BAC Custom Engineered Controls Product Detail Product Introduction......................................... K2 BAC Custom Engineered Controls Benefits.................................................... K4 Construction Details......................................... K6 Custom Features & Options................................... K8 Engineering Specifications.................................. K13 K1
K2 Spotlight
Combined Drive Enclosure Baltilogic Sequencing Software and Cover Controls Factory Start-up Factory Mounted Terminal Box K3
Benefits BAC Controls Single Source Responsibility BAC has designed the controls taking into consideration the exact specifications of the fan and spray pump motors, heaters and other accessories, providing you with a single source solution. Indoor/Outdoor Applications BAC offers a variety of enclosures for location flexibility; whether in a mechanical equipment room or outside next to the equipment. Products Indoor Rated NEMA 12 NEMA 1 (Dust Tight) NEMA 3R (Rainproof) Combined Drive Enclosure VFD Combined Drive Enclosure Enclosure Type Outdoor Rated NEMA 3R (Rainproof, SST) NEMA 4 (Watertight) NEMA 4X (Watertight, SST) Enclosed Control Safety Disconnect Switch Terminal Box Industrial Grade Components IEC contactors are provided with all BAC combined drive enclosures. NEMA contactors are provided with all BAC standard enclosed controls (25 amps and above). Circuit breaker protection is provided for the main panel as well as separate circuit breakers for each motor. For multi-speed motors, additional circuit breakers are provided. Each control panel is UL/CSA or UL/CUL rated. K4 Baltimore Aircoil Company
Easy Installation Combined Drive Enclosures incorporate the VFD into the controls enclosure, offering a standardized, compact single enclosure, pre-wired for a single-point field connection. The fan motors, spray pump motors and other electrical accesories must be powered separately. Optional universal mounting kits and factory pre-wired unit mounted terminal boxes are also available for ease of panel mounting and field wiring. Contact your local BAC Representative for availability. Energy Standard Compliance BAC Controls can help you comply with the speed control requirements of current energy standards such as ASHRAE Standard 90.1 and California Title 24. These standards require all motors 7.5 HP and above to have the ability to run at 2/3 or less of full speed. BAC offers many alternatives to comply with this requirement, depending on your unique system needs. These methods include variable frequency drives, the BALTIGUARD and BALTIGUARD PLUS Fan Systems, or multi-speed motors. The automatic motor speed control requirements of these standards can be satisfied through the controllers and temperature/ pressure sensors available with BAC Controls for any of these methods. BAC Factory Temperature/Pressure Sensor BAC temperature and pressure sensors are factory tested and approved for compatability with all BAC Control devices. High quality sensors provide accurate signals offering precise system control. Proper system control is crucial to operating your system at peak efficiency under all combinations of atmospheric and load conditions. Using a BAC provided sensor ensures reliable operation and peak efficiency for the life of your unit. VFD with Pre-wired Terminal Box BAC Factory Temperature Sensor BAC Custom Engineered Controls...because temperature matters K5
BAC Controls Construction Details Combined Drive Enclosure: 1 2 3 4 5 6 7 8 9 10 11 Main Disconnect Switch with Circuit Breaker Easily re-settable Lockable operator handle VFD Keypad/Baltilogic Sequencing Software Standard keypad with Hand-Off-Auto & Bypass Monitors Fan Speed, Actual Temp/Pressure or Set-point Water Temp/Pressure Ready, Run and Fault lights BALTILOGIC Sequencing Software controls and stages all components Eliminates need for temperature controller (Programmable Logic Controller) 24VDC Power Supply 24VDC power supply ensures redundancy Space Heater Maintains minimum operating temperature inside panel Thermostat control Power supplied by line voltage 3-Contactor Bypass Bypass VFD to across the line power No downtime during VFD replacement 120V Transformer Provides 120V, single-phase control circuit power Power available for accesories Factory Pre-wired Teminal Strip Single point connection for all accessory interfaces 120V power supply terminal Includes all VFD termination points Standardized terminal locations Auxillary Fan Motor Starter Full voltage, non-reversing IEC Rated starter Supports main or pony fan Spray Pump Motor Starter(s) Full voltage, non-reversing IEC Rated starter WET/DRY Operating Mode Supports up to 2 spray pump motors Basin Heater Contactor(s) Standard ground fault protection Supports up to 2 basin heaters Cover Controls Hand-Off-Auto switches for fans and pumps Pilot lights for accesory interfaces Remote fault reset button 2 4 5 Combined Drive Enclosure (NEMA 3R Shown) 3 8 9 6 10 1 7 11 Combined Drive Enclosure Front Panel (NEMA 3R Shown) K6 Baltimore Aircoil Company
