CaptiveAire CELDEK Installation Manual

Standard and

CELDEK

Evaporative Cooler

Modules

Installation, Operation, and Maintenance Manual

Save these instructions

RECEIVING AND INSPECTION

WARNING!!

Standard Evaporative Cooler

Upon receiving unit, check for any interior and exterior damage, and if found, report it
immediately to the carrier. Also check that all accessory items are accounted for and are
damage free.

CELDEK Evaporative Cooler

Installation of this module should only be performed by a qualified professional who has read
and understands these instructions and is familiar with proper safety precautions. Improper
installation poses serious risk of injury due to electric shock, and other potential hazards.
Read this manual thoroughly before installing or servicing this equipment. ALWAYS
disconnect power prior to working on module.

. This document is the property of the owner of this equipment and is
required for future maintenance. Leave this document with the owner when installation or
service is complete.

November 2010 Rev. 12

A0011028

TABLE OF CONTENTS

WARRANTY ............................................................................................................................................ 3

INSTALLATION ....................................................................................................................................... 4

Mechanical .......................................................................................................................................... 4

Site Preparation .............................................................................................................................. 4

Assembly ........................................................................................................................................ 4

Roof Mount Installation .................................................................................................................... 5

Indoor (Inline) Installation ................................................................................................................ 6

Electrical ............................................................................................................................................. 6

Copper Wire Ampacity .................................................................................................................... 6

Freeze Protection ............................................................................................................................ 7

OPERATION ........................................................................................................................................... 8

Timer Settings: .................................................................................................................................... 8

Nozzle Replacement: ........................................................................................................................ 10

Start Up ............................................................................................................................................. 12

Special Tools Required ................................................................................................................. 12

Start Up Procedure ....................................................................................................................... 12

Component Description/Detail ....................................................................................................... 13

Electrical Cabinet Detail:.................................................................................................................... 13

Units with Freeze Protection Option: .................................................................................................. 13

3-way Solenoid Valve Detail (Field Installed under Roofline): ............................................................. 13

Troubleshooting ................................................................................................................................ 14

Troubleshooting Chart ................................................................................................................... 14

MAINTENANCE .................................................................................................................................... 15

General Maintenance ........................................................................................................................ 15

Every 3 months ................................................................................................................................. 15

Yearly................................................................................................................................................ 15

Cooling Media Size and Quantity ................................................................................................... 15

Start-Up and Maintenance Documentation ........................................................................................ 16

Evaporative Cooler Information ..................................................................................................... 16

Maintenance Record ..................................................................................................................... 16

Factory Service Department .......................................................................................................... 16

November 2010 Rev. 12

A0011028

WARRANTY

This equipment is warranted to be free from defects in materials and workmanship, under normal use and
service, for a period of 12 months from date of shipment. This warranty shall not apply if:

1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation
instructions shipped with the product,

2. The equipment is not installed in accordance with federal, state and local codes and regulations,

3. The equipment is misused or neglected,

4. The equipment is not operated within its published capacity,

5. The invoice is not paid within the terms of the sales agreement.

The MANUFACTURER shall not be liable for incidental and consequential losses and damages
potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be
defective in material or workmanship within the 12-month warranty period, upon examination by the
MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The
BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall
not be returned without MANUFACTURER’S prior authorization and all returned equipment shall be
shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.

3

INSTALLATION

Condui

Evaporative

Equipment

Screen

Drain Trap

Liquid

It is imperative that this unit is installed and operated with the designed airflow and electrical supply in
accordance with this manual. If there are any questions about any items, please call the service
department at 1-866-784-6900 for warranty and technical support issues.

Mechanical

WARNING: DO NOT RAISE VENTILATOR BY THE INTAKE HOOD, FILTER
TRACKS, OR PIPING – USE LIFTING LUGS PROVIDED OR A SLING

Site Preparation

1. Provide clearance around installation site to safely rig and lift equipment into its final position.
Supports must adequately support equipment. Refer to manufacturer’s estimated weights.

