Amendment 0002_25Q000041.pdf

(x)

69056725Q000041 x x x

690567

Vancouver WA 98661

610 E FIFTH STREET

FHWA WESTERN FED LANDS DIVISION

Federal Highway Administration

08/26/20250002

13. THIS ITEM ONLY APPLIES TO MODIFICATION OF CONTRACTS/ORDERS. IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

12. ACCOUNTING AND APPROPRIATION DATA (If required) is not extended.is extended, Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended , by one of the following methods: (a) By completing Items 8 and 15, and returning _(One)_______ copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted ; or (c)

By separate letter or electronic communication which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGEMENT TO BE

RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR

OFFER. If by virtue of this amendment you desire to change an offer already submitted , such change may be made by letter or electronic communication, provided each letter or electronic communication makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

FACILITY CODE CODE

10B. DATED (SEE ITEM 13)

10A. MODIFICATION OF CONTRACT/ORDER NO.

9B. DATED (SEE ITEM 11)

9A. AMENDMENT OF SOLICITATION NO.

CODE

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code)

7. ADMINISTERED BY (If other than Item 6)CODE 6. ISSUED BY

PAGE OF PAGES

4. REQUISITION/PURCHASE REQ. NO.3. EFFECTIVE DATE2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO. (If applicable)

1. CONTRACT ID CODE

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

08/11/2025

CHECK ONE A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority) appropriation data, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

E. IMPORTANT: Contractor is not is required to sign this document and return __________________ copies to the issuing office.

ORDER NO. IN ITEM 10A.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

Cooling Tower Wet Deck Media Replacement and Cleaning

By way of this amendment, amendment 0002, amend to:

1. Revise Section C SOW_Page C-4

2. Add Attachment 0007_Cooling Tower Specs and O&M

All changes are indicated by red and/or lined-through text on the attached pages.

All other stipulations remain unchanged.

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)15A. NAME AND TITLE OF SIGNER (Type or print)

15C. DATE SIGNED 16B. UNITED STATES OF AMERICA 15B. CONTRACTOR/OFFEROR 16C. DATE SIGNED

(Signature of person authorized to sign) (Signature of Contracting Officer)

Douglas Taylor

STANDARD FORM 30 (REV. 11/2016)

Prescribed by GSA FAR (48 CFR) 53.243

Previous edition unusable

Except as provided herein, all terms and conditions of the document referenced in Item 9 A or 10A, as heretofore changed, remains unchanged and in full force and effect .

haydar.mohammad Highlight haydar.mohammad Highlight

C-4

The Government anticipates the timeframe to complete the administrative close out of this contract will not exceed 30 days. The costs incurred in the administrative closeout of task orders and contract files are unallowable direct costs under the contract and, therefore, cannot be charged as direct costs to the Government. Contractors are to handle such costs in accordance with their disclosure statements/cost accounting systems.

19. LIST OF ATTACHMENTS

Attachment 0001_Offeror Work Experience, (one page). To be excluded from the award documents.

Attachment 0002_Past Perf Questionnaire, (5 pages). To be excluded from the award documents.

Attachment 0003_Scope, Task Details and General Requirement, (4 pages).

Attachment 0004_Wage Determination No.2015-5563, (15 pages).

Attachment 0005_Facility Site Image, (one page).

Attachment 0006_Site Visit (one page).To be excluded form the award documents.

Attachment 0007_Cooling Tower Specs_O&M(25 pages).To be excluded form the award documents.

Amendment 0002

Attachment 0007 Cooling Tower Specs

O p era tio n

M a in ten a n ce M a n u a ls FXV Closed Circuit Cooling Tower and CXV Evaporative Condenser Table of Contents..............................................................Page Recommended Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N60

Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N61

Initial and Seasonal Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N61

Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N62

Detailed Component Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N63

Cold Water Basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N63

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N63

Fan Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N64

Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N67

Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N68

Heat Transfer Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N68

Water Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N68

Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N69

Figure 1a - Single Side Air Inlet FXV/CXV

Recirculating Water Pump

Coil Connection:

FXV Fluid In/

CXV Refrigerant Out

Coil Connection:

FXV Fluid Out/

CXV Refrigerant In

Access Door

Bleed Line and Valve

Air Inlet Louvers

Cold Water Basin

BACross® Fill with Integral Drift Eliminators

Spray Water Distribution System

Axial Fan(s)

BALTIDRIVE®

Power Train

N59...because temperature matters™

Attachment 0007 Cooling Tower O&M

F X

V /C

X V

N60 Baltimore Aircoil Company

Figure 1b - Dual Air Inlet FXV/CXV-T

Table 1: Recommended Maintenance Services[1]

Type Service Start-Up Monthly Quarterly Annually Shutdown

Insp ect and clean as necessary:

Inspect general condition of the unit[2] and check unit for unusual noise or vibration

X X

Inspect cold water basin/Spray nozzles X X

Drain basin and piping X X

Inspect air inlet louvers X X

Check and adjust water level in basin X X

Check operation of make-up valve X X

Check and adjust bleed rate X X

Inspect unit finish X

Mechanical equipment system:

Check belt condition X X

Adjust belt tension[3] X X

Lubricate fan shaft bearings X X X

Lubricate motor base adjusting screw X X X

Check and lubricate optional gear drive See gear drive section for detailed instructions and schedule

