Service Manual No 14 - Cooler Contour Seriesbrivis.com.au/marketing/manuals/evaporative_cooling...4 Introduction Brivis introduces 2 new models to the Contour Series, for the season

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Contents Page Introduction: . . . . . . . . . . . . 4 - 5 Technical Information: . . . . . . . . . . . . 6 - 12 Cooler Circuit Diagram: . . . . . . . . . . . . 13 Motor Circuit Diagram: . . . . . . . . . . . . 14 - 15 Installer Commissioning Instructions: . . . . . . . . . . . . 16 - 17 Installing Multiple Coolers: . . . . . . . . . . . . 18 Installer Set-Up Programming: . . . . . . . . . . . . 19 Cooler Operation: . . . . . . . . . . . . 20 - 57 General Operation . . . . . . . . . . . . 20 - 21 Networker Control in Auto Mode . . . . . . . . . . . . 22 Networker Control in Manual Mode . . . . . . . . . . . . 23 Wash Service . . . . . . . . . . . . 24 - 25 Flush Service Operation . . . . . . . . . . . . 26 N-E2 Electronic Controller Module Operation . . . . . . . . . . . . 27 - 29 Fan Operation . . . . . . . . . . . . 30 - 40

N-E2 Module Cooler Model Configuration . . . . . . . . . . . . 30 Speed Feedback . . . . . . . . . . . . 31 FAN_LIMP Mode - Networker Error 30 . . . . . . . . . . . . 32 DC Brake . . . . . . . . . . . . 33 Axial Fan Impellor Checks and Adjustments . . . . . . . . . . . . 34 - 35 Motor Failure - Networker Error 60 . . . . . . . . . . . . 36 Fan Will Not Operate . . . . . . . . . . . . 36 - 39 Fan Will Not Operate - Flowchart . . . . . . . . . . . . 39 Dismantling Fan and Fan Motor Removal . . . . . . . . . . . . 40

Pump Operation . . . . . . . . . . . . 41 - 46

Dismantling Procedure . . . . . . . . . . . . 41 Pump Will Not Operate . . . . . . . . . . . . 42 Electrical Checks . . . . . . . . . . . . 43 - 44 Mechanical Checks . . . . . . . . . . . . 45 Electrical & Mechanical Checks - Flowchart . . . . . . . . . . . . 46

Water Inlet Solenoid . . . . . . . . . . . . 47 - 51

Dismantling Procedure . . . . . . . . . . . . 47 Water Inlet Solenoid Does Not Supply Water Into Tank . . . . . . . . 48 - 50 Water Inlet Solenoid Does Not Turn OFF . . . . . . . . . . . . 51

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Contents Page ServoSeal and Drain Valve Operation . . . . . . . . . . . . 52 - 57

Dismantling Procedure . . . . . . . . . . . . 53 ServoSeal Will Not Open / Drain Close . . . . . . . . . . . . 54 ServoSeal and Drain Valve Diagnostic Checks . . . . . . . . . . . . 54 - 56 ServoSeal Motor Circuit Diagram . . . . . . . . . . . . 57

Trident Water Management Operation: . . . . . . . . . . . . 58 - 71

Trident Operation . . . . . . . . . . . . 59 Abnormal Operation . . . . . . . . . . . . 60 - 65 Water Limp Modes . . . . . . . . . . . . 60 Low Water Level Sensor - Networker Error 40 . . . . . . . . . . . . 61 High Water Level Sensor - Networker Error 41 . . . . . . . . . . . . 62 Drain - Networker Error 42 . . . . . . . . . . . . 63 - 64 Water Sense Failure - Networker Error 50 . . . . . . . . . . . . 65 Test Procedure and Service Checks . . . . . . . . . . . . 66 - 70 FlushService Guide Table . . . . . . . . . . . . 71 Dismantling . . . . . . . . . . . . 71

Networker Service Parameters: . . . . . . . . . . . . 72 - 74 Dealing With Problem Installations: . . . . . . . . . . . . 75 -79

Excessive Internal Noise From Unit . . . . . . . . . . . . 75 Excessive External Noise From Unit . . . . . . . . . . . . 75 - 76 Operation Noise . . . . . . . . . . . . 77 Condensation . . . . . . . . . . . . 78 Water Entering Building . . . . . . . . . . . . 79

Service Maintenance: . . . . . . . . . . . . 80 - 84

Pre Season Maintenance . . . . . . . . . . . . 80 - 83 End of Season Maintenance . . . . . . . . . . . . 84 Dismantling the Water Distribution System . . . . . . . . . . . . 84

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Introduction Brivis introduces 2 new models to the Contour Series, for the season of 1998. The new L10 and L20 models, in a new smaller cabinet, replace the temporary L10T and L20T units. All models are available in 6 different colours. Beige, Slate Grey, Terracotta, Caulfield Green, Heritage Red and Chocolate. Brivis Contour Coolers use the Networker wall control exclusively, and employ N-E2 electronic control system, which operates on a 2 wire bus communication scheme with the Networker. This system is capable of handling multiple Coolers, as well as combined cooling and gas ducted heating control, when using Brivis MPS and Auto EMS heaters. The Contour Cooler not only has a revolutionary new design and shape, but its construction is also unique. Radiating from the strength and support of the dropper duct, Contour Coolers engage a triangulation suspension construction. The external panels and tank are colour co-ordinated in UV stabilised plastic, and the low profile base design has allowed Contour Coolers to achieve greater performance with less water storage. A motorised duct damper called a ServoSeal, is built into the Cooler's base. The ServoSeal is integrated with a tank draining system, known as the Auto Refresh Tube (A.R.T.), which is an improved form of the conventional principle of a dump valve. Contour Coolers also feature a new water management system, that electronically controls the water levels, and tank water quality. During operation, the Cooler flushes away water with any salt build up, at intervals relating to the current operating conditions. At the end of use the Cooler performs a tank wash operation. All these innovative Brivis Contour features bring true meaning to the term "seasonal maintenance". Apart from good looks and superior control functions, Contour Cooler's design has provided a special dry compartment to house most of the unit's controls, components and wiring circuits.

5

Introduction (cont.)

The water circulation system of the Contour has been specially designed, by locating the Synchro-Drive pump in the dry compartment, with sealed piping to the pump's inlet and outlet. The pump itself has a magnetic coupling drive, and thermal protection on the motor windings. The N-E2 module controls the fan motor through a speed sensor circuit. This provides superior control of the motor's operation with smoother motor starts and speed adjustments, irrespective of duct resistance. The speed sensor also provides the motor with a DC voltage brake locking operation, to arrest the reverse rotation of the fan due to air up draught from within the building. The Contour N-E2 module has also been programmed to automatically engage Pre-Wetting of the filter pads, to ensure optimum performance of the Cooler.

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Technical Information Contour L 10 Sizing Guide Reference Figure 1000 - 1450

Cabinet detail

Width 960 mm

Height front 740 mm

Height back 430 mm

Length 960 mm

Dry Weight 46 kg

Wet Weight 56 kg

Filter Pad Details Down

Quantity 4

Thickness 75 mm

Type CELDEK 5090

Duct Outlet Size Down

Width 550 mm

Length 550 mm

Motor Pump/Water Distribution

Type 240 V - 1 ph Type ASKOLL.

Model BETTS Rating 240 V / .22 Amps 855BNVA-A12 Capacity 20 L/minute

Watts 315 Overflow size 40 mm

Amps 2.8 Waste Outlet Size 40 mm

R.P.M. 1400 Tank Capacity 10 Litres

Capacitor Size 8 uF Coil Resistance 169 Ohm

R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE

R.P.M Max Setting 1450 Inlet Valve Type Tech/Comp C202/89

Motor Selection No. Model 7 Inlet Valve Size 1/2" BSP (Male) Thread

Inlet Valve Rating 240 V - 0.033 Amps

Inlet Valve Capacity 12 L/minute

Fan Impellor ServoSeal Motor

Size 485 mm Type S.A.I.A

Types AUSWING 92 Rating 240 V 50 Hz 0.23W

Blades 5 RPM 500

Blade Angle 25o TIP Resistor 100 nF

Capacitor 470 Ohm Wall Controller

Type Networker

Water Connection

Flexible Hose Connection with 1/2" BSP (Male) Thread

Drain Connection

40 mm PVC

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Technical Information Contour L 10T Sizing Guide Reference Figure 1000 - 1450

Cabinet detail

Width 1060 mm

Height front 800 mm

Height back 480 mm

Length 1060 mm

Dry Weight 52 kg

Wet Weight 64.5 kg


Quantity 4

Thickness 75 mm

Type CELDEK 5090


Width 550 mm

Length 550 mm


Type 240 V - 1ph Type ASKOLL.














Blades 5 RPM 500



Type Networker

Water Connection


Drain Connection

40 mm PVC

8

Page 8


Cabinet detail

Width 960 mm

Height front 740 mm

Height back 430 mm

Length 960 mm

Dry Weight 46 kg

Wet Weight 56 kg


Quantity 4

Thickness 90 mm

Type CELDEK 5090


Width 550 mm

Length 550 mm



Model BETTS Rating 240 V / .22 Amps 855BQVA-A14 Capacity 20 L/minute













Blades 10 RPM 500



Type Networker

Water Connection


Drain Connection

40 mm PVC

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Technical Information Contour L 20T Sizing Guide Reference Figure 1250 - 1800

Cabinet detail

Width 1060 mm

Height front 800 mm

Height back 480 mm

Length 1060 mm

Dry Weight 52 kg

Wet Weight 64.5 kg


Quantity 4

Thickness 75 mm

Type CELDEK 5090


Width 550 mm

Length 550 mm


Type 240 V - 1ph Type ASKOLL.














