Coolerado M50C, C60A Installation Manual

COOLERADO, 4430 GLENCOE STREET, DENVER, COLORADO 80216
INSTALLATION AND SERVICE PROVIDER
Coolerado Installation Manual
M50C, C60A
Version 2017-3
Date: November 30, 2017
COMPANY______________________________________
ADDRESS_______________________________________ _______________________________________________ _______________________________________________ _______________________________________________
TELEPHONE_____________________________________
Customer Information
Installer Information
Name
Company
Address Line 1
Address Line 1
Address Line 2
Address Line 2
City City State / Prov.
State / Prov.
Postal Code
Postal Code
Phone #
Phone #
Installation Date: Installation Information
Air Filters installed (Y/N)
Water Filter Installed (Y/N)
Water Hardness
Type of Air Filter Installed
Type of Water Filter Install
Size of Air Filter Installed
Make of Water Filter
Water Pressure @ unit
Plenum Air Pressure Measurements
Conditioned Air
Exhaust Air
Outside Air Temp
Outside Humidity Level
Conditioned Air Temp
Power
Line Voltage
Line Amperage
Phase
Control Voltage
Equipment Information
Unit Model #
Unit Serial #
Thermostat Make
Thermostat Model #
An electronic format of the Coolerado Installation Manual can be found on the Coolerado Web Site at:
www.coolerado.com
, click on Products, Unit number desired and Downloads.
MUST BE COMPLETED AFTER INITIAL INSTALLATION
Page 2 of 63
Table of Contents
Installation Notes 4
Safety Considerations 5
Installation Recommendations 5
Installation Steps
Step 1 – Check Equipment and Job Site 6 Step 2 – Inspect Filters and Heat Exchangers 7 Step 3 – Clearance Requirements 8 Step 4 – Install on Solid and Level Foundation 9 Step 5 – Drain Connections 9 Step 6 – Outdoor Intake Air 10 Step 7 – Conditioned Air Ducts 10 Step 8 – Working Air Ducts 12 Step 9 – Water Supply Connections 14 Step 10 – Electrical Power Connection 17 Step 11 – Control Wiring 18 Step 12 – Control Board Set-up and Operation 19 Step 13 – Thermostat 20 Step 14 – HMX Wet Out Logic 20 Step 15 - Operational Startup 21 Step 16 – Final Checks 22
Post Installation / Seasonal Start-up 22 Normal Operating Procedure 23 Seasonal Shutdown 23 Care and Maintenance 23
Appendix
Appendix 1 – Coolerado Water Quality Requirements 25 Appendix 2 – Control Board and Wiring Diagram 26 Appendix 3 – Water Control Board LED Indicators 28 Appendix 4 – Coolerado Thermostat Wiring Picture 29 Appendix 5 -- Multiple Unit Control Wiring 30 Appendix 6 – Thermostat Operations for (TEC2145-4) 31 Appendix 7 – Freeze Protection 37 Appendix 8 – M50B Dimensional Specifications 39 Appendix 9 – M50 Exhaust Duct Fabrication 41 Appendix 10 – M50B Air Flow Performance Table 42 Appendix 11 – M50B Curb Mount Unit 43 Appendix 12 – C60A Air Dimensional Specifications 44 Appendix 13 – C60A Flow Performance Table 47 Appendix 14 – Water Pressure Charts 48 Appendix 15 – Limited Warranty 50 Appendix 16 – Installation Check List 52 Appendix 17 – Preventative Maintenance, (PM) Checklist 57 Appendix 18 – Cleaning HMX’s 58 Appendix 18 – Troubleshooting 61
Installation Notes
Page 3 of 63
Coolerado Installation
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions, which may cause death, personal injury, or property damage.
Use this product only in a manner intended by
manufacturer.
Ensure the fan has completely stopped prior to
changing filters.
Before servicing or cleaning, other than changing
filters, ensure power to the unit is disconnected and locked out.
Keep body, hands, and foreign objects away from air
intake while unit is in operation.
To avoid fire hazard, do not block any air intake. Do not use the unit cabinet as a platform or storage. Do not attempt to sit, stand, or climb on the unit. Do not use the unit’s fan with any solid state speed
control device.
Consult a qualified installer, service agency, or your product distributor for more information, or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.
WARNING: Follow all safety codes. Wear safety glasses, protective clothing, and work gloves.
Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. These instructions are intended as a general guide and do not supersede local codes in any way. Authorities having jurisdiction should be consulted before installation.
Recognize safety information, symbols and words:
(DANGER) will identify serious hazards, which will result in
severe personal injury or death.
(CAUTION) will identify unsafe practices, which would result
in minor personal injury or poor unit performance, product damage and property damage.
(NOTE) will be used to highlight suggestions, which will result in enhanced installation, reliability, or operation.
INSTALLATION RECOMMENDATIONS
NOTE: Any restrictions to air movement, either for intake
air, conditioned air, or exhaust air, will reduce the capacity and efficiency of the unit.