Check drive alignment X

Check motor voltage and current X X X

Clean fan motor exterior X X

Check fan motor for proper rotation X

Check general condition of the fan X

Check and unplug fan drain holes (hollow blade fans) X

Check fan for uniform pitch X

Check fan for rotation without obstruction X X

Suction Strainer Spray Riser Pipe

Bleed Valve

Spray Pump Access Door

Spray Pump Motor

Make-up Valve

Coil Connection:

FXV Fluid In/ CXV Refrigerant Out

Coil Connection:

FXV Fluid Out/ CXV Refrigerant In

Prime Surface Coil

Access Door

Air Inlet Louvers

Cold Water Basin

BACross® Fill with Integral Drift Eliminators

Spray Water Distribution System

BALTIDRIVE®

Power Train

Fan Guard

Casing

Removable Drift

Eliminators era tio n

M a in ten a n ce M a n u a ls

N61...because temperature matters™

WARNING: Do not per form any service on or near the fans , motors, drive s, or inside the unit without fi rst ensuri ng that the fans and the pum ps are disc onnected and locked out .

NOTES:

1. Recommended service intervals are for typical installations. Different environmental conditions may dictate more frequent servicing.

2. When operating in ambient temperatures below freezing, the unit should be inspected more frequently.

Refer to “Cold Weather Operation” on Page N102 for more details.

3. Tension on new belts must be readjusted after the first 24 hours of operation and quarterly, thereafter.

Operation and Maintenance Initial and Seasonal Start-up

General

• If the unit is mounted on vibration isolators or isolation rails, refer to the vibration isolation manufacturer’s guidelines before loading/unloading weight from the unit.

• Verify fan and spray pump motors are disconnected and locked out.

• Conduct overall external inspection of the equipment. Check for leaks, corrosion, and any structural damage.

• Inspect piping and connections.

Cleaning

• Drain the cold water basin with the strainer in place.

• Clean and inspect the fan deck.

• Remove all dirt and debris from the fan guard.

• Clean all mechanical components, such as the fan and motor.

• Flush the cold water basin interior to remove any accumulated dirt and debris.

• Remove, clean, and replace the strainer.

Inspect ion

WARNING: Do not per form any service on or near the fans , motors, drive s, or inside the unit without fi rst ensuri ng that the fans and the pum ps are disc onnected and locked out .

• Thoroughly inspect the fans for any mechanical or physical damage.

• At seasonal start-up or after prolonged shutdown, check the motor insulation with an insulation tester prior to the motor start-up.

• Prior to the seasonal start-up, check and adjust the belt tension or check gear drive oil levels. At the initial start-up, the belt tension may not require adjustment as the drive will be properly tensioned at the factory prior to shipment.

• Start the fan motor(s) and check for proper fan rotation. The fan should rotate in the direction of the arrow indicated on the fan cowl.

• Run the fan in manual mode for several minutes to check for any unusual noise or vibrations.

• For the BALTIGUARD™ Fan System, BALTIGUARD PLUS™ Fan System or 2-speed motors: check that the starter incorporates a 15 second time delay when switching from high to low speed.

• Check that the float operated make-up valve is operating freely.

WARNING: Check to ensur e the controls for the fan motor are set to allow a maximum of 6 on-off cyc les per hour.

Figure 2 - Adjustable Motor Base

V /C

X V

N62 Baltimore Aircoil Company

Start -up

WARNING: Do not per for m any service on or near the fans , motors, drives , or inside the unit without fi rst ensuri ng that the fans and the pum ps are disc onnected and loc ked out .

• Prior to seasonal start-up, lubricate the motor base adjusting screw (see Figure 2) and the fan shaft bearings. At initial start-up, no bearing lubrication is required since the bearings are factory lubricated prior to shipment.

• Fill the cold water basin with fresh water to the overflow level via the make-up valve.

o Water treatment for new installations: Initiate the biocide water treatment program at this time. Refer to

“Biological Control” on Page N106 for more details.

o Water treatment for seasonal start-up or after a shutdown period in excess of 3 days: Resume the biocide treatment program and administer a shock treatment of appropriate biocides prior to operating the fans. This will eliminate accumulated biological contaminants. Refer to “Biological Control” on Page N106 for more details.

• Set the make-up valve float so the water shuts off at the overflow level.

• Start the spray pump and check for the proper rotation indicated by the arrow on the pump cover. On installations where the unit pump was not furnished by BAC, a globe valve should be installed in the pump discharge line and the pump flow rate adjusted to the correct water flow and pressure (2 psig at spray header connection). Pressure greater than 10.0 psig may cause damage to the dis tribution system.

• Inspect the spray nozzles and heat transfer section.

• Open the supply valve slowly until the design flow is reached, based on the pressure in the distribution system. Refer to “Water Distribution System” on Page N68 for more details.

• Open the valve in the unit bleed line, and adjust the bleed by closing or opening the valve.

• Once the unit is operating, check the current and voltage of all three phases (legs) of the fan motor with a heat load on the unit under warm ambient conditions. The current must not exceed the nameplate ratings.

• Check the operation of the optional vibration cutout switch.

Afte r 24 hours of operat ion under thermal load, perform the foll owin g services:

• Check the unit for any unusual noise or vibrations.