Blades 5 RPM 500



Type Networker

Water Connection


Drain Connection

40 mm PVC

10


Cabinet detail

Width 1060 mm

Height front 800 mm

Height back 480 mm

Length 1060 mm

Dry Weight 52 kg

Wet Weight 64.5 kg


Quantity 4

Thickness 75 mm

Type CELDEK 5090


Width 550 mm

Length 550 mm
















Blades 10 RPM 500



Type Networker

Water Connection


Drain Connection

40 mm PVC

11


Cabinet detail

Width 1060 mm

Height front 800 mm

Height back 480 mm

Length 1060 mm

Dry Weight 52 kg

Wet Weight 64.5 kg


Quantity 4

Thickness 90 mm

Type CELDEK 5090


Width 550 mm

Length 550 mm
















Blades 10 RPM 500



Type Networker

Water Connection


Drain Connection

40 mm PVC

12


Cabinet detail

Width 1060 mm

Height front 800 mm

Height back 480 mm

Length 1060 mm

Dry Weight 52 kg

Wet Weight 64.5 kg


Quantity 4

Thickness 110 mm

Type CELDEK 5090


Width 550 mm

Length 550 mm
















Blades 10 RPM 500



Type Networker

Water Connection


Drain Connection

40 mm PVC

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Cooler Circuit Diagram Internal Circuit Diagram

PUMP

FAN MOTOR

N-E2 TRIDENT

WATER

MANAGEMENT

SYSTEM

NETWORKER

SPEED

SENSOR

WATER

INLET SOLENOIDMAINS

SUPPLY

A N

E

RU

N

ST

AR

T

CO

MM

ON

N

SERVOSEAL DAMPER / DRAIN VALVE

CAPACITOR

A N

SWITCHMOTOR

BLACK

RED

YELLOW

YELLOW

CAM

(CLOSE)

(OPEN)

RESISTOR /

CAPACITOR

N - E 2 B a s e T e r m in a l C o n n e c to r

M o u n t in g B ra c k e t

B r o w n

V a c a n tW h i te

R e dB la c k

P u rp leR e d

V a c a n t

D a r k B lu e

L ig h t B lu e

V a c a n t

B r o w n

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Motor Circuit Diagram Betts 315 Watt Motor 855BNVA-A12

GR

EE

N /

YE

LLO

W

BR

OW

N

BLU

E(C

OM

MO

N)

ST

AR

T 3

8.8

MA

IN 1

0.6

EA

RT

H

BLA

CK

(S

TA

RT

)

OV

ER

LO

AD

15

Motor Circuit Diagram (cont.)

Betts 750 Watt Motor 855BQVA-A12

GR

EE

N /

YE

LLO

W

BR

OW

N (

RU

N)

BLU

E(C

OM

MO

N)

ST

AR

T 1

5.8

MA

IN 3

.8

EA

RT

H

BLA

CK

(S

TA

RT

)

OV

ER

LO

AD

R esis tances a t 20 Co

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INSTALLER COMMISSIONING INSTRUCTIONS Wiring the Cooler to the Networker The first step is to run a twin wire cable (i.e. figure 8 cable - 0.75mm2) from the Cooler to the Networker. Next mount the Networker backing plate. Remove the backing plate from the Networker by unclipping it at the bottom. Be sure to draw the wires from the wall cavity, and feed them through the centre opening of the wall plate. Then mount the wall plate on the wall. Connect the cable to the Networker connection lead terminal block at the Cooler, and to the terminal block at the Networker.

Networker

If the Cooler is integrated with a Brivis MPS or Auto EMS heater(s), then simply connect the wiring in parallel with the heater's circuit to the Networker.

N e tw o rker

C o n tro l

T W 1

T W 2 N ET

W O RKER

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INSTALLER COMMISSIONING INSTRUCTIONS (cont.)

Wiring the Cooler to the Networker (cont.)

If more than one Cooler is connected on the system to one Networker, then all the Coolers will be wired in parallel to the Networker as shown. Ensure each Cooler is then configured correctly to the Networker, using the instructions on page 18.

Networker

Cooler No. 1

Cooler No. 2

Cooler No. 3

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Installing Multiple Coolers on the Network The Networker is capable of controlling multiple evaporative Coolers on the one system. When more than one Cooler is installed on a Networker, each Cooler must be given a different specific identification number, starting at No. 1, and each Cooler must also be designated to a zone (refer to the Networker - Advanced Programming Manual). First, complete the installation and wiring of all the units, as described on page 16 - 17, then proceed as follows: Each Cooler must be powered and configured individually, whenever any Cooler identification number is to be changed. Isolate the power from all other Coolers and Network appliances, other than the unit which the identification number is being changed, and proceed to make the change at the Networker wall control through the Installer Set-Up program as follows: • Turn the Networker OFF (ON/OFF button). • Press the Clock key to enter "Clock Set-Up" program. • Now simultaneously press, and hold the 2nd & 4th keys for 3 - 5 seconds, until the

screen changes to display:

1 07 E 1P aram e te r V a lu e P a ra m e ter N u m b er C o oler & U nit N o .

• Rotate the circular dial to change the parameter value displayed at the top left of

screen, to the unit number required for this Cooler i.e.:

2 07 E 1P aram e te r V a lu e P a ra m e ter N u m b er C o oler & U nit N o .

• Press the Networker ON/OFF button and exit the program.

• Turn the power supply at the Cooler OFF, to save the new identification number.

• Repeat the sequence for each Cooler, then follow the Networker Advanced Programming instructions to allocate the Coolers to their respective Networker zones.

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Installer Set-Up Programming Networker Wall Control Set-Up Parameters Example

01 01 n1Parameter Value Parameter Number Networker Wall

Control Parameter Display Parameter Description Entry Reference

1 00 n1 Networker Wall control Not Adjustable

1 01 n1 Refrig Common Zone Refrig Unit No. 0 03 n1 Refrig Zone A Refrig Unit No. 0 04 n1 Refrig Zone A damper Damper Relay No. 0 06 n1 Refrig Zone B Refrig Unit No. 0 07 n1 Refrig Zone B damper Damper Relay No. 0 09 n1 Refrig Zone C Refrig Unit No. 0 10 n1 Refrig Zone C damper Damper Relay No. 0 12 n1 Refrig Zone D Refrig Unit No. 0 13 n1 Refrig Zone D damper Damper Relay No.

1 15 n1 Heating Common Zone Heater Unit No. 0 17 n1 Heating Zone A Heater Unit No. 0 18 n1 Heating Zone A damper Damper Relay No. 0 20 n1 Heating Zone B Heater Unit No. 0 21 n1 Heating Zone B damper Damper Relay No. 0 23 n1 Heating Zone C Heater Unit No. 0 24 n1 Heating Zone C damper Damper Relay No. 0 26 n1 Heating Zone D Heater Unit No. 0 27 n1 Heating Zone D damper Damper Relay No.

1 29 n1 Evap Common Zone Evap Unit No. 0 31 n1 Evap Cooling Zone A Evap Unit No. 0 34 n1 Evap Cooling Zone B Evap Unit No. 0 37 n1 Evap Cooling Zone C Evap Unit No. 0 40 n1 Evap Cooling Zone D Evap Unit No.

0 43 n1 Circulation Fan Operation

(Heat) 1 = ON 0 = OFF

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Cooler Operation General Operation When the Networker is turned OFF, or is in a mode other than "Cooler", then the Contour Cooler will have the ServoSeal closed, and the tank drained, provided the unit has been in the OFF condition for longer than 60 minutes (originally 20 minutes). When the Networker is turned ON in Cooler mode, no function will occur until the Networker signals the Cooler to operate, i.e. the ServoSeal will remain closed and the tank empty. If either the fan or the pump is required to operate, then the ServoSeal will be driven open, before any other activity can run. The ServoSeal opening delay time is 20 seconds. The ServoSeal has a direct linkage to the drain valve, and the drain valve closes as the ServoSeal opens, and vice versa. On completion of the ServoSeal opening and drain valve closing action, if the Networker calls for the pump to operate, the water inlet solenoid will be energised to open, and the tank will begin to fill with water. The N-E2 module will not permit the pump to be energised, until the water has reached the low water level, on the Trident water management system. The water inlet solenoid will remain open until the water fills to the high water level on the Trident. If the Cooler pump has been OFF longer than 2 minutes the Cooler is programmed to automatically Pre-Wet the filter pads when the pump is turned ON, before the fan can start operating for both Networker Auto and Manual modes. This is to ensure in all circumstances the filter pads reach full saturation, and optimum cooling potential when the fan starts. The automatic Pre-Wetting time of the dried filter pads, will depend on how long the Cooler's pump has been OFF, as follows:

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Cooler Operation (cont.)

General Operation (cont.)

• If the pump has been OFF for less than 2 minutes (ShortDryPadTime), then no Pre-Wet will occur.

• If the pump has been OFF for less than 10 minutes (LongDryPadTime), but

longer than 2 minutes (ShortDryPadTime), a 1 minute (ShortPrewetTime) will apply.

• If the pump has been OFF for longer than 10 minutes (LongDryPadTime) then a

4 minute (LongPrewetTime) will occur. • If the power supply to the N-E2 has been interrupted, the first Pre-Wet will be 4

minutes (LongPrewetTime).

Pump ON

Pump OFF

No pre-wet

Fan ON

Pump ONPower

Interruption

Time interval from prior

pump operation more than

2 mins and less than 10

mins

1 minute pre-wet

(ShortPrewetTime)

Pump ON

4 minute pre-wet

(LongPrewetTime)

Pump ONPump ON

4 minute pre-wet

(LongPrewetTime)


pump operation less than

2 mins

(ShortDryPadTime)


pump operation more than

10 mins

(LongDryPadTime)

If the unit is turned OFF (i.e. pump and fan OFF) for longer than 60 minutes (originally 20 minutes) (ServoCloseDelay), the N-E2 module will automatically isolate the water inlet solenoid, and drive ServoSeal closed, closing the dropper duct and draining the tank.

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Networker Control in Auto Mode The following sequences are normal operation in Auto mode, with the Networker at a set comfort level, and the room temperature varying according to the Cooler's operation and load conditions. When the Networker is turned ON in Cooler Auto mode, an immediate signal is sent to the cooler to indicate if the unit is required to operate or not. If the comfort level setting is adjusted on the Networker when operating in Cooler Auto mode, an immediate signal is also sent to the cooler. Whenever the Networker sends an OFF or ON signal to the N-E2 module, both the pump and the fan will be turned OFF or ON, however, their operation may be delayed by the fill and Pre-Wet functions.

