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Coolerado C60A, Installation Manual

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Coolerado C60A Installation Manual Download Page 33

Coolerado Installation 

Page 

33

 of 

53

 

 

8 Dipswitchs

C

AO

FAN

R

AIN

Y

RC

WC

C

C

C

C

Water 

Solenoid

Thermostat 

Cool Call

Thermostat 

Fan Speed

Fan Speed

Soap Pump

Transformer

C

2

1

2

 A

m

p

, 2

5

0

 V

 

Sl

o

w

 B

lo

w

 F

u

se

P

o

w

er

W

at

er

C

o

o

l C

al

l

Fl

u

sh

Freeze Control 

Daughter Board 

(Optional from 

Coolerado)

24 VAC 

to Relay

Temperature/Humidity 

Sensor

Max Fan 

Speed Pot

Coolerado Water Control Board

 

Figure 1, Daughter Board Mounted on Coolerado Water Control Board 
 

 

Main Valve, 

Normally Closed 

 

½” Water Line 

Drain Valve, 

Normally Open

110 VAC

24 VAC

To Drain

 

Freeze Protection System 

Located In Heated Space

(Possibly a 3 Way Valve) 

 

Manual 

Ball Valve

Outdoor

Indoor 

Heated 

Space

Min ½” Pipe, typ.

Roof Line

NO

NO

 
R

RA

RA

24 VAC

Coolerado ERV 

Control Baord

Suggested 

8"x8"x4" 

Enclosure

Fuse

By Others

Water 

Filter

From 

Water 

Supply

Coolerado 

ERV

  

Figure 2, Freeze Protection Diagram  

Summary of Contents for C60A

Page 1: ...VER COLORADO 80216 INSTALLATION AND SERVICE PROVIDER COMPANY______________________________________ ADDRESS_______________________________________ _______________________________________________ _______________________________________________ _______________________________________________ TELEPHONE_____________________________________ __ ...

Page 2: ...lters installed Y N Water Filter Installed Y N Water Hardness Type of Air Filter Installed Type of Water Filter Install Size of Air Filter Installed Make of Water Filter Water Pressure unit Plenum Air Pressure Measurements Conditioned Air Exhaust Air Outside Air Temp Outside Humidity Level Conditioned Air Temp Power Line Voltage Line Amperage Phase Control Voltage MUST BE COMPLETED AFTER INITIAL I...

Page 3: ...onal Shutdown 23 Care and Maintenance 23 Appendix Appendix 1 Coolerado Water Quality Requirements 25 Appendix 2 Wiring and Control Diagram 26 Appendix 3 Coolerado Thermostat Wiring Picture 27 Appendix 4 Multiple Unit Control Diagram 28 Appendix 5 Water Control Board Indicators Dip Switch Settings 29 Appendix 6 Thermostat Operations for TEC2145 4 30 Appendix 7 Thermostat Programming TEC2145 4 31 Ap...

Page 4: ...Page 4 of 53 Installation Notes ...

Page 5: ...erty damage NOTE will be used to highlight suggestions which will result in enhanced installation reliability or operation INSTALLATION RECOMMENDATIONS NOTE Any restrictions to air movement either for intake air conditioned air or exhaust air will reduce the capacity and efficiency of the unit NOTE Working air exhaust will always be heavier than ambient air until it fully mixes and comes to equili...

Page 6: ...ing company No return shipment will be accepted without written return authorization UNPACK UNIT Move to final location Remove carton or packaging taking care not to damage unit INSPECT EQUIPMENT Check the unit for any signs of shipping damage Fan should spin freely and all covers and parts should be secured properly To reduce the shipping footprint on a C60 the conditioned air plenum may be shipp...

Page 7: ...it must be at least 4 1 2 m or a spreader bar is needed to prevent squeezing the box Care should be taken not to rack or torque the units when moving or lifting units into position as this may cause poor door fitting Heat and Mass Exchanger racking and leaking air leaks etc M50B Lifting Lugs Figure 2 Lifting Straps Banding Figure 3 Step 2 Inspect Filters and Heat Exchangers 1 Inspect the unit s fi...