NOTE: Working air (exhaust) will always be heavier than
ambient air until it fully mixes and comes to equilibrium with outside air.
NOTE: Do not drill, cut, or compromise the powder coat finish within the wet section of the unit. See Figure 19
The unit may be installed either indoors or outdoors.
Indoor installations require inlet air duct and working air, (humid air exhaust), duct which may increase costs and often add to static duct pressure loss, create tight working spaces and require flexible connections to allow future maintenance.
Flexible duct connectors should be installed between
any rigid ductwork and the unit to allow for leveling requirement and to mitigate vibration. If the unit is mounted indoors, a 2 ft. service area in front of the Coolerado inlet fan plenum for servicing must be designed for. The inlet air duct attached to this plenum will need to be easily removable for maintenance access.
Leave room for maintenance such as filter changing
on the C60 requires 25” on at least one side. If the units are hung from the ceiling it can be difficult to change filters.
If unit is installed indoors, install an emergency drain
pan that extends beyond the unit by at least 6” (152 mm) on all sides along with separate overflow drain in accordance with local plumbing codes.
Be sure to provide adequate support for the unit and
associated ductwork.
Be sure that there is no exposure to flammable
vapors, excessive dust, or other contaminants in the air.
To obtain the greatest cooling capacity, air will need
to flow into and out of the unit as freely as possible.
Humid working air must be allowed to flow freely
away from the unit and directed away from the
Page 4 of 63
Coolerado Installation
unit’s intake air supply. If ducted, ensure adequate condensate drains are available.
The intake air opening must be kept free from
obstruction and allowed to draw in fresh dry air.
The conditioned air must be unobstructed to the
building or space to be cooled.
All ductwork must be properly sealed and insulated. Keep all ductwork runs as short as possible between
the unit and conditioned space.
If exhaust ducts are needed they must be sealed. If unit is installed outdoors, install rain shields as
needed.
In unheated environments, provide adequate freeze
protection for system water supply and drain.
Ensure level mounting to allow the internal water
distribution to work correctly.
If the potable water supply is considered moderately
hard, hard or very hard include a sodium-based water softener, see Appendix 1.
properly. To reduce the shipping footprint on a C60, the conditioned air plenum may be shipped wrapped to the inlet of the unit rather than bolted on. If shipment is damaged or incomplete, file a claim with the shipment company as soon as possible. No return shipment will be accepted without return authorization.
NOTE: The unit is shipped with air filters for initial use.
CHECK BUILDING UTILITIES AND GEOMETRY
Check for plumbing vent location Check for exhaust vents and fumes from heaters Check water location and hookup Check for location of sanitary sewer drain Check for storm sewer Do downspouts connect to the storm sewer drain? Check power Check control connections Check water hardness
LOCATION OF EQUIPMENT
Select a location for the unit as close as possible to the supply air diffuser and away from any building exhaust or sources of high humidity levels.
NOTE: If tying into existing HVAC equipment check for complete functionality before starting any work.
NOTE: Make any necessary duct modifications to implement seasonal Duct Blocks during initial installation.
It is recommended that off-season duct blocking devices be installed as part of the end-of-season shutdown procedures.
Step 1—Check Equipment and Job Site
CAUTION: Take the necessary precautions and use appropriate equipment to move and install.
INSPECT PACKAGING OF EQUIPMENT BEFORE ACCEPTANCE
Check the unit for any signs of shipping damage before accepting equipment from the freight carrier. If shipment is damaged do not accept shipment or it may become yours as is. If damaged, file an immediate claim with the shipping company. No return shipment will be accepted without written return authorization.
UNPACK UNIT
Move to final location. Remove carton or packaging, taking care not to damage unit.
INSPECT EQUIPMENT
Check the unit for any signs of shipping damage. Fan should spin freely and all covers and parts should be secured
NOTE: Prevailing winds and building geometry must be taken into consideration in determining air inlet and exhaust locations. Additional ductwork for either the intake or exhaust may be required to assure proper separation of the air streams.
Prevailing wind consideration, Figure 1
NOTE: Inlet hoods should not be located near driveways, parking lots, gas meters, oil fill pipes, dryer vents or other
Page 5 of 63
Coolerado Installation
Model
Filter Size
M50C
3- 2”x20”x25” (50x500x625 mm), nominal
pleated filter size, not recommended)
C60A
4- 2”x16”x25” (50x500x625 mm), nominal
pleated filter size, not recommended)
areas. Avoid areas where objectionable vapors, contaminants, or excess particles could be drawn into the unit. Humid working air must be directed into a free air outdoor space and away from any condensing surface.
NOTE: Humidity sources include the Working Air exhausts from the unit itself or from adjacent units, cooling towers, open drains, grass, bushes, trees, swampy areas, swimming pools, water features, plumbing vents, etc.
DANGER: Do not expose the unit intake air to flammable liquids or vapors and away from excessive dust sources.
LIFTING EQUIPMENT
Forklift / crane Crane Straps and spreader bar Upper security banding (as seen below)
The lifting point above the unit must be at least 4’ (1.2 m) or a spreader bar is needed to prevent squeezing the box.