Standard VFD: 1 2 3 4 5 6 Main Disconnect Switch with Circuit Breaker Easily re-settable Lockable operator handle Adjustable instantaneous trip point Ventilation Hood Required for NEMA 3R Drives VFD Keypad/Keypad Connector Standard keypad with Hand-Off-Auto & bypass Monitors fan speed, actual temp/pressure or set-point water temp/pressure Ready, run and fault lights Multi-monitor display RS-232 connection provides compatibility interface with a PC to troubleshoot or reprogram the VFD 24VDC Power Supply 24VDC power supply ensures redundancy Space Heater Maintains minimum operating temperature inside panel Thermostat control 3-Contactor Bypass Bypass VFD to across the line power No downtime during VFD replacement Standard Enclosed Controls: 1 2 3 4 5 Main Disconnect Switch with Circuit Breaker Lockable operator handle 120V Transformer Provides 120V, single-phase control circuit power from high voltage, three-phase supply (from 200-575V) Switches, Pilot Lights & Buttons Hand-Off-Auto switches for pumps, fans and basin heaters Vibration cutout switch remote reset button Auxilliary Fan Motor Starter Full voltage, non-reversing starter NEMA rated starters (25A and above) IEC rated starters (25A and below) Temperature Controller/Operator Interface Externally mounted controller interface monitors and adjusts desired parameters. (See Combined Drive Enclosure section on page K8 to eliminate need for temperature controller). 5 2 4 1 3 5 6 Standard VFD - (NEMA 3R shown) 2 1 3 4 BAC Custom Engineered Controls Standard Enclosed Controls - (NEMA 12 shown)...because temperature matters K7
Custom Features & Options BAC Controls Combined Drive Enclosure (CDE) Combined Drive Enclosure incudes Baltilogic sequencing software that is preprogrammed into the VFD to offer temperature based control of auxillary fan motors (BALTIGUARD PLUS ). Baltilogic sequencing software also controls the spray pump starters, basin heaters, vibration cutout switches, electronic water level control, and positive closure dampers. The combined drive enclosure is UL508A/CUL rated. Baltilogic Sequencing Software: Simplified user interface allows quick and easy access to commonly adjusted parameters. Incorporates updated start-up wizard to aid in field start-up. Combined Drive Enclosure Cover Controls: Easy to follow operator logic. Complete auto control mode. Hand mode for manual operation. BAC Factory Start-up: Ensures successful configuration and operation of BAC VFDs and Controls. Extends standard two year (parts only) to three year warranty (parts and labor). Combined Drive Enclosure Cover Controls Standard VFD includes an enclosure, 24VDC power supply, main circuit breaker, disconnect switch with lockable operator handle, 3-contactor bypass, modular cooling fan and a detachable, programmable VFD keypad. The standard VFD is UL508C/CSA rated. 3-Contactor Bypass is standard on all BAC drives. The input contactor electrically isolates the drive during bypass operation. The output and bypass contactors are mechanically interlocked to regulate power to the fan motor. The bypass allows for 100% fan speed operation back-up if the drive is not functional for any reason. Multi-monitor Display with Baltilogic Sequencing Software K8 Baltimore Aircoil Company
Standard Enclosed Controls BAC controls, designed with the highest grade components, are packed with operation-friendly features to ensure a long life expectancy and lower life cycle costs. The modular design of BAC panels allows for consistency across projects and simplifies upgrades or future replacements, yet can be customized to meet your particular application. The enclosed controls are UL 508A listed and CUL certified and are provided with a standard one year warranty (parts only). Standard Panel with Auxillary Fan Motor Starter(s) includes an enclosure, control power transformer, main circuit breaker, disconnect switch with lockable operator handle, hand-off-auto switch, run pilot lights for each starter, and full voltage, non-reversing starter with overload relay and double-break silver alloy contacts. (If fan requires reverse operation, use a VFD in lieu of a fan motor starter.) Circuit Breaker Protection allows for quick reset and is standard for all BAC control panels. The main circuit breaker is sized for the maximum current draw for the panel configuration. Each fan motor starter includes individual branch circuit protection. Safety Disconnect Switches Since control panels can be installed indoors, NEC Article 430-102b requires a disconnect switch located within sight of the motor and the driven machinery location. BAC safety disconnect switches are rated for 600 VAC and sized specifically for the current draw of the components. The safety disconnect switches are UL E239 listed and CSA certified and are provided with a standard one year warranty (parts only). Standard Panel With Auxillary Fan Motor Starter BAC Custom Engineered Controls Standard Safety Disconnect Switch meets the NEC requirements and includes an enclosure, knife blade style contacts, door lock provision, interlock, ground lug and a clear line shield. NEMA 4X Safety Disconnect Switch...because temperature matters K9
