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Service Manual 32 – Contour 3 Series, Profiler & Advance – Approved Issue 5 Printed 2/13/2014 11:50:17 AM

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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-E5 turning OFF the power supply.

Check the water pressure is sufficient to fill the tank within the 15 minute Fill-

Time, 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-E5,

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).

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Summary of Contents for advance

Page 1: ...Service Manual 32 Contour 3 Series Profiler Advance Approved Issue 5 Printed 2 13 2014 11 50 17 AM 1 ...

Page 2: ...F 43 24 Advance F 53 25 MOTOR CIRCUIT DIAGRAMS 26 27 COOLER CIRCUIT DIAGRAM 28 INSTALLATION Wiring the cooler to Networker 29 30 Installing Multiple coolers on a Network 31 Installing dual Networkers 32 34 Networker Installer Parameters 35 COOLER SERVICE PARAMETERS 36 39 COOLER OPERATION General Operation 40 43 Wash Service 44 Flush Service 46 Aquasave Operation 47 N E5 Electronic Control Operatio...

Page 3: ... the Contour with its sloping base but slight changes have been made to the decorative panels The Brivis Profiler cooler is also slightly smaller in height than the Contour Brivis Contour Brivis Profiler Both models Brivis Profiler and Contour now use the N E5 control box instead of the older N E4 The main difference in the N E5 control is the removal of the isolating switch from the top of the co...

Page 4: ...t the cooler should be located high enough on the roof to prevent the back from touching the roof The PAD FRAMES are attached in a similar fashion to the Contour and Profile unit The front and rear pads can be removed by first lifting the roof assembly and then lifting the pad assembly out the same way the Contour and Profiler work The SIDE PAD FRAMES are slightly different and involve the pad fra...

Page 5: ...ion and can only be accessed by using a Networker N E5 parameter adjustments Parameter number Parameter description Default setting 0 Series Contour 1 Series Contour 2 Series Contour 3 Series Contour or Profiler 3 Series Advance 05 Model selection number Determines min max fan speeds 1 Check specification sheet Check specification sheet Check specification sheet Check specification sheet Check spe...

Page 6: ... was 60 meaning 60 minutes before the cooler would dump New setting is 6 meaning 6 lots of 10 minutes which equals 60 minutes If service parameter 01 on the newer N E5 is changed to 60 when we service these units it will then dump after 10 hours 60 x 10 minutes 600 minutes Vice Versa if Parameter 01 on the first version N E5 is set to 6 it will then dump after 6 minutes In both cases this will cau...

Page 7: ...cause analysis has since proven that the cause of Servo seal failures is due to power spikes degrading PCB components The version 9A is the latest N E5 control which has been upgraded to protect components from power spikes Field tests have already proven that the version 9A N E5 is very reliable The Version 9A controllers can be identified by the marking 9A on the box Action Technicians when atte...

Page 8: ...s action should only be performed on 1 or 2 series Contour coolers if they exhibit the above symptoms The installation of a modified water sensor should be carried according to the installation instructions Plastic Housing Modified Sensor Installation Modifications have been made to Trident water sensor to help prevent this electrical tracking on the water sensor The plastic legs on the trident pr...

Page 9: ...tre ELBI of the original solenoid but a water sensing issue However the supplier of these solenoids had already delivered 10 000 5 5 litre solenoids thus they were used in production Action The introduction of the 5 5 litre solenoid is not expected to make any dramatic change to the coolers operation However there is a slight increase of water hammer occurring on the premises Tests conducted by ou...

Page 10: ...0 V 0 2 Amps Model FASCO Pump Capacity 20 L minute 855BNVA A12 Winding Resistance 206 Ohms 8 20oC Watts 315 Overflow size 40 mm Amps 2 4 Waste Outlet Size 40 mm R P M 1400 Tank Capacity 12 Litres Capacitor Size 8 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 2 ...