Page 8: ...gure 6 Pre Cut 16 406 mm Diameter Exhaust In Top High Voltage Power Factory Wired Connections Soap Pump Control Wiring Low Voltage Do Not Block Filter Access Door Filter Access Door Handles Pre Cut 16 x 16 406 x 406 mm Louver Cover Lifting Lugs Drain Water In Low Voltage Wire Terminals In High Voltage Wire Terminals In Outdoor Air In Identifying System Components M50A Figure 6 NOTE Ensure unit is ...

Page 9: ...the bottom of the base see Appendices 8 10 and 12 The M50A comes with lifting lugs located in the bottom four 4 corners with 6 35 mm x 20 mounting bolts that can also be used for installation attachment to a frame M50A Leveling Feet Figure 8 If unit is installed indoors install an emergency drain pan that extends beyond the unit by at least 6 150 mm on all sides along with separate overflow drain ...

Page 10: ...rements The drain line must be vented as it enters the building sanitary sewer drain line Step 6 Outdoor Intake Air NOTE The intake air duct must not be located near the units working air duct Install and inspect ductwork if needed The intake air can enter the unit directly or through a properly sized duct Use intake sizes from Table 1 Model Intake Duct Size Intake Duct Size M30 16 inches 20 at fa...

Page 11: ... be 0 01 to 0 15 inches of water column 2 5 Pa to 37 Pa greater than the working air exhaust plenum under full air flow This will prevent water migration from the exhaust side to the conditioned air side and provide adequate working air Seal duct work If the conditioned air ducts are located external to the building or in an attic space a minimum of R6 insulation is required Follow local building ...

Page 12: ...lenum inside Box Figure 16 NOTE Set the conditioned air plenum inside the box or the HMX frame so that water will be directed into the box rather than to the outside Seal outside edge at bottom of plenum see Figure 16 NOTE The conditioned air plenum is not insulated in the factory Insulate plenum after duct holes have been cut out In outside installations the plenum should be fully insulated and s...

Page 13: ...0 for an example CAUTION Failure to prevent sunlight from reaching the heat exchanger will allow degradation of the heat exchanger material and possibly allow green algae growth if there is enough dissolved nutrients in the water supply and or air The Clean HMX material will not support mold or algae growth CAUTION A bird screen must be installed over the outlet exhaust to keep birds and squirrels...

Page 14: ...t comes with matching blind rivets mounted in the box Inside Cover Figure 22 Step 9 Water Supply Connections Note Do not turn water on unit till Step 15 See Appendix 14 for line size and pressure charts CAUTION Clean potable water should be connected to the Coolerado air conditioner see Appendix 1 Coolerado Water Quality Requirements for more details Water lines should be insulated from heat sourc...

Page 15: ...ure 23 WATER FILTER WARNING INSTALL the IN LINE 30 micron WATER FILTER supplied with unit The water filter should be installed upstream before any solenoid valves or water pressure regulator on the Coolerado unit so that these devices will be protected by the water filter CAUTION Failure to install an in line water filter will void system warranty NOTE In addition to water pressure water quality h...

Page 16: ...ater Booster Hose Bib and Ball Valve Figure 24 NOTE Use a minimum of 1 2 12 7 mm diameter supply water line which should be free draining for winter shut down BACK FLOW PREVENTION NOTE The unit is equipped with a self draining water regulating valve designed with a vacuum break in the HMX Water Distribution System M50A Figure 25 Freeze protection can be done manually 1 Install supply water shut of...

Page 17: ...tall unit in system where voltage may fluctuate outside of normal voltage fluctuations NOTE Use copper conductors only between the disconnect switch and the unit ROUTE GROUND AND POWER WIRES DANGER The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur The ground may consist of electrical wire or metal conduit when installed i...

Page 18: ...m terminal connections and control board CAUTION Do not allow wiring to block access to filter door Step 11 Thermostat Wiring Note Do not start unit till Step 15 See Appendix 2 for wiring instructions CONTROL REQUIREMENTS The control power is 24 VAC Input call Y 1 st stage cooling call and 0 10 VDC fan speed signal if applicable NOTE The water control board provides24 VAC via terminal RC to be swi...