Options Vibration Cutout Switch Interface includes wired interlock to the fan motor starter, provisions for an alarm contact/light, and a remote fault reset button outside the panel. BAC Controls Electric Water Level Control Interface includes wired interlock to the solenoid make up valve and can include a provision for high and low level alarms, along with a low water cutout. Communications Cards (for VFDs) can be provided when a Building Automation System is used. BAC offers Modbus, Lonworks, Johnson N2, BACNet, and Siemens cards. Baltilogic Sequencing Software has been developed for typical applications including BALTIGUARD and BALTIGUARD PLUS Fan systems. The BAC Start-up Wizard guides the operator step-by-step through the required parameters and useful settings. Baltilogic includes temperature controller logic to control auxillary fans and pumps without a seperate temperature controller (PLC). NEMA 1 VFD with Multi-Monitor Display and Custom VFD Software Start-up (Commissioning for VFDs) is available to ensure successful configuration and operation of BAC drives. Completion of factory authorized start-up extends the standard two year (parts only) to three year warranty (parts and labor.) Fan Motor Starters are available for one speed/one winding; two speed/one winding; two speed/two winding or main/pony motor configurations such as the BALTIGUARD Fan System. Spray Pump Motor Starter(s) include full voltage, nonreversing starter with overload relay and double-break silver alloy contacts, in addition to a Hand-Off-Auto switch. Basin Heater Controls are equipped with definite purpose contacts, a resettable circuit breaker, ground fault protection, Hand-Off-Auto (HOA) switch, and pilot light. Basin heater controls include Ground Fault Interrupt Protection as required by NEC Article 427. Basin Heater Controls with Ground-Fault Protection K10 Baltimore Aircoil Company
Positive Closure Damper Interface provides line power and includes wired interlock to the fan motor starter. Standard Enclosed Controls Temperature/Pressure Controller sequences multiple devices such as: VFD(s), auxillary fan starter(s), heater(s), spray pump(s), damper(s) based on a factory programmed sequence of operation. (Combined drive enclosure includes integral temperature/ pressure control logic in the Baltilogic sequencing software; a seperate controller (PLC) is not required.) Externally Mounted Factory Pre-wired Terminal Box (Currently available on Series 3000, PT2, and VCA models) All wiring for the fan motor(s) and vibration cutout switch leads are pre-wired from the factory and terminated on the outside face of the BAC unit in a clearly marked terminal box. This feature saves installation labor required to run conduit and wiring to the motor and vibration cutout switch, while saving material costs for the internal conduit, wire, couplings and hardware. The externally mounted terminal boxes are UL 1773 listed and CSA certified. The externally mounted terminal boxes are provided with a standard five year warranty. The Terminal Box includes a factory-mounted enclosure, factory wiring to terminal blocks for the fan motors and vibration cutout switches, and grounding lugs. Pre-wired in factory for unit acccesories Ships factory mounted to unit Eliminates field casing penetrations reducing possibility of leaks and corrosion. Factory Wiring to the Fan Motor and Vibration Cutout Switch to the Terminal Blocks BAC Custom Engineered Controls Series 3000 Factory Mounted Terminal Box...because temperature matters K11
Energy Savings and Reliability BAC Controls Variable Frequency Drives (VFDs) VFDs offer many benefits including: Precise leaving fluid temperature control provides a more efficient method to vary airflow compared to fan cycling, fan dampers, or mechanical speed changers. Soft-starts, stops, and smooth accelerations prolong the mechanical system (fans, motors, belts, bearings, etc) life while reducing maintenance. The soft-start feature minimizes start-up noise and smooth acceleration making the tower sound less noticeable to the neighbors. Reduces wear on the motor. The standard VFDs are UL 508C listed and CSA certified and are provided with a standard two year parts warranty. The combined drive enclosures are UL 508A listed and CUL certified. With factory certified start-up, parts warranty is extended to three years and includes a three year labor warranty. NEMA 3R VFD BALTIGUARD PLUS TM Fan System The BALTIGUARD PLUS Fan System builds on the advantages of the BALTIGUARD Fan System by adding a VFD to either the pony or the main motor, depending on system requirements. This offers the benefits of additional capacity control and energy savings, along with the redundancy offered by the BALTIGUARD Fan System. Alternatively, a VFD can be added to BOTH the pony and main motor, for complete capacity control and redundancy under any load. BALTIGUARD Fan System K12 Baltimore Aircoil Company