Care should be taken not to rack or torque the units when moving or lifting units into position as this may cause poor door fitting, Heat and Mass Exchanger racking and leaking, air leaks, etc.
Lifting Straps/Banding, Figure 3
Step 2— Inspect Filters and Heat Exchangers
1.) Inspect the unit’s filters for damage or debris.
2.) Spin the fan for freedom of movement.
3.) Remove filters and inspect heat and mass
exchangers (ensure flow arrow on filter is correct).
4.) Inspect surfactant soap container for proper level.
NOTE: Coolerado provides three ply panel filters with about a MERV 8 rating. This is a depth loaded synthetic media that will hold twice the dirt than the pleated filters with the same pressure drop. They also do not allow dirt bypass round the perimeter or between filters, are not affected by water and are about the same cost. We highly recommend replacing filters with panel filters.
1.75”x19.5”x24. 5” (44.5x495x622mm), (actual
1.75”x15.5”x24. 5” (44.5x495x622mm), (actual
M50C Lifting Lugs, Figure 2
Page 6 of 63
Coolerado Installation
Exhaust Out Back,
(Removable for Duct
Installation)
High Voltage Power
Factory Wired
Connections
Soap
Pump
Control Wiring,
Low Voltage
Do Not Block
Filter Access Door
Filter Access
Door Handles
Lifting Lugs
Drain
Water In
Low Voltage Wire
Terminals In
High Voltage Wire
Terminals In
Outdoor
Air In
Panel
Filter
3
-
Ply Panel
Filter
2.) Familiarize yourself with the unit’s connection and
service points. See Figure 6.
3-Ply Panel Filter, Figure 4
DANGER: Do not expose the intake air to flammable liquids or vapors.
CAUTION: Do not substitute 2” (50 mm) filter with two 1” (25 mm) filters, this will significantly reduce the airflow through the unit. See Figure 5
Step 3—Clearance Requirements
1.) Inspect clearances and position the unit for
installation – see Appendices 8, 10 or 12 for unit dimensions and clearance details per model.
Filter image, Figure 5
Identifying System Components, M50C, Figure 6
NOTE: Ensure unit is positioned so that filters, soap pump and electrical service areas are easily accessible for maintenance and seasonal changes.
NOTE: Figure 7 shows the working exhaust air from the top. For units using side working air exhaust.
CAUTION: Ensure a minimum of 24” (610 mm) clearance for side mounted working air exhaust.
NOTE: Take precautions not to block service areas of unit and that the ductwork connection has enough flexibility for leveling or seasonal re-leveling purposes.
Page 7 of 63
Coolerado Installation
Outdoor Air
Inlet
Supply Air
Exhaust Air
Note, Opening cut into Supply
Plenum by Contractor
Outdoor Air
Inlet
Contractor
Fabricated
Exhaust Duct
Supply Air
Exhaust Air
Clearances:
-- Sides: 0
-- Top: as needed for installation
-- Outside Air Intake to Fan: 24" (600 mm)
-- Supply Air Plenum: as needed for installation
structural engineer and comply with local code requirements.
If unit is installed indoors, install an emergency drain pan that extends beyond the unit by at least 6” (150 mm) on all sides along with separate overflow drain directed to a sink or outside location where the leak can be seen and in accordance with local plumbing codes, see Figure 9.
Step 4— Install on a Solid and Level Foundation
Mount the unit on a solid and level foundation with
proper sub-base and drainage to ensure the unit will not shift during its lifetime.
Take the proper precautions when mounting the
unit to reduce noise and vibration.
If mounted on rafters, use appropriately sized
vibration damping springs and duct isolation attachments.
If installed on a roof, an attic, or any place where
structural support may be an issue, consult with a
Clearance Requirements, Figure 7
Overflow/Drain Example, Figure 9
LEVEL UNIT
The weight of the wet unit will require a stable base. During installation, the unit must be properly supported and leveled to stay stable over time. The water delivery to all areas inside the unit depends on the unit being level within 1/16” per foot (5.2 mm/meter) in both directions. CAUTION: Failure to do
so will void system warranty.
CAUTION: Foundation racks or solid drainage footing/concrete pads must be used on ground installations to ensure the unit remains level and secure. Proper preparation of ground is necessary to maintain level footing over time.
CAUTION: Do not place unit directly underneath roof, eaves or drip lines without adequate gutters.
Step 5 – Drain Connections
NOTE: The units drain connection is located underneath the unit’s intake air plenum.
Install system drain piping that can be 1 ½” (38.1 mm) pipe over outside; 1 ¼” (31.75 mm) inside or 40mm deeper inside
If local or state codes allow drain water to be used for Irrigation, it must be drained away from the pad to eliminate any settling that will prevent the unit from remaining level. If this occurs, the drain line must slope a minimum of 1/8” per foot (10.4 mm/meter).
