Installation, use and Maintenance manual Evaporative Cooler AD 14 Evaporative cooling is a completely natural way of producing refreshing cool air for warehouses or factories
EDITION: 04/2014 Code: D-LBR483 This manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of this manual is prohibited. The original is filed at Robur S.p.A. Any use of this manual other than for personal consultation must be previously authorised by Robur S.p.A. The rights of those who have legitimately filed the registered trademarks contained within this publication are not affected With the aim of continuously improving the quality of our products, Robur S.p.A.
FOREWORD This manual is for anyone who must install or use the Robur AD 14 evaporative cooler. This manual especially applies to the plumbers who must install the evaporative cooler, to the electrician who must connect the heating unit to the electrical system and to the end user who must check that it functions properly. This manual is also for the technicians regarding the principle maintenance operations. CONTENTS 1 – General Information …………………………………………………………..
SECTION 1 GENERAL INFORMATION In this section you will find the general instructions to follow for the installation and use of the AD 14 evaporative cooler, a brief mention of the operation of the unit, the constructive characteristics and the technical data. 1.1 GENERAL WARNING This manual is an integral and essential part of the product and must be given to the user. This unit must be exclusively used for the purpose it was intended. Any other use is to be considered improper and therefore dangerous.
1.2 OPERATION OF THE UNIT Evaporative cooling is a completely natural way of producing refreshing cool air that have been specifically designed for the cooling of industrial and commercial building. It is designed for outdoor installation with down, top and side discharge and also as internal suspended cooler. Cooling is provide by Evaporative heat exchange which take advantage of the principles of the latent heat of evaporation where tremendous heat is exchanged when water evaporates.
1.4 TECHNICAL DATA Air Flow Rate Water Supply Pressure min/max Minimum Water Flow Rate Water Sump Capacity m3/h 14.000 bar 1/7 l/min 8 l 23 Electrical Supply 230 V – 50 Hz Water Supply Connection “ ½ Water Drain Connection “ 1 Square Duct Dimensions mm 645 x 645 Axial Fan Rating kW 1,5 Water Pump Rating kW 0,05 dB(A) dB(A) 74 64 mm mm mm 1.170 1.
SECTION 2 INSTALLATION This installation section describes the installation of the cooler with standard controls. If other control such as a thermostat or humidistat is to be used the 5 speed control panel instructions must be consulted 2.1 - Delivery The unit is delivered mounted on a pallet which is used to support the unit during installation. A protective cardboard cover is, together with internal polystyrene pads, banded to the pallet. This is a fragile item and must be handled carefully.
The side frames are also act as a guard for the fan. Set screws prevent their removal unless a tool is used to comply with guarding regulations. To remove the side panel first remove the security screws. Then lift the panel and the top edge can be removed. To replace the panel reverse the above. There are location points for the cooler to sit on the duct. When the cooler sits on a level duct these points ensure the cooler is level.
The cooler is then fixed to the ductwork using fixings appropriate for the duct material. It is recommended than a minimum of 3 fixings are made on each side. Appropriate weather proofing should be made according to the roof structure and local weather conditions. It is normal to support the weight of the cooler on supports on the underside of the roof. 2.3 - Support brackets installation Every Evaporative Cooler AD 14 is standard delivered with no. 2 adjustable support brackets.
To install the brackets, please proceed like follows: - install the cooler, connecting the cool air down discharge to the duct system below - fix the brackets to the duct as shown in the diagram below - adjust the brackets so that the water tank is levelled and well-supported by the brackets 2.4 – Services connections The services are all fed from the bottom at the points shown Installation, use and Maintenance manual - ed.
2.5 – Electrical supply The electrical connections must be done by Qualified service engineering. Before beginning this operation, cut off the electrical supply. 1. Check that the voltage supply is 240/50Hz single-phase 2. Carry out the electrical connections accordino to the installation wiring diagram 3. When connecting, censure that the earth wire is longer than the live wires, so that i twill be the last wire to break if the supply cable is stretched, thus ensuring a good earth continuità.
2.7 - Drain The drain outlet is a 1”bsp fitting. The drain capacity must exceed 2000 l/hr to an appropriate disposal point which conforms to local water regulations. The drain valve, on delivery, requires fitting to the base of the sump. A 1” bsp nut and gasket is supplied which are used to fix to the sump. To avoid damage to the water and drain valves during the winter months of non-use of the AD 14 it is necessary to discharge the hydraulic circuit (including water supply pipe). 2.
