Reznor RBL User Manual

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Page 1

NOTE: After installation, keep this

booklet with the makeup air system

installation/operation manual.

OPTIONS AS3, AS4, AS5, AND AS8 EVAPORATIVE COOLING MODULE

INSTALLATION/OPERATION/MAINTENANCE

FORM RZ/NA I-OPT-EC

OBSOLETES FORM 400EC

1. Description/ Application

2. Dimensions

58-3/4 (1492mm)

1 (25mm)

APPLIES TO: Models RGBL,RPBL,SSCBL,PGBL;

Models ADF/ADFH 700/1200; Model RBL

The optional evaporative cooling module for packaged indirect-fired system Model Series RGBL, RPBL, SSCBL, PGBL, blower cabinet Model RBL, and direct-fired makeup air Models ADF/ADFH 700/1200 is factory assembled but requires field

installation. Evaporative cooling module Option AS3 includes 6” rigid cellulose media; Option AS4 includes 12" rigid cellulose media; Option AS5 includes 6" rigid glass fiber media; and Option AS8 includes 12" rigid glass fiber media. The

base parts for supporting the evaporative cooling module and the transition duct for connecting it to the unit are shipped with the module for field assembly and installation. If optional moisture elimination pads, a drain and fill kit, and/or a water hammer arrestor are to be included in the installation, they also require field installation.

Indoor Installation Note: The evaporative cooling module cannot be suspended;

it must be placed on a platform. If the installation is not conducive to providing a platform for the optional evaporative cooling module to attach directly to the cabinet, install a compatible Reznor ® Model REC evaporative cooling module which also must be mounted but requires a field-fabricated transition duct and can be located further away. All evaporative cooling modules require outside air.

(610)

(305)

54-1/16 (1373)

Opening Size

56-3/4 (1441) x 48 (1219)

Inlet View

2(51)

6 (152)

47-3/4 (1213)

3. Installation Preparation Check List:

3 (76)

29-3/4

(756)

Adjustable

21-9/16 (548)

maximum

14-9/16 (370)

minimum

Water Connection (1/4 tubing)

5-1/32

Drain/Overflow Connection

)

(128

(centerline)

56-5/8 (1438)

Water

Connection

(Control

Side)

Transition Duct Opening

for Reznor Model Series

RGBL, RPBL, SSCBL, and

PGBL; Blower Model RBL;

and Model ADF/ADFH

Sizes 700 and 1200.

Outlet View

9-1/2 (241)

2(51)

Drain/Overflow

Connections

47-3/4 (1213)

5-1/2 (140)

Adjustable Legs

16 (406) maximum

9 (229) minimum

2(51)

AIR

FLOW

Control

Side

View

6 (152)

21-1/2

(546)

Control Pump

Access Panel

o Make certain the installation complies with all local, utility and federal build-

ing and safety codes and regulations.

o Check module for shipping damage. If damage is found, document the damage

with the transporting agency and immediately contact your Reznor Distributor.

o Check fabricated parts in the duct kit

package against parts list shown in

FIGURE 2, page 3. The package

also includes the hardware listed here.

Transit ion D uct Hard w are Pack age

#10x1/2” Screws (58) 11813 1/4 - 20 Hex Head Bolts

(10) 16246

1/4 - 20 Nuts (10)16050

Mfg No. 160202, Page 1

Page 2

3. Installation Preparation Check List (cont’d):

In addition, the following parts for making electrical and water connections are shipped in the bottom pan of the evaporative cooling module.

Qty P/N Descrip ti on

1 105945 1/4" Hose I.D. x 1/2" N.P.T. Bleed Line Fitting (not used

with optional timed metering AquaSaver® system)

2 16835 Bushings, Heyco #SR-7W-2

o If the evaporative cooling module is being installed indoors (Model SSCBL,

PGBL, or ADF/ADFH 700/1200), outside makeup air must be provided.

o If optional shipped-separate equipment will be included (Drain and Fill Kit,

Freeze Protection Kit, Moisture Elimination Pads, and/or Water Hammer Arrestor), check to be sure that these parts are available for installation.

o Make certain the roof or platform is capable of handling the additional load of

a cooling module with a full reservoir.