2. Consider general service and installation space when locating unit.

3. Do not allow air intake to face prevailing winds. Support unit above ground or at roof level high
enough to prevent precipitation from being drawn into its inlet. The inlet must also be located at
least 10 feet away from any exhaust vents.

Assembly

There are several items shipped
loose with the evaporative coolers.
These items include the drain trap
components, sheet metal screws,
nuts and bolts, screen intakes (for
outdoor installations), equipment
legs (for outdoor installations), and
hanging cradles (option for indoor
applications). Upon unit arrival,
follow the following procedure to
assemble the evaporative cooler:

1. Attach the evaporative
cooler to the ventilator or
duct using the sheet metal
screws and nuts and bolts
included. Ensure that there is a liquid tight seal formed between the evaporative cooler and the
ventilator.

2. Screw the flanges of the intake screen to the unit with the supplied sheet metal screws. (Outdoor
installations only)

3. Fans designed for outdoor installation are provided with adjustable equipment legs. The
adjustable legs should be used to support and level the front end of the evaporative cooler.

Ventilator

Curb

Tight

Liquid

Conduit

Tight

Assembly

Cooler

Intake

Legs

4

Plumbing Connections

There are two field plumbing connections required for proper
evaporative cooler operation. It is recommended that all
plumbing connections be sealed with Teflon tape or pipe
dope. Use care not to contaminate the interior surfaces of
the water lines when plumbing the unit, as small particulate
can clog the orifices of the spray nozzles.

1. The P-Trap drain should be attached underneath the
cooler (hardware is provided and drain is installed).
The trap is important for two reasons. First, it can be
piped to drain in the most convenient area. Second,
it keeps air from being drawn through the drain hole
in the bottom of the pan, impeding drainage.

2. Pipe the main water supply line (50 psi. max.) to
quick seal on the bottom of the unit. Install a strainer
with sediment trap on the water inlet. It is highly

recommended that a water-softener be installed
up-stream of the unit to extend cooling media life
and prevent scale build-up in unit.

Roof Mount Installation

5

Indoor (Inline) Installation

WARNING!!

Electrical

Before connecting power to the module, read and understand
the entire section of this document. As-built wiring diagrams
are furnished with each module by the factory, and are
attached either to the door of the unit or provided with a
paperwork packet.
Electrical wiring and connections should be done in
accordance with local ordnances and the National Electric
Code, ANSI/NFPA70. Be sure the voltage and phase of the
power supply and the wire amperage capacity is in accordance
with the unit nameplate. For additional safety information refer
to AMCA publication 410-96, Recommended Safety Practices

for Users and Installers of Industrial and Commercial Fans.

1. Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch or
breaker to prevent accidental power up.

2. An electrical drop containing the line voltage power
wiring is shipped with every evaporative cooler. The
electrical drop should be brought through one of the
conduit openings located in the front of the module and

Disconnect power before
installing or servicing module.
High voltage electrical input is
needed for this equipment. This
work should be performed by a
qualified electrician.

Copper Wire Ampacity

Wire Size AWG Maximum Amps

14 15
12 20
10 30

8 50
6 65
4 85

6

connected to an appropriate power source.

3. Make certain that the power source is compatible with the requirements of your equipment. The
evaporative cooler wiring schematic identifies the proper phase and voltage of the equipment.

4. Before connecting evaporative cooler to power source, verify power line wiring is de-energized.

5. Secure the power cable to prevent contact with sharp objects.

6. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot
surfaces or chemicals.

7. Before powering up the evaporative cooler make sure that the interior of the unit is free of loose
debris or shipping materials.

8. If any of the original wire supplied with the cooler must be replaced, it must be replaced with type
THHN wire or equivalent.

