Brivis Service Manual

Transcription

1 Brivis Service Manual Evaporative Cooler AD/C 5 Series N-E1 & Tekelek Supplement This manual is to be used in conjunction with the Service Manual 12 - Cooler - AD / CC (series 4 & 5) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 1

2 Index Pages TRODUCTION: TECHNICAL FORMATION: AD AD AD AD AD AC AC Cooler Circuit Diagram Motor Circuit Diagram OPERATION OF THE COOLER & WALL CONTROLS: Tekelek 485 Wall Control (Manual) The Brivis Networker (N-C1) Tekelek 461 Controls N-E1 Operation Dump alve Operation (N-E1 Models Only) N-E1 Control Fan Operation (N-E1 Models) Fan Speed Feedback (N-E1 Models Only) DC Brake GENERAL OPERATION: Using Multiple Coolers on the Network Changing an Identification Number Networker Configuration Link Cabinet & Component Modifications SERICE DIAGNOSTICS & PROCEDURES: Fan Motor Will Not Operate Pump Operation Axial Fan Impellor Checks & Adjustments Fill alve Service Procedure Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 2

3 Introduction This manual is to be used in conjunction with the Service Manual 12 - Cooler - AD / CC (series 4 & 5). The AD series Coolers for the summer season will have 2 Cooler electronic control modules available in the range of 3 models. The Premium AD range, uses the N-E1 module, a Networker, Dump alve, and is supplied with a Winter Seal. The Midline AD range, will be available with either a N-E1 or Tekelek 461 module, and can be optioned to have a Networker or Dump alve on the N-E1 version, or a Winter Seal. The Classic AD (base) range will use the a Tekelek 461 Cooler control module, and will only be supplied by Brivis with the Tekelek 485 Manual (24 olt) wall control. This model will not be available with Dump alve option, and the Tekelek controls do not offer the Cooler automatic pad Pre-Wet, speed sense fan control, or DC fan brake operation facilities. All models will have the option of being supplied without Decor panels for a reduced cost. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 3

4 Technical Information A D 15 Sizing Guide Reference Figure Cabinet detail Decor Panel Standard / Option without Height Length Down 980 mm 720 mm 980 mm Dry Weight Wet Weight 42.0 kg 55.7 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 480 mm Thickness 75 mm Type CELDEK Duct Outlet Size Length Down 555 mm 555 mm Motor Pump/Water Distribution Type 240-1ph Type Askoll Model Fasco Rating 240 /.22 Amp 855BNA-A12 Capacity 20 L/minute Watts 315 Overflow size 40 mm Amps 2.8 Tank Capacity 30 Litres R.P.M Ball Float Type PHILMAC 1527 with Filter Capacitor Size 8 uf Float Washer Size RUBBER 20/35 mm Tekelek461 Min Setting 140 olts Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 533 mm Types AUSWG 92 Blades 5 Blade Angle 25 deg TIP Cooler Control Module Tekelek 461 Brivis N-E1 Wall Control Tekelek 485 (Manual) Networker Tekelek 485 (Manual) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 4

5 Technical Information A D 25 Sizing Guide Reference Figure Cabinet detail Decor Panel Standard / Option without Height Length Down 980 mm 720 mm 980 mm Dry Weight Wet Weight 42.0 kg 55.7 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 480 mm Thickness 75 mm Type CELDEK Duct Outlet Size Length Down 555 mm 555 mm Motor Pump/Water Distribution Type 240-1ph Type Askoll Model Fasco Rating 240 /.22 Amp 855BNA-A12 Capacity 20 L/minute Watts 315 Overflow size 40 mm Amps 2.8 Tank Capacity 30 Litres R.P.M Ball Float Type PHILMAC 1527 with Filter Capacitor Size 8 uf Float Washer Size RUBBER 20/35 mm Tekelek461 Min Setting 140 olts Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 533 mm Types AUSWG 92 Blades 5 Blade Angle 25 deg TIP Cooler Control Module Tekelek 461 Brivis N-E1 Wall Control Tekelek 485 (Manual) Networker Tekelek 485 (Manual) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 5