Page 11: ...0 V 0 2 Amps Model FASCO Pump Capacity 20 L minute 855BNVA A12 Winding Resistance 206 Ohm 8 20oC Watts 315 Overflow size 40 mm Amps 2 4 Waste Outlet Size 40 mm R P M 1400 Tank Capacity 12 Litres Capacitor Size 8 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 I...

Page 12: ... 0 2 Amps Model FASCO Pump Capacity 20 L minute 80855BQVA A22V Winding Resistance 206 Ohms 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 2...

Page 13: ... 0 2 Amps Model FASCO Pump Capacity 20 L minute 80855BQVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 2 ...

Page 14: ...V 0 2 Amps Model FASCO Pump Capacity 20 L minute 80855BQVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1...

Page 15: ...V 0 2 Amps Model FASCO Pump Capacity 20 L minute 80855BQVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1...

Page 16: ...NVA A12 Winding Resistance 206 Ohm 8 20oC Watts 315 Overflow size 40 mm Amps 2 4 Waste Outlet Size 40 mm R P M 1400 Tank Capacity 12 Litres Capacitor Size 8 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 Inlet Valve Capacity 4 L or 5 5L minute Coil Resistance ...

Page 17: ...VA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 2 Inlet Valve Capacity 4 L or 5 5L minute Coil Resistance...

Page 18: ...VA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 Inlet Valve Capacity 4 L or 5 5L minute Coil Resistance...

Page 19: ...QVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 Inlet Valve Capacity 4 L or 5 5L minute Coil Resistanc...

Page 20: ...QVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 12 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 Inlet Valve Capacity 4 L or 5 5L minute Coil Resistanc...

Page 21: ... 855BNVA A12 Winding Resistance 206 Ohm 8 20oC Watts 315 Overflow size 40 mm Amps 2 4 Waste Outlet Size 40 mm R P M 1400 Tank Capacity 15 Litres Capacitor Size 8 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 2 Inlet Valve Capacity 4 L minute Coil Resistance 4 1...

Page 22: ...te 855BNVA A12 Winding Resistance 206 Ohm 8 20oC Watts 315 Overflow size 40 mm Amps 2 4 Waste Outlet Size 40 mm R P M 1400 Tank Capacity 15 Litres Capacitor Size 8 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 Inlet Valve Capacity 4 L minute Coil Resistance 4...

Page 23: ...855BQVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 15 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1150 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 3 Inlet Valve Capacity 4 L minute Coil Resistance 4 ...

Page 24: ...0855BQVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 15 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1250 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 2 Inlet Valve Capacity 4 L minute Coil Resistance 4...

Page 25: ...0855BQVA A22V Winding Resistance 206 Ohm 8 20oC Watts 750 Overflow size 40 mm Amps 4 9 Waste Outlet Size 40 mm R P M 1350 Tank Capacity 15 Litres Capacitor Size 25 uF Distribution Hose Size 20 mm CLEAR HOSE R P M Min Setting 500 Inlet Valve Type ELBI E V Type 329 R P M Max Setting 1350 Inlet Valve Rating 240 V 0 03 Amps N E5 Model Selection Model 1 Inlet Valve Capacity 4 L minute Coil Resistance 4...

Page 26: ...vance Approved Issue 5 Printed 2 13 2014 11 50 17 AM 26 Motor Circuit Diagram MOTOR WIRING CIRCUIT DIAGRAM BETTS 855 BNVA A12 MOTOR 315 WATT DIRECT WIRED GREEN YELLOW BROWN BLUE COMMON START 38 8 MAIN 10 6 EARTH BLACK START OVERLOAD CAPACITOR 8 u F ...

Page 27: ...filer Advance Approved Issue 5 Printed 2 13 2014 11 50 17 AM 27 Motor Circuit Diagram MOTOR 750 WATT DIRECT WIRED BETTS MODEL 808855BQVA A22V GREEN YELLOW BROWN RUN BLUE COMMON START 9 6 MAIN 4 4 EARTH BLACK START OVERLOAD CAPACITOR 25 u F ...

Page 28: ...Service Manual 32 Contour 3 Series Profiler Advance Approved Issue 5 Printed 2 13 2014 11 50 17 AM 28 Circuit Wiring Diagram ...