Weights of Evaporative Cooling Module - With Wet Media & Full Reservoir

Module with 6" rigid cellulose media (Opt AS3) ............... 379 lbs (172 kg)

Module with 12" rigid cellulose media (Opt AS4) ............ 431 lbs (195 kg)

Module with 6" rigid glass fiber media (Opt AS5) ............. 420 lbs (191 kg)

Module with 12" rigid glass fiber media (Opt AS8) ........... 514 lbs (233 kg)

o Make certain the surface is level and free of debris where cooling module will

be mounted.

o Do not mount directly on soft tar roofs where the legs could sink and tilt the

cooler. Provide a weather-resistant, solid wood or metal base under the cooling module support base.

o Make certain that there will be adequate clearance between the bottom of the

reservoir and the roof or platform to allow for drain and overflow pipe connections.

4. Base and Transition Duct Installation Instructions

FIGURE 1- Assembled Base for Evaporative Cooling Module

Adjustable Leg Height

16” (406mm) Maximum 9” (229mm) Minimum

Attach the evaporative cooling module after the makeup air unit is in its permanent

location. Do not install the evaporative cooling module and connecting duct while the blowers are in operation. Steps 2-11 are illustrated on FIGURE 2, page 3.

Steps 12-20 are illustrated in FIGURE 4, page 4. FOLLOW EACH STEP IN ORDER.

STEP 1:

1) Be sure all preparations have been made. Review Preparation Checklist, pages

1 and 2.

Assembling Base, FIGURE 1 & STEPS 2-5, FIGURE 2:

2) Using four bolts and nuts per leg, fasten the two leg halves (ITEM 4) together. See FIGURE 2, Step #2. The top flange of the assembled legs should be level

with the bottom of the system cabinet. Adjust legs to proper height and tighten bolts securely. Assemble all four legs.

3) Approximately two feet (610mm) from the air inlet side of the cabinet, posi-

tion the four assembled legs in a rectangular pattern corresponding to the size of the cooler. Depending on the type of surface, it may be necessary to set the legs on a weather-resistant, solid wood or metal base. Check again to be sure that the top of the legs are level with the bottom of the makeup air system cabinet.

4) Place rail sides (ITEM 3) on the inside of the top flanges of the leg assemblies.

Using the bolts and nuts provided, bolt the side rail to the top three holes located on the legs just below the top flange. Repeat on the remaining three legs. Tighten nuts securely.

5) Place the rail ends (ITEM 2) on the inside of the top flange of the leg assem-

blies. Bolt the end rail to the top three holes located on the legs just below the top flange. Repeat on the remaining three legs. Tighten nuts securely.

Form I-OPT-EC, Page 2

Page 3

Cooling Module

FIGURE 2 - Parts List and Illustration for

Assembling Base and Transition Duct for

Optional Evaporative Cooling Module

Cooling Module Base (must be field assembled)

Step 4

ITEM 1

ITEM 3 (2)

ITEM 2

(2)

ITEM 4 (4 sets)

Step 2

Step 7

ITEM 7 (2)

ITEM 5

Step 9

Step 5

Step 8

ITEM 6

Transition Duct (connects cooling module to makeup air system)

ITEM 8

ITEM 9 (2)

Step 11

Item Qty P/N Description Where Us ed:

1 Evaporative

Cooling Module

2 107235 Support Ends Base Assembly

2 107227 Support Sides Base Assembly

8 107236 Leg Halves Base Assembly

1 107228 Front Top Cover Cooling Module

1 107229 Duct Top Transition Duct

2 107231 Duct Side Transition Duct

1 107230 Duct Bottom Transition Duct

2 107233 Duct Extensions “BL” Models 500 and 600

2 107234 Duct Extensions “BL” Models 700 and 1050

Used on BL Sizes 500, 600, 700, & 1050 only. Not required on other Models and Sizes.

Factory-assembled for field attachment to a makeup air system

Attaching Cover and Assembling Transition Duct (FIGURE 2, STEPS 7-11)

6) Carefully lift the evaporative cooling module (ITEM 1) from both ends and place it on the

completed base assembly. Be certain that the cooling module is level and all base assembly bolts are secure.

7) Attach front top cover (ITEM 5) to cooling module, as shown in STEP #7 using 13 of the

# 10 x 1/2" long sheetmetal screws. There will be three screws per side and seven screws across the top.

8) Attach transition duct sides (ITEM 7) to duct top (ITEM 6) using eight, #10 x 1/2" long sheetmetal screws. As shown in STEP #8, there will be four screws per side.

9) Fasten the duct bottom (ITEM 8) to the transition duct sub-assembly begun above by following STEP #9, using eight of the #10 x 1/2" long sheetmetal screws

provided. Again, there will be four per side.

