dry bulb, 80ºF (27ºC) wet bulb, 40ºF (4ºC) chilled water = 50ºF (10ºC) leaving air temperature.
Figure 8
Chilled Water Coil Pressure Drop Chart

Page 20 BFC Series Blown Film Cooling Systems
Figure 9
Blower Performance Curves
3-6 Air Handling System Considerations
In many cases, cooling coil assemblies can be integrated into
existing air handling systems, provided blower capacity and air
handling distribution is adequate.