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Coolerado Installation
Model
Intake Duct Size
Intake Duct Size
M50
20 inches
500 mm
C60
22 inches, (20” at fan inlet)
560 mm, (508 mm at fan inlet)
Pooling of water near the unit will also allow excess humidity to be drawn into the unit, which will reduce the cooling performance of the unit.
CAUTION: Do not discharge to roof top drains that drain to parking lots or alleys. (The continual flow of water will cause a slick green alga growth).
Drain Connection, Figure 10
If the unit drain line is connected to an internal building sanitary sewer drain line, it must feed into a 1-1/4” (40mm), (or larger) plumbing drain line that meets all plumbing code requirements. The drain line must be vented as it enters the building sanitary sewer drain line.
NOTE: If rigid duct is used to connect to the unit’s intake air, it must be designed to be easily removed to allow service access.
NOTE: In some roof top installations, parapet walls can trap the heavy cool humid working air below the walls causing the intake air to have a high humidity resulting in higher conditioned air temperatures. In these situations, the intake air may need to be brought from a higher location, see Figure 11.
High Parapet Walls, Figure 11
Step 6—Outdoor Intake Air
NOTE: The intake air duct must not be located near the units working air duct.
Install and inspect ductwork if needed.
The intake air can enter the unit directly or through a properly sized duct. Use intake sizes from Table 1:
Intake Duct Sizes, Table 1
NOTE: If the unit is installed in a building (attic or other) a duct may be needed to draw fresh intake air into the unit from outside the building.
NOTE: The free open area of the intake grill must equal the duct area. Failure to do so may cause excessive pressure drop across the grill, see duct sizes in Table 1.
Intake Snorkel, Figure 12
Step 7 –Conditioned Air Duct
1.) Install properly sized, sealed and insulated
conditioned, R6 minimum, air duct to unit.
2.) For all units the conditioned air plenum is shipped
without pre-cut duct openings. This allows the installer to add the ducts where desired on location.
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Coolerado Installation
Duct openings should only be cut into the front of the supply plenum. DO NOT CUT OPENING IN THE BOTTOM OF SUPPLY PLENUM or within 2” (20mm) of the bottom. Coat and seal any exposed metal, see
Appendices 8, 10 and 12.
NOTE: Seasonal shut off dampers or easily accessible duct blocks should be installed for easy winterization changeover.
NOTE: A flexible duct connector should be installed between the unit and any rigid ductwork to allow for seasonal leveling and to mitigate vibration.
Recommendations for reducing temperature loss and creating displacement ventilation conditions:
The air pressure at the units conditioned air plenum
should be 0.01 to 0.15 inches of water column (2.5 Pa to 37 Pa) greater than the working air exhaust plenum under full air-flow. This will prevent water migration from the exhaust side to the conditioned air-side and provide adequate working air.
Ductwork Example, Figure 13
Seal duct work.  If the conditioned air ducts are located external to
the building or in an attic space, a minimum of R6 insulation is required. Follow local building and insulation code requirements.
Size ducts to about 0.08 inches of water column per
100 feet (66 Pa per 100 m) of duct. Typically, a round duct connection to the C60 or M50 supply or conditioned air plenum would be a 16 inches (400mm) in diameter.
Maximize the trunk duct and minimize the length of
duct branches, see Figure 13.
Too many air-drops can cause excessive temperature
losses.
Large, non-mixing type diffusers (positioned low) are
recommended.
High ceiling installations should direct the air down
at low velocities, less than 200 ft/min (60 m/min), preferably 50 ft/min (15 m/min). Do not mix air, see
Figure 18.
Duct Insulation, Figure 14
NOTE: Additional duct insulation may be required in high heat gain areas such as attics, see Figure 14.
CAUTION: To get proper air movement it is sometimes necessary to install several barometric dampers and/or building exhaust fans.
NOTE: Adjust barometric dampers to optimize air distribution.
Diffuser location examples:
Installation of a room diffuser might have the
conditioned air delivered at the opposite side of the room from the door and sweep toward the door to a barometric duct in the ceiling, see Figure 17.
A room with a window may have the diffuser
installed on the opposite side from the window, with cooled air sweeping the room toward the window and removing the hot air above the window, see
Figure 18.
NOTE: Avoid sharp bends and sudden reductions in ducting causing pressure drops which impede air-flow.
Page 10 of 63
Coolerado Installation
Conditioned Air Plenum Duct Connection Figure, 15
C60 Conditioned Air Plenum inside Box, Figure 16
NOTE: Set the conditioned air plenum inside the box or the HMX frame so that water will be directed into the box rather than to the outside. Seal outside edge at bottom of plenum, see Figure 16.
Barometric Damper Example, Figure 17
Installation Example, Figure 18
Step 8 – Working Air Ducts, (unit exhaust)
NOTE: Do not drill, cut, or compromise the powder coat finish in the wet section or behind the HMX’s or drive screws into filter areas or where internal wiring, soap bottles, etc has been installed. See Figure 19
NOTE: The conditioned air plenum is not insulated in the factory. Insulate plenum after duct holes have been cut out.