• Check the operating water level in the cold water basin. Adjust the balancing valves if necessary.

• Adjust make-up valve if necessary.

• Check the belt tension and readjust if necessary.

• Inspect the spray nozzles and heat transfer section.

Extended Shutdown

WARNING: Do not per for m any service on or near the fans , motors, drives , or inside the unit without fi rst ensuri ng that the fans and the pum ps are disc onnected and loc ked out .

Perform the fo llowing services whene ver the unit is shutdown in excess of 3 days:

• If the unit is mounted on vibration isolators or isolation rails, refer to the manufacturer’s guidelines before loading/unloading weight from the unit.

• Drain the cold water basin and all the piping (excluding the coils) that will be exposed to freezing temperatures. Heat trace and insulate all exposed piping.

• Clean all debris, such as leaves and dirt, from the interior and exterior of the unit.

• Clean and flush the water distribution system and cold water basin with the basin strainer in place.

• Leave the cold water basin drain open so rain and melting snow will drain from the unit.

• Clean the basin strainer and re-install.

• Cover the fan discharge opening to keep out dirt and debris.

• Lubricate the fan shaft bearings, motor base, and motor base adjusting screw.

• Close the shut off valve in the make-up water line (supplied by others), and drain all exposed make-up water piping. Heat trace and insulate all exposed piping.

• Inspect the protective finish on the unit. Clean and refinish as required. Refer to “Corrosion Protection” on

Page N106 for more details.

• Secure the fan motor starting device in the “OFF” position to ensure personal safety in case of future inspection or service.

era tio n

M a in ten a n ce M a n u a ls

N63...because temperature matters™

Detailed Component Maintenance Procedures Cold Water Basin The fluid to be cooled is circulated inside the tubes of the unit's heat exchanger. Heat flows from the process fluid through the coil to the spray water outside which is cascading over the tubes. The spray water collects in the cold water basin, passes through the suction strainer and is pumped back to the distribution system. The cold water basin is constructed from one of the following materials of construction:

• Galvanized steel

• Thermosetting Hybrid Polymer

• Welded Type 304 stainless steel

Water Levels

Table 2: Cold Water Basin Water Levels

• The make-up valve controls the operating level, which is maintained at the levels shown in Table 2.

• The operating water level in the cold water basin will vary with system thermal load (evaporation rate), the bleed rate employed, and the make-up water supply pressure.

• Check the operating water level monthly, and readjust the float when necessary to maintain the recommended operating level.

Inspect ion and Maint enance

WARNING: Openings and/or submerged obs tructions may exist in the bottom of the cold water basin.

Use caut ion when walking inside this equipment.

• Inspect the cold water basin regularly. Remove trash or debris accumulated in the basin or on the strainer.

• Quarterly, or more often if necessary, drain, clean, and flush the entire cold water basin with fresh water.

This will remove the silt and sediment, which normally collects in the basin during operation. If not removed, sediment can become corrosive and deteriorate the protective finish of metallic basins.

• When flushing the basin, leave the strainer in place to prevent the sediment from re-entering the system.

• Remove the strainer after the basin has been flushed.

• Clean and replace the strainer before refilling the basin with fresh water.

• Adjust the float to maintain the design operating level. See Table 2: “Cold Water Basin Water Levels.”

Fan The FXV and CXV use an axial fan. Thoroughly inspect the fan for damaged or deteriorated fan blades and replace the fan as required.

Inspect ion and Maint enance

• If the unit is already in operation, while the fan is running, check for any unusual noise or vibration.

• With the fan off and the motor locked out and tagged, check the general condition of the fan:

o Inspect for any loose or missing bolts in the fan shaft bushing, the fan hub, and the fan shaft bearing(s).

o Check the fan blades for looseness, first by twisting the blade by hand; and then, by moving the blade tip up and down. There should be no play or slippage.

o Inspect each blade for excessive scale build-up that could cause vibration.

o Check each blade, in the area of the shank, for any signs of cracking. If cracking is found, the fan motor should be locked out immediately. Contact your local BAC Representative for assistance.

Model Number At Overflow Level (in.) At Operating Level (in.)

FXV-4xx, CXV-64 to CXV-206 15” 10”

FXV-6xx, CXV-196 to CXV-305, CXV-310 to CXV-481, CXV-420 to CXV-610, CXV-620 to CXV-962, CXV-N465 to CXV-N687

15” 7-1/2”

FXV-288-xxx, CXV-T645 to CXV-T1888 14” 10-1/2”

FXV-364-xxx 13-1/2” 10-1/2”

V /C

X V

N64 Baltimore Aircoil Company

• Tip Clearance: Check the clearance between the tip of the blade and the fan cowl. The clearance should be within 5/16” to 1/2” for single air inlet FXV/CXV and within 1/2” to 7/8” for dual air inlet FXV/CXV-T.

• Drain Holes: On hollow blades, the drain hole in the blade tip should be unobstructed. (Hint: Use a piece of wire to probe the hole.)

• Blade Pitch : Check to ensure that the blades are all at the same pitch. If uncertain, measure the pitch with an inclinometer. All blades should be within -1/2° to 0° .

• Rotation : Turn the fan by hand to ensure that it moves freely with no rough spots, binding or other malfunctions that could cause vibration or fan motor overload. While rotating the fan, check the blade tracking. All blades should track within a 3/4” to 1” band at any single point around the cowl.

