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Baltimore Aircoil Company S3000E, Operating And Maintenance Instructions Manual

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Summary of Contents for S3000E

Page 1: ...S3000E Open Cooling Towers XES3000E Open Cooling Tower OPERATING AND MAINTENANCE INSTRUCTIONS MS3000Ev08EN ...

Page 2: ...r basis thereafter in accordance with recognized Codes of Practice such as EUROVENT 9 5 6 ACOP HSC L8 Guide des bonnes pratiques Legionella et tours aéroréfrigérantes etc Water sampling test results and corrective actions should be recorded in the cooling system logbook For more specific recommendations on keeping your cooling system efficient and safe contact your local BAC Balticare service prov...

Page 3: ...rterly 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 ...

Page 4: ...control 11 Chemical treatment 12 Passivation 12 4 Cold Weather Operations 13 About cold weather operation 13 Protection against sump water freezing 13 Capacity control 13 5 Maintenance Procedures 15 Checks and adjustments 15 Inspections and corrective actions 23 Lubrication 28 Gear drive system 30 Cleaning procedures 32 6 Comprehensive Maintenance 34 About comprehensive maintenance 34 Prolonged ou...

Page 5: ...n 1 Wet deck surface with integral drift eliminators 2 Top water inlet 3 Cold water basin 4 Suction strainer with suction hood 5 Water outlet 6 Make up valve with adjustable float 7 Combined inlet shields 8 Corrosion resistant fan sheave 9 Fan 10 Distribution pan covers optional 11 Fan deck 12 Fan motor 13 Casing S3000E XES3000E 1 ...

Page 6: ...in compensators to eliminate vibrations carried through the external pipework The equipment outlet piping must be installed under the operating level of the equipment to prevent air suction and pump cavitation 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 inst...

Page 7: ...trol 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 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 ...

Page 8: ...ocal 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 equi...

Page 9: ...after 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 determin...

Page 10: ... sulfates parameters does not exceed 650 mg l for Baltibond SST304L Baltiplus protection pH 6 5 to 9 0 pH during initial passivation Below 8 2 Total hardness as CaCO3 50 to 600 mg l Total alkalinity as CaCO3 500 mg l max Total dissolved solids 1500 mg l max Conductivity 2400 µS cm Chlorides 250 mg l max Sulfates 250 mg l max Total suspended solids 25 mg l max Chlorination as free chlorine halogen ...

Page 11: ... 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 calculat...

Page 12: ...ude 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 ...

Page 13: ...on to protecting the sump water all exposed water piping in particular make up water lines should be heat traced and insulated It is necessary to prevent the recirculating water from approaching freezing conditions when the system is operating under load The most critical situation occurs if operation at subfreezing conditions coincides with light load conditions The key to protecting the recircul...

Page 14: ... to provide sinus filters on the VFD to prevent bearing damage on fan motors and premature wear due to fretting on couplings CAUTION Refer to fan motor nameplate data when programming a VFD The purpose of a low level cut out switch for pump protection is to protect the pump from running dry in case of make up failure or extreme water loss The status of the alarm can be checked prior to pump start ...

Page 15: ...n become corrosive and cause deterioration of the metallic basin fittings When flushing the basin the strainers should be left in place to prevent the sediment from re entering the unit system After the basin has been flushed the strainers should be removed cleaned and replaced before refilling the basin with fresh water CAUTION Do not use acid to clean the strainers Remote Basin The water level i...

Page 16: ...ptional distribution pan covers OPERATING LEVEL AND MAKE UP Before initial start up the straps that prevent the float ball from moving during transport as well as the protective bag around this ball need to be removed Fixation and wrapping of float ball As the water circulating through the unit is cooled it collects in the cold water basin and passes through the strainers into the system The opera...

Page 17: ...ling equipment It is located inside the unit within easy reach from the access door The standard make up assembly see figure below consists of a make up valve connected to a float arm assembly and actuated by a large diameter plastic float The float is mounted on an all thread rod which is held in place by wing nuts The operating water level in the cold water basin can be adjusted by repositioning...

Page 18: ...o prevent the sump water from freezing when the water pump s and the fan s are shut off Under no circumstances should sump heaters operate at other times as they could potentially heat the water to temperature levels which are favourable to bacteriological growth Ensure every six months the heater thermostat is properly set and clean Also ensure that control and safety devices such as low level cu...

Page 19: ...ION No service work should be performed on the drive system without first ensuring the fan and pump motors have been isolated tagged and locked in the off position Drive train 1 Fan sheave 2 Belt s 3 Motor sheave Belt Tensioning Belt tensioning can be adjusted by changing the position of the fan motor s by rotating the motor base adjustment screw which extends through the bottom frame angel Check ...

Page 20: ... 24 hours operation If belt tensioning is required please proceed as follows 1 Loosen the lock nuts on the motor base adjusting screws 2 Turn the motor base adjusting screws clockwise to tension the belt or counter clockwise to relieve belt tension During adjustment of belt tension the drives should be rotated several times by hand to evenly distribute the tension throughout the belt 3 When the be...

Page 21: ...ng the shaft 4 Re tighten the screw 5 Install access panel s and start fan s Locking collar assembly 1 Locking collar 2 Lubrication fitting 3 Set screw hole GEAR DRIVE SYSTEM Inspection All gear drives are shipped with oil installed The initial oil level should be at or near the middle of the oil level sight gage and should be maintained so that the oil level is always visible in the sight gage wi...