In outside installations, the plenum should be fully insulated and sealed to reduce air temperature increases within the plenum. Any increase in the conditioned supply air temperature will result in an increased building temperature and run time.
NOTE: Barometric Dampers and /or building exhaust fans are installed to relieve conditioned space pressure at the highest temperature locations.
Wet Area, Figure 19
Page 11 of 63
Coolerado Installation
Air Block
Plate
If units are located inside or multiple units are
mounted side by side requiring a common working air duct:
o Seal ducts to prevent condensation from
leaking from the ducts
o Provision must be made for the duct to
drain condensation back to the unit. Connect to an appropriate drain if ducting is lower than unit. Duct joints should be constructed to drain water such that it will not catch in seams.
Top Mounted Exhaust, C60A, Example, Figure 20
screw holes in M50C to mount ducting such as in a building to exhaust air outdoors. See Appendix 11 for duct details.
Note: When using a 3-phase, 480 VAC factory installed motor, considerably more air flow and pressure drop can be obtained. A 5.5” high by 9” wide plate has been included to block the exhaust flow when the Supply air static pressure exceeds 0.6”. The plat clips into the expanded metal bird guard screen.
NOTE: C60A, if side louvers cannot be used, it is suggested to extend the exhaust duct so that it is approximately 12 in (30.5 cm) above the rooftop. This will help to prevent working air from entering the system and decreasing performance.
CAUTION: All duct connections to the unit must be able to drain back into the unit. Ensure duct flanges mount to the inside of the cabinet to prevent leakage of condensate. See Figure 20 for an example.
CAUTION: Failure to prevent sunlight from reaching the heat exchanger will allow degradation of the heat exchanger material and possibly allow green algae growth if there is enough dissolved nutrients in the water supply and or air. The Clean HMX material will not support mold or algae growth.
Top Factory Mounted Exhaust, M50C, Figure 20
Air Block Plate for use with M50 3 Phase Fan, Figure 21
The top mounted exhaust hood on the M50C is removable and can be replaced with rectangular ducting. Use existing
CAUTION: A bird screen must be installed over the outlet exhaust to keep birds and squirrels out.
CONSIDERATIONS: The working air is always cooler than the
outside air. This air can be used to cool the back of solar panels or directed to condenser coils (Most applications that will not be affected by moisture).
CAUTION: Working air being drawn into the intake air will seriously impact the temperature performance of the unit and add significant humidity to the inside of the building.
When installing the unit on the roof or ground, use working air louvers with protective screening (these louvers are sold separately). Using louvers other than those supplied by Coolerado may void the warranty.
NOTE: At least 24 inches (600 mm) should be left between side louvers and any object to allow free air-flow. Additionally, this will allow access for the louver panel (which houses a filter pad that prevents water from spitting from louver).
NOTE: Side louvers may have some condensation and excess water carry over from the working air (which may contain
Page 12 of 63
Coolerado Installation
minerals) and should be located where mineral buildup outside the unit will not be a problem.
Exhaust Louvers, Figure 22
C60A units are shipped with precut holes for louvers.
NOTE: two (2) side louvers are required for C60A’s to prevent spiting from the side of the unit.
CAUTION: The working air expels excess water, minerals and salts at all times it is in operation. Any holes cut into this section or screws attached must be coated on the inside with a high quality duct sealer to prevent corrosion. In most cases the HMX’s will need to be removed to adequately seal any punctures to the inside of the working air section and prevent rusting of the box. This may void warranty if not properly sealed.
Side Cover and Louver Attachment:
To seal the side covers or louver very little torque is needed to tighten the screws. Over tightening will cause warping of the cover or louver. Eight (8) 10 – 32 stainless steel screws are used to hold the louvers or covers on. The unit comes with matching blind rivets mounted in the box.
Inside Cover, Figure 23
Step 9 – Water Supply Connections
Note: Do not turn water on unit till Step 15.
See Appendix 14 for line size and pressure charts.
CAUTION: Clean potable water should be connected to the Coolerado air conditioner, see Appendix 1 Coolerado Water Quality Requirements for more details.
CAUTION; Do Not use galvanized or black iron piping anywhere in the water supply system.
Water lines should be insulated from heat sources such as the sun to prevent overheating and scaling of the water. If the water line insulation will see sun light at any point it should be UV protected material. When hard water is heated, it increases its scaling potential such as in a water heater.
NOTE: When choosing to insulate exposed water lines, UV protection must be accounted for. If using non-UV rated insulation, it is suggested to coat the insulation with a weatherproofing finishing paint or jacket.
The instantaneous water flow rate to the HMX’s is the water required when turned on by the water control board. The water is turned off most of the time. A clean and consistent water supply capable of instantaneous 85 GPH (gallons per hour) (322 LPH(liters per hour)) for a M50, and 102 GPH (386 LPH) for a C60, for proper operation of the units.
NOTE: Install a hose bib at the main water line near the unit. This will allow for quicker and easier servicing as well its double use for cleaning the units.