Page 29: ...raw 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 either the top two terminals or the bottom two terminals on the Networker Backing plate If these two pairs of terminals are mixed around the Networker will not function Networker If...

Page 30: ...IONS 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 24 Networker Cooler No 1 Cooler No 2 Cooler No 3 ...

Page 31: ... 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 E01 ID07 1 Unit Number Parameter Number Parameter Value Eg Evap cooler number 1 Eg Number seven Eg Setting of 1 Not...

Page 32: ...or service parameters There is only one room temperature set point which can be adjusted on either Networker An Adjustment that is made on one Networker is immediately reflected on the other Networker Once each Networker is given its specific Networker ID number or address Master 1 or Slave 2 they can be assigned to operate the zones according to difference between the sensed temperature and the s...

Page 33: ...t as Masters so both Networkers should have the word clock next to key 5 while in the off position The system should not be operated in this state as there will be communication errors Determine which Networker you wish to be the Slave On the Networker you wish to be slave push the clock key The message Clock setting mode should be displayed After the message has finished ensure the time on the di...

Page 34: ... the parameter value for setting Master and Slave addresses can be set Networker ID Parameter Number Parameter Value Rotate the circular dial to change the parameter value displayed at the top right of screen to the number required for Slave Refer to the table for settings e g Slave 2 The Master Networker address can also be set if necessary n01 ID00 0 Networker Address or Number 1 Master or 2 Sla...

Page 35: ...emp Sense Networker ID No n01 ID17 0 Heater Zone A Unit Number Heater ID No n01 ID18 0 Heater Zone A Relay Number Relay No 1 to 4 n01 ID19 0 Heater Zone A Networker Temp Sense Networker ID No n01 ID20 0 Heater Zone B Unit Number Heater ID No n01 ID21 0 Heater Zone B Relay Number Relay No 1 to 4 n01 ID22 0 Heater Zone B Networker Temp Sense Networker ID No n01 ID23 0 Heater Zone C Unit Number Heate...

Page 36: ... special service access code on the Networker and the screen will move into the service parameter section Press the mode key to select the appropriate appliance i e Networker or Heater or Cooler 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 approp...

Page 37: ...peed Max Fan Speed 4 60 135 10 x RPM Maximum fan speed Model Selection Number 5 1 7 1 Cooler model selection number Sets the default fan speed by selecting the unit number as per the Specification sheets Short Dry Pad Time 13 1 255 minutes 2 Time the pump can be off before a normal Pre Wet is necessary Service Flush Count 15 1 255 cycles See notes Number of tank refills before a flush will occur P...

Page 38: ...flush operation above every 20 refills Dump Check Installer Parameter 16 This parameter was provided so that the cooler Dump valve and Winter seal operation could be checked instantly upon installation By setting this parameter to 1 the cooler will instantly perform a dump and close the Servoseal and after the normal delay times it will then resume normal operation This dump function will only occ...

Page 39: ...Dry Pad Time This is the time in minutes the pump can be OFF and the filter pads not wetted before a Pre wet will be required Service Flush Count 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 Service technicians can adjust the occurrence of the flush operat...

Page 40: ...valve will operate off the same mechanism The ServoSeal opening delay time is 20 seconds 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 E5 module will not permit the pump to be energised until the water has reached the high water ...

Page 41: ...terrupted the first Pre wet will be 2 minutes LongPrewetTime Pump On Pump Off Pump On Pump On Pump On Power Interuption Time interval from prior pump operation more than 2 mins but less than 10 mins Time interval form prior pump operation less than 2 mins Pump On 1 Minute Pre wet Short Pre wet time No Pre Wet 2 minute Pre wet Long Pre wet time 2 minute Pre wet Long Pre wet time Fan On Time interva...

Page 42: ... 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 ...

Page 43: ...ed 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 air circulation NOTE Should the pump be turned ON whilst the fan is...

Page 44: ...er 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 completi...