• Direction of Rotation: On initial start-up, or if the fan motor has been rewired, bump the fan motor and note the direction of rotation. It should rotate in the direction indicated by the arrow on the fan cowl.

• Operation : On initial start-up, run the fan in the manual position for several minutes and check for any unusual noises or vibration.

Fan Drive System

BALTIDRIVE® Power Train/BALTIGUARD™ and BALTIGUARD PLUS™ Fan System The BALTIDRIVE® Power Train consists of a solid-backed, multi-groove, neoprene/polyester belt rated for cooling tower service, and corrosion-resistant sheaves. These components provide high reliability with low maintenance requirements.

The BALTIGUARD™ Fan System consists of two standard single-speed fan motors and drive assemblies. One drive assembly is sized for full speed and load, and the other is sized for approximately 2/3 speed and consumes only 1/3 the design horsepower.

The BALTIGUARD PLUS™ Fan System builds on the advantages of the BALTIGUARD™ Fan System by adding a VFD to one of the motors.

Inspection and Maint enanc e:

• These drives require a periodic check of the belt condition and, when necessary, tension adjustment. The recommended service intervals are as follows:

o Ini tial Start-up : Servicing is not required prior to initial unit start-up. The drive has been tensioned and aligned at the factory.

o Seasonal Star t-up : Readjust the belt tension.

o Operati on : After the first 24 hours of operation, readjust the belt tension on a new unit start-up or installation of a new belt. Thereafter, check the belt condition monthly, and adjust tension as necessary. Readjust tension at least once every 3 months.

• Belt tension check:

o Place a straight edge along the belt from sheave to sheave as shown in Figure 4a, or use a tape measure as shown in Figure 4b, to measure belt deflection.

o Apply a moderate force by hand (approximately 40 lbs/18.1 kg) evenly across the width of the belt in the center of the span between the sheaves.

o There is adequate belt tension if the belt deflects between 1/4” and 3/8” as shown in Figures 4a and

4b.

Belt Tension

DRIVEN SHEAVEDRIVEN SHEAVE

BELTBELT

DRIVER SHEAVEDRIVER SHEAVE

STRAIGHT EDGESTRAIGHT EDGE

1/4” TO 3/8” DEFLECTION = PROPER BELTTENSION 3/8” DEFLECTION = PROPER BELT TENSION

D DRIVEN SHEAVEDRIVEN SHEAVE

BELTBELT

DRIVER SHEAVEDRIVER SHEAVE

TAPE MEASURETAPE MEASURE

1/4” TO 3/8” DEFLECTION = PROPER BELTTENSION3/8” DEFLECTION = PROPER BELT TENSION

Figure 4a Figure 4b

Figure 3 - BALTIGUARD™ Fan System era tio n

M a in ten a n ce M a n u a ls

N65...because temperature matters™

• Belt tension adjustment (if required):

o Loosen the lock nut on the motor base adjusting screw.

o Turn the motor base adjusting screw clockwise to tension the belt, or counterclockwise to relieve belt tension. During adjustment of belt tension, rotate the drives several times by hand to evenly distribute the tension throughout the belt.

• When the belt is properly tensioned, retighten the locking nut on the motor base adjusting screw.

NOTE: There should be no “chirp” or “squeal” when the fan motor is started.

Alignment:

• Check the drive alignment annually to ensure maximum belt life.

• Drive alignment check and adjustment:

• Place a straight edge across the driver and the driven sheaves as shown in Figure 5a for standard drives and in Figure 5b for the BALTIGUARD™ Fan System or the BALTIGUARD PLUS™ Fan System.

• The straight edge should contact all four points as shown in Figure 5a indicating proper drive alignment.

• There should be no more than 1/16” deviation from four points of contact.

• In case of realignment, loosen the motor sheave and align it with the fan sheave. Allow 1/4” for draw-up as the bushing screw is retightened.

Gear Drive System (Optional for Dual Air Inlet FXV/CXV-T Only)

Initial Start-up:

• BAC ships all gear drives filled with oil. The initial oil level should be at or near the middle of the oil level sight glass.

• Internally mounted gear drives are factory installed, aligned, and tightened. Double check all gear drive fasteners after the unit has been installed.

• On units with externally mounted motors, install and align the motor and driveshaft in accordance with

BAC’s installation instructions. Recheck the alignment and all external fasteners after 2 weeks of operation.

• Prior to the start-up, check all fittings on the gear drive to ensure that there are no visible leaks. Refer

Figure 6 for locations of the gear drive fittings.

Figure 6 – Single Reduction Gear Drive

Air Breather Plug

Oil Level Sight Glass

Drain Plug

Name Plate

Points of Contact

Standard Driver Sheave

1/16”

MAX

1/16”

MAX

BALTIGUARD™ &

BALTIGUARD PLUS™

Fan System Driver Sheave

Straight Edge

Driven Sheave

Points of Contact

Points of Contact

1/16”

MAX

1/16”

MAX

1/16”

MAX

1/16”

MAX

Standard Driver Sheave

P

Figure 5a - Standard Drive Alignment Figure 5b - BALTIGUARD™ Fan System Drive Alignment

V /C

X V

N66 Baltimore Aircoil Company

Change Interv al:

• Initi al oil change : Replace the original oil after 500 hours or 4 weeks of operation, whichever comes first.