The Cooler will be turned ON, if the room temperature is 0.50C. higher than the set comfort level, and OFF if the room temperature is lower. The ON fan signal from the Networker accompanies a fan speed signal, to determine the speed required according to the temperature differential between the room temperature and set comfort level.

The fan will operate at minimum speed, when the room temperature is up to 10C. above the set comfort level, and is incremented to be at maximum fan speed, when

the room temperature is 50C. or more above the set comfort level. During normal operation, at 5 minute intervals, the Networker updates the N-E2 module on the temperature differential between room temperature and the set comfort

level, and if the temperature has varied by 0.50C. or more then the cooler is adjusted.

However, if the temperature changed rapidly by 2.50C or more, within the 5 minute update interval, then the Networker will signal the N-E2 module to adjust immediately. If the room temperature is higher than the set point when the Networker is turned ON, then the fan will immediately operate at the speed according to the set point, following the normal ServoSeal, water fill and Pre-Wet operations.

23


Networker Control in Manual Mode When operating the Cooler in manual mode, the Networker screen changes to display a pump and fan button for manual selection. The rotary dial is used to select the constant fan speed. The Pre-Wet times apply to manual mode, in the same way described for Auto mode. However in manual mode, the Pre-Wet period can be extended by simply operating the pump longer without the fan. Fan only operation is available for air movement in high humidity climate conditions, or for ventilation and circulation. NOTE: Should the pump be turned ON whilst the fan is operating, then the fan will be forced OFF for the Pre-Wet period, then come back ON again automatically.

24


Wash Service When the Networker is turned OFF, at the end of use, or the pump and fan have been OFF for more than 60 minutes (originally 20 minutes), the ServoSeal closes and the drain valve lowers to drain the tank water. Following the ServoSeal closing, the Cooler will automatically perform a tank washing action, after the time delay allowed for closing the ServoSeal ServoTime (20 seconds). A further 45 second delay (WashWaitTime) allows time for the tank to be drained completely, and initially wash out any sediment from the tank. With the drain valve still in the lowered position, the water inlet solenoid is opened for 30 seconds (WashTime), allowing clean water to further flush sediments from the tank base. On completion of the wash, an additional 45 second delay applies, before any other (new) operation can be performed i.e. Networker turned back ON again. The Cooler then remains idle until the Networker is turned ON again, and calls for cooling.

25


Wash Service (cont.)

Networker ON - No call for Operation

Call for Fan Operation

Call for Pump Operation with or without Fan

ServoSeal opens

Delay = 20 seconds

(ServoTime)

Fan turns ON

ServoSeal opens

Delay = 15 seconds

(ServoTime)

Inlet Valve opens and

Tank fills

Water at low level

Pump turns ON

Pre-Wet time starts

Pre-Wet complete

Fan turns ON if required

Networker turned OFF or call for

pump and fan to OFF

Delay = 60 m inutes (ServoCloseDelay)

ServoSeal Closes 15

seconds

Delay = 45 seconds

(WashWaitTime)

Water Inlet Valve opens 30 seconds

(WashTime)

Delay = 45 seconds

26


Flush Service Operation The N-E2 module program performs a tank flush at regular intervals, to dilute any salt and sediment build up as the unit is operating. The flush service will not affect the normal pump, or fan functions of the Cooler. The flush service timing is determined by the number of times the water has filled to the Trident High Water Level Sensor, and then evaporated down to the Trident Low Water Level Sensor. After 15 tank re fills (originally 10), the Flush Service commences. Each sequence of 15 refills of the tank, will force another the flush service operation, although the time between each Flush Service can vary, according to the conditions and Cooler settings. When the water level evaporates down to the Low Water Level Sensor for the 15th tank re fill, the water inlet solenoid will open and fill the tank to the high water level, then remain open for a further 100 second (originally 75 seconds) period. The water level will continue to rise above the High Water Level Sensor, and over flow out the drain valve / overflow pipe. The action of the fresh water entering, mixing and overflowing out from the tank, dilutes the salt and sediment ratio back to the original supply water condition.

27


N-E2 Electronic Control Module Operation The N-E2 module controls all the Cooler's working operations, using the signals from the Networker sent on a 2 wire bus network. The N-E2 will communicate with the Networker about the status of the Cooler's operation, including malfunction errors. Note: Although this error reporting is available on models later than September 1998, it's initial introduction will be restricted to the Melbourne market. The N-E2 is universal to all Contour Cooler models, but may require configuring to the model type, using the service parameters accessed through the Networker. The power supply input and output terminals to the N-E2 module, are via the base terminal connection mounting bracket. The module is correctly located into the mounting bracket via side slide rails. The N-E2 module has a isolating switch, that isolates the output power supply to all components within the Cooler. WARNING: The incoming 240 Volt power supply is not isolated using the N-E2 switch, and therefore some terminals within the Cooler will remain energised, until the main power supply on the unit's 3 pin plug and lead, has been disconnected. Wiring connections direct to the N-E2 module are, the Networker connection loom, the motor speed sensor and water level control looms. All installer and service parameter access is done through the Networker wall control.

M O T O R S P E E D

S E N S O R L O O M

W A T E R L E V E L

C O N T R O L L O O M

J 5J 6

J 1J 2

N E T W O R K E R

L O O M

A L T E R N A T IV E N E T W O R K E R

C O N N E C T IO N P O IN T

28


N-E2 Electronic Control Module Operation (cont.)

The N-E2 controller is fitted with an internal 8 Amp fuse to protect the PCB circuitry. The 8 Amp fuse will protect the N-E2 controller from short circuit and/or high current draw, on the following circuits: • Pump • Water inlet solenoid • Fan motor • PCB relays Important Note: The N-E2 internal 8 Amp fuse does not protect the control against short circuit on the ServoSeal / drain valve motor circuit. The N-E2 controller will maintain a minimum voltage on the output to the water inlet solenoid in the OFF cycle. Originally the N-E2's OFF cycle voltage was 60 Volt, and was later reduced 10 Volt. The N-E2 version with the 10 Volt OFF cycle voltage can be recognised by the inclusion of a 3rd (smaller) capacitor on the PCB (view through the case opening). N-E2 modules on models later than October 1998 have a new design plastic housing, which can be unclipped to access the PCB.

29


N-E2 Electronic Control Module Operation (cont.)

Service Checks N-E2 not operating: • Check for power supply to into the unit at the power point and Active - Neutral

incoming supply terminals.

• Check if the N-E2 power indicator LED is illuminated.

• Check the N-E2 is correctly located in the base terminal connector and mounting bracket.

• Check the N-E2 is set to the correct Network ID number.

• Check if the N-E2 internal 8 Amp fuse is in circuit or is open circuit.

• If fuse NOT open circuit:

• Check the Servoseal / Drain valve wiring loom, motor and switch mechanisms for short circuit.

• If fuse IS open circuit (blown):

• Check the pump motor and wiring loom for short circuit.

• Check the water inlet solenoid and wiring loom for short circuit.

• Check the fan motor and wiring loom for short circuit.

• Replace 8 Amp fuse and re test.

30


Fan Operation N-E2 Module Cooler Model Configuration The N-E2 module is capable of being set for up to 7 different Cooler models. This setting relates to the Cooler's motor capacity and the appropriate RPM range for correct operation. The minimum RPM setting is 500 RPM for all models, and the maximum RPM varies by the model setting selected (see table below). N-E2 Model Minimum Maximum Contour Models

Number RPM RPM Model 1

500 1350 L30, L40, L50

Model 2

500 1250 -

Model 3

500 1150 L30, L20T

Model 4

500 1050 L10T

Model 5

500 950 -

Model 6

500 850 -

Model 7

500 1450 L10, L20

Fan Operation The N-E2 controls the level of voltage output to the fan and this is determined within parameters of the Model Selection settings. The fan speed will vary on a linear scale between the minimum and maximum settings, even if the differential is minimal. Other service adjustments can be made within the Model No. range, and are discussed in the section regarding special adjustments using the Networker.

31


Fan Operation (cont.)

Speed Feedback The fan motor is fitted with a speed sensor which signals the motor RPM back to the N-E2 Cooler control. The N-E2 must have a speed sensor fitted and operating or the unit will operate in a FAN LIMP mode. The sensor is fitted to the special stub shaft provided on the motor and uses a light beam across the shaft flat section to register the revolutions of the motor's shaft. The purpose of the sensor is to: • Detect if the fan motor (impellor) is rotating when the power is first applied to the fan

motor.

• Detect if the fan motor is locked.

• Detect if the fan motor is not rotating within the correct operating range. If the N-E2 doesn't receive any signal from the speed sensor, or looses the signal, the N-E2 will adopt a FAN LIMP mode operation. Initially, when the motor is required to run and the speed signal is lost, the fan will immediately be driven to the maximum power (speed) for 60 seconds. Then the FAN_LIMP mode will commence, however, there will be a 4 minute delay before the error is displayed on the Networker (where available). If the condition rectifies itself, and the speed sensor signal is restored, then the Cooler will resume normal fan operation.

32



FAN_LIMP Mode - Networker Error 30

FAN_LIMP mode is displayed at the Networker as Error 30 whilst this condition is current (only on models later than Sept. 1998). In FAN_LIMP mode the fan speed is controlled to a phase angle, associated with the fan output level of the Networker, according to its mode and/or comfort setting. Therefore the fan can still vary in speed, whilst operating in LIMP mode and the user may not even notice any difference in the unit's operation.

Service

Service Check List

Check the speed sensor wire loom for damage, and plug connection into the N-E2.

Check the speed sensor is correctly located in the hub of the motor end plate.