10)If the packaged heating system is a “BL” 500, 600, 700 or 1050 size, the duct

extensions (ITEM 9) must also be installed on the transition duct. If the packaged

heater is a “BL” 400, 800, or 1200 size, an RBL, or an ADF/ADFH, skip STEP

11 and continue with STEP 12.

11)There are two sizes of the duct extensions. One is used to fit the “BL” 500 or 600

size heaters; one fits the 700 and 1050 size heaters. To fasten the duct extension (ITEM 9) to the transition duct assembly, use 14 #10 x 1/2" long metal screws as

shown in STEP #11. Five screws will be used on each side of the extension and

one up through the bottom of the extension.

Mfg No. 160202, Page 3

Page 4

Assembling Transition Duct (cont’d)

Attaching Transition Duct and Cooling Module to System Cabinet (FIGURE 4, STEPS 12-

21):

FIGURE 3 Assembled Transition Duct

12)Following Step #12A, remove the screws from along the top rear lip of the blower cabinet panel. Slip the transition duct flange underneath the cabinet top edge and loosely insert two screws through the top edge, through the transition duct flange, and into the cabinet end panel. Follow STEP #12B.

13)If the transition duct has duct extensions (FIGURE 2, ITEM 9), insert the duct extension

mounting flanges into the slots on the cabinet end panel.

14)With the transition duct attached to the cabinet, carefully tilt the transition duct upward

enough to clear the cooler reservoir pan and slide the evaporative cooling module underneath the catch pad mounting trough. Squeeze the cooling module and transition duct assembly into the system cabinet until a tight fit is obtained.

15)Following STEP #15, line up the holes in the cooling module corner leg with the holes in

the transition duct sides. Using five #10 x 1/2" long sheetmetal screws per side, fasten the transition duct sides to the cooling moduler.

16)Following STEP #16, fasten the transition duct top lip to the front top cover of the

cooling module with seven of the #10 x 1/2" long sheetmetal screws provided.

17)With the cooling module and transition duct properly positioned on the blower cabinet, tighten the two screws loosely inserted in STEP 12B. Insert and tighten screws in the

remaining holes along top edge of cabinet.

NOTE: When attaching the transition duct to the cabinet (STEP 18 or 19), you may find it easier with the media pads removed. See FIGURES 5 and 7 and the corresponding

Evaporative Cooling Module

Front Top Cover

Catch Pad

Mounting Trough

Step 15

Step 16

FIGURE 4 - Illustration for attaching Transition Duct and Evaporative Cooling Module to the System Cabinet (illustration is angled for clarity; actual connections will be in a straight line)

Makeup Air

Transition

System Cabinet

Duct

Flange (must go under edge of cabinet top)

Step 12A

& Step 17

Step 19

Step 12B

Duct extensions (if used)

Step 18

are attached to the transition duct. Duct extension flanges go into slots on the cabinet.

Step 20

Form I-OPT-EC, Page 4

Page 5

instructions on pages 5 and 6 for removal and replacement of media pads. If optional moisture elimination pads are being included, media pads will have to be removed to complete the installation.

18)

If there are no duct extensions on the transition duct, reach inside the cooling module and fasten the cooler to the back of the cabinet and panel as shown in

STEP #18. There are no holes in the cabinet end panel, so six #10x1/2" long

self-drilling sheetmetal screws must be used. The screws are provided in the duct kit and are recognizable by their drill bit type cutter and slotted head.

19) If there are duct extensions on the transition duct, reach inside the cooling

module and fasten the duct extensions to the back of the cabinet end panel as

shown in STEP #19. There are no holes in the end panel, so four #10x1/2"

long self-drilling sheetmetal screws must be used. The screws are provided in the duct kit and are recognizable by their drill bit type cutter and slotted head.

20) Attach bottom of duct assembly, by using seven #10 x 1/2" long self-drilling screws, to the cabinet end panel as shown in STEP #20.

21) The evaporative cooling module should now be installed. Be certain all

screws are in place. Seal all corners of the transition duct assembly with a waterproof silicone sealant to prevent moisture from entering the cabinet.

5. Installing Optional Moisture Elimination Pads

Option ASA1 moisture elimination pads are shipped separately for field installation. Follow these installation instructions. If this option is not being installed, continue to Paragraph 6.

Media pads must be removed to install the moisture elimination pads (See FIG- URE 5). FIGURE 6 illustrates installation of the moisture elimination pads.

Remove Media Pads

FIGURE 5 - Removal (and Replacement) of Media Pads

1) Remove the three sheetmetal screws that hold the top

pad retainer.