Page 22: ...eed allow a minimum of 15 seconds time delay for the fan to slow down before energising the low speed winding When reversing the direction of rotation allow the fan to come to a complete stop before restarting the motor Variable Frequency Drive Operation On installation with variable speed motors do not operate standard gear drives below 450 RPM motor speed gear input speed Modifications to the lu...

Page 23: ...m 1 000 000 Ohms 2 Thermistors if fitted should be checked for continuity with a multi meter but never Megger tested 3 Ensure supply voltage and frequency correspond to the motor nameplate rating 4 Ensure shaft turns freely 5 Wire the motor in accordance with the wiring diagram as shown on the motor nameplate and or in the motor terminal box 6 Turn on unit and check amp draw does not exceed namepl...

Page 24: ...s on page 32 Regular checking of the total aerobic bacteria count TAB and maintaining it within acceptable levels are the key to prevent fouling HOT WATER BASIN The inspection procedure is as follows 1 With fan s and pump s running visually check condition of hot water basin internally and externally 2 Remove any dirt or debris which may clog the orifices 3 If necessary balance the water flows to ...

Page 25: ...ed in bracket 3 To remove the combined inlet shields lift each section and pull at the lower end Remove combined inlet shields 4 Reinstall the cleaned combined inlet shields 5 Reinstall tie rod 6 The supporting steel strip does not need to be reinstalled because it is only required for safe transport purposes W W W B A L T I M O R E A I R C O I L E U 25 5 Maintenance Procedures 5 Maintenance Proce...

Page 26: ...terly or at least every 6 months Any signs of surface corrosion must be treated This involves 1 Removal of the protective coating with a suitable cleaning medium 2 The removal of any surface corrosion with emery cloth 3 The re coating of the shaft with soft seal Fan shaft AXIAL FAN Due to its size and speed the axial fan has great potential for injury and destruction if damaged Inspect closely and...

Page 27: ...n the bearings shaft and windings The only servicing required during operation is to clean the outside surface of the motor at least quarterly to ensure proper motor cooling After prolonged shutdowns the motor insulation should be checked with a Megger insulation tester before restarting the motor Do not wash down the motor unless it is IP66 rated On a quarterly basis check electric connections mo...

Page 28: ...ure Under normal operating conditions the bearings should be greased every 1000 operating hours or at least every three months The bearings should be lubricated with one of the following water resistant inhibited greases which are good for ambient temperature ranging from 20 C to 120 C Ball bearing 1 Bearing with locking collar 2 Lubrication fitting 3 Extended lubrication line The bearings should ...

Page 29: ...pears at the seal GREASE PRODUCTS Shell Alvania grease RL3 20 C to 120 C Texaco Multifak Premium 3 30 C to 140 C Klüber Isoflex LDS Special A 50 C to 120 C Mobil Mobilith SHC 100 40 C to 175 C Total Fina Elf Multis 3 20 C to 120 C Grease products ADJUSTABLE MOTOR BASE BELT DRIVEN UNITS The motor base adjusting screw see figure below should be coated every six months using a good quality corrosion ...

Page 30: ...s provisions for an internal oil reservoir heater Heaters and synthetic oil are extra cost accessories and can be ordered with new units or may be ordered and installed in existing units The vertical and horizontal shafts are equipped with grease lubricated dual seals Re lubrication is not required Ambient temperature at gear drive 7 C to 49 C AGMA Lubricant Number 5 ISO Grade 220 Manufacturer Oil...

Page 31: ...gear drive components therefore any synthetic lubricant not listed in this manual should not be used without first consulting Baltimore Aircoil International nv CHANGE INTERVAL The original oil should be replaced after 500 hours or four weeks of operation whichever comes first After that the interval is 2500 hours or 6 months It is recommended that the oil be drained through the drain plug when it...

Page 32: ... recommended cleaning procedures are described below 1 Disconnect fan and pump motor s and shut off make up supply 2 Remove combined inlet shields eliminators and drain system Do not remove sump strainer 3 Clean debris from exterior and fan s with soft brush if necessary use water and soap 4 Clean interior with soap water and soft brush if necessary use high pressure water jet 5 Remove any debris ...

Page 33: ...sult your BAC Balticare representative for further information Excessive levels of chlorine must be avoided as this quickly can lead to corrosion and damage to your system Chlorinated water should be de chlorinated before draining and after disinfection the system must be thoroughly flushed through with clean water A proper regularly monitored biocide programme reduces the need for cleaning and di...

Page 34: ...s Insist on factory authorised parts to avoid loss of efficiency or an operational risk which may occur when non authorised parts are used Prolonged outdoor stay Should the unit s be stored outside prior to installation and or start up for approximately one month shelf life or longer or stored in severe climates it is imperative that certain actions be performed by the installing contractor in ord...

Page 35: ... 2002 30p Guide des Bonnes Pratiques Legionella et Tours Aéroréfrigérantes Ministères de l Emploi et de la Solidarité Ministère de l Economie des Finances et de l Industrie Ministère de l Environnement Juin 2001 54p Voorkom Legionellose Minsterie van de Vlaamse Gemeenschap December 2002 77p Legionnaires Disease The Control of Legionella Bacteria in Water Systems Health Safety Commission 2000 62p H...

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Page 39: ...W W W B A L T I M O R E A I R C O I L E U ...

Page 40: ...RAGE EVAPORATIVE CONDENSERS HYBRID PRODUCTS PARTS EQUIPMENTS SERVICES www BaltimoreAircoil eu info BaltimoreAircoil eu Please refer to our website for local contact details Industriepark Zone A B 2220 Heist op den Berg Belgium Baltimore Aircoil International nv ...

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