• After the initial oil change, change the oil every 2500 hours or 6 months, whichever comes first.

• Drain the oil at operating temperature through the drain plug.

• Refill the gear drive through the air breather port with the recommended type (Table 3 and 4) and amount of lubricant (Table 5). Refer to Figure 6 for locations of these components.

Inspection and Maint enanc e:

• Maintain the oil level at or near the middle of the oil level sight glass. The oil level should always be visible in the sight glass window when the unit is not operating/energized, and the oil is at ambient temperature.

• Check oil level weekly with the unit idle.

• Add oil if level is below the oil level sight glass.

• The standard oil provided is mineral oil. Synthetic lubricants are also available as an option (see Table 4).

• Refer to Table 5 for normal operating oil capacity of each gear drive.

• Refer to Table 6, Table 7 or the gear drive nameplate for specific gear model number for each unit.

• Periodically check to ensure proper alignment of all system components.

• Check to ensure that all bolts and external fasteners are tight.

• BAC recommends daily visual inspections and observation for oil leaks and unusual noises and vibrations.

If any of these occur, shutdown the unit until the cause is found and corrected.

Routi ne Mainte nanc e Dur ing Operation:

• Periodically recheck the alignment and tighten external fasteners as necessary. No special break-in procedures are required.

• Excessive noise or vibration at initial operation is an indication of one or more of the following:

o Misalignment o Imbalance of the fan or other rotating parts o Improperly adjusted fan blades o Operation at the mechanical equipment resonant frequency

WARNING: If noi se or vibra tion persists, shut the unit down and correc t the cause before cont inuing operat ion.

• Installations with 2-speed motors: When slowing from high speed, allow a minimum 15-second time delay for the fan to slow down before energizing the low-speed winding.

CAUTION: When reversing the direction of rotation, allow the fan to come to a complete stop before restart ing the motor .

• During periods of inactivity, the lubricant does not constantly lubricate the internal parts of the gear drive, leaving the gear drive susceptible to corrosion. Therefore, the following special precautions are necessary during periods of inactivity:

o For best results, let the gear drive cool for approximately 4 hours after shutdown.

o Start the fan and let it run for approximately 5 minutes. This will coat the internal parts of the gear drive with cool oil.

o Thereafter, run the fan for 5 minutes once a week, throughout the shutdown period to maintain the oil film on the internal parts of the gear drives.

• During seasonal shutdown:

o Completely fill the gear drive with oil through the air breather plug.

o Cover the gear drive with a tarpaulin or other protective covering.

o Drain the excess oil before returning the gear drive to service at the end of the seasonal shutdown period.

Lubri cation:

• Use only rust and oxidation inhibited gear oils in accordance with AGMA (American Gear Manufacturer’s

Association), Standard 9005-E02.

• Refer to Table 3 and Table 4 for general operating conditions, AGMA lubricant number and corresponding

ISO Grade.

era tio n

M a in ten a n ce M a n u a ls

N67...because temperature matters™

• When the ambient temperature exceeds 180°F (82°C) or the gear drive is started at an ambient temperature less than 20°F (-7°C), a synthetic lubricant is recommended. When mineral oils are used in operation at ambient temperature less than 20°F (-7°C) lube oil heaters are required. Each unit has 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. Relubrication is not required.

Table 3: Recommended Mineral Oils Table 4: Recommended Synthetic Lubricants

NOTE: Do not mix synthetic lubricants and mineral oils. Attempt to use only one brand of lubricant at all times.

Synthet ic Lubric ants :

• Refer to Table 4 for general operating conditions, AGMA lubricant number, and corresponding ISO Grade.

• Certain gear drive components might be incompatible with the various base stocks used to make lubricants. Contact your local BAC Representative prior to using any synthetic lubricant not listed.

Table 5: Normal Operating Oil Capacity

Table 6: Gear Model/Unit - Standard Fan Table 7: Gear Model/Unit - Low Sound Fan

Fan Motors FXV and CXV units use cooling tower duty, premium efficient, totally enclosed, single-speed, single-winding, reversible ball bearing type motor(s).

Inspect ion and Maint enance

• Clean the outside of the motor at least quarterly to ensure proper motor cooling.

• After prolonged shutdowns, check the motor insulation with an insulation tester prior to restarting the motor.

Gear Model Gallons Liters

65 0.5 2

85 1 4

110 2 8

135 3 11

155 5.5 21

175 5.5 21

Ambient Temperature at Gear Drive: -20˚F to 150˚F (-29˚C to 66˚C)

AGMA Lubricant Number: 5S

ISO Grade: 220

Manufacturer Oil Type*

Chevron Oil Conoco Mobil Oil

Clarity 220 Synthetic Syncon 220 - R70 Oil

SHC 630

* List of brand names is for the purpose of identifying types and should not to be construed as exclusive recommendations.