Page 19: ...d period of time In some locations cooling is required all year round but still may experience temperatures below 32 o F and require shut down There are cooling situations such as small data centers where the water is turned off for winter operation and only the fan is used to cool with outdoor air and the freeze protection should be turn off In this case the low water pressure switch must be bypa...

Page 20: ...ll need to be primed with wetting solution at installation The pump is controlled by the circuit board and is engaged any time the unit is powered up and there is a cool call The pump and surfactant lines must be primed full of surfactant before the system is started for wetting heat and mass exchangers The pump will operate as long as the override primer switch is held down When filters are chang...

Page 21: ... bottom of the unit 4 Power up the unit 5 Prime the soap pump by pressing the button on the Manual Overide Switch see Figure 32 Soap should be just entering the T in the line before the header 6 Turn on the water and check for leaks at the solenoid valve connections 7 Create a cool call by closing contacts across terminals RC and Y on the water control board and check for leaks do not deliver volt...

Page 22: ...n the supply water and verify there are no leaks 8 Open the cooled air supply or conditioned air damper and or remove any air blocks that were used to winterize the air conditioner 9 Turn on the power 10 Set the thermostat to a low temperature to get a cool call to start the unit The water will begin to fill the cooling system The first fill will take about an hour to completely wet the heat excha...

Page 23: ...stem Fan Maintenance Inspect all fan parts including air intake blades motor and shroud as well as for free movement Check for the accumulation of material on the impeller surfaces which could cause imbalance resulting in vibration excess noise and premature bearing wear Clean as needed The inspection frequency is determined by the severity of the application and local conditions Strict adherence ...

Page 24: ...way to the top of the filter frame Pull the bottom of the filter towards the fan and drop the filter until the top of the filter clears the M50 cabinet Lift the filter out of the unit 3 The middle and bottom filters can now be lifted up and out of the filter frame 4 Reverse this process to re install the filters 5 Re install the filter access cover Side Mounted Working Air Exhaust Louvers If side ...

Page 25: ...MX plate surface In these cases a biocide such as chlorine may be required Temperature When water is heated dissolved minerals like calcium will come out of solution and form scale the reason hot water heaters and pipes build up scale For this reason we recommend water supply pipes to the Coolerado units be kept in cool places or insulated when exposed to the sun Dissolved minerals There are a lot...

Page 26: ... Soap Priming Switch Water Control Board 24 VAC Soap Relay AV To Fan Solenoid Valve T Stat AV Fan In FAN C AO C R C C WV Y RC C AIN 8 Dipswitches NO Low Water Pressure Door Magnet Fan On Off Switch Com 1 10 VDC Y 24 VAC IN RC 24 VAC OUT 277 VAC 240 VAC 208 VAC NEUTRAL PE GND Com Blk 208 VAC Red 240 VAC Org Optional 277 VAC Brn Com 24 VAC Transformer Ziehl Abegg Fan 24V 10V GND D1 E1 11 14 L1 L2 N ...

Page 27: ...Coolerado Installation Page 27 of 53 Appendix 3 Coolerado Thermostat Wiring Picture NOTE This wiring diagram applies to M30 M50 and C60 Models only For M50A Models please see Appendix 2 ...

Page 28: ...of 53 Appendix 4 Multiple Unit Control Diagram This diagram is for multi unit wiring and configuration when connecting to a JOHNSON CONTROLS TEC2145 2 THERMOSTAT M30 and C60 Models are on the left while the M50A Model is on the right ...

Page 29: ...Coolerado Installation Page 29 of 53 Appendix 5 Water Control Board LED Indicators and Dip Switch Settings LED Indicators Note If Dip Switch 8 is positioned off the soap pump will run continuously ...

Page 30: ...n deactivated with Coolerado settings See the Configuring the TEC2145 4 Thermostat section in the Johnson Control manual for reprogramming UP DOWN arrow keys adjust the configuration parameters and activate a set point adjustment Backlit LCD The TEC2145 4 Thermostat includes a 2 line 8 character backlit display Low level backlighting is present during normal operation and it brightens when any use...