6 Technical Information A D 35 Sizing Guide Reference Figure Cabinet detail Decor Panel Standard / Option without Height Length Down 980 mm 720 mm 980 mm Dry Weight Wet Weight 42.0 kg 55.7 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 480 mm Thickness 75 mm Type CELDEK Duct Outlet Size Length Down 555 mm 555 mm Motor Pump/Water Distribution Type 240-1ph Type Askoll Model Fasco Rating 240 /.22 Amps Model 855BQA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Tank Capacity 30 Litres R.P.M Ball Float Type PHILMAC 1527 with Filter Capacitor Size 15 uf Float Washer Size RUBBER 20/35 mm Tekelek461 Min Setting 140 olts Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 533 mm Types AUSWG 92 Blades 10 Blade Angle 25 deg TIP Cooler Control Module Tekelek 461 Brivis N-E1 Wall Control Tekelek 485 (Manual) Networker Tekelek 485 (Manual) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 6

7 Technical Information A D 45 Sizing Guide Reference Figure Cabinet detail Decor Panel Standard / Option without Height Length Down 1100 mm 770 mm 1100 mm Dry Weight Wet Weight 44.0 kg 65.5 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 530 mm Thickness 75 mm Type CELDEK Duct Outlet Size Length Down 555 mm 555 mm Motor Pump/Water Distribution Type 240-1ph Type Askoll Model Fasco Rating 240 /.22 Amps 855BQA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Tank Capacity 32 Litres R.P.M Ball Float Type PHILMAC 1527 with Filter Capacitor Size 25 uf Float Washer Size RUBBER 20/35 mm Tekelek461 Min Setting 140 olts Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 533 mm Types AUSWG 92 Blades 10 Blade Angle 33 deg TIP Cooler Control Module Tekelek 461 Brivis N-E1 Wall Control Tekelek 485 (Manual) Networker Tekelek 485 (Manual) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 7

8 Technical Information A D 55 Sizing Guide Reference Figure Cabinet detail Decor Panel Standard / Option without Height Length Down 1100 mm 770 mm 1100 mm Dry Weight Wet Weight 44.0 kg 65.5 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 530 mm Thickness 100 mm Type CELDEK Duct Outlet Size Length Down 555 mm 555 mm Motor Pump/Water Distribution Type 240-1ph Type Askoll Model Fasco Rating 240 /.22 Amps 855BQA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Tank Capacity 32 Litres R.P.M Ball Float Type PHILMAC 1527 with Filter Capacitor Size 25 uf Float Washer Size RUBBER 20/35 mm Tekelek461 Min Setting 140 olts Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 533 mm Types AUSWG 92 Blades 10 Blade Angle 33 deg TIP Cooler Control Module Tekelek 461 Brivis N-E1 Wall Control Tekelek 485 (Manual) Networker Tekelek 485 (Manual) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 8

9 Technical Information A C 60 For release in Queensland Only Cabinet detail Dropper Transition 650 mm X 650 mm to 800 mm X 560 mm (optional) Down 1100 mm Height 770 mm Length 1100 mm Dry Weight Wet Weight 44.0 kg 65.5 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 530 mm Thickness 100 mm Type CELDEK 5090 Duct Outlet Size Length Down 655 mm 655 mm Motor Pump/Water Distribution Type ph Type J.R.M. Model BETTS Rating 240 /.5 Amps 855BQA-A14 Capacity 38 L/minute Watts 750 Overflow size 115 mm hgt X 40 mm dia Amps 5.7 Waste Outlet Size 1 1/2" BSP R.P.M Tank Capacity 32 Litres Capacitor Size 20uF Ball Float Type PHILMAC 1527 R.P.M Min Setting Refer N-E1 version Float Washer Size RUBBER 20/35 mm R.P.M Max Setting Refer N-E1 version Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 638 mm Types AUSWG 92 Blades 10 Blade Angle 22 deg TIP Wall Controller Type Tekelek 485 Networker Manual Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 9