Remove speed sensor from motor end plate and check;

• That no foreign matter has entered the sensor cap • The sensor PCB is firmly secured within the sensor cap. • The 2 sensor probes on the PCB are vertically aligned. • The wiring circuit within the speed sensor and the PCB is not damaged. • Check the motor start winding is not open circuit. • Check the motor capacitor - replace and retest. • Check the N-E2 is not faulty - replace and re test.

33



DC Brake Whenever the fan motor is required to operate, the N-E2 uses the motor speed sensor to checks if the motor is rotating. This rotation of the fan and motor, may be due to air up draught in the dropper duct, whilst the unit was not running. The N-E2 will apply a brake to stop the rotation by energising the motor with DC Voltage. This is to ensure the fan motor will not be energised and driven in the reverse direction. DC power will only be applied to the motor, if at the time the fan motor is powered, the motor has not been previously powered for a least 10 seconds, and that rotation is detected above the minimum RPM requiring the brake. The DC brake will then remain ON until the motor speed sensor registers the fan motor has slowed to a RPM not requiring the brake, before powering the motor for a normal start. The rate that the DC brake is applied, is a factory setting, and cannot be field modified. If the fan is operating in FAN_LIMP mode, then the DC brake will not be applied. Allow for the 4 minute delay period to register the error on the Networker, before the DC brake is disabled.

34



Axial Fan Impellor Checks and Adjustments The fan impellor blade angle is required to be set at the correct pitch angle for each model, check the Technical Information sheet for the model details. An incorrect blade angle setting may result in the following: - Too high current draw to the fan motor (especially at maximum speed). - Excessive operation and air noise. - Reduced airflow output from the fan (especially at maximum speed). - Reduced variation of fan speed selection or function. The fan impellor is designed to be located flush at the top of the fan motor shaft. The blade tips should be positioned centrally within the bell housing. This position has been determined to give the optimum performance of the unit, without generating excessive levels of noise. The fan impellor retaining bracket bolts are required to be tightened to the minimum tension of 8 Nm torque, to ensure the fan impellor is securely held in position.

35



Axial Fan Impellor Checks and Adjustments (cont.) The Auswing fan impellor has a notch indicator on the hub adjacent to the blade. The diagram below shows the approximate notch setting, refer to the Technical Information sheets for the blade angle required for the model.

Fan Blade

Reference Points

25

33o

o

36



Motor Failure - Networker Error 60

Should the motor circuit and or the Coolers motor main winding be open circuit, the N-E2 module will lockout and display the error at the Networker

This error condition requires a power up reset to restore the Coolers operation. Refer to motor diagnostics for check list.

Service

Fan Motor will not Operate

• Turn the fan ON in manual mode and make sure the motor is not in an operation delay period i.e. Servoseal open time.

• Check the impellor is free to turn.

• Check the motor shaft is free to rotate and is not jammed.

• Remove the N-E2 and check the motor wiring terminals are correctly positioned on the circuit board and that the connections are good.

• Check the motor winding resistance (refer Motor Circuit Diagram and Technical Information Sheet).

OFF

10 A V

COM1000V- - -

750V

V

OHMS

Multimeter

FUSED

MOTOR/COMMON-BLUE

MOTOR/START-BLACK

MOTOR/RUN-BROWN

• Check the motor is not HOT and the thermal over load switch is not open circuit.

• Check the incoming power supply is ON and is the correct polarity.

37


Fan Motor will not Operate (cont.)

Check for 240 Volts at terminals MOTOR/RUN-BROWN and MOTOR/COMMON-BLUE on the motor supply loom terminals, located on the service compartment back wall (max fan speed selected).

OFF

10 AV

COM

FUSED

1000V- - -

750V

V

VOLTS

Multimeter

240

MOTOR/RUN-BROWN

MOTOR/COMMON-BLUE

If 240 Volts present:

• Check for Volts at terminals MOTOR/COMMON-BLUE and MOTOR/START-BLACK on the motor supply loom terminals located on the service compartment back wall (max fan speed selected).

• Replace capacitor and test again.

• Replace fan motor.

OFF

10 AV

COMFUSED

1000V- - -

750V

V

VOLTS

Multimeter

240MOTOR/COMMON-BLUE

MOTOR/START-BLACK

38



Fan Motor will not Operate (cont.)

If no Volts present:

• Bridge terminals MOTOR/RUN-BROWN and MAINS/ACTIVE-IN using a multimeter set on Amps (check current for motor - refer motor specs).

NOTE: Because the start winding is not in circuit, the motor may need to be manually turned to start.

OFF

10 AV

COM

FUSED

1000V- - -

750V

V

Amps

Multimeter

4.7

A

MOTOR/RUN-BROWN

MAINS ACTIVE-IN

If motor runs:

• Check the motor wiring loom and all terminals.

• Check minimum RPM setting (see section - Service Adjustments using the Networker.

• Check the N-E2 internal 8 Amp fuse is not open circuit.

• Replace N-E2 and test again.

• Check that the ServoSeal has been driven open, indicating Networker signal operating correctly.

• If ServoSeal not open

• Replace Networker and test again.

If motor doesn't run: • Replace motor.

39



Fan Motor will not Operate - Flowchart

Fan Checks

Check if the impellor and motor shaft are free to rotate and are not jammed.

Check the incoming power supply is ON and is the correct polarity.

Check for 240 Volts at terminals Motor/Run - Brown & Motor/Common -

Blue on the motor supply loom terminals located on the service compartment back wall.

If 240 Volts Present If NO Volts Present

Check for 240 Volts at terminals

Motor/Common - Blue and

Motor/Start - Black

Replace capacitor and test again.

Replace fan motor

Bridge terminals

Motor/Run - Brown and

Mains/Active - In

If motor runs If motor doesn't run

Replace motor

Check minimum RPM setting

Check the N-E2 8 Amp fuse

is open circuit

Check the motor wiring loom

and all terminals

Replace N-E2 and test again

Check that the ServoSeal has been

driven open, indicating Networker

singnal operating correctly

If ServoSeal not open -

Replace Networker and test again

40



Dismantling - Fan and Fan Motor Removal • Remove thumb screws from roof panel.

• Remove the 4 filter pad frames and support tube brackets.

• Isolate power supply on service access cover switch.

• Close the ServoSeal / Drain valve and drain tank of water.

• Remove the 2 screws from the service access panel and open cover.

• Unplug the Trident loom plug from the N-E2 control.

• Remove the pump inlet lock nut from the tank base.

• Remove the 4 screws that secure the tank to the coolers sub frame, then lift up and remove the tank assembly.

• Remove motor wire loom terminals on the motor supply loom terminal block located on the service compartment back wall.

• Feed back the wiring into the fan motor assembly area and disconnect the cable ties from the motor bracket

• Disconnect the speed sensor loom from the N-E2 circuit board, and feed back the wiring loom to the motor assembly.

• Loosen and remove the nuts on the fan impellor retaining bracket bolts.

• Place a 50mm or larger socket fitting or similar, over the motor shaft and fan impellor retaining bracket, so that it seats on the fan impellor hub body. Use a mallet to hit the 50mm socket fitting, to release the tapered bracket cone from the hub, loosening the impellor on the motor shaft.

• Remove impellor.

• Support the motor's weight, then loosen and remove the 2 nuts and washers on the bolts, that secure the fan motor mounting bracket around the motor's case.

• Lower fan motor down and out of the mounting bracket.

41


Pump Operation The Contour Cooler's pump has a synchronous motor with thermal protection, and a magnetic coupling drive to the pump impellor. The pump impellor may be driven in either rotation direction, which lessens the likelihood of the pump blocking. The pump base is integrated into the tank base and should not require removal. The pump will be turned OFF for 10 seconds at 15 minute intervals, to allow the water head in the feed tube to the distribution spreader to back flush the pump, and keep it clear of blockages. Additionally, if the pump had an air lock, this pump stoppage will allow water into the pump, to resume normal operation again. All servicing and maintenance can be done through the service access compartment. Dismantling • Isolate the 240 Volt power supply to the pump (N-E2).

• Open service access compartment cover.

• Drain the tank of water.

• Disconnect the wiring terminals on top of the pump motor.

• Remove 3 screws on the perimeter of the pump upper housing.

• Separate the upper pump housing from the base, which remains plumbed in the

tank.

• Unclip the motor winding cover.

• Slide the winding and lamination plate assembly up and off the pump housing centre.

• Slide the winding coil out from the lamination plates.

42


Pump Operation (cont.)

Pump will not operate

• Check that the pump is switched ON and that the pump is not in an operation delay

period i.e. water contact across Trident probes or Servoseal open time.

• Check for 240 Volt output to the pump, at the PUMP-NEUTRAL and PUMP-ACTIVE terminals on the pump.

OFF

10 AV

COM

FUSED

1000V- - -

750V

V

VOLTS

Multimeter

240PUMP - NEUTRAL

PUMP - ACTIVE

43



Electrical Checks

If power present: • Check the pump wire loom and connections.

• Refer to mechanical pump checks on page 45.

• Check the pump motor winding is not open circuit.

• Isolate the electrical supply and use a multimeter on the Ohm's setting to check

the circuit resistance at terminals PUMP-NEUTRAL and PUMP-ACTIVE (169

Ohms +/- 5% @ 200C.)

• Replace pump winding assembly.

OFF

10 AV

COMFUSED

1000V- - -

750V

V

Ohms

Multimeter

169

A

PUMP - NEUTRAL

PUMP - ACTIVE

If pump doesn't operate: • Refer to mechanical checks.

• Replace pump.

44



Electrical Checks (cont.)

if NO power:

• Check the Cooler's operation is not in a delay period preventing the pump from functioning.

• Check the power supply is turned ON and is the correct polarity and voltage

(MAINS/ACTIVE-IN and NEUTRAL terminals).

• Check the N-E2 module is turned ON and is correctly located in the mounting plug.

• Bridge terminals PUMP-ACTIVE and MAINS/ACTIVE-IN using multimeter set on Amps.

If pump functions:

• Check the pump loom and all terminals. • Check the N-E2 internal 8 Amp fuse is not open circuit. • Replace N-E2 and re-test. • Replace Networker and re-test.