Engineering Specifications See our website at www.baltimoreaircoil.com for an electronic copy of product engineering specifications. 1.0 Equipment Controls (Optional) 1.1 Combined Drive Enclosure (Variable Frequency Drive with Accessory Control Devices): A UL 508A/CUL listed Combined Drive Enclosure (CDE) panel shall be provided for each cell of the evaporative cooling equipment. The CDE panel shall include a variable frequency drive (VFD) for fan motor control, [a full voltage, non-reversing (FVNR) auxiliary fan motor starter], [(a) full voltage, non-reversing (FVNR) spray pump motor starter(s)], [(a) basin heater contactor with Earth Leakage Breaker containing ground fault protection and resettable short circuit protection], [electric water level controls power with low water cutout, [high level alarm], [low level alarm], [high and low level alarms], [Positive closure damper power and interface], [Electronic (Mechanical) Vibration cutout switch interface with local reset, [remote reset], [alarm contact], [delay]]. The VFD portion shall include factory programmed digital output cards with software that sequences the included tower components. External programmable logic controllers or temperature controllers (thermostats) shall not be acceptable. The VFD operating software shall incorporate a start-up wizard to aid in field start-up. The VFD shall have a 3-contactor bypass, 3% input line reactor, a removable keypad, an RS232 terminal for PC connection, drive current rating of 100 kaic, bypass rating of 36 kaic, and 500,000 hours of MTBF. The VFD shall be compatible with a [ModBus] [LonWorks] [Johnson N2] [BACNet] [Seimens] Building Automation System. The CDE panel shall use a main circuit breaker disconnect and separate circuit breakers for each motor/speed. Fuse protection shall not be acceptable. Starters shall be IEC rated. Panel shall include a 120V/60Hz control power transformer, Hand-Off-Auto switches for fan(s) and pump(s), pilot lights for each component. CDE shall be capable of operating in full-auto mode or in manual (hand) mode via a selector switch mounted on the front of the panel. Panel enclosure should not exceed 40 in x 60 in x 20 in. [,and shall be provided with freestanding legs]. CDE shall be rated NEMA [1] [3R] [3R SST]. OR 1.1 Variable Frequency Drive(s): A variable frequency drive (VFD) shall be provided for each fan motor. The supplier of the VFD shall be the manufacturer of the evaporative cooling equipment. The VFD shall have a 3-contactor bypass, 3% input line reactor, a removable keypad, an RS232 terminal for PC connection, drive current rating of 100 kaic, bypass rating of 5 kaic, 500,000 hours MTBF and a circuit breaker disconnect. Fuse protection will not be accepted. Control voltage shall be 24V to minimize the size of the enclosure which should not exceed ft x ft x ft and the weight of the enclosure should not exceed lbs. VFD shall be provided in a UL Listed 508C NEMA [1] [12] [3R] [3R SST] enclosure. The VFD shall be compatible with a [ModBus] [LonWorks] [Johnson N2] [BACNet] [Siemens] Building Automation System. AND/OR 1.1 Enclosed Controls: An enclosed control panel shall be provided for each cell of the evaporative cooling equipment. The panel shall include full voltage, non-reversing (FVNR) fan motor and (pump motor) starters in a common enclosure. The panel shall use a main circuit breaker disconnect and separate circuit breakers for each motor/speed. Fuse protection will not be accepted. Panels containing basin heaters shall have ground fault protection and resettable circuit protection. Starters above 25 A shall be NEMA rated. IEC starters will be accepted for motors 25A and below. Panel shall include a 120V/60Hz control power transformer, Hand-Off-Auto switches for each starter or contactor, and pilot lights for each component. Enclosed controls shall be provided in a UL Listed 508A NEMA [1] [12] [3R] [4] [4X] enclosure. Optional enclosed control features: [A temperature sensor shall be provided with the enclosed controls.] [A temperature controller shall be provided with the enclosed controls.] [A basin heater contactor with circuit breaker shall be provided.] [A vibration cutout switch input shall be provided.] 1.2 Safety Switch(s): A heavy-duty, non-fusible safety disconnect switch shall be provided by the manufacturer of the evaporative cooling equipment. Switch shall be single-throw, 3- pole design, rated up to 600 VAC. Switch shall have triple padlocking capability, a visible double break rotary blade mechanism, a clearly visible On/Off handle, an interlocking mechanism to prevent door from opening with handle in the On position, and a clear line shield. Safety switch shall be provided in a NEMA 3R enclosure. BAC Custom Engineered Controls...because temperature matters K13
Externally Mounted Pre-wired Terminal Box Product Report BAC can simplify controls and unit installation by pre-wiring the fan motor(s) and vibration cutout switch(es) on Series 3000 and PT2 Cooling Towers. On the VCA, the electric water level control, basin heater(s), and spray pump(s) can be pre-wired at the factory. All wiring is terminated in a clearly marked, Type 304 stainless steel, UL Listed NEMA 3R terminal box. The power wiring only needs to be run to the controls, the terminal box and extra accessories. This option is available with BAC supplied controls. Series 3000 Terminal Box with Factory Wiring Features Include: All field wiring can be easily connected to the outside of the BAC unit Material costs (conduit, wire, couplings, hardware) associated with internal wiring are reduced Field casing penetrations are eliminated Enclosure is constructed of Type 304 stainless steel and NEMA 3R rated (rainproof and suitable for outdoor location) VCA Terminal Box with Factory Wiring K14 Baltimore Aircoil Company