Page 13 of 63
Coolerado Installation
HMX Water Usage (gal/HMX
Water Usage (Liters/HMX
Model
Number of HMX’s
M50
5
C60
6
NOTE:
water usage and drains on a continuous basis
It is also suggested to install ½ in. ball valves to the
main water line of the unit if installing multiple. This will allow individual units to be shut off during maintenance rather than shutting all units off.
The water connection is a ½” (12.7 mm) FNPT at the unit base. The water pressure at this connection must be between 40 psi (225 kPa) and 80 psi (550 kPa). For your convenience, Appendix 14 provides water pressure drop information. Note that the water pressure will decrease 1 psi for every 27.7” (9.8 kPa for every 1 m) of height do to gravity. So for a 30’ (9.14 m) rise, the water pressure will decrease by 13 psi (90 kPa), this does not include pressure drop due to friction in the piping and pipe fittings.
Note: A Water Pressure Switch has been installed on the water line inside the unit that will disconnect the fan control wire turning the fan off until the water pressure rises again, see Figure 25. This means a dirty water filter or low water main pressure will turn the fan off. If the main water pressure is low a, booster pump may be required.
16.0
-hr)
14.0
12.0
10.0
Coolerado Water Usage per HMX
4.0
-hr)
3.0
2.0
1.0
0.0 110 100 90 80 70 60
Ambient Temperature (F)
Coolerado Water Usage per HMX
8.0
6.0
0 F Dew Pt
20F Dew Pt
40F Dew Pt
50F Dew Pt
60F Dew Pt
70F Dew Pt
- 18C Dew Pt
- 7 C Dew Pt 4 C Dew Pt 10 C Dew Pt 16 C Dew Pt 21 D Dew Pt
CAUTION: Dynamic water supply pressure of between 25 PSI (172 kPa) and 80 PSI (550 kPa) is required at the unit.
Water Consumption:
Water consumption or water usage is based on the outdoor temperature, humidity and air flow rate. The water is turned off for two minutes than back on for the length of time needed to keep the HMX’s with adequate water. The water usage is shown in the attached tables.
4.0
2.0
HMX
0.0 43 38 32 27 21 16
Ambient Temperature (C)
Water Consumption Table (per HMX), Figure 24.
1. Assume full product flow rate at 1400 cfm or 40
3
/min (M50)
m
2. Water usage rates are +/- 15%
3. Drain water equals approximately 25% of total
WATER FILTER
WARNING: INSTALL the IN-LINE 30 micron WATER FILTER supplied with unit. The water filter should be installed upstream (before) any solenoid valves or water pressure regulator on the Coolerado unit so that these devices will be protected by the water filter.
Page 14 of 63
Coolerado Installation
Check Val ve , CV
Booster
Pu mp
Pressu re
Tan k
Pressu re
Gaug e
Union
Relief Valve
Pressu re
Sensor
Circuit Breaker
Disconnect (110VAC, 20 amp)
Cont rol for Boost er Pu mp
Need 25 psi (172 kP a)
Minimum at Coolerado Unit
By Co ntr a ct or :
CV
Main Water Line
Hose Bib
Ball Valve
CAUTION: Failure to install an in-line water filter will void system warranty.
NOTE: In addition to water pressure, water quality has a major impact on performance. Reducing undissolved particulates increases performance and longevity of the system’s heat exchangers.
The filter will need to be changed when the pressure drop across the filter reduces the main line water pressure below 25 psi at the units when they are calling for water, the toilets are being flushed and the irrigation system is running. Realistically the water pressure needs to be at least 40 psi. How fast a water filter needs to be replaced depends on the amount of un-dissolved minerals or debris that is in the water.
NOTE: If incoming water pressure is more than 80 psig (550 kPa), a pressure-reducing valve should be installed to the incoming water supply line.
WATER PRESSURE REQUIREMENTS
NOTE: If incoming water pressure is ever less than 25 psig (172 kPa) when the unit is running, a water pressure booster pump may be required. District water line pressures are often decreased due to irrigation activities, especially at night. A minimum building pressure is generally 40 psi to maintain the pressure at the unit of 25 psi when considering water filter pressure drop, perhaps a water softener, toilets being flushed, the units may be mounted on the roof causing pressure loss due to gravity and height, and the irrigation system running.
Water Booster, Hose Bib, and Ball Valve, Figure 25.
NOTE: Use a minimum of 1/2” (12.7 mm) diameter supply water line, which should be free draining for winter shut down.
BACK FLOW PREVENTION
NOTE: The unit is equipped with a self-draining water regulating valve designed with a vacuum break in the HMX.
Low Water Pressure:
In certain locations, a reduction or potential loss of water pressure can occur due to high demand conditions on the municipal or district water supply. Install a booster pump to ensure water pressure is maintained. If required, mount booster equipment near ground level, see Figure 25.
Water Distribution System – M50C, Figure 26
Freeze protection can be done manually:
1.) Install supply water shut off valve between the
water supply line and the unit.
2.) Install a drainage valve downstream of the manual
water valve. The drain valve should be located within a conditioned space.