O F F

10 A V

C O MF U S E D

100 0V - - -

7 50 V

V

A m ps

M u ltim e te r

.22

A

M A IN S A C T IV E -IN

P U M P - A C T IV E

If pump doesn't operate:

• Refer to mechanical checks.

• Replace pump.

45



The following checks are required if the pump has power, but will not operate, or is not pumping sufficient water to the filter pads. Mechanical Checks • Check that the tank water level is correct.

• Check the water distribution piping is not blocked.

• Dismantle the pump as per the instructions on page 47.

• Check and clear the lower pump housing of any obstruction.

• Check the pump impellor is not damaged, and can rotate within the upper pump

housing.

• Replace upper pump housing assembly, if impellor damaged or jammed.

46



Electrical & Mechanical Checks - Flowchart

P u m p E le c tr ica l & M e ch a n ica l

C h e cks .

P u m p w ill n o t o p e ra te .

I f N O p o w e r

C h e ck th e C o o le r's o p e ra tio n is n o t in a d e la y

p e rio d p re ve n tin g th e p u m p fro m fu n ct io n in g .

C h e ck th e p o w e r su p p ly is tu rn e d O N a n d is th e co rre c t

p o la rity a n d v o lta g e

C h e ck th e N -E 2 m o d u le is tu rn e d O N a n d is co rre c tly

lo ca te d in th e m o u n tin g p lu g .

C h e ck th a t th e p u m p is sw itch e d O N a n d th a t th e re is 2 4 0 V o lt o u tp u t to th e p u m p a t

th e P U M P -N E U T R A L & P U M P -A C T IV E te rm in a ls .

C h e ck th e p u m p m o to r w in d in g is n o t o p e n c ircu it.

Iso la te th e e le c tr ica l su p p ly , a n d ch e ck O h m 's a t P U M P -N E U T R A L &

P U M P -A C T IV E te rm in a ls .

I f p o w e r p re se n t

C h e ck th e p u m p w ire lo o m a n d co n n e c tio n s .

B rid g e te rm in a ls P U M P -A C T IV E &

M A IN S -IN .

If p u m p fu n c tio n s :

R e p la ce N -E 2 a n d re -te s t.

R e fe r to M e ch an ica l P u m p

ch e cks .

C h e ck th a t th e ta n k w a te r le ve l is

co rre ct.

C h e ck th e w a te r d is trib u tio n p ip in g

is n o t b lo cke d .

C h e ck a n d c le a r th e lo w e r p u m p h o u s in g o f

a n y o b s tru c tio n s.

C h e ck th e p u m p im p e llo r is n o t d a m a g e d a n d ca n ro ta te w ith in th e u p p e r

p u m p h o u s in g .

R e p la ce u p p e r p u m p h o u s in g a sse m b ly if im p e llo r is d a m a g e d .

D ism a n tle p u m p a s p e r in s tru c tio n

o n P a g e 4 7

If p u m p d o e sn 't o p e ra te :

R e fe r to m e ch a n ica l ch e cks .

R e p la ce p u m p .

R e p la ce p u m p w in d in g a sse m b ly

R e p la ce N e tw o rke r

a n d re -te s t.

If p u m p d o e sn 't o p e ra te :

R e fe r to m e ch a n ica l ch ecks .

R e p la ce p u m p .

C h e ck th e p u m p

lo o m a n d a ll

te rm in a ls

C h e ck th e N -E 2

in te rn a l 8 A m p

F u se is n o t o p e n

c ircu it

47


Water Inlet Solenoid Operation The Contour Cooler has a 240 Volt water inlet solenoid on the under side of the base, at the high side of the roof. The water inlet solenoid has a flexible hose attached with a filter inserted in the hose connections at each end. A 3/4" to 1/2" BSP nipple is provide for the installer for a convenient connection to the hose. The water inlet solenoid is assembled in a bracket to support the pipe connection and the outlet discharge, which is direct to a fitting moulded into the Cooler base on the high roof side. The wiring loom to the water inlet solenoid is concealed under the base, and feeds back into the service access compartment. Note: The water inlet solenoid uses the water supply pressure to it's diaphragm in the closing action of the valve. Ensure the solenoid closes within 5 seconds of turning the 240 Volt power OFF to the water inlet solenoid. Dismantling • Turn OFF the water and disconnect the water supply pipe.

• Remove the screw on the water inlet solenoid support bracket.

• Slide the assembly across and out to disconnect the wire loom.

• Retract the pipe from the base tank fitting and remove inlet solenoid assembly.

• Remove the water inlet solenoid screws, and remove water inlet solenoid.

OR

• Unscrew pipe fittings from the water inlet solenoid.

To access filter, remove the inlet nipple from solenoid, remove filter insert from the inlet opening of the solenoid.

48


Water Inlet Solenoid Operation (cont.)

Water inlet solenoid does not supply water into the tank (empty): • Check that the Cooler is turned ON calling for cooling (pump operation) and is not in

an operation delay period i.e. Servoseal delay. • Check the water supply tap is turned ON. • Check that the water supply pressure is within the operation range (300 kPa - 1000

kPa). • Check that an Error 50 (both High and Low Level Water Sensors are open circuit) is

not current. • Check that the water inlet solenoid is energised (240 Volt), at the water INLET

SOLENOID-ACTIVE and INLET SOLENOID-NEUTRAL terminals, on the service compartment back wall.

OFF

10 AV

COM1000V- - -

750V

V

VOLTS

Multimeter

240

FUSED

INLET VALVE - NEUTRAL

INLET VALVE - ACTIVE

49



If power present and inlet solenoid doesn't open: • Check the water inlet solenoid wire loom and connections.

• Isolate power and check the Water Inlet Solenoid coil resistance (3.9 kOhms).

INLET VALVE - NEUTRAL


OFF

10 A V

COM1000V- - -

750V

V

kOHMS

Multimeter

FUSED

3.9

• Check if the water inlet solenoid is blocked.

• Replace water inlet solenoid.

50



if NO power:

• Check the Cooler's operation is not in a delay period preventing the water inlet

solenoid from functioning.

• Check the power supply is turned ON and is the correct polarity and voltage (Mains Active In and Neutral terminals).

• Check the N-E2 8 Amp fuse is not open circuit.

• Check the N-E2 module is turned ON and is correctly located in the mounting plug.

• Bridge power supply using a multimeter in series on Amp setting between

MAINS/ACTIVE-IN and WATER INLET SOLENOID-ACTIVE terminals.

OFF

10 A V

COMFUSED

1000V- - -

750V

V

Amps

Multimeter

A

MAINS ACTIVE-IN


If water inlet solenoid operates:

• Replace N-E2 module, and check for output voltage to the water inlet solenoid.

If water inlet solenoid doesn't operate:

• Check wiring terminals & loom.

• Check water inlet solenoid is not blocked or jammed.

• Replace water inlet solenoid.

51



Water inlet solenoid does not turn OFF • Check the water inlet solenoid closes within 5 seconds of turning the 240 Volt power

OFF. • Check the Trident wiring loom is connected to the N-E2 and the plug connection is

good. • Check the Trident loom circuit output and water contact sensitivity at both the probe

and the N-E2 plug terminals (see test procedure Trident Water Management section page 58)

If loom not connected (open circuit) • N-E2 Error 50 - Water inlet solenoid open for 15 minutes before lockout.

• Check that the water inlet solenoid is not energised (240 Volt) at the WATER INLET SOLENOID-ACTIVE & NEUTRAL terminals.

If power present:

• Check if the Networker is turned ON and cooling required.

• Check the Cooler water level is not at a level that requires the water inlet solenoid to

be energised.

• Check the Cooler is not in a pre-program operation, requiring the water inlet solenoid to be operating i.e. wash or flush function.

If no power:

• Check the water inlet solenoid has not blocked or jammed open.

52


ServoSeal and Drain Valve Operation Contour Coolers have a new and unique mechanism, to close off the duct and simultaneously drain and empty the Cooler's tank, at the end of use. The ServoSeal is a set of adjustable louvres constructed in the Cooler's base, which are driven closed and prevent heat loss from the building, when the unit is not in use. An electric motor drives a linkage that opens and closes the louvres. This motor has another lever that operates at the same time, to raise and lower a flexible drain outlet tube. When the ServoSeal closes the dropper duct, the drain outlet tube is lowered to a position that all the tank water is naturally drained from the Cooler. The motor that drives both the ServoSeal and drain linkages, is 240 Volts controlled through a geared cam shaft and switch. The motor is powered to open on one switch circuit, and powered to close on another. The cam shaft causes the switch contacts to open, stopping the motor and mechanism at the correct position, whether the motor is to be driven forward or reverse.

53


ServoSeal and Drain Valve Operation (cont.)

Dismantling ServoSeal / Drain Valve Motor (only) removal: • Isolate the 240 Volt power supply (N-E2).


• Disconnect the ServoSeal / drain valve motor wiring loom.

• Remove the motor retaining clip holding the motor onto the gear linkage

mechanism.

• Retract the motor. With the motor removed the gear linkage mechanism action can be manually operated and checked. Motor and gear linkage mechanism removal: • Remove the drain valve level set screw and release the level from the geared cam

shaft.

• Remove the fan impeller from the fan motor shaft, to gain access to ServoSeal louvre linkages (refer to fan dismantling procedures).

• Remove the 2 linkage retaining screws that hold the lower linkage arm onto the

ServoSeal louvre coupling.

• Remove the 3 screw retaining the gear linkage mechanism to the service compartment back wall.

• Manoeuvre the linkage arms through the service compartment back wall opening,

and remove assembly.

• Disconnect motor cam lever switch.

• Disconnect linkage arm and cam shaft.

54



ServoSeal will not open / drain close • Check the power supply is turned ON, and is the correct polarity and voltage

(MAINS/ACTIVE-IN and NEUTRAL terminals).

• Check the N-E2 module is turned ON, and is correctly located in the mounting plug.

• Check that the Networker is turned ON, and calling for a pump or fan operation (allow 45 seconds following a wash operation).