2) Release the top pad retainer from the cooling module.

3) Remove the three sheetmetal screws that hold the

bottom pad retainer. Release the bottom pad retainer from the cooling module.

4) Disengage the screen retainers from the sides of the

media.

5) Disengage the inlet screen from the media pads and

remove from the cooling module.

6) Slide all media pads horizontally away from cooling

module until clear of bottom reservoir pan.

Install Moisture Elimination Pads (See FIGURE 6, page 6.)

1) Prepare module by attaching two catch pad clamps to one side of the cooler’s

front legs. Screw through the legs into the clamp with four of the #10 x 1/2" long sheetmetal screws provided.

2) Prepare catch pads by assembling them together. Use three of the #10 x 1/2"

long sheetmetal screws provided.

3) Guide the catch pad assembly through the inlet of the cooling module and

place the bottom of the lower pad into the catch pad mounting trough. The screen part of the catch pad assembly should always be facing the attached air mover. Slip the catch pad assembly into the two slots located in the catch pad clamps installed in Step (1).

4) With the pads in place, complete the assembly by sliding one of the two

remaining clamps over the middle seam where the assembled catch pads meet. Slip the other clamp over the top catch pad frame and fasten both clamps to the cooling module leg using sheetmetal screws provided.

Top Pad Retainer

Screen

Screen Retainer

Screw

Bottom Pad

Retainer

Media Pads

Mfg No. 160202, Page 5

Page 6

5. Installing Optional Moisture Elimination Pads (cont’d)

FIGURE 6 - Installation of Optional Moisture Elimination Catch Pads, Option ASA1

Install clamps on one side of cooler

Catch Pad Mounting Trough

Catch Pad

Step

Replace Media Pads (See FIGURE 5 and FIGURE 7, page 5.)

Reverse procedure in FIGURE 5 to replace the media.

Media must be installed as

shown in FIGURE 7.

6. Re-Position Pump/ Junction Box Assembly

To avoid shipping damage, the pump/junction box assembly is attached to the top of the side panel for shipment. Support the pump and remove the four screws that hold the assembly in position. Re-position the as-

sembly as shown in FIGURE 8 and attach using the same

screws.

Catch Pad

Step

FIGURE 7 - Airflow Direction through the Media Pads

IMPORTANT: Cooling media is made

Outside

Airflow

45°

up of two different sheets of cooling material. Each has its own unique angle. When replacing the cooing media, BE CERTAIN the 45° angle slopes downward toward the incoming outside air. If the media is not installed

Airflow

to Space

properly , water blo woff from the media pads will occur.

FIGURE 8 Re-position pump/ junction box

For shipping, pump/ junction box is attached at the top.

assembly.

Remove pump/ junction box from shipping position (above) and re-attach in “working” position (illustrated).

Catch Pad Clamp

Form I-OPT-EC, Page 6

Page 7

7. Electrical Connections

Line voltage wiring must be field installed between the blower junction box and the evaporative cooling module junction box. The tubing-encased wires are factoryconnected in the cooling module junction box.

NOTE: Models ADF/ADFH have only 115V optional evaporative cooling module

pumps. A transformer is included on the unit.

FIGURE 9A - Diagram of Evaporative Cooling Module Factory-Installed Wiring -- “BL” Models with 115/230/1/60 or 230/ 460/575/3/60 (Heater Options AK3, 6, 7 or 8) and Models ADF/ADFH 700/ 1200 (see Note above)

FIGURE 9B - Diagram of Evaporative Cooling Module Factory-Installed Wiring -- Systems with 208/ 1-3/60 (Heater Option AK2 or AK5)

EVAPORATIVE COOLING MODULE

COOLING CIRCUIT

115-230/1/60

111145 REV #4

EVAPORATIVE COOLING MODULE

SWITCH

FLOAT

SWITCH

PUMP MOTOR

W BK

LINE VOLT

PUMP MOTOR

W BK

N.O. TWO WAY

DRAIN VALVE FILL VALVE

BUCK-BOOST

40 VA. TRANSFORMER

230 VOLTFLOAT

OPTIONALOPTIONAL

THREE WAY

BL BR

Instructions for “Internal FieldRequired Wiring From Cooling Module to System Cabinet

WARNING: Disconnect power to the unit.

208/1/60

COOLING CIRCUIT

OPTIONALOPTIONAL

THREE WAY

111452 REV #4

N.O. TWO WAY

DRAIN VALVE FILL VALVE

NOTE: The two snap strain relief bushings are shipped in the bottom pan of the

cooling module.