Page 15 of 63
Coolerado Installation
Measure Header
Pressure Between
Solenoid Valve and
Soap Tee Using ½”
OD Tube Connectors
Solenoid Valve
Soap Tee
3.) Slope the line from the unit to the drain valve for
proper draining and freeze protection.
4.) To drain the line and water distribution system it
must be turned on for a few minutes to allow the water to drain and air to pulled into the system. This is done by turning the thermostat to require a cool call.
WATER DISTRIBUTION SYSTEM
The water distribution system, (located inside the unit) is a combination pressure regulator, 24 VAC solenoid valve and water distributions manifold. The valve is designed to deliverer the correct water flow to each of the systems heat exchangers.
NOTE: Water Distribution System pressure should be adjusted in the field to 5.5 psi, (38 kPa). The adjustment must be made in the field to adjust for elevation above sea level.
CAUTION: It is absolutely essential that the pressure regulator be set to deliver the proper pressure at the water distribution head before installation can be considered complete. For the most accurate setting possible, take a dynamic pressure reading at the point where the water supply enters the water distribution head. This can be done
Step 10 –Electrical Power Connections
Note: Do not power on the unit until Step 15.
See Appendix 2 for Details. See Appendix 4 for multi-unit wiring.
DANGER: To avoid personal injury or death, do not supply power to unit with the units’ high voltage terminal box cover removed.
WARNING: NOT SUITABLE FOR USE WITH SOLID-STATE SPEED CONTROLS
CAUTION: Be sure field wiring complies with all local and national fire, safety, and electrical codes, and voltage to system is within limits shown on unit rating plate. Contact local power company for correction of improper voltage. See unit rating plate for recommended circuit protection device.
NOTE: Keep wiring color coded according to system drawings for easy troubleshooting and standardization. For color code reference, see Appendix 2.
NOTE: Operation of the unit on improper line voltage constitutes abuse and could affect unit reliability. See the unit rating plate. Do not install unit in system where voltage may fluctuate outside of normal voltage fluctuations
by temporarily installing a pressure gage immediately at the point where the water supply enters the water distribution header, as in the following picture, and adjusting the dynamic pressure to the desired level.
Water Header Pressure Location, Figure 27.
NOTE: Use copper conductors only between the disconnect switch and the unit.
ROUTE GROUND AND POWER WIRES
DANGER: The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. Failure to follow this warning can result in an electric shock, fire, or death.
CAUTION: Without an uninterrupted or unbroken ground the motor can have arcing across the bearings causing premature failure of fan motor.
Remove access panel and electrical box cover to gain access to unit wiring. Extend wires from disconnect through power wiring hole provided and into unit control box. Size wires per National Electric Code.
CONNECT GROUND AND POWER WIRES
Single Phase Motors: The unit fan motors will run on 200 to
277 VAC, 50/60 Hz single phase with an electrical circuit breaker of 5 amperes. The transformers provided are 208 VAC or 240 VAC to 24 VAC only. In some instances, a 277 VAC
Page 16 of 63
Coolerado Installation
is required and the transformer can be requested at time of purchase.
15 amperes is generally the smallest circuit breaker that can be purchased. Local electrical codes shall be applied and take precedence over any recommendations given here.
The M50 has a terminal electrical box at the bottom of the unit, see Appendix 10. Notice the Black Jumper wire with the spade connection must be moved from the blank terminal to the 208, 240 or 277 VAC terminals see Figure 28.
1~ Electrical Power Connections, Figure 28
3~ Electrical Power Connections, Figure 29
CAUTION: The transformer was not designed to power other equipment. NOTE: The electrical access panels have screw holes to fit most electrical box covers making it easy to install switches, outlets, etc.
CAUTION: Line Voltage and Control wires must be routed clear of any system components such as filter access doors to prevent wiring chafing / electrical shorts.
CAUTION: Ensure line and control voltage wires are routed away from terminal connections and control board.
Step 11 – Control Wiring
Note: Do not start unit till Step 15. See Appendix 2 for wiring
instructions.
CONTROL REQUIREMENTS
st
Input Cool Call “Y” (1 Variable Speed Fan, 0-10 VDC signal or no signal and
full speed; dipswitch 7 OFF
stage cooling call)
Three Phase Motors; 480 VAC, 50/60 Hz with an electrical circuit breaker of 10 amperes each leg.
Winter/Summer mode; if fan to be used in winter Freeze Protection relay; if needed
NOTE: The water control board provides 24 VAC (via terminal RC) to be switched thru a dry contact back to terminal Y.