• Check if 240 Volt power present on the ServoSeal / drain valve MOTOR-SWITCH

(a) and MOTOR (b) Active Open terminals and Neutral (see diagram). If power is present to the switch terminal, but not to the motor terminal: • Check wiring loom and connections between the motor and the micro switch for

open circuit.

• Check the MOTOR/MICRO-SWITCH cam shaft is not damaged.

• Replace the faulty motor micro switch.

OFF

10 AV

COM

FUSED

1000V- - -

750V

V

VOLTS

Multimeter

240(a)MAINS ACTIVE-IN

(b)

MOTOR/MICRO-SWITCH

MOTOR-ACTIVE

55



If power is present at the motor terminal: • Check the ServoSeal / drain valve motor winding resistance

(12.5 kOhm @ 200C.) on both motor windings (ACTIVE to NEUTRAL). Refer to diagram below and circuit on page 57.

• Replace faulty ServoSeal / drain valve motor.

OFF

10 A V

COM1000V- - -

750V

V

kOHMS

Multimeter

FUSED

12.5

(a) (b)MOTOR-ACTIVE

MOTOR-ACTIVE

MOTOR-NEUTRAL

If ServoSeal / drain valve motor does not operate: • Remove motor from gear linkage mechanism and re test.

• Replace motor resistor / capacitor (RC) with same at terminal block, and re-test. If motor operates: • Check linkages are free moving and not jammed.

• Check gear linkage mechanism is not jammed.

• Replace gear linkage mechanism.

56



If NO power present at ServoSeal motor Active Open terminal: • Check the N-E2 module is turned ON, and is correctly located in the mounting plug

and re-test for power.

• REMOVE N-E2 and bridge power supply using a multimeter in series on Amp setting, between MAINS/ACTIVE-IN and ServoSeal / drain valve MOTOR-ACTIVE Open terminal (Black) (see diagram).

WARNING When powering the ServoSeal drain valve motor, ensure the ServoSeal is in a position to open/close, depending on which direction the motor is to be driven. If the motor is driven too far in either direction, damage will occur to the linkages and mechanism.

OFF

10 A

V

COM

FUSED

1000V- - -

750V

V

Amps

Multimeter

A

MAINS ACTIVE-IN

MOTOR-ACTIVE

If ServoSeal / drain valve motor operates:

• Check wiring and connections for open circuit. • Replace N-E2 module and re test.

If ServoSeal / drain valve motor doesn't operate:

• Remove motor from gear linkage mechanism and re-test. • Replace motor.

57



ServoSeal will not close / drain open: • Check that the ServoSeal / drain valve action is not in a delay period, from a prior

Cooler operation. i.e. 60 minute - ServoCloseDelay.

• Follow check procedures as above for ServoSeal will not open / drain close, with

power test to Active Close terminal on ServoSeal motor and switch. Circuit Diagram:

SWITCHMOTOR

BLACK

RED

BLACK

RED

YELLOW

YELLOW

12.5 kOhm @ 20 CO

CAM

To N-E2

(CLOSE)

(OPEN)

(CLOSE)

(OPEN)

RESISTOR /

CAPACITOR

58

Trident Water Management System The Contour Cooler's tank water level is regulated, by turning ON and OFF the water inlet solenoid as required, according to the operating conditions. After the initial filling, at which point the water inlet solenoid turns OFF, the Cooler looses tank water volume due to evaporation, in the normal course of the unit's operation. The rate of water evaporation is dependant on the current climatic conditions, the Cooler's operating fan speed and the condition of the filter pad material. All of these of course are infinitely variable. The water management system uses 3 stainless steel probes, to detect the water level within the tank. Original Trident Probe Configuration A low voltage output from the longest probe (at the bottom of the tank), will make a closed circuit through the water, when the water rises and contacts the other 2 probes. The shortest probe will have a closed circuit at the high water level, and the N-E2 module control circuit will turn OFF the water inlet solenoid at this point, during normal operation. The 3rd mid level probe, the low water level registers when the water level has dropped within the tank due to evaporation or is filling to a level the pump can start operation. Revised Trident Design (post Nov. 1997) The mid level probe is the common low voltage output. The shortest probe is the high water level. The longest probe is the low water level. The switch function of both version are the same, however, the revised version design has the common voltage output probe, at a closer position to both low and high level probes.

59

Trident Water Management System Trident Operation When the Networker is turned ON, and the cooler is required to start from an empty tank, the pump is delayed until the tank has sufficient water for it to operate. As the tank fills, the water eventually makes contact between the Common Water Sensor probe and the Low Water Level Sensor probe, at which point the pump can start operation (Pre Wet). When the tank fills to the high water level the N-E2 switches OFF the water inlet solenoid. During the course of normal operation, with the water inlet solenoid closed, the tank water level is evaporated down to the low water level. The water contact between the Common Water Sensor and the Low Water Level Sensor probes becomes open circuit. The N-E2 will then switch on the water inlet solenoid again to refill the tank to the high water level. The N-E2 module is programmed as part of the overall control, if the expected water levels are not achieved within designated times, then the N-E2 will go to water level limp mode operation. As the water level control probes will be constantly subjected to water and electrical power during normal operation, it is expected that a coating will eventuate, depending on the water quality.

60

Trident Water Management System (cont.)

Abnormal Operation Water Limp Modes The Trident water management system will automatically adopt a controlled operation, if it detects the malfunction of the sensing probes, or detects water in the tank when it's not expected. There are 4 water management errors modes, and these operation modes are communicated to the Networker (models later than Sept. 1998) to indicate the malfunction. Low Water Level Sensor (failure) - Error 40 High Water Level Sensor (failure) - Error 41 Drain (operation failure) - Error 42 Water Sense Failure (both low and high level sensors) - Error 50 Water Limp mode errors 40, 41 and 42, do not require the cooler to be shut down, but the coolers filling and flush operation is time controlled. These errors (where available) will only be displayed during the time the water inlet solenoid is open and will alternate between the error screen and the normal display. The N-E2 module will delay, for 4 minutes, any Limp mode error display at the Networker, just in case the error rectifies itself. Should the Limp mode condition correct itself, then normal operation and function times will be restored. Error 50 is different and will cause a lockout, but provides the user the facility to reset the operation at the Networker. However, if the condition is still present after reset, the unit will lockout again.

61


Abnormal Operation (cont.)

Low Water Level Sensor (failure) - Networker Error 40

Low Water Level Sensor - Fails to sense or is short circuit. Fails to sense:

• Water detected at the High Water Level Sensor, but not seen at the Low Water Level Sensor.

Short circuit:

• Closed circuit on Low Water Level Sensor for 120 minutes (was 20 minutes) of pump operation, since water detected on the High Water Level Sensor (i.e. low evaporation).

Temporary

Low Water Level Sensor Limp Mode Operation: • Pump starts operation at the High Water Level Sensor

• Water inlet solenoid closes when water is sensed at the High Water Level Sensor.

• Water inlet solenoid is timed OFF for 90 seconds, then refills to High Water Level

Sensor again. To rectify this condition, refer to Service Checks on page 70.

62



High Water Level Sensor (failure) - Networker Error 41

High Water Level Sensor - Fails to sense or is short circuit. Fails to sense:

• Open circuit on High Water Level Sensor after 3 minutes of detecting water on the Low Water Level Sensor.

• Water is detected at the Low Water Level Sensor only, and

inlet solenoid has open for 15 minutes.

Temporary

Short circuit: • From start up the Low Water Level Sensor is open

circuit (normal), and the High Water Level Sensor is closed circuit.

High Water Level Sensor Limp Mode Operation • Water inlet solenoid closes after 3 minutes of the water detected at the Low Water

Level Sensor. • Water inlet solenoid open when open circuit occurs on Low Water Level Sensor. • Water inlet solenoid timed to fill for 40 seconds, then closes again. To rectify this condition, refer to Service Checks on page 70.

63



Drain (operation failure) - Networker Error 42

Drain - Failure to drain tank once the ServoSeal is closed.

Water is sensed on both high and low sensors, on completion of a WashWaitTime (45 seconds) following a Wash.

i.e. • blocked drain • shorted contacts - stick, leaf

Temporary

Operation sequence on shutdown cycle: • Pump and fan OFF for 60 minutes.

• ServoSeal closes and drain valve opens (20 seconds).

• WashWaitTime period starts (45 seconds).

• Water inlet solenoid opens for 30 seconds. (WashTime).

• WashWaitTime period starts (45 seconds).

• N-E2 checks for closed circuit on the Low and High Water Level Sensors.

• Closed circuit on the Low and High Water Level Sensors with ServoSeal closed and

drain valve open is registered.

• Malfunction remains current on next operation of cooler.

• Error 42 will display only when water inlet solenoid opens.

• Error 42 can only reset at the end of Wash sequence with no closed circuit to the Water Level Sensors.

Even if the closed circuit on the water sensors has cleared by the next start up of the cooler, this error remains current until it completes a successful shut down without this error condition.

64



Networker Error 42 Drain - Failure to drain tank once the ServoSeal is closed (cont.) Operation sequence on start up cycle: If the closed circuit on the water sensors has not cleared on the next start up of the cooler, then the Cooler operation will commence as follows: • ServoSeal opens and drain valve closes (20 seconds). • The Water inlet solenoid will open provided the water level is not already at the High

Water Level Sensor (closed circuit). • The pump will start operating because the Low Water Level Sensor indicates water

is at a sufficient level for the pump. However, if both the Low and High Water Level Sensors have failed short circuit, then the Low Water Level Sensor failure will be forced after 120 minutes (was 20 minutes) of pump operation. Error 40 code will be displayed, alternating with this drain error, when and if the water inlet solenoid is open. Because both the Low and the High Water Level Sensors are closed circuit, the water inlet solenoid will remain closed. As the water inlet solenoid will not open, the coolers tank will not fill, and/or any water that was present will eventually evaporate. This condition will not harm the pump, but will result in poor and inadequate cooling performance. To rectify this condition, refer to Service Checks on page 70.