Page 45: ...ut 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 minutes ServoCloseDelay ServoSeal Closes 15 seconds Delay 45 seconds WashWaitTime Water Inlet Valve open...

Page 46: ... 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 20 tank refills the Flush Service commences Each sequence of 20 or 250 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 setti...

Page 47: ...event the growth of bacteria and micro organisms in the water The Aquasave module will only operate when the pump is operating and has an internal timer that will cycle the Aquasave on and off The timer is set to cycle the unit 7 minutes on and 7 minutes off The module has an internal air pump which draws the air though a filter located under the front of the cooler trough This air then passes thr...

Page 48: ...mounting bracket via side slide rails The N E5 module no longer has a isolating switch on the control box itself There is a new isolating switch that is located under the front of the cooler allowing the power to be cut to the unit without removing the front filter pad This isolates the output power supply to all components within the Cooler There is a new service N E5 control box which has a swit...

Page 49: ...tect the PCB circuitry The 8 Amp fuse will protect the N E5 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 E5 internal 8 Amp fuse does not protect the control against short circuit on the ServoSeal drain valve motor circuit The N E5 controller will maintain a minimum voltage on the output to the w...

Page 50: ...Check the N E5 is correctly located in the base terminal connector and mounting bracket Check the N E5 is set to the correct Network ID number Check if the N E5 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 ...

Page 51: ...Maximum Number RPM RPM Cooler Models Model 1 500 1350 L40 L50 L21 L23 L22 L52 L51 L53 L62 L63 P23 P43 P53 P63 F23 F53 Model 2 500 1250 L11 L13 L31 L33 L41 L22 L32 L42 L43 P33 F13 F43 Model 3 500 1150 L20T L30 F33 Model 4 500 1050 L10T Model 5 500 950 Model 6 500 850 Model 7 500 1450 L10 L20 Fan Operation The N E5 controls the level of voltage output to the fan and this is determined within paramet...

Page 52: ...or 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 E5 doesn t receive any signal from the speed sensor or looses the signal the N E5 will adopt a FAN LIMP mode operation Initially when the motor is required to run and the speed signal is lost the fan will imme...

Page 53: ...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 E5 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 secure...

Page 54: ...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 at 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 ...

Page 55: ...urn 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 E5 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 Diagr...

Page 56: ... service compartment back wall max fan speed selected OFF 10 A V 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 A V CO...

Page 57: ... should perform this procedure NOTE Because the start winding is not in circuit the motor may need to be manually turned to start OFF 10 A V 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 E5 internal 8 Amp fuse is not op...

Page 58: ...Service Manual 32 Contour 3 Series Profiler Advance Approved Issue 5 Printed 2 13 2014 11 50 17 AM 58 Cooler Operation cont Fan Operation cont Fan Motor will not operate Flowchart ...

Page 59: ... 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 E5 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 ...

Page 60: ...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 E5 Open service access compartment cover Drain the tank of ...

Page 61: ...mp 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 A V COM FUSED 1000V 750V V VOLTS Multimeter 240 PUMP NEUTRAL PUMP ACTIVE ...

Page 62: ...er 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 A V COM FUSED 1000V 750V V Ohms Multimeter 169 A PUMP NEUTRAL PUMP ACTIVE If pump doesn t operate Refer to mecha...

Page 63: ...rectly located in the mounting plug Empty the tank of all water and then drive the pump with your multimeter on Amps Caution only a qualified electrician should perform this procedure because this involves full current 240 volt electricity 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 E5 internal 8 ...

Page 64: ...te 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 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 impello...

Page 65: ... NEUTRAL PUMP ACTIVE terminals No Yes Check the power supply is turned ON and is the correct polarity and voltage Check the N E5 module is ON and is correctly loctaed in the mounting plug Bridge terminals PUMP ACTIVE MAINS IN If pump doesn t operate Check the N E5 internal 8 amp fuse is not open circuit Replace the N E5 and re test Refer to mechanical checks Replace pump Refer to mechanical pump c...

Page 66: ...t 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 pow...

Page 67: ...ation 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...