Ambient Temperature at Gear Drive: 20˚F to 120˚F (-7˚C to 49˚C)

AGMA Lubricant Number: 5

ISO Grade: 220

Manufacturer Oil Type*

Atlantic Richfield Chevron Oil Cities Service Oil Conoco Exxon Gulf Oil Mobil Oil Pennzoil Philips Petroleum Shell Oil Sun Oil Texaco Total

Duro 220 Machine Oil A W 220 Citgo Pacemaker 220 Hydroclear Multipurpose R&O Oil 220 Teresstic 220 Harmony 220 DTE Oil BB Pennzbell TO 220 Magnus 220 Morlina 220 Sunvis 9220 Regal 220 R & O, Code 1531 Carter 220

Model Number Gear Model

FXV-288-xxM 85

FXV-288-xxN,O,P,Q,R and FXV-364-xxN,O,P 110

CXV-T6xx, CXV-T7xx, CXV-T876-PM 110

FXV-364-xxQ,R 135

CXV-T827, CXV-T857, CXV-T876, CXV-T906 135

FXV-264-xxS 155

CXV-T857-SM, CXV-T944 155

Model Number Gear Model

FXV-288-xxM,N,O,P,Q,R 135

CXV-T6xx, CXV-T717, CXV-T729, CXV-T729-OM, CXV-T763

CXV-T717-RM, CXV-T792 155

FXV-364-xxN,O,P,Q,R,S 175

CXV-T791, CXV-T8xx, CXV-T9xx 175

V /C

X V

N68 Baltimore Aircoil Company

Adj usta ble Motor Base Coat the motor base slides and adjusting screws (refer to Figure 2 on Page N61) every 3 months using good quality corrosion inhibiting grease such as one of those recommended for lubricating the fan shaft bearings below.

WARNING: Check to ensure the controls for the fan motor are set to allow a maximum of 6 on-off cyc les per hour.

Fan Shaft Bearings Two pillow block ball bearings support the fan shaft. Each bearing is equipped with a lubrication fitting and a slinger/locking collar to keep out moisture.

Inspect ion and Maintenance

• Lubricate the bearings with only a manual grease gun. Do not use high-pressure grease guns since they may rupture the bearing seals.

• Lubricate the bearings with only one of the following compatible water resistant greases* which are suitable for ambient temperatures ranging from -65ºF (-53.9ºC) to +250ºF (121.1ºC).

*NOTE: List of brand names is for identification only and are not exclusive recommendations.

• Lubricate the bearings as follows:

o Ini tial Start-up : Normally, no lubrication is required since the bearings have been lubricated at the factory prior to shipment. However, if the unit has been stored at the job site for more than 1 year, both bearings should be lubricated with new grease before initial operation. When lubricating, purge the old grease from the bearing by gradually adding greas e until a bead of new greas e appears at the seal on the unde rside of the bearing.

o Seasonal Star t-up : Purge both bearings with new grease prior to start-up.

o Operati on : Purge bearings every 2,000 hours of operation or once every 3 months, whichever occurs first.

o Extended Shutdown : Purge bearings with new grease prior to any prolonged storage or downtime.

Heat Transfer Section

Fil l and Dri ft Elimin ator The FXV and CXV have PVC fill with integral drift eliminators.

Inspection and Maint enanc e:

• Inspect and clean the fill with the integral eliminators at least quarterly.

• The inspection procedure is as follows:

o Shut off the fan and the spray pump.

o Inspect the fill for obstructions, damage and fouling.

• Remove any obstructions from the fill.

• Remove any minor fouling chemically. Contact your local water treatment consultant for advice.

• Major fouling requires cleaning and flushing. Follow the procedures listed in “System Cleaning”, Page

N107.

Water Distribution System The hot water is distributed through a corrosion resistant polyvinyl chloride (PVC) system. The fill and drift eliminators are also made of PVC, which requires no protection against rot, decay, rust, or biological attack.

Inspect and clean the spra y nozzles and heat trans fer section each month.

Amoco - Rycon Premium #3 Exxon - Polyrex® EM Shell - Alvania #3 Chevron - SRI Exxon - Unirex N™ Shell - Dolium “R” Citgo - Polyurea MP2™ MobilGrease® - AW2 SKF - LGHP2™ Conoco - Polyurea 2™ Shell - Alvania RL3™ Unocal 76 - Unilife Grease™ era tio n

M a in ten a n ce M a n u a ls

N69...because temperature matters™

The inspection procedure is as follows:

• Shut off the fan, but leave the spray pump running.

• Check to see if the nozzles are producing the spray pattern shown in

Figure 7.

• Clean any nozzles which are clogged. If necessary, the nozzle and rubber grommet may be removed for cleaning.

• Inspect the coil surface. Any corrosion, damage, or obstructions must be corrected.

Caution: Do not use steam or high pres sure water to clean PVC eliminato rs or materials other than steel.

Water Level Control There are two types of water level controls used on BAC units:

• Mechanical make-up valve assembly

• Optional electric water level control package

The FXV/CXV water make-up valve assembly is located on the air inlet face.

Mechanical Make-up Valve Assem bly A float-operated mechanical water make-up assembly is furnished as standard equipment on the unit. The standard make-up assembly consists of a corrosion resistant make-up valve connected to a float arm assembly actuated by a polystyrene-filled plastic float. The float is mounted on an all-thread rod held in place by wing nuts. The cold water basin operating water level can be adjusted by repositioning the float and all-thread rod using the wing nuts provided.

NOTE: If the unit has been ordered with the optional electric water level control package or is intended for remote sump application, a mechanical water make-up valve will not be provided.