Freeze Protection

On units shipped with the optional freeze protection drain kit, additional field wiring and piping is required.
A 3-way water solenoid is provided; containing a normally open and a normally closed valve, and should
be installed below the roof line and be wired and piped as shown to the right. Additional details on how
to install this 3 way solenoid valve are included in the “Component Detail” section of this manual.
A 2-stage thermostat is also provided in the evaporative cooler when the freeze protection option is
ordered. The evaporative cooler will automatically drain when the ambient temperature falls below the
internal two stage thermostat set-point.

7

OPERATION

Prior to starting up or operating the evaporative cooler, check all fasteners for tightness. Ensure that the
cooling media is installed properly and that the interior of the cooler is free of loose debris.

The evaporative cooler is equipped with a 2 setting timer control. The LOWER 2 dials are used to denote
the length of time the manifold sprays water while the UPPER 2 dials control the amount of time between
spray periods. Both of these settings are factory set and should not have to be adjusted during initial
installation of the unit. It is important to understand that the spray timing pattern is cyclic in nature with
the manifold discharging water on and off continuously based on the timers dial settings. Both the
standard and Celdek evaporative coolers are shipped from the factory with specific nozzles with varying
characteristics regarding flow rates and anti-drip protection. It is imperative that the correct nozzle is

used in the correct location and type of cooling module to ensure quality performance and
leakage prevention. Information regarding the nozzles and timer control should be read and
understood before commencing unit start-up procedures.

Timer Settings:

Both the upper and lower timer settings are adjusted using the same procedure. The LOWER section
controls the length of time the manifold sprays water, while the UPPER section controls the amount of
time between spray periods. Both of these parameters are set in the factory and should not have to

be adjusted during initial start-up. If adjustments to airflow are made, the timer settings will need
to be adjusted to sustain proper performance.

The procedure for setting the Timer control is as follows:

1) Set the two smaller, coarse adjustment dials located in the middle of the timer to “1 MIN”. THIS
IS ALWAYS SET TO “1 MIN” FOR ALL UNITS REGARDLESS OF SIZE AND TYPE.

2) Set the larger fine adjustment dial located on the UPPER portion of the timer. THIS IS ALWAYS
SET TO “1.0” FOR ALL UNITS REGARDLESS OF SIZE AND TYPE.

3) Using the table at the bottom of this page, calculate the time parameter of how many seconds the
manifold will spray based on the given CFM of the unit.

8

4) Set the larger fine adjustment dial located on the LOWER portion of the timer. For each time

*

Time "Spray

- On" (

LOWER

timer setting

parameter, the values of both the large fine adjustment and small coarse adjustment dials are
multiplied by one another to denote the total time of the parameter. This large red dial is the
percentage of the small dial. For example, if the small dial is set to 1 minute, and the large red
dial is set to 0.5, the selected time period would result in 30 (1 minute * 0.5 = 30 Sec) seconds.

Check to ensure that the parameter for “spray time on” matches the amount of time
calculated in step 3.

Unit Size

in SEC.)

1 CFM*(15/3000) + 6.5
2 CFM*(15/4000) + 1.5
3 CFM*(15/4500) - 1
4 CFM*(15/9000) - 1
5 CFM*(15/12,000) - 3.5
6 CFM*(15/15,000) - 5

*NOTE: THE VALUE GENERATED FROM THE EQUATIONS IN THE
TABLE IS FOR SECONDS THAT THE MANIFOLD IS TO SPRAY WATER. IT IS NOT
THE LARGER DIAL SETTING. STEP “4” MUST BE CARRIED OUT IN ORDER TO
PROPERLY SET THE LARGE DIAL.

9

Nozzle Replacement:

The standard and Celdek style evaporative units each have each been designed with their own
specific water manifolds and nozzles in order to deliver maximum spray coverage and correct
quantity of water to the cooling media. It is imperative that in the event of a nozzle change-out,
the nozzles match what is specified in this section of the manual. Nozzle threads must be
wrapped in Teflon tape to prevent leakage.