The first terminal block is used for all of the manual controls (plus the purple automatic cable). The second terminal block is for the Alarm, Timer, Humidistat and Thermostat. Note that the Alarm and Timer contacts must be made for the cooler to operate. 13 Installation, use and Maintenance manual - ed.
SECTION 3 3.1 CONTROL SYSTEM Overview of system The control system comprises of a main control panel which controls the above components by communicating with a wall mounted control box and a set of external inputs.
o Alarm Highlights the system has an error The number of pulses indicates the fault present.
3.2 - The Control Board- The Controller The heart of control system is a printed circuit board. The layout with the key input/output locations is shown below N - Spare A -LED Display O Drain - B - Dip switches P – Drain fuse C - RS232 Port Q -Circulation pump D - ISP System Port R -Circ. Pump fuse E - Water probes S - Scavenge pump F - External alarm T - Scav. Pump fuse.
3.3.2 - Dip Switches All variable parameters are set by changing the positions of the dip-switches located on the main control board. These changes can only be made during mains power off for a minimum of 5 seconds. Switch Default 1 2 3 4 5 6 7 8 Off Off On On Off Off Off Off Function Pre Cool Cycle Salinity 1 Salinity 2 Salinity 3 24 hr dry cicle Off speed 1.390 on max speed 1.200 Off speed1.390 On max speed 1.
Dip-Switch 5 – 24hr Dry Cycle: The cooler will dry out for 30 minutes during every 24 hours of continuous operation. This can be applied to in certain circumstances to improve the hygiene of the cooler Dip-Switches 6 and 7 – Maximum speed settings This enables the top speed of the fan to be limited. This may be used to either reduce overall capacity or reduce noise. The standard motor used is a double wound 4 pole/6pole motor.
Inlet valves V1 and V2 are alternated in this way to validate their operation. If either one fails then the water will rise to the Very High Level which will result in an alarm condition and the other valve will close. This gives a high degree of protection from over-flow. This cycle continues according to the dip switch 2, 3&4 settings. When the set point is reached the water is then drained until Low Level probe is uncovered.
SECTION 4 COMMISSIONING L’AD 14 comes fully operational and ready for use. There are a number of options which are enabled using the dipswitches mounted on the main control board inside the machine. These are described in the previous section. A commissioning sequence is built into the control system. To initiate this sequence operate the test switch located on the control panel for 3 to 8 seconds. The cooler then follows the following sequence.
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ 1 2 3 4 5 6 7 8 9 0 21 Level HH ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ Water fills to LL Water fills to L Water fills to H Manually operate HH Cooler drains Circulation pump ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ Level H ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ Level L ▼ ▼ ▼ ▼ ▼ ▼ ▼ Level LL ▼ ▼ ▼ ▼ ▼ ▼ ▼ Valve V2 ▼ ▼ ▼ ▼ Valve V1 ▼ ▼ ▼ ▼ Scavenge pump ▼ ▼ ▼ ▼ Spare Speed 5 Speed 4 Speed 3 ▼ ▼ ▼ ▼ Drain 1 2 3 4 5 6 7 8 9 10 11 12
The only other points to check are 1 – Are the pads fully seated in the side frames. They can work loose in transit and must be correctly located to ensure efficient and leak free operation. 2 – Is the cooler level? The cooler is designed to sit on a duct which is finished with a horizontal plain edge. If it is not level the water controls may not operate correctly. Installation, use and Maintenance manual - ed.
SEZIONE 5 - OPERATION OF THE UNIT AND SETTINGS 5.1 – Automatic Sequence If a humidistat is used set this to 100% so the contacts are closed. Set the thermostat to a low temperature set point so the contacts are closed. Put the cooler into Automatic Mode. The cooler will start at speed 3 in cooling mode. After 10 minutes the cooler will move to speed 4 and after a further 10 minutes the cooler will move to maximum speed 5. Now set the thermostat to a high temperature set point so the contacts are open.