Inspection and Maintena nce:

• Inspect the make-up valve assembly monthly and adjust if necessary.

• Inspect the valve annually for leakage. Replace the valve seat if necessary.

• Maintain the make-up water supply pressure between 15 psig and 50 psig for proper operation. BAC recommends a surge protector (provided by others) for pressures over 50 psig.

• Set the initial basin water level by adjusting the wing nuts, so that the make-up valve is completely closed when the water level in the cold water basin is at the overflow connection.

• With the design thermal load and the average water pressure (15 to 50 psig) at the valve, the above setting will produce operating water levels as stated in Table 2 on Page N63.

• If the thermal load is less than the design load at the time of unit start-up, the procedure may produce operating levels greater than those shown in Table 2. If operating levels are higher than specified, readjust the float in order to attain the recommended operating level.

• Closely monitor the water level in the cold water basin and adjust the level if necessary during the first 24 hours of operation.

• Operating at the recommended water level will ensure that the unit basin contains sufficient water volume to prevent air entrainment in the circulating pump during system start-up.

Opt ional Elect ric Water Level Contro l Package As an option, an electric water level control package is available in lieu of the mechanical make-up assembly.

The package consists of a probe-type liquid level control assembly and a slow-closing solenoid valve.

Stainless steel electrodes, factory-set at predetermined lengths, extend from an electrode holder into the cold water basin.

Inspection and Maintena nce:

• Clean the stainless steel electrodes periodically to prevent accumulations of scale, corrosion, sludge or biological growth, which could interfere with the electrical circuit.

• The water level is maintained at the recommended operating level regardless of the system thermal load.

Therefore, it is not recommended that the operating level be adjusted.

• During the start-up of units equipped with the electric water level control package, by-pass the control unit in order to fill the unit to the overflow connection.

Figure 7 - Nozzle Spray Pattern

S a re

P a rt s

N70 Baltimore Aircoil Company

RReeccoommmmeennddeedd SSppaarree PPaarrttss BAC parts are the “Perfect Fit” for your cooling tower. These parts are specifically designed, engineered and manufactured to work in a cooling tower environment. They are the right parts, at competitive pricing levels, and BAC offers the best deliveries in the industry.

BAC stocks most common repair and retrofit parts in our Parts DepotSM and can ship other parts, often overnight, from any of our three manufacturing facilities strategically located in California, Delaware, and Illinois. In addition, most BAC Representatives maintain a local inventory of commonly used parts.

Even with this fast delivery capability, it is still recommended that certain essential, emergency repair parts be maintained in your local inventory, to minimize any potential downtime.

Basic Recommended Spare Parts Bearing set

Float valve or repair kit

Float ball

Solenoid valve (if unit is equipped with electric water level control)

Powerband or set of belts

Spray nozzle kit with grommets

Basin heater and low water cut out

Door gasket

Strainer (inlet and suction)

Fan and sheave bushings

Pump seal and gasket kit for coil products

Automatic bearing greaser refill kit

Parts to Consider if Extended Downtime is a Concern Spray pump for coil products

Fan or fan wheel

Fan shaft

Sheave set

Fan motor era tio n

M a in ten a n ce M a n u a ls Common Operation & Maintenance Section Table of Contents..............................................................Page Variable Frequency Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N101 Remote Sump Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102 Fan Section Icing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N102 Coil Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N103 Basin Water and Internal Piping Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N104

Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N104 Corrosion and Treatments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N105 Corrosion and Scale Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N105 Chemical Treatment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N106 Passivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N106 Biological Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N106 System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N107

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N107 Bleed Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N107

Basin Heater and Stand Alone Heater Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N109 Basin Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N109 Stand Alone BAC Heater Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N109

Electronic Vibration Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N110 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N110

Instructions for Installing Field Connections (Equalizer/Bypass/Outlet) on a Cold Water Basin with the TriArmor® Corrosion Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N111 Factory Authorized Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N112

Variable Frequency Drive Operation

• Applications utilizing variable frequency drives (VFDs) for fan motor control must use inverter duty motors built in compliance with NEMA standard MG-1, Part 31.

• The standard efficiency fan motors are not intended for inverter duty and will not be warranted if so applied.

• On installations with variable frequency motors, do not operate the standard gear drives below 450 RPM motor speed (gear input speed). For speeds less than 450 RPM, a low speed option gear drive must be supplied.

• Continued operation at a resonant frequency condition will result in torsional vibrations within the gear, which can damage system components. The most common indicator of torsional vibrations is an unusual rumbling or grinding noise from the gear drive at a sharply defined speed. The noise will disappear when the speed is increased or decreased. This noise is not indicative of a defect but results when the vibratory torque exceeds the drive torque causing the gear teeth to separate and clash together very rapidly. On variable frequency applications, avoid operation close to a resonant speed by locking out resonant frequency ranges.

• At start-up, increase the variable frequency drive from 0 RPM to maximum motor speed. Gradually increase the speed and observe the unit for the onset of any unusual rumbling or grinding at specific speeds. These resonant speeds (+/- 10%) should be “locked out” by the variable speed drive. Continuous operation at resonant speeds can result in fan failure and possible personal injury or damage.

• Please refer to the manufacturerʼs variable frequency drive recommended start-up procedure for further information or consult with your local BAC Representative for any VFD applications. For projects with BAC controls, visit www.BaltimoreAircoil.com.

