Breezaire RPX900D User Manual
RPX900D
INDUSTRIAL
EVAPORATIVE
AIR COOLERS
Assembly
Instructions
A
dvanced natural cooling
RPX ASSEMBLY INSTRUCTIONS
INDEX
Description Page
Index 2
Important Notice/ Tools required 3
Installing Fan Housing to Tank 1/5 5
Installing Top Channel 10
Sealing Fan Housing to Tank 1/2 11
Sealing Fan Housing to Tank Bottom 13
Prepare Motor and Controls 1/4 14
Fan Pulley Attachment 18
Fit and Tension V Belts 19
Fitting the Water Pumps 20
Connecting the Water System 21
Corner Pillar Installation 22
Centre Rail Installation 23
Top Rail Installation 1/2 24
Bottom Rail Installation 26
Centre Pillar Installation 27
Water Spreader Installation 28
Distributor Cap Installation 29
Water Distributor Connection 1/2 30
Installing Cab Top Blanking Cover 32
Cabinet Top Installation 1/2 33
Squaring the Cooler 35
Cabinet Top Final Assembly 1/3 36
Final Riveting 39
Installing the Bleed Tap 40
Clean and Test Cooler 41
Washer Part Numbers 42
Bolt and Nut Part Numbers 43
Screw and Rivet Part Numbers 44
Panel Part Numbers 45
Miscellaneous Part Numbers 1/2 47
Special jig securing Flashing Angle 49
RPX 900 D Kit 1/2 50
RPX 900 D&T Pallet Specifications. 52
RPX 900 T Exploded View 53
3 Phase Wiring Diagram 54
2
RPX ASSEMBLY INSTRUCTIONS
IMPORTANT NOTICE
The assembly of evaporative air conditioning units has the potential to create Occupational Health and Safety issues
for those involved. Assemblers are advised to ensure they are familiar with relevant State and Federal legislation, such
as Acts, Regulations, approved Codes of Practice and Relevant Standards, which offer practical guidance on these health
and safety issues. Companies with these regulations will require appropriate work practices, equipment, training and
qualification of workers.
Note:
Stainless steel bolts and nuts are used in the assembly of coolers.
A thread lubricating compound anti seize should be used at assembly.
(Anti Seize not supplied)
Tools Required
Pneumatic Drill. Pneumatic Driver.
Pneumatic Riveter
Long nose type.
3
Pneumatic Silicone
Applicator.
RPX ASSEMBLY INSTRUCTIONS
Tools Required cont.
Screwdriver No3. Spanners 10 and 13mm
Hex Key 4mm. Hex Key 5mm.
Metal twist drill 5mm Metal twist drill 6.5mm
Metal twist drill 12.5mm. Pliers.
4
RPX ASSEMBLY INSTRUCTIONS
Installing Fan Housing to Tank. Step 1 of 5.
Select Base Frame and Tank Assembly
for Down discharge model.
2
1
Place supplied
Template to
top of Tank.
Align holes with
3
template bolts.
4
Mark with text pen, inside
edge of template.
Remove template, place
20 mm hole saw to 6mm
hole and drill through.
Total four.
5
5
Drill 6 mm hole to corners
of template. Total four.
6
Use Jig saw and cut
along marked line.
RPX ASSEMBLY INSTRUCTIONS
Installing Fan Housing to Tank. Step 2 of 5.
Installing Base Channels.
Tank to accept square
end of Fan Housing.
Place Base Channels on
Base Frame Assembly.
R/H Base Channel
Part No 623160.
L/H Base Channel
Part No 627168.
Base Frame Assembly.
Note:
Position of Base Channel
to Base Frame Assembly
Insert holes for motor
platform nearest to drain hole.
Drain Hole.
Align Base Channel holes
with Base Frame holes.
6
RPX ASSEMBLY INSTRUCTIONS
Installing Fan Housing to Tank. Step 3 of 5.
All holes and fasteners will need to be sealed to ensure
there are no water leaks outside the cooler.
"Virginia" Sealing Putty has been supplied for this task.
Place Sealing Putty to
Base Frame Assembly.
Clear hole before fitting
channel.
Base Frame Assy.
Secure Base Channel to Base Frame.
At this stage do not fully tighten bolts.
Refer to notes on Page 17.
BOLT NUT WASHER
M8x30 M8 8x19mm
P/N0 628257 P/No 628288 P/No WAS163
Repeat process for other ends of Base Channels.
7
RPX ASSEMBLY INSTRUCTIONS
Installing Fan Housing to Tank. Step 4 of 5.
Use lifting crane to raise
Fan Housing and H-Frame
Assembly over Base Frame
Assembly.
Align and lower
bottom of fan housing
to Tank cut out.
Align bottom hole of
vertical channel to
Base channel holes.
Secure Vertical Channel to Base Channel
H-Frame Vertical Channel.
BOLT NUT WASHER
M8x20 M8 8x19mm
P/N0 628240 P/No 628288 P/No WAS163
Note: 2 Bolts, 4 Washers and
2 Nuts per vertical Channel.
Base Channel.