65



Water Sense Failure - Networker Error 50

Water Sense Failure Fails to sense - Both the Low and High Level Water Sensors fail to sense (open circuit) within 15 minutes of Water Inlet Solenoid opening.

Service

Reset

Operation sequence: • Water inlet solenoid opens. • Open circuit on Low Water Level Sensor after 15 minutes. • Open circuit on High Water Level Sensor after 15 minutes. • Lockout forced (error displayed at Networker). • Water inlet solenoid closes. • 20 minutes delay till ServoSeal closes and drain valve opens. • ServoSeal closes and drain valve opens (20 seconds). • WashWaitTime period starts (45 seconds). • Water inlet solenoid opens for 30 seconds (WashTime). • WashWaitTime period starts (45 seconds).

If both the Low and High Water Level Sensors have failed short circuit, then the Low Water Level Sensor failure will be forced after 120 minutes (was 20 minutes) of pump operation. Error 40 code will be displayed, alternating with this drain error, when and if the water inlet solenoid is open.

Because both the Low and the High Water Level Sensors are closed circuit, the water inlet solenoid will remain closed.

As the water inlet solenoid will not open, the coolers tank will not fill, and/or any water that was present will eventually evaporate. This condition will not harm the pump, but will result in poor and inadequate cooling performance. To rectify this condition, refer to Service Checks on page 70.

66


Trident Test Procedure & Service Checks The N-E2 has a 14 Volt output to the Trident water sensing probes. This voltage can be measured between the Common and the High and Low Level Water Sensors in a dry tank. With water contact between the probes, the voltage drop across the Common and the Low and High Water Level Sensor probes varies, depending on the quality of the tank water. Dry Tank Test: With the tank empty of water • Check for 14 Volt across the Common (black) Water Sensor probe and the Low

Water Level (white) probe. • Check again for 14 Volt (with no voltage drop) across the Common (black) Water

Sensor probe and the Low Water Level (white) probe whilst gently wiggling the Trident loom plug and connection on the N-E2.

• Check for 14 Volt across the Common (black) Water Sensor probe and the High

Water Level (red) probe. • Check again for 14 Volt (with no voltage drop) across the Common (black) Water

Sensor probe and the High Water Level (red) probe whilst gently wiggling the Trident loom plug and connection on the N-E2.

Refer to diagrams on pages 68 & 69. If less than 14 Volts: • Check the Trident wire loom and loom connections. • Check the Trident loom for continuity. • Check the N-E2 Trident connection for 14 Volt output. • Check the N-E2 8 Amp fuse is not open circuit. • Check for N-E2 PCB track fracture adjacent Trident plug connection (may be

intermittent).

67


Trident Test Procedure & Service Checks (cont.)

Wet Tank Test: Commence filling the tank with water then: • Check the pump operates when water makes closed circuit at the Common and Low

Water Level Sensor probes. • Check for voltage drop (must be less than 9 Volt) across the Common (black) Water

Sensor probe and the Low Water Level (white) probe. • Check that the water doesn't overflow out the drain tube before the water reaches

the High Water Level Sensor. • Check for voltage drop (must be less than 9 Volt) across the Common (black) Water

Sensor probe and the High Water Level (red) probe. Refer to diagrams on pages 68 & 69. If voltage doesn't drop below 9 Volts: • Check for coating on the Water Sensor probes preventing circuit. • Check for high water quality (not able to make circuit - refer to Brivis).

68



R ED

W H ITE

BLA CK

G uard W ater

Sensor

Loom C ntrl-

W ater Sensor

M O TO R SPEEDSEN SO R LO O M

W ATER LEVEL

C O N TR O L LO O M J 5J 6

J 1J 2

N ETW O R KERLO O M

ALTER N ATIVE N ETW O R KERC O N N EC TIO N

PO IN T

H igh W ater Level

C om m on Sensor

Low W ater leve l

OFF

10 AV

COM

FU S ED

1000V - - -

7 50 V

V

VOLTS14 14 Volts - D ry

W hen water m akes closed circuit

m ust be less than 9 volts - W et

Com m on Sensor and H igh W ater Level

Heatshrink Sensor

S trip (100m m )

Com m on

Pin

H igh W ater

Sensor P in

Plastic Guide

69



RED

WHITE

BLACK

Guard Water

Sensor

Loom Cntrl-

Water Sensor

MOTOR SPEEDSENSOR LOOM

WATER LEVEL

CONTROL LOOM J 5J 6

J 1J 2

NETWORKERLOOM

ALTERNATIVE NETWORKERCONNECTION

POINT

High Water Level

Common Sensor

Low Water level

OFF

10 AV

COM

FUSED

1000V- - -

750V

V

VOLTS14 14 Volts - Dry

When water makes closed circuit

must be less than 9 volts - Wet

Common Sensor and Low Water Level

Heatshrink Sensor

Strip (100mm)

Common

Pin

Low Water

Sensor Pin

Plastic Guide

70

Page 70



Service Checks • Check the water inlet solenoid is energised.

• Check the water supply stop tap is turned ON.

• Check the water inlet solenoid operates.

• Check the water inlet solenoid and supply hose filters are not blocked.

• Check if the pump operates when powered ON and delivers sufficient water to the

distribution system.

• Check the water distribution system is not blocked.

• Check the filter pads are in good condition and not damaged.

• Check if low evaporation rate conditions have applied.

• Check if the ServoSeal opens and the drain valve is closes fully.

• Check if the ServoSeal closes and the drain valve opens fully.

• Check for coating on the sensor probe which may prevent proper circuit.

• Check if the sensor probe wiring and terminals are open circuit.

• Check if the sensor probe wiring and terminals are short circuit.

• Check the N-E2 internal 8 Amp fuse is not open circuit.

• Check the N-E2 module is located correctly in the base terminal connection mounting bracket.

• Check the Trident loom and plug connections.

• Check in the N-E2 is a 10 Volt output to the water inlet solenoid in the OFF cycle.

• Check the water inlet pressure is within 300 - 1000 kPa.

71


FlushService Guide Table The higher the quality of the water supply to the cooler, the more tank refills Cooler can operate before a FlushService will be required. As the water quality also varies the Wet Test voltage readings, the appropriate FlushService cycle may be individually set to that water quality. The following table is a guide to the FlushService cycle rates based on the entering water supply quality. The voltage reading should be based on the initial fill of the tank, when using this guide. The voltage may vary between the Low and High Level Water Sensors, so average the 2 voltage readings.

Trident Voltage 0 <--> 2 Volt 2 <--> 3 Volt 3 <--> 6 Volt FlushService Cycle

Rate 10 Cycles 15 Cycles 25 Cycles

Dismantling: • Isolate the 240 Volt power supply to the pump (N-E2).


• Disconnect the water level sensor loom from the N-E2.

• Remove the 2 retaining screws at the top of the probe assembly and remove.

72

Networker Service Parameters To access the Cooler's service parameters, first enter Cooler installer mode as if to change the Coolers ID number as described earlier. Turn the Networker OFF.

Press Clock key to enter "Clock Set-Up" program.

Now simultaneously press, and hold the 2nd & 4th keys for 3 - 5 seconds, until the screen changes to display:

1 07 E 1P aram ete r V a lue Param eter N um b er C o oler & U nit N o .

Rotate the circular dial to change the parameter value displayed at the top left of screen, to the unit number required for this Cooler i.e.:

2 07 E 1P aram ete r V a lue Param eter N um b er C o oler & U nit N o .

Next enter the special service access code on the Networker, and the screen will move onto the parameter numbers as detailed on the table that follows. To change to the parameter number requiring adjustment, press the top button to select the next parameter number, and the second button to select the previous parameter number. Rotate the dial when the appropriate parameter number is selected, to vary the value as displayed. Display as typical default setting when entering adjustment mode:

60 01 E1Parameter Value Parameter Number Cooler & Unit No.

The values are presented in one of the following units: • Time increment of either seconds, minutes or hours. • RPM. • Numerical number where 0 = OFF & >0 = ON (i.e. 1 - 255).

73

Networker Service Parameters (cont.)

Descriptions: ServoCoseDelay - This is the time delay in minutes, from when both the fan and the pump stop operating, until the ServoSeal closes and the drain tube lowers to drain the tank water. FillTime - This is the time in minutes, from when the water inlet solenoid opens, that water must be sensed on either of the water level probes, before a lockout will occur. MinSpeed / MaxSpeed - These are the adjustment parameters, to vary the minimum and maximum fan RPM, from the default settings as per the N-E2 model selection. This may be required to reduce the Cooler's performance, due to cooler over/under sizing or inadequate duct sizing etc. It is not possible to set the minimum speed higher than the maximum speed, and vice versa. The closer the minimum and maximum speeds are set, the less variation there will be in the Cooler's fan output. ShortDryPadTime - This is the time in minutes, the pump can be OFF and the filter pads not wetted, before a Pre-Wet will be required. FlushService - This is the number of filling operations, between the high and low water sensors, due to the evaporation of water during operation, before the tank will be flushed to dilute the salt build up. ShortPrewetTime - This is the Pre-Wet time in seconds, that occurs if the pump has been OFF longer than the ShortDryPadTime, and less than the LongDryPadTime. LongPrewetTime - This is the Pre-Wet time in seconds, that occurs if the pump has been OFF longer than the LongDryPadTime. ShortDryPadTime - This is the time in minutes, the pump can be OFF and the filter pads not wetted, before a Pre-Wet is required. LongDryPadTime - This is the time in minutes, the pump can be OFF and the filter pads not wetted, before a LongPrewetTime Pre-Wet will be required.

74

Networker Service Parameters (cont.)

Name No. Range Units Default Description

ServoCloseDelay 1 1-255 Minutes 60** Delay after pump and fan turn OFF, before ServoSeal

closes

FillTime 2 1-255 Minutes 15 Maximum time for an empty tank to fill to a water sensor

level

MinSpeed

3

*

RPM

*

Minimum fan speed.

MaxSpeed 4 * RPM * Maximum fan speed.