Eight Pin plug in Cable Connector on water control board and wired to a wire terminal block
1. Y – Cool Call dry contact
2. RC - 24 VAC
3. Variable Speed Fan controlled by 0-10 vdc
4. Common
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Coolerado Installation
Unit Control
Thermostat TEC3620
Color
Y-24 VAC IN
FAN
Yellow
RC-24 VAC OUT
24V
Red
Variable Fan
CGL
Blue
COM
COM
Black
Dip switch
1
Power Failure Rewet; OFF less than 1 Hour, ON
2
Water Quality, OFF good, ON poor
3
Model Number, Factory Set
4
Model Number, Factory Set
Elevation
0
2000’ (610M)
4000’
6000’ (1830M)
5
Off
On
Off
On
6
Off
Off
On
On
On for Variable Speed Fan, 0 to 10 VDC OFF = Single Speed Fan Setting (10 VAC)
8
On Freeze Protection mode see Appendix 8
5. Winter/Summer; winter mode when contact
closed. Allows fan to run without water pressure. It initiates Freeze Protection relay, this turns off the main water line, (if connected to a solenoid valves), opens the water drain line, and opens up the unit water solenoid valve for 5 minutes. Closed contact or Winter mode takes precedence over Winter/Summer Switch on the Water Control Board. White light comes on.
6. 24 VAC
7. Freeze protection relay.
8. Common
Control Terminal, Figure 30
2. Low and High water quantity, OFF plus 25%, ON
plus 50% over the calculated evaporation rate.
3. Model Number, in conjunction with 4; factory
setting.
4. Model Number
5. Elevation, in conjunction with 6.
6. Elevation
7. Auto Variable Fan, OFF 10 vdc, ON from AIN
8. Freeze Protection, OFF no freeze protection, ON
freeze protection, (requires connection to solenoid valves by others).
If a variable speed thermostat is used, set control dip switch setting 7 to the “on” position. This will vary the water flow based on the amount of air flow. If dip switch 7 is set in the off position, 10 VAC will be delivered to the fan motor control wiring and it will run full speed whenever cooling is called for.
Dip switch setting 8 controls if freeze protection is on or off, see appendix 8 for additional installation details. Freeze protection allows the unit to be automatically pulled out of service during a cold spell but keep the unit ready for cooling. It should not be used for end of season shut down when cooling is no longer needed for an extended period of time. In some locations cooling is required all year round but still may experience temperatures below 32 temporary shutdown to prevent breakage of valves or line. Freezing will not harm HMX.
o
F and require
If using the recommended variable control thermostat model TEC3620:
Thermostat Connections, Table 2
Step 12Control Board Set-up and Operation
Note: Do not start unit till Step 15.
CONTROL BOARD 8 DIP SWITCHES
1. Initiates the Wet Out cycle after a power failure
with two possible settings, OFF over one hour, ON over four hours.
7
Table 3: Control Board Dip Switch Settings
Control Operation
See Appendix 2, 3, 4 and 5 for more information.
There are five (5) LED’s on the control board to indicate:
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Coolerado Installation
Soap Pump
Water Control Board
Transformer
Solenoid Valve,
Pressure Regulator
and Pressure Switch
Soap
Bottle
Power on: Green LED light Water solenoid is powered: Clear light Cool call: Yellow light Flush cycle is on: Red light Winter /summer: White light
The water control board has a fan speed potentiometer, (see appendix 2). This is a single turn pot that controls the maximum voltage going to the fan. If dip switch 7 is in the off position the fan voltage can be turned between 0 and 10 VDC. If dip switch 7 is on, then this pot will proportionally vary the voltage received at the water control board allowing a maximum fan speed to be set. The factor setting is full speed.
Note: If a three-speed fan is used the fan speed potentiometer mentioned directly above may need to be used to reduce fan speed, see appendix 10.
The water control board also has three switches mounted on it for ease of maintenance, (see appendix 2):
NOTE: The thermostat should be mounted on an interior building wall, free of drafts, and in an area unaffected by heat producing machinery or appliances.
See Appendix 5, Thermostat Operation. For additional information on the thermostat see Appendix 2, Control
Board and Wiring Diagram; Appendix 4, Coolerado Thermostat Wiring; Appendix 5, Multiple Unit Control Wiring and Appendix 6, Thermostat operation.
Step 14 – HMX Wet Out Logic
Note: Do not start unit till Step 15.
The unit is equipped with an automatic wetting system that provides a significant boost to the heat and mass exchangers wetting operations when the unit is powered up at initial installation, for seasonal restart, or any other time that the heat exchangers have dried out after the power has been shut off.
1. WINTER switch allows the fan to be operated
through the cool call and AV fan but with the water off. Putting in winter mode will also cause it to go into freeze protection. The terminal connection precedence over the board winter switch.
2. WETOUT momentary switch allows a maintenance
person to start a wet out cycle as long as there is a Cool Call. A jumper across the Y and RC terminals will cause a Cool Call.
3. PRIME momentary switch allows a maintenance
person to prime the soap pump by pushing it and holding it till primed.
Step 13 – Thermostat
Note: Do not start unit till Step 15.
A standard thermostat can be used however most thermostats do not have 0 to 10 VDC capabilities to drive the Coolerado fully auto variable fan. For this reason, Coolerado sells a variable speed thermostat.
NOTE: The efficiency of the Coolerado goes up significantly as the speed is reduced, (4x at half speed), so variable speed control is encouraged when possible.
Water and Soap System, Figure 31
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