CELDEK Evaporative Cooler Water Manifold:

10

Standard Evaporative Cooler Water Manifold:

11

Start Up

Special Tools Required

• AC Voltage Meter

• Amperage Meter

• Standard Hand Tools

Start Up Procedure

1. Remove the access door and check all electrical connections for tightness and continuity.

2. Inspect the air-stream for obstructions and install cooling media if missing.

3. Compare the supplied voltage with the unit’s nameplate voltage. If this does not match, correct
the problem.

4. Set the internal thermostat to a set-point cooler than the entering air temperature for start-up
purposes. The cooling circuit will be energized when the entering air temperature is hotter than
the thermostat set-point.

5. Check the timers dial settings. Ensure that the timers settings match what is specified in the
above section of this manual under “Timer Settings”.

6. Install the access door and apply power to the unit. If the entering air temperature is hotter than
the thermostat set-point, the cooling circuit will be energized and water will begin spraying from
the nozzles. If no water sprays, the unit is either not powered, has no water pressure or the
entering air temperature is cooler than the thermostat set-point.

7. Observe the spray timing sequence. Make sure that the sequence observed matches what is
specified based on CFM to optimize evaporative cooler performance. The unit should spray
enough to keep the media wet with minimal run-off and light drainage. It takes roughly 20
minutes for the cooling media to become fully saturated and come up to steady state operating
conditions. If there is no water in the drain pan and no run-off of the media, the “spray-time on”
parameter should be increased to lengthen the time water is sprayed. If there is excessive runoff
and quantities of drainage, the “spray-time on” parameter should be decreased to shorten the
time water is sprayed. Set the thermostat back to the desired cooling temperature (typically
about 75°F). Remember, the cooling circuit will only be energized when the entering air
temperature is higher than the set-point.

12

Component Description/Detail

Component

The following table lists controls used in the evaporative cooler and their function:

Number

1 Timer

2 Thermostat

3

4

5*

6*

Component Description of Operation

Solenoid

Overflow

switch

Pressure

Switch

3 Way

solenoid Valve

Valve

Electrical Cabinet Detail:

Controls spray timing

sequence. Runs continuously

from spray time on and spray

time off.

Energizes cooling circuit when

entering air temperature

exceeds set-point

Normally closed valve.

Energized when liquid level

controller senses “dry” condition

Normally closed switch.

Detects clogged drain to

prevent overflow.

Normally closed switch.

Prevents unit from continually

spraying if 3way solenoid valve

used for freeze protection is not

installed in field.

Installed under roof-line. Allows

gravity-fed drainage in sub-

freezing ambient conditions.

Units with Freeze Protection Option:

3-way Solenoid Valve Detail (Field Installed under

Roofline):

*NOTE: Only installed on units
with Freeze protection.

NOTICE: IT IS THE
RESPONSIBILITY OF THE
INSTALLER TO ENSURE 3-WAY
SOLENOID VALVE IS
INSTALLED UNDER THE ROOF­LINE ON THE WATER-LINE
UPSTREAM OF THE UNIT. THE
MANUFACTURER IS NOT
RESPONSIBLE FOR ANY
DAMAGE RESULTING FROM
THE FAILURE OF INSTALLING
THIS 3-WAY SOLENOID VALVE
PRIOR TO START-UP.

13

Troubleshooting

Cooling media dirty

Clean or replace cooling media

The following table lists causes and corrective actions for possible problems with evaporative coolers.
Review this list prior to consulting manufacturer.

Troubleshooting Chart

Problem

Insufficient Cooling Media not wet Check for even spray pattern

Potential Cause

Clogged nozzles Clean or replace nozzles
Timer Settings improperly set Ensure that the timers dial

Internal thermostat set to high Set thermostat to lower setting.

No water pressure Turn main building water valve
Clogged drain causing pan overflow

switch to activate

Excessive ambient humidity Wrong application for

Corrective Action

from all nozzles

setting settings correspond to
those specified in the reference
table of this manual based on
face velocity.