Page 31: ...limit value is between occupied and unoccupied cooling set points Unocc HT 62 Sets Unoccupied Heating set point values Range 40 90 o F 4 5 32 o C Unocc CL 80 Sets Unoccupied Cooling set point values Range 54 100 o F 12 37 5 o C Heat max 90 Sets Occupied and Unoccupied maximum Heating set point values Range 40 90 o F 4 5 32 o C Cool min 65 Sets Occupied and Unoccupied Cooling minimum set point valu...

Page 32: ... important to have the Coolerado solenoid valve closed until the Main Water Supply Solenoid Valve has been closed or the water will run unfettered If there are multiple Coolerado Air Conditioners on the same water line and located on the same area i e building roof only one unit needs the Daughter Board mounted to the Water Control Board All of the Coolerado units will need to have their respectiv...

Page 33: ...y Sensor Max Fan Speed Pot Coolerado Water Control Board Figure 1 Daughter Board Mounted on Coolerado Water Control Board Main Valve Normally Closed Water Line Drain Valve Normally Open 110 VAC 24 VAC To Drain Freeze Protection System Located In Heated Space Possibly a 3 Way Valve Manual Ball Valve Outdoor Indoor Heated Space Min Pipe typ Roof Line NO NO R RA RA 24 VAC Coolerado ERV Control Baord ...

Page 34: ...Coolerado Installation Page 34 of 53 Appendix 9 M30 Dimensional Specifications ...

Page 35: ...88 0 40 99 5 710 1 206 335 100 0 0 580 985 274 0 50 124 4 660 1 121 312 103 1 6 540 917 255 0 60 149 3 610 1 036 288 107 2 1 1 510 866 241 0 70 174 2 560 951 264 110 3 1 7 470 799 222 0 80 199 1 510 866 241 113 4 2 2 430 731 203 0 90 224 460 782 217 117 5 2 8 390 663 184 1 00 248 9 420 714 198 120 6 3 3 360 612 170 Performance at sea level Performance increases 0 5 for every 1 000 feet 305 m incre...

Page 36: ...Coolerado Installation Page 36 of 53 Appendix 11 M50B Dimensional Specifications ...

Page 37: ...5 0 40 99 5 1060 1810 500 100 0 0 790 1340 370 0 50 124 4 990 1690 466 103 1 6 730 1240 345 0 60 149 3 920 1560 433 107 2 1 1 680 1150 320 0 70 174 2 850 1440 399 110 3 1 7 630 1070 295 0 80 199 1 780 1320 366 113 4 2 2 570 970 271 0 90 224 710 1200 332 117 5 2 8 520 880 246 1 00 248 9 630 1080 298 120 6 3 3 470 800 221 Performance at sea level Performance increases 0 5 for every 1 000 feet 305 m ...

Page 38: ... On Curb See Following Page for Curb Mount Fan Top View Fan Side View Side View Top Exhaust Option Requires Installation of Hood On Top to Prevent Sun Light Entry Side Exhaust Option with Louvers from Coolerado M50B Down Flow Skirt Mount For Curb Bottom Veiw Top View Side View End View Supply Inlet Supply Inlet Shipping Brackets ...

Page 39: ...Coolerado Installation Page 39 of 53 Appendix 14 C60A Dimensional Specifications Weight 375 lb 170 kg Dry 435 lb 200kg Wet ...

Page 40: ...Coolerado Installation Page 40 of 53 C60A Dimensional Specifications Continued ...

Page 41: ...70 0 40 99 5 1220 2070 570 100 0 0 940 1080 440 0 50 124 4 1130 1910 530 103 1 6 870 1000 410 0 60 149 3 1050 1780 490 107 2 1 1 810 930 380 0 70 174 2 970 1640 460 110 3 1 7 750 860 350 0 80 199 1 900 1520 420 113 4 2 2 700 800 330 0 90 224 810 1370 380 117 5 2 8 630 720 300 1 00 248 9 720 1220 340 120 6 3 3 560 640 260 Performance at sea level Performance increases 0 5 for every 1 000 feet 305 m...