1. Remove the compartment door panels and electrical compartment cover. Remove the service panel in line with the hole in the cooling module.

2. Drill a 7/8" hole in the cabinet end panel in line with the hole in the cooling module junction box.

3. Pull the tubing-encased wires through the hole in the blower cabinet. Place the strain relief bushings around the tubing and insert the bushing into the hole (Bushing must be used to prevent water from leaking into the cabinet). Route the wires across the cabinet bottom. If there are any filters, run the wires through the slot in the bottom filter rack. If there are inlet dampers, be careful that the wires do not interfere with the damper controls. Run the wires up to the electrical compartment, remove a plug from one of the bottom entrance hole, and push the tubing-encased wires into the electrical compartment. Place the other strain relief bushing around the tubing and insert the bushing into the hole in the electrical compartment.

4. Follow the wiring diagram included with the heater to properly connect the wires to the terminal blocks. If there is excess tubing and/or wiring, trim before making connections.

5. Before unit is operated, replace all door panels and fasten all latches.

Mfg No. 160202, Page 7

Page 8

Evaporative

Cooling Module

Float valve inlet water connection (1/4 compression) or inlet water connection to solenoid valve for metering system (1/2 male fitting)

Overflow fitting -

3/4 garden hose

thread tapped with

1/2 female NPT

Drain fitting - 3/4

garden hose thread

tapped with

1/2 female NPT

2-way solenoid valve

(normally open)

3-way

solenoid

valve

To drain

Pressure regulator (10 psi max)

Service valve

Roof

= Field-installed water piping

A (N.O.)

B (N.C.)

Water inlet

= Field supplied

8. Water Connections

FIGURE 10 - Connect Fresh Water Supply to Inlet of Float Valve

WARNINGS: Water reservoir (outdoor systems) must be drained and pump motor turned off when outside temperature falls below

32°F. Pump must never be operated without water in the reservoir.

Supply and Drain Water Connections Float Valve (FIGURE 10) - In a module with pump and float controls, a float valve

maintains the appropriate water level in the reservoir. Use a field-supplied 1/4" diameter tubing with a compression nut and tubing ferrule to connect the fresh water supply to the inlet of the float valve. Place nut and ferrule over tubing and insert tubing into the float valve stem. Tighten nut securely.

Compression Nut and

Float Valve Rod

Tubing Ferrule

FIGURE 11 - Water Connections including Optional Drain and Fill Kit

Instructions for Installing Optional Fill & Drain Kit

NOTE: Follow instructions included in the valve packages for attaching valves to the water line only. The remainder of the installation instructions with the valves do not apply to this type of application.

W ater Line Connections (See illustration.):

Supply (3-Way Valve) Connections - Connect the water

supply line to "B" (normally closed). Connect the water drain line to "A" (normally open). Connect the middle outlet to supply the water to the cooling module reservoir.

Drain (2-Way Valve) Connections - Connect the drain pipe

from the reservoir to "A". Connect the outlet side to "B" and connect into drain lines from the cooling reservoir and the supply valve.

Electrical Connections (requires black and white 14-gauge

wire) - Refer to Wiring Diagram provided with the furnace:

WARNING: Risk of electrical shock. Disconnect the power.

1. Refer to the wiring diagram for terminal connections. (NOTE: If kit is not ordered with the system, connections will not be shown on the diagram. Terminal connections are specific to each system. Contact the factory for terminal connections. Be prepared to provide all model information. )

Form I-OPT-EC, Page 8

An optional automatic fill and drain kit will automatically release supply water to the cooling module when a call for cooling is made and will drain all water from the reservoir when the cooling switch is deactivated or a cooling thermostat is satisfied. If

installing an optional fill and drain kit, see FIGURE 11 and follow the instructions that

apply. Consult the wiring diagram for electrical connections.

AquaSaver Timed Metering Control System - If the cooling module is equipped

with a timed metering system, connect a 1/2" water line to the fitting on the side of the cooling module. Due to various water pressures and installation conditions, the water supply line may bang abruptly when the solenoid valve in the AquaSaver system closes. This banging

Inside

Cabinet

Use 1/4” tubing for fresh water supply.

Simulates

Side

Panel

2. Run field-supplied black wire from the electrical compartment (terminal on the wiring diagram) of the evaporative cooling module and connect to the black wire on both the 3-way and the 2-way valve.

3. Run field-supplied white wire from the electrical compartment (terminal on the wiring diagram) of the evaporative cooling module and connect to the white wire on both the 3-way and the 2-way valve.