N101...because temperature matters™

C o m m o n

S ec ti o n

N102 Baltimore Aircoil Company

Remote Sump Application The water level in the basin of the equipment designed for remote sump operation is a function of the circulating water flow rate; water outlet connection size, quantity and location, and outlet piping size and configuration. The remote sump unit is supplied without a water make-up assembly, and the basin operating level during remote sump operation is fixed.

Cold Weather Operation BAC products can be operated at subfreezing ambient temperatures provided proper operating methods are established and diligently followed.

Inspection and Maintenance

• Carry out the frequent visual inspections and routine maintenance services during operation in subfreezing weather.

• Ensure all controls for capacity and freeze protection are set properly and functioning normally.

• Prevent excessively high water levels and possible overflow of the cold water basin due to over pumping, clogged strainers, or make-up valve malfunction.

• Resolve any icing condition that may severely develop to damage the unit or the supports or impair the system performance.

Fan Section Icing Protection There are three basic operational methods which can be used to provide the systemʼs required cooling:

Temperature Setting, Fan Control, and Dry Operation*. The method of controls employed on a given application depends upon the climatic extremes which are expected, the variations in heat load that will be encountered, and the compatibility of the control system with other portions of the installation. Effective icing control in subfreezing ambient conditions will require a combination of these three methods.

*NOTE: Dry Operation applies only to closed circuit cooling towers and evaporative condensers.

Temperatur e Sett ing Low leaving fluid temperature promotes ice formation. During operation in subfreezing ambient temperatures, maintain the leaving fluid temperature as high as possible. Ensure the unit operates with the maximum possible heat load. The recommended minimum fluid temperature is:

• 43°F (6.1°C) for Crossflow Cooling Towers

• 42°F (5.5°C) for Counterflow Cooling Towers

• 50°F (10°C) for Closed Circuit Cooling Towers with water (non-glycol)

• 45°F (7.2°C) for Closed Circuit Cooling Towers with glycol

Fan Cont rol Reduce the unit capacity by cycling fans thus modulating the airflow through the unit. Rapid on-off cycles can cause the fan motor to overheat. Set the controls to allow a maximum of 6 on-off cycles per hour. Periodically, cycle the fans off to prevent ice formation and/or to melt ice that accumulates on the intake louvers or combined inlet shields and face of the fill.

Fan Cycli ng: Operate each unit with the highest thermal load it can handle, rather than evenly dividing the total heat load across all cells. During prolong periods, bypass the idle units and drain the basins.

Multi-Speed Motor s: If the unit is equipped with 2-speed motors or BALTIGUARD™/BALTIGUARD PLUS™ Fan System, operation at a lower speed may be sufficient to prevent icing. When 2-speed motors are used, the motor starter should include a minimum 15 second time delay when switching from high to low speed.

Variable Freque ncy Drives: VFDs offer the most precise method of capacity control, by modulating fan motor speed. When using VFDs, avoid operating at or near “critical speeds.” Units with VFDs require inverter duty motors.

In subfreezing ambient temperatures, cycle the fan off for 5 minutes every 15 to 20 minutes for each cell. If ice continues to build on the louvers, decrease the on-time. Observe inlet louvers of the towers every 4 to 8 hours.

era tio n

M a in ten a n ce M a n u a ls

N103...because temperature matters™

NOTE: Modulating the water flow rate to the unit is NOT a recommended method of controlling cooling capacity.

Dry Operation (for Models VF1, VFL, VC1, VCA, VCL, and HXV) One method of protecting fans from icing is dry operation. Dry operation of the closed circuit cooling tower or evaporative condenser protects fans from ice formation due to mist and splash from the cold water basin.

Coil Freeze Protection Use an industrial grade inhibited glycol solution for protection against coil freeze-up. When the use of glycol is not practical, the system must be designed to meet both minimum flow and minimum temperature requirements.

• Recommended solutions are an industrial grade inhibited ethylene glycol or propylene glycol solution.

• The Product & Application Handbook provides the coil volumes for Models FXV, HXV, VF1, and VFL. Coil volume for CXV, VC1, VCL, and VCA condenser models using liquid cooling circuits is job specific.

Minimum Operation When a glycol solution is not utilized, operate the system to meet both of the following conditions.

• Maintain the minimum recommended flow through the coil at all the times (see Table 5).

• Maintain a minimum heat load on the circulating fluid so that the temperature of the fluid leaving the coil will not fall below 50°F (10°C).

• To maintain the leaving fluid temperature at 50°F (10°C) when the process load is extremely light or shut off, apply an auxiliary heat load to the circulating fluid.

Table 1: Minimum Coil Flow

Positive Closure Damper Hood and Insulation The amount of auxiliary heat required can be substantially reduced by the use of a positive closure damper hood and insulation. The heat loss data can be found in the corresponding product section of this handbook.

Emergency Coil Drain Do not drain the coil as a normal method of freeze protection. Frequent draining promotes corrosion inside the coil tube. However, draining is acceptable as an emergency method of freeze protection if the coil is not protected by a glycol solution. If the coil is not protected, an automatic drain valve and vacuum breaker are recommended to drain the coil if flow stops or fluid temperature drops below 50°F (10°C) when the ambient temperature is below freezing.