Page 42: ...etermine the water pressure that will be available for use For this reason it is best to reduce the water pressure losses through the piping valves and fittings To assist in selecting pipe sizes please consult the tables below NOTE Higher pressure drops are not recommended but rather are shown to help understand the significance of larger pipe sizes NOTE For every 2 3 0 7 m of height above where t...

Page 43: ...Coolerado Installation Page 43 of 53 Too High Pressure Drop Too High Pressure Drop Too High Pressure Drop Too Large Tubing ...

Page 44: ...ranty covers only the Coolerado Product The following specifically void the Limited Warranty 1 Weather damage 2 Improper installation including inadequate sealing of the unit that exposes the unit s interior to outside elements 3 Installation disassembly or repairs not performed by a licensed installation contractor or technician or that do not follow the owner s manual or installation manual or d...

Page 45: ...nable us to contact you in the unlikely event of service notifications or product defects http www coolerado com company warranty form You may want to write down the serial numbers of the units you want to register in the space below Serial Number _____________________________________________ Serial Number _____________________________________________ Serial Number ________________________________...

Page 46: ...installed See Step 2 in Installation Manual Yes No 4 Are the unit clearances adequate for service and operation See Step 3 in Installation Manual Yes No 5 Is the unit level to within Coolerado specifications See Step 4 in Installation Manual Yes No 6 Is water being drained away from the unit per local state plumbing code See Step 4 in Installation Manual Yes No 7 If unit is installed indoors is a ...

Page 47: ...stallation Manual Yes No 16 Have all electrical connections been tested for tightness See Step 10 in Installation Manual Yes No 17 Does the electrical service correspond to the unit nameplate See Step 10 in Installation Manual Yes No 18 What is the voltage to the unit See Step 10 in Installation Manual Volts 19 Is water turned on See Step 15 in Installation Manual Yes No Post Installation Checklis...

Page 48: ...M30 Watts 5 7 5 3 5 1 4 8 4 6 4 3 4 0 3 7 psig Yes No 3 What is the dynamic water pressure psig to the unit between 25 and 80 psi 172 and 552 kPa See Step 9 in Installation Manual psig 4 Are any visible leaks from water supply drain line and or unit See Step 9 in Installation Manual Yes No 5 Is working air mixing with product air See Step 15 in Installation Manual Yes No 6 Has client been informed...

Page 49: ...sure WC4 Meets Pressure Specification Yes No 1 Product Air 2 Working Air 3 Value should be positive number near 0 1 wc 4 Water Column 5 Value of 0 2 WC magnehilic gage or equal recommended WAa WAb PA reading Depending on how the unit is setup you ll take WA readings at the top of the unit a if ducts are installed or at the bottom if louvers are installed b ...

Page 50: ...mance4 Inlet DB1 Temp o F Inlet WB2 Temp o F PA3 DB Temp o F PA DB temp Inlet WB Temp o F 1 Dry bulb 2 Wet bulb 3 Product Air 4 Digital thermometer used to get within or 0 2o F 0 1o C PA DB reading taken approx 2 from the rear of the unit DB and WB readings ...

Page 51: ...sh and vinegar do not insert anything inside the HMX then rinse with water If damaged contact Coolerado Water Distribution Valve Check valve for water leaks Check tubing and header assembly for leaks 6 Month PM Checklist Please initial date upon completion of each checked item Component Every 6 Months Every 6 Months Water Pressure Reference Pressure Table 2 operating range for dynamic water pressu...

Page 52: ...pen Check to see if the red LED light marked W is On indicating the water is on At the control board listen to see if the timer clicks to turn on the water and the red LED marked W illuminates Ensure the water line is not leaking Are the unit s level Is working air properly exhausted so it isn t drawn back into the unit Check that water filter is not plugged Remove the air filters and inspect wate...

Page 53: ...ntake air volume If the unit is leaking water Check to see if the drain piping is free flowing Check to see if the seals have been broken on the conditioned air outlet plenum If so re seal from the inside Check product air pressure so that it s at least 01 higher than working air If any of the above procedures do not correct the problem call your installing contractor or authorized servicing agent...

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