Page 9

can be minimized by installing a water hammer arrestor in the supply line. If installing an optional water hammer arrestor, select an indoor (above 32°F) location, either horizontal or vertical, in line with and as close to the solenoid valve as possible. Follow the manufacturer's instructions to install and maintain the water hammer arrestor. A freeze protection kit is available for a module with a timed control system. It includes a two-way valve and is shipped separately for field installation.

All Cooling Modules - A manual water shutoff should be installed upstream of the

inlet, at a convenient non-freezing location, to allow the water supply to be turned on and off. If necessary, install a bleed line between the manual valve and the cooling module inlet to allow drainage of the line between the shutoff valve and the cooling module. All cooling modules are equipped with an overflow and drain fitting. The fittings are in the cabinet bottom and come complete with a locknut and a sealing gasket. Check these fittings for tightness before installing the overflow and drain piping. The drain and overflow fitting will accommodate a 3/4" garden hose thread and is tapped with a 1/2" female pipe thread for iron pipe.

FIGURE 12 - Air Inlet Side of Evaporative Cooling Module Showing Bleed Line Fitting

Bleed

Line

Fitting

Install bleed line fitting (shipped in the bottom pan of the evaporative cooling module).

Bleed Line Connection (module equipped with pump and float controls only; does not

apply to module with AquaSaver nylon bleed line fitting (shipped in evaporative cooler bottom pan), thread the fitting into the female adapter on the distribution pipe. The hose barb will protrude from the

side of the cabinet (See FIGURE 12). Attach a 1/4" I.D. hose to the barb and run to the

nearest drain. Discharging a quantity of water by “bleed off” will limit the concentration of undesirable minerals in the water being circulated through the cooling module. Minerals buildup because evaporation only releases “pure water vapor” causing the concentration of contaminants in the water to increase as the evaporation process continues to occur. The minerals accumulate on the media, in the water lines, on the pump, and in the reservoir. Adequate bleed off is important to maintaining an efficiently operating evaporative cooling system.

Filling and Adjusting the W ater Level in the Reserv oir (module equipped with pump

and float controls only; does not apply to module with AquaSaver

trols) – Turn on the water supply. Check for a good flow. When the float valve (FIG- URE 10) shuts off the water supply, measure the water depth. The depth of the water

should be approximately 3". It may be necessary to adjust the float valve to obtain the proper water level or to free the float valve from obstructions. To adjust the float valve, carefully bend the float valve rod upward to raise the water level or downward the decrease the water level.

While the reservoir is full, check for any water leaks. The reservoir was tested, but if any small leaks are present, drain the reservoir and apply a waterproof silicone sealer around corners and welds.

timed controls) – Using the 1/4" I.D. x 1/2" N.P.T.

timed metering con-

9. Adjust Water Flow Over Pads

WARNING: Adjust ball valve only when power is disconnected from the unit. Failure to do so can cause electrical shock, per-

sonal injury, or death.

Proper water flow over the evaporative cooling media is critical to extend the life and maintain the efficiency of the pads.

CAUTION: Do not flood the media pads with extr eme quantities of water for long periods as this will cause premature breakdo wn of the media. An even flow fr om top to bottom of the media with the least amount of water is all that is required to assure maximum efficiency and media life span. More water does not provide more evaporation or more

cooling.

Float and Pump Control System - Using the ball valve (FIGURE 13, page 10), lo-

cated in the middle of the length of hose running from the pump to the sprinkler pipe inlet, adjust the valve handle to allow the flow to completely dampen the media pads from top to bottom.

Mfg No. 160202, Page 9

Page 10

9. Adjust Water Flow Over Pads

(cont’d)

FIGURE 13 - Disconnect the power and adjust the water flow with the ball valve.

Ball V alve

Operate the unit watching the water flow. After 15 minutes with the blower in operation, the water should have completely dampened the pads but should not be flowing off the entering side of the media. If water is flowing off the entering side of the media, turn the system off, disconnect the power, and reduce the entering water flow.

AquaSaver Timed Metering Control System - NOTE: Water flow and pad wetting time

should be adjusted at maximum airflow and wet bulb depression to assure complete wetting of the media at the extreme operating conditions. In addition to adjusting water flow, the timing of the water on/off cycle can be adjusted.

Adjustments are correct when l) the water rises from the holes in the sprinkler pipe (See FIGURE 14) consistently along the entire pipe length, 2) the media pads wet evenly after a few "ON" cycles (no dry spots or dry streaks), and 3) a slight amount of excess water

collects at the drain at the completion of the "ON" cycle.