ModelNum

5

1-7

Units

1

Model type number

Short DryPadTime

13

1-255

Minutes

2

Time pump can remain OFF before a pre-wet is required.

FlushService 15 1-255 Cycles 15** Number of tank refills before a FlushService

ShortPrewetTime

18

1-255

seconds

60

Normal (short) Pre-Wet time

LongPrewetTime 19 0-255 seconds 240 Long Pre-Wet time

LongDryPadTime 20 0-255 Minutes 10 Time pump is OFF to force long pre-wet

*Defaults to RPM specified by model number selection

** Pre 1/2/98 ServoCloseDelay = 20

&

FlushService = 10

75

Dealing with Problem Installations Excessive External Noise from Unit Check the ducting system for any restriction or sizing error, that would contribute to higher than recommended back pressure on the fan. Note the dropper duct take off sizes and details of the main, branch ducts and outlet diffusers. Assess the installation requirements in regard to the maximum airflow, to determine if the fan maximum speed can be reduced, without compromising the effectiveness of the system. Use the Networker service access to adjust fan as required.

Excessive Internal Noise from Unit Outlet Air Noise: Check to see if the correct unit size has been selected for the application. Use the sizing guide factor for the locality, and the type of cooled area to determine the unit size, as per table below.

Cooler Model Maximum Output Selection

Guide L10

L20

L 30

L 40

L 50

1000 - 1450

1250 - 1800

1500 - 2250

2000 - 2750

2400 - 3200

76

Dealing with Problem Installations (cont.)

Calculate the volume of the individual areas the Cooler's outlets are serving. The locality factor is used to multiply by the room volume, to determine the correct minimum duct and register sizes. Check that the duct and outlet sizes selected, are capable of delivering the total output of the Cooler selected, as per the minimum recommended size tables.

Duct Capacity Outlets Capacity

Duct Size Cooling Airflow

Size (mm) Airflow Capacity

250 mm 150 L/s

250 X 250 Up to 100 L/s

300 mm 275 L/s

300 X 300 Up to 250 L/s

350 mm 425 L/s

350 X 350 Up to 375 L/s

400 mm 600 L/s

400 X 400 Up to 500 L/s

450 mm 990 L/s

450 X 450 Up to 600 L/s

500 mm 1080 L/s

550 mm 1230 L/s

600 mm 1420 L/s

If the room and/or the area air requirement calculation is less than 85% of the Cooler's maximum output (midway between the minimum and maximum Output Selection figure) , then the duct and outlet sizes should be increased to meet this level.

77


Check if the unit selection is excessively over sized, which would require the duct and outlets to be significantly upgraded to carry the additional air quantity of the Cooler. The Cooler Selection Chart can be used as a reference in this respect, for the calculation of minimum sized ducting and outlets to upgrade to.

Operation Noise: • Check that the ducting has not been damaged or restricted.

• Check the dropper duct has been secured to the roof timbers, or supported

sufficiently, so as not to transfer vibration through other structural members of the building.

• Check the water pipe and wiring (conduit) is not transferring vibration to structural members of the building.

• Check the duct and fittings are insulated.

• Check the Cooler is not transferring excessive vibration onto the dropper duct of the buildings structure.

78


Condensation: Condensation in evaporative systems may be a result of the humidified air from the outlets, passing over a surface that has a temperature cool enough to condense the vapour suspended in the air, onto the cool surface. An example of this is an outlet air stream directed onto a refrigerated cabinet in a shop, or moist air contacting a cool tile floor surface. In most cases, the concentration of the air from the outlet is the main contributing factor for the condensation, therefore it is advisable to redirect the air stream. Condensation may also result from excessive humidity, due to either the current climate conditions, or that the conditions have changed rapidly, cooling the room air that has a high humidity or water vapour content. Excessive humidity may also be a result of an inadequate exhaust area. Make sure enough window and/or door area is open, for the unit to work correctly. The table below shows a guide to the amount of opening required, for effective cooling for each model.

MODEL Highest Fan Setting Lowest Fan Setting L10 1.0 m2 0.6 m2

L20 1.5 m2 0.9 m2

L 30 1.9 m2 1.1 m2

L 40 & L 50 2.3 m2 1.4 m2

79

Page 79


Water Entering Building When dealing with the problem of water entry in a building, it is often difficult to ascertain the water source, due to water tracking and capillary action. The following checks relate to both Cooler faults and installation faults: • Check the Cooler's base and trough is not damaged.

• Check the Cooler is installed level and the overflow pipe can function correctly.

• Check the water distribution system is not blocked causing incorrect / excessive

water to pads or water tracking.

• Check the operation of the filter pads and ensure there is no water lift off.

• Check the flashing of the dropper duct, water supply pipe, electrical conduits and drain pipes for leakage.

• Check internal water pipe and drain pipe lines and fittings for leakage.

• Check the roof (tiles etc.) for damage.

• Check for any sign of water/moisture, on the inside of the ductwork and bell housing.

• Check the route of any water discharge from the Cooler i.e. roof guttering and water run off area down stream of Cooler.

80

Service Maintenance

Pre Season Maintenance The service to a Contour Cooler requires access to the home to check the performance of the unit through the duct system and the function of the wall control. Service work performed without access cannot be responsible for the system operation, only the Coolers function.

General checks

Check and seal the dropper duct flashing and any other roof penetrations.

Check the drain discharge point is appropriate for the installation - rectify or advised owner.

Check if the tank and internal surfaces require cleaning and clean as required using 5 mL / 10 L (4%) chlorine as per page 83.

Check the unit is not operating in a Water or Fan Limp mode, refer to service manual to diagnose and correct.

Water Inlet Solenoid Check the Water Inlet Solenoid and water supply hose has filters fitted and are

clean.

Check the water supply hose and clamps are in good condition and upgrade the hose if the hose clamps are the pressed clamp type.

Check the Water Inlet Solenoid opens in the normal operation sequence and closes within 5 seconds of the N-E2 turning OFF the power supply.

Check the water pressure is sufficient to fill the tank within the 15 minute FillTime, otherwise adjust service parameter to suit.

Check for 14 Volts on the Trident Common and Low & High Level Sensor probes with the tank dry.

Repeat the check gently wiggling the Trident loom plug connection at the N-E2, and check if the voltage varies (refer service manual).

Check the voltage on the Trident Common and High & Low Level Sensor Probes with the tank full (must be less than 9 Volt).

81

Service Maintenance

Pre Season Maintenance (cont.)

Check the pump operation commences at the water contact point of the Common and Low Water Level Sensors.

Check the Water Sensor probes for coating build up and clean as required.

Set the FlushService cycle parameter relevant to the wet voltage reading (see service notes).

Check the water Inlet Solenoid closes at the contact of water at the High Level Water Sensor.

Check the water doesn't overflow out the Drain tube before the water is sensed at the High Level Water Sensor.

Check the pump water discharge is sufficient for correct pad saturation.

Aqua Duct

Check the Aqua Duct water distribution system is clean and has no blockages on the pad distribution Outlets.

Motor and Fan Checks

Check the fan motor rotates freely and that the motor bearings are not worn.

Check the motor speed sensor is clean, the beam sensors are vertically aligned, and that the sensor is correctly located in the motor's end plate.

Check the DC brake is operating correctly.

Check the fan impellor is centred within the bell housing.

Check the motor stator bracket and mountings are not damaged.

Check the fan impellor is correctly tensioned and has the correct blade height and angle.

Check the fan motor varies through the entire range.

Check the minimum and maximum RPM setting are appropriate for the duct installation.

82

Service Maintenance

Pre Season Maintenance (cont.) ServoSeal and Drain Valve

Check the ServoSeal louvers seal correctly in the closed position.

Check the ServoSeal louvers drive open fully in the open position.

Check the Drain Valve raises to the correct height above the High Water Level Sensor

Check the Drain Valve lowers to the correct position allowing the tank to be completely drained.

Check the ServoSealCloseDelay parameter is set correctly. Filter Pads

Check the pads are not damaged or have deteriorated and require replacing.

Check the pads are correctly fitted.

Check the pads are wetted evenly. System Operation

Check the outlet diffusers are correctly positioned and the louvre blades are configured for best room air mixing.

Check the air distribution is correctly balanced.

Check there is adequate exhaust opening available for correct operation.

Check the Networker wall control is located in a suitable position for correct operation.

Check the Coolers Pre Wet function is operating correctly.

Check the unit operates in both Manual and Auto modes.

83

Service Maintenance

Pre Season Maintenance (cont.)

The following procedure is the recommended practice set out by the Australian Department of Health:

Add 5 ml of available 4% Chlorine (household bleach) for every 10 Litres of tank water.

Mix the Chlorine in the water and wipe all internal surfaces.

Operate the pump only for 30 minutes to flush the pads with the water solution.

Drain the tank and refill with clean water.

Operate the pump for 5 minutes to rinse the pads and drain again.

Refill the tank with clean water, operate the pump for 5 minutes to rinse the pads and drain again to complete.

84

Service Maintenance End of Season Maintenance Turn OFF the water supply to the unit at the isolating stop tap. NOTE * Do not turn OFF the power supply to the Cooler for longer than is necessary

for carrying out maintenance. * If the power supply is turned OFF, the Networker will lose its Time/Day

settings. * If power must be switched OFF, first make sure the ServoSeal is completely

closed.

Dismantling the Water Distribution System

• Remove the 4 plastic thumb screws from the roof. • Remove the front and back pad frames, lift the roof to release the frames from the

cabinet. • Disconnect the 19mm clear water feed tube to the roof assembly at the base

connection. • Remove the roof assembly. • Release the 4 plastic thumb screw bushes from the inner distribution tray of the roof

assembly. Push the bushes out of the distribution tray. • Separate the roof outer and the inner distribution tray. • Clean the components and reassemble.

Documents

Service Manual No 14 - Cooler Contour Seriesbrivis.com.au/marketing/manuals/evaporative_cooling...4 Introduction Brivis introduces 2 new models to the Contour Series, for the season