Page 68: ...n cont 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 4 1 kOhms INLET VALVE NEUTRAL INLET VALVE ACTIVE OFF 10 A V COM 1000V 750V V kOHMS Multimeter FUSED 3 9 Check if the water inlet solenoid is blocked Replace water inlet solenoid ...

Page 69: ... 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 Note Only a Qualified electrician should perform this procedure as it involves full current 240 volt electricity OFF 10 A V COM FUSED 1000V 750V V Amps Multimeter A MAINS ACTIVE IN INLET VALVE ACTIVE If ...

Page 70: ...N E5 plug terminals see test procedure Trident Water Management section If loom not connected open circuit N E5 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 no...

Page 71: ...ge that opens and closes the louvers 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 Profiler cooler only has the Drain valve connected to the Servo motor The motor that drives both the...

Page 72: ...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 louver linkages refer to fan dismantling procedures Remove the 2 linkage retaining screws that hold the lower linkage arm onto the Se...

Page 73: ... 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...

Page 74: ... NEUTRAL Refer to diagram below and circuit on page 57 Replace faulty ServoSeal drain valve motor OFF 10 A V COM 1000V 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 l...

Page 75: ...ervoSeal 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 ...

Page 76: ...Valve Operation cont 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 ...

Page 77: ...f 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 The mid level probe is the common low voltage output The shortest probe is...

Page 78: ...FF 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 E5 will then switch on the water inlet solenoid again to refill the tank to the high water level The N E5 module is pro...

Page 79: ...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 E5 module will delay ...

Page 80: ...t seen at the Low Water Level Sensor Short circuit Closed circuit on Low Water Level Sensor for 120 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 sole...

Page 81: ...minutes of detecting water on the Low Water Level Sensor Short circuit From start up the Low Water Level Sensor is open circuit normal and the High Water Level Sensor is closed circuit Temporary 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 L...

Page 82: ...s 20 seconds WashWaitTime period starts 45 seconds Water inlet solenoid opens for 30 seconds WashTime WashWaitTime period starts 45 seconds N E5 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...

Page 83: ... 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 of pump operation Error 40 code will be displayed alternating with this drain error when and if the water inlet solenoid is open Bec...

Page 84: ...ns 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 of pump operation Error 40 code will be displayed alternating with this drai...

Page 85: ...r 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 E5 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 ...

Page 86: ...age 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 75 and 76 If voltage doe...

Page 87: ...Loom Cntrl Water Sensor MOTOR SPEED SENSOR LOOM WATER LEVEL CONTROL LOOM J 5 J 6 J 1 J 2 NETWORKER LOOM ALTERNATIVE NETWORKER CONNECTION POINT High Water Level Common Sensor Low Water level OFF 10 A V COM FUSED 1000V 750V V VOLTS 14 14 Volts Dry When water makes closed circuit must be less than 9 volts Wet Common Sensor and High Water Level Heatshrink Sensor Strip 100mm Common Pin High Water Senso...

Page 88: ... Loom Cntrl Water Sensor MOTOR SPEED SENSOR LOOM WATER LEVEL CONTROL LOOM J 5 J 6 J 1 J 2 NETWORKER LOOM ALTERNATIVE NETWORKER CONNECTION POINT High Water Level Common Sensor Low Water level OFF 10 A V COM FUSED 1000V 750V V VOLTS 14 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...

Page 89: ... 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 ...

Page 90: ...lity The following table is a guide to the Flush service 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 6 8 Volt Flush service Cycle Rate 10 Cycles 15 Cycles 2...

Page 91: ...ation 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 ty...

Page 92: ... of the Cooler selected as per the minimum recommended size tables Duct Capacity Outlet 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 ro...

Page 93: ...is 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 stru...

Page 94: ... 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 inadequa...

Page 95: ... 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 line...

Page 96: ... 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 ...

Page 97: ...sor 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 correctl...

Page 98: ...tely 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 louver blades are configured for best room air mixing Check the air distribution is correctly bala...

Page 99: ...alth 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...

Page 100: ... 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...

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