1) AquaSaver Water Flow Adjustment - Using the ball valve illustrated in FIGURE 13, adjust the water flow depending on the pad height. See FIGURE 14.

FIGURE 14 Adjust W ater Flow with the Ball Valve in

Sprinkler Pipe

FIGURE 13.

2) AquaSaver Timer Adjustment - At any given temperature, the media pads should

completely wet from top to bottom during the ON cycle. The microprocessor has three preset timing settings based on media size. The appropriate setting is selected by changing the position of the suitcase jumper at J2 on the microprocessor. Remove the

cover and check the setting (See FIGURE 15).

Pad Height

24" (610mm) 1/8" to 1/2" (3 to 13mm)

48" (1219mm) 1/4" to 1/2" (6 to 13mm)

= Water rise from PVC

Sprink ler Pipe

FIGURE 15 AquaSaver Microprocessor Control in the Junction Box

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

12-36

(305-914mm)

Media

Height

NOTE: Prior to 2003 the AquaSaver timed cycle was con-

trolled by a mechanical timer. Turn the adjustment screw clockwise to increase the ON time or counterclockwise to decrease the ON time. One complete turn will adjust the cycle by 12 to 14 seconds.

If the jumper is at the appropriate location for the media, replace the cover. If the jumper needs to be moved, move it to the appropriate setting. The setting will go into effect when the power is restored. Check the "ON" timing; the media pads should be wet from top to bottom during the ON cycle.

If the preset timing is not suitable for the application, follow the instructions supplied with the microprocessor to change the calibration of the "On" and/or "Off" cycle.

All Modules - Check the reservoir for any water leaks. The reservoir was water tested, but

if any small leaks are present, drain the reservoir and apply a waterproof silicone sealer around corners and welds.

37-48

(940-1219mm)

Media

Height

49-72

(1245-1829mm)

Media Height

Maintenance

10. Media

Form I-OPT-EC, Page 10

Media - Over time, excessive amounts of mineral deposits will begin to build up on the

media. Annually, scale and dirt should be washed off the entering surface of the media. Remove the pad retainers and screen. Clean the media using a garden hose, mild soap, and a soft bristled brush. When the media becomes too clogged with mineral deposits and dirt that it cannot be cleaned, the pads should be replaced. The average pad life is approximately three cooling seasons.

Page 11

WARNING: Disconnect all power to the unit before doing any maintenance. Failure to do so may cause electrical shock, personal injury or death.

Instructions for Replacing Evaporative Cooling Media Pads (FIGURE 16)

Select the correct replacement part numbers and order replacement media pads through your Reznor Distributor. Follow the instructions below and remove and replace pads as

shown in FIGURES 16 and 17.

1. Remove the three sheetmetal screws that hold the top pad retainer in place. Release the top pad retainer from the cooling module.

2. Remove the three sheetmetal screws that hold the bottom pad retainer in place. Release the bottom pad retainer from the cooling module.

3. Disengage the screen retainers from the sides of the media.

4. Disengage the inlet screen from the media pads and remove from the cooling module.

5. Slide all media pads horizontally away from the cooling module until clear of bottom reservoir pan. Dispose of media properly.

6. Slide new media pads over both support rails until back stop is encountered. Media

MUST be placed with airflow as shown in FIGURE 17.

7. Center screen on the incoming air side of the media.

8. Re-position the two side screen retainers by fitting them between the side of the media pad and the side of the cooling module. The retainers should fit snugly, pinching the screen against the media pads.

9. Position the bottom pad retainer between the pad and the reservoir pan. Fasten with the three sheetmetal screws removed in Step 2.

10. Position the top pad retainer between the pad and the top of the cooling module.

Fasten with the three sheetmetal screws removed in Step 1.

Evap orative Coo ling M odu le Media Pads

Media Pad Sizes 6” 12” 6” 12” 48x12 4 107190 107194 107199 107201 48x8-5/8 1 107191 107195 107200 107202

Qty

Rep lacemen t Part N o.

Cellulose Glass Fiber

FIGURE 16 - Removal and Replacement of Evaporative Cooling Media

Media Pads

Screen

Screen Retainer

Top Pad

Retainer

Screw

Bottom Pad

Retainer

11. Water Lines

12. Water Pump

W ater Feed Line and PVC Distribution Piping – Annually, the water supply line and the

PVC water distribution pipe should be flushed of debris and contaminants. Remove the media pads following the instructions above. Remove the water feed line from the downstream side of the ball valve and unscrew the water bleed line barbed hose fitting. Force a fresh water supply up through the water inlet hose and thoroughly flush the distribution pipe.