5.3 - Alarm This connection is intended to be used to shut down the cooler in a controlled manner and show an alarm condition at the Wall Control Box and the LED in the Main Controller. This has to be closed for the cooler to operate. Typical applications are: • Connection to a fire alarm system • Connection to a smoke detector When the connection is broken the cooler fan stops and the cooler drains if it is in cool mode.
Light Yellow (Alarm) Yellow/black (Alarm) Light Green (Timer) Green/black (Timer) Orange/black (Thermostat) White/black (Humidistat) Red/black (Common) 5.5 - Alarm and timer Alarm and Timer These functions can be combined. Both contacts have to be closed for the cooler to run. This function operates in both Manual and Automatic Modes Yellow/black (Alarm) Light Yellow (Alarm) Green/black (Timer) Light Green (Timer) Orange/black (Thermostat) White/black (Humidistat) Red/black (Common) 5.
5.7 – Thermostat and Humidistat The Humidistat is only used in Automatic Mode when a Thermostat is fitted. It is intended to be used to prevent high humidity levels during periods of high external relative humidity. When the Humidity exceeds the set point the water circuit is disabled. Yellow/black (Alarm) Light Yellow (Alarm) Light Green (Timer) Green/black (Timer) Orange/black (Thermostat) White/black (Humidistat) Red/black (Common) 5.
5.9 - Connection of Multiple Coolers to Common Control Items An unlimited number of coolers use the same control items. When connection is made it is important that the Dark Green (Common) from each cooler is connected to the same side of each switch. An example of this for linking two coolers to a common thermostat is shown below.
SECTION 6 - MAINTENANCE AND SERVICE 6.1 – FAULT FINDING Alarm light and LED Faults are reported by the flashing alarm light on the wall mounted panel and this is replicated in the cooler by the LED When the cooler enters an alarm condition the LED on the wall controller flashes to give an indication of the problem. There are 6 different alarms which are identified in this way.
3 flashes – Probes out of sequence Manual reset If any probe is covered out of sequence this alarm is activated. Possible causes • Floats not operating • Sticking float: Clear debris and clean float • Sinking float: Replace float • Float switches faulty, contact should be closed at low level: Replace • Incorrect connection or wiring: Check contacts and connection Black is common.
6 flashes – External alarm Auto reset In the control panel there are a set of contacts which can be connected to an external alarm switch. If this is activated this alarm is operated. Possible causes External alarm circuit open Wiring fault Auto reset : the alarm will automatically clear when the fault clears. Manual reset : A manual reset alarm requires the cooler to be turned off at the wall box after the fault has been cleared.
Other Fault Finding Problem Cause No external alarm fitted but still fault Pre-cool cycle enabled Cooler will not start .
6.2 – MAINTENANCE It is recommended that a evaporative cooler is regularly maintained. The frequency of maintenance is dependent upon the quality of water, the cleanliness of the air and the frequency of use. In normal conditions a 6 monthly service will maintain the reliability, efficiency and hygienic operation of the cooler. 6.2.1 Preparing the cooler for maintenance 1. Ensure the cooler is fully drained by switching the cooler on in vent mode. Any water will then be automatically drained. 2.
6.2.5 Insect screen cleaning 1. 2. 3. 4. 33 Remove insect screens carefully by lifting from the side frames Clean using low pressure water Inspect and replace if damaged Replace in side frame. Installation, use and Maintenance manual - ed.
AD14 Evaporative Cooling Operating Instructions All controls are accessed from the wall mounted control box using the inputs shown below: Alarm light Power This switches the cooler on and off The number of flashes gives the fault Fan speed This set the spped of the fan Auto/Manual Cooling This switches between Vent and Cool mode This enables automatic control when a thermostat is connected 1 flash – Slow fill Auto reset If the high level probe is not covered within 20 minutes this means there is a
Installation, use and Maintenance manual - ed.
Codice: D-LBR483 Rev.D 14 MCM SDC 009 - 10/04/2014 Robur is dedicated to dynamic progression In research, development and promotion of safe, environmentally-friendly, and energy-efficient products, trough the commitment and caring of our employees and partners. Robur Mission Robur S.p.A. advanced heating and cooling technologies Via Parigi 4/6 24040 Verdellino/Zingonia (Bg) Italy T +39 035 888111 F +39 035 884165 www.robur.com Installation, use and Maintenance manual - ed.
