Below is a general, field-proven procedure for replacing BAC (Baltimore Aircoil Company) cooling tower fill. Exact steps may vary slightly by model (VXT, Series V, FXV, FXVS, 1500 Series, etc.), but the workflow is consistent.
1. Safety & Preparation (Critical) - Bac Cooling Tower Fill Replacement Instructions
✔ Lock out / tag out fan motor and pump
✔ Drain basin to below fill support level
✔ Allow tower to cool (no hot water)✔ Use fall protection and PPE
✔ Review BAC unit drawing & serial number
> ⚠️ Never work under suspended fill packs or with fans energized.
2. Identify BAC Tower Type - Bac Cooling Tower Fill Replacement Instructions
Crossflow Towers (most BAC HVAC units)
* Fill located between hot water basins and drift eliminators
* Access through louver panels
Counterflow Towers
* Fill located below spray system
* Access from side or top panels
3. Remove External Panels - Bac Cooling Tower Fill Replacement Instructions
1. Remove air inlet louvers or access panels
2. Remove drift eliminators above fill (if required)
3. Label panel locations for reassembly
4. Inspect panel gaskets and fasteners
4. Remove Old Fill - Bac Cooling Tower Fill Replacement Instructions
1. Lift out fill pack by pack (do not force)
2. Cut heavily fouled fill into sections if necessary
3. Remove broken support bars or hold-down clips
4. Clean debris from basin and support structure
> ⚠️ Do not step directly on fill sheets—use planks or platforms.
5. Inspect & Prepare Supports - Bac Cooling Tower Fill Replacement Instructions
Check:
* Fill support beams (FRP / stainless)
* Air seals and water seals
* Hot water basin leaks (crossflow towers)
* Spray headers and nozzles (counterflow)
Repair or replace before installing new fill.
6. Install New BAC Fill - Bac Cooling Tower Fill Replacement Instructions
Key Rules
✔ Install correct BAC-specific fill geometry
✔ Observe airflow direction arrows
✔ Maintain proper pack orientation and spacing
✔ Do not mix old and new fill
Installation Steps
1. Place fill packs on support beams
2. Ensure packs sit flat—no sagging
3. Install retaining clips / hold-down bars
4. Maintain BAC-specified pack gaps
7. Reinstall Internal Components - Bac Cooling Tower Fill Replacement Instructions
* Reinstall drift eliminators
* Reinstall louvers / air inlet panels
* Check tight seals to prevent air bypass
8. Startup & Commissioning - Bac Cooling Tower Fill Replacement Instructions
1. Refill basin
2. Start circulation pump only
3. Check for **uniform water distribution**
4. Start fan
5. Measure:
* Motor amps
* Vibration
* Water splash-out
6. Inspect after 24 hours of operation
9. Model-Specific Notes (Important) - Bac Cooling Tower Fill Replacement Instructions
| BAC Model | Fill Notes |
| VXT | Modular PVC film fill, louver access |
| Series V | Film fill with precise pack alignment |
| FXV / FXVS | Often uses splash fill |
| 1500 Series | Larger packs, heavier supports |
10. Common Mistakes to Avoid - Bac Cooling Tower Fill Replacement Instructions
❌ Installing fill upside-down
❌ Ignoring airflow direction
❌ Stepping on fill sheets
❌ Skipping water distribution inspection
❌ Reusing damaged supports
11. Typical Replacement Interval - Bac Cooling Tower Fill Replacement Instructions
* PVC fill: 8–12 years (HVAC)
* PP fill: 10–15 years (industrial)
* Depends heavily on water treatment
Tools Required
* Hand tools (socket set, screwdrivers)
* Safety harness
* Utility knife (for removal only)
* Lift equipment (large towers)
* BAC unit drawing