Water Pump and Inlet Basket Screen – Annually, the pump and inlet basket should be

removed, disassembled and cleaned.

WARNING: Do not expose pump motor or any part of the electrical box to water. Evaporative cooling pump is NOT submersible.

FIGURE 17 - Airflow Direction through Media Pad

Outside

Airflow

45°

Airflow

to Space

IMPORTANT: Cooling media is made up of two differ-

ent sheets of cooling material. Each has its own unique angle. When replacing the cooling media, BE CERTAIN the 45° angle slopes downward toward the incoming outside air. If the media is not installed properly, water blowoff from the media pads will occur.

Mfg No. 160202, Page 11

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Maintenance (cont’d)

12. Water Pump

(cont’d)

FIGURE 18 Remove Junction Box, Pump and Float Switch as an Assembly

1. Disconnect the power supply to the unit.

2. Remove the junction box door and disconnect the two power supply wires from the terminal block inside the junction box.

3. Disconnect the water feed line hose from the upstream side of the ball valve.

4. Unscrew the four sheetmetal screws holding the junction box to the cooling module. Remove the junction box-pump-float switch assembly.

5. Dislodge the inlet basket screen from the pump and clean any buildup of debris and dirt. Carefully remove the base cover plate from the bottom of the pump. Using a mild soap solution, wash all deposits from the inside of the pump and remove all debris from the impeller.

6. Reassemble the pump. Replace the parts in exact reverse order, being careful that everything is returned to its proper position.

Pump Motor

Float

Switch

Junction Box

(Note: Only 208V unit will have a transformer in the junction box.)

Pump

Carefully remove basket and snap-on cover plate to clean pump.

SERVICE

WARNING: Disconnect the power before servicing the cooling module. Failure to do so can cause

13. Troubleshooting Chart

PROBLEM PROBABLE CAUSE REMEDY P

p doesn’t run

um (pump & float system) – Unit is calling for cooling and reservoir Required water level (3") not being maintaine d ( pump & float control system) Wat er r unning off of me dia pads Water not distributing evenly

Media pads becom ing cl ogged and discol o red quic kly (scale and salt deposits)

Water blowoff from me dia pads or w a t er bei ng pulled f rom reservoir.

1. Electrical connections (low voltage) 1. Verify all electrical connections . Verify correct voltage at pump terminals H

Electric float switch. 2. Check position of the actuators on the electric float switch.

3. Di

rty pump.3. Clean pump. See Paragraph 10.

Defective pump.4. Replace pump.

1. Fl

oat valve 1. Adjust float valve. See Paragraph 8.

2. Optional drain and fill valves 2. Check valves for proper operation. See Paragraphs 8 and 9.

Incorrect overflow pipe nipple (should be 3-1/2"). 3. Replace pipe nipple.

Drain leaking.4. Tighten drain fittings

1. Exc

essive water flow 1. Adjust ball valve in distribution line. See Paragraph 9.

2. Med

ia pads need cleaned or replaced 2. Clean or replace media pads . See Paragraph 10.

Distribution line clogged. 1. Flush distribution line. See Paragraph 12.

Holes in distribution line turned 2. Check position of distribution line. Holes should be spraying upward toward

3. Pump not running on correct voltage. 3.Check voltage at pump terminal in cooling module junction box

Bleedoff line clogged or inadequate bleedoff

(pump & float control system)

2. Excessive water flow. 2. Reduce flow by adjusting ball valve in distribution line. See Paragraph 12.

1. Me

ia pads installed incorrectly. 1. Install media pads correctly. See Paragraph 8.

Requires moisture elimination pad (Over 600

FPM)

3. Water level not 3" (pump & float system). 3. See second problem listed (Required water level not being maintained)

electrical shock, personal injury or death.

diffuser. If not positioned with holes toward top, adjust pos ition of line.

1. Clean bleed line. See Paragraph 8. A uniform buildup of minerals on the entering air face of the media indicates insufficient bleedoff. Increase the rate until the mineral deposits dissipate.

2. Install moisture elimination pad. Follow instructions, page 5.

Form I-OPT-EC, Page 12

(800) 695-1901 www.RezSpec.com

0514 OG POD Form I-OPT-EC (Version .2)

is registered in the United States and other countries.