8
Repeat process for other three vertical channels.
RPX ASSEMBLY INSTRUCTIONS
Installing Fan Housing to Tank. Step 5 of 5.
Securing Base Channel to Fan Housing.
Secure Base Channel
to Fan Housing.
Fix two Screws between
Fan Housing and Base
Channel.
SCREW - Phlp.
6x25 mm
P/No SCR 384
SPIRE NUT - P/No FAS115.
Fit Spire Nut to
end of Screws.
Inside of Fan Housing.
Note: The Spire Nut can
be fitted when Fan
Housing assembly is tilted.
Refer to notes on Page 13.
Repeat process for opposite side.
9
RPX ASSEMBLY INSTRUCTIONS
Installing Top Channel.
Install Top/Bearing
Channel to Vertical
Channels.
Part N/o 623139
Secure Channels.
Tighten all bolts.
BOLT NUT WASHER
M8x20 M8 8x19mm
P/N0 628240 P/No 628288 P/No WAS163
Repeat process for
other end.
10
Repeat process for opposite side.
RPX ASSEMBLY INSTRUCTIONS
Sealing Fan Housing to Tank. Step 1 of 2.
Apply a generous bead of
silicone sealant along
Fan Housing and Tank.
Fan Housing
Tank
FAN
HOUSING
FLASHING
ANGLE
SILICONE
TANK
Illustrated
assembly view.
Apply silicone sealant bead
to Flashing Angle.
Flashing Angle
P/No 100152
Place Flashing Angle
to Fan Housing and Tank.
11
RPX ASSEMBLY INSTRUCTIONS
Sealing Fan Housing to Tank. Step 2 of 2.
Secure Flashing
Angle to Fan Housing
and Tank, with supplied
screws: Total 10 places.
SCREW - Phlp.
4x25 mm
P/No SCR506
Note: If end of fan housing
bows inwards and cannot
be easily fixed, a special
clamp can be utilised to
aid fixing. P49 has details
to enable manufacture
of clamp.
12
Apply additional silicone
to top and bottom
edge of Flashing Angle.
Check that silicone
has a good seal to
Fan Housing and Tank.
Smooth out silicone to
give neat appearance.
Repeat Steps1&2foropposite side.
RPX ASSEMBLY INSTRUCTIONS
Sealing Fan Housing to Tank Bottom.
Use crane to tilt cooler.
Silicone sealant
between Fan Housing
and Tank,
apply thick bead to
all four sides.
Fit spire nut to ends
of screws.
Refer to notes on Page 9.
SPIRE NUT - P/No FAS 115.
Use crane and
raise cooler to
up right position.
13
RPX ASSEMBLY INSTRUCTIONS
Prepare Motor and Controls. Step 1 of 4.
Place Motor Platform to a
suitable work bench.
Note: Control box
mounting holes.
Place Control Box and
water pump assembly to
motor platform.
14
Securing Control Box
panel to Motor Platform.
BOLT NUT WASHER
M6x20 M6 6x14mm
P/N0 628226 P/No 628271 P/No WAS029
RPX ASSEMBLY INSTRUCTIONS
Prepare Motor and Controls. Step 2 of 4.
Use crane and fit electric
motor to platform,
align holes and
secure with
supplied fasteners.
15
Secure Motor to Platform.
BOLT NUT WASHER
M8x30 M8 8x19mm
P/N0 628257 P/No 628288 P/No WAS163
Repeat for all 4 motor mounting bolts.
Ensure motor is square to Platform.
Tighten all bolts.
RPX ASSEMBLY INSTRUCTIONS
Prepare Motor and Controls. Step 3 of 4.
Feed seven wires from the electrcal control box wiring
loom through the motor terminal cover opening.
Attach all wires and secure motor terminal cover.
Motor terminal cover.
Wiring loom to
electrical control box.
Gland
Wire connection.
For low speed connect.
Wire, tag numbered 1 to U1
2to V1
3toW1
For high speed connect.
Wire, tag numbered 4 to W2
5toU2
6toV2
Connect earth wire to motor casing earth point.
Cable tie wire loom
to Motor Platform.
16
RPX ASSEMBLY INSTRUCTIONS
Prepare Motor and Controls. Step 4 of 4.
Motor Pulley Attachment
The motor pulley attaches
to the motor shaft via a
Taper Lock Bush screwed
to the Pulley.
Do not fully tighten Bush
locking screws now, Pulley
may need to move on shaft
to align V-Belts.
Use crane to install
Motor Platform to
Base Channels.
Base Channel.
Secure Motor Platform to
Base Channels.
BOLT WASHER
M8x30 8x25mm
P/N0 628257 P/No 627984
At this stage do not fully
tighten. Refer to notes
Belt Tension, P19.
17
Repeat same for
opposite side.
Note:
Fully tighten all Bolts securing
Base Channel to Base frame.
Loading...