Cooling circuit will be energized
when the outside air temperature
is higher than thermostat set­point

on
Clear any debris from drain and
ensure bottom pan drains
properly. Ensure that the
overflow switch float mechanism
is able to travel up and down
freely

evaporative cooling

Insufficient Airflow Cooling media clogged Clean or replace cooling media
Excessive Airflow Cooling media missing Install cooling media

14

CELDEK Installation

Intake

Quantity

Size

MAINTENANCE

To guarantee trouble free operation of this evaporative cooler, the manufacturer suggests following these
guidelines. Most problems associated with unit failures are directly related to poor service and
maintenance.

Please record any maintenance or service performed on this equipment in the documentation section
located at the end of this manual.

WARNING: DO NOT ATTEMPT MAINTENANCE ON THE EVAPORATIVE COOLER
UNTIL THE ELECTRICAL SUPPLY HAS BEEN COMPLETELY DISCONNECTED

General Maintenance

1. Inlet and approaches to evaporative cooler should be kept clean and free from any obstruction.

2. All fasteners should be checked for tightness each time maintenance checks are performed prior
to restarting unit.

3. Evaporative coolers require little attention when moving clean air. Occasionally oil and dust may
accumulate on cooling media causing low airflow or reduced cooling. Cooling media should be
inspected and cleaned every 3 months and replaced every cooling season.

Every 3 months

1. Cooling media needs to be cleaned and/or replaced (if damaged)
quarterly, and more often in severe conditions. Cooling media can
be washed with a standard water hose. When re-installing cooling
media, be sure to install with the airflow in the correct direction.
The standard v-bank style evaporative cooler media should be
installed with the metal mesh side of the pad on the leaving air
side of the media. The CELDEK media should be installed with
the 15° holes along the air stream path as indicate d in the
CELDEK installation illustration.

2. Check all fasteners, sensors and electrical connections for proper tightness and continuity.

3. Check all nozzles for proper and evenly distributed water flow. If nozzles are clogged, clean or
replace.

Yearly

1. Replace cooling media prior to cooling season.
Cooling media should be replaced yearly to guarantee
proper cooling performance. The following table
illustrates proper media quantities and sizes.

2. Check the piping manifold and evaporative cooler
housing for water tightness. Replace or repair any
leaking or damaged components.

3. Every cold season requires that the evaporative cooler
water piping system be drained to prevent freezing
and cracking of the water piping. The main water
supply should also be turned off for the cold season.
Standard mesh filters may be used in standard v-bank
coolers in cold seasons.

15

Cooling Media Size and Quantity

Size 1 V-Bank/Evap
Size 2 V-Bank/Evap
Size 3 V-Bank/Evap
Size 4 V-Bank/Evap 15 16” x 20”
Size 5 V-Bank/Evap 12 20” x 25”
Size 1 CELDEK 1 24” x 20”
Size 2 CELDEK 1 32” x 25”
Size 3 CELDEK 1 36” x 30”
Size 4 CELDEK 1 43” x 38”
Size 5 CELDEK 1 54” x 45”

3 20” x 25”
8 16” x 20”
8 20” x 25”

Start-Up and Maintenance Documentation

START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN
AIR BALANCED (Warranty will be void without completion of this form)

Job Information

Job Name Service Company
Address Address
City City
State State
Zip Zip
Phone Number Phone Number
Fax Number Fax Number
Contact Contact
Purchase Date Start-Up Date

Evaporative Cooler Information

Refer to the start-up procedure in this manual to complete this section.

Name Plate and Unit Information
Model Number
Serial Number
Volts
Hertz
Phase

Field Measured Information
Voltage
Thermostat Set-Point °F
Time spray on (Sec)
Time spray off (Sec)
Airflow Direction Correct
Incorrect

Maintenance Record

Date Service Performed

Factory Service Department

Phone: [phone]

Fax: [phone]

16