10 Technical Information A C 65 Sizing Guide Reference Figure Cabinet detail Dropper Transition 650 mm X 650 mm to 800 mm X 560 mm (optional) Height Length Down 1100 mm 1030 mm 1100 mm Dry Weight Wet Weight 59.0 kg 98.0 kg Metal Type Colour Grade Thickness Cabinet - ALUMIUM BIRCH GREY 5005 T34 (MARE GRADE) 0.8 Roof - ColourBond BIRCH GREY 0.55 Filter Pad Details Down Quantity mm Height 800 mm Thickness 100 mm Type CELDEK Duct Outlet Size Length Down 655 mm 655 mm Motor Pump/Water Distribution Type 240-1ph Type J.R.M. Model Fasco Rating 240 /.5 Amps 855BQA-A14 Capacity 50 L/minute Watts 750 Overflow size 115mm hgt X 40mm dia Amps 5.4 Tank Capacity 32 Litres R.P.M Ball Float Type PHILMAC 1527 Capacitor Size 25 uf Float Washer Size RUBBER 20/35 mm Tekelek461 Min Setting 140 olts Distribution Hose Size 20 mm CLEAR HOSE Bleed Adjustment ROTATG BLEED TRAY Fan Impellor Size 638 mm Types AUSWG 92 Blades 10 Blade Angle 22 deg TIP Cooler Control Module Tekelek 461 Brivis N-E1 Wall Control Tekelek 485 (Manual) Networker Tekelek 485 (Manual) Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 10

11 Technical Information Cooler Circuit Diagram TERMAL FOR THE WIRE LOOM LOW OLTAGE WALL SWITCH TEK 400 SPEED CONTRL TEKELEK PTY LTD MAX CURRENT RATGS: FAN WDG 5.0A FAN TOTAL 8.0A MOTOR 0.6A SULATION COER-DO NOT REMOE FAN IOLET FAN ACTIE HEATSK COER REAR Minimum olt adjustment screw FAN MOTOR 240 AC IOLET ACTIE ARISTOR (COMMON) () () GREEN / YELLOW (EARTH) 7 6 COMMON COMMON 8 9 OUT WHITE 12 / ALTERNATIE FAN CONTROL GREY SWITCH LOOP / FAN CONTROL ACTIE OUT ACTIE ACITOR COMMON 1 WALL SWITCH MAS Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 11

12 Climate Systems AM Technical Information Cooler Circuit Diagram (cont) WIRG DIAGRAM ALL DIRECT WI MOTORS TON-E1 MODULE Mon Day DUMP ALE brivis Clock Auto Mode Prog On Off Climate Control N - E1 LID DUMP EARTH TOMANUAL WALL CONTROL GREY LID CONNECTIONS COMMON ACTIE IOLET SPEED SENSOR MOTOR MAS ACITOR FAN MOTOR GREEN Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 12

13 Technical Information Motor Circuit Diagram MOTOR WATT Direct Wired Betts/Fasco 855BNA - A12 (COMMON) () GREEN /YELLOW EARTH OERLOAD 38.8 MA 10.6 Capacitor 8 u/f Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 13

14 Technical Information Motor Circuit Diagram (cont) MOTOR WATT DIRECT WI BETTS MODEL - 855BQA - A14 (COMMON) () () GREEN /YELLOW EARTH OERLOAD 9.6 MA 4.4 ACITOR 25 u/f Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 14

15 Operation of the Cooler & Wall Controls Tekelek 485 Wall Control (Manual) The 24 volt low voltage manual wall control is wired, using the Tekelek 400 WL, 20 metre wiring loom with polarised plugs. The wall control consists of a fan switch, a pump switch and a rotating dial, to vary the fan speed between minimum and maximum air output. The pump switch activates the pump ON and OFF manually, the fan switch activates the fan ON and OFF and the rotating dial sets the level of fan (air) output delivered within the range of the Cooler's fan motor settings. Cooler Control Fan Cool Note: A special version Tekelek 485 wall control with a maximum speed set potentiometer is available for Service Technicians. The potentiometer is clearly marked on the back of the control PCB, the same as the Tekelek 425 wall control. The special wall control should only be used to deal with excessive air flow and or noise problem installations. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 15

16 AM Operation of the Cooler & Wall Controls (cont) The Brivis Networker (N-C1) The Networker can operate in Manual mode (as for Tekelek 485), or in Auto mode, which activates the pump and fan and its speed, according to the room conditions and comfort level setting. Mon Day Clock Networker Auto Mode Auto Mode Prog brivis Climate Systems Climate Control On Off 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, if the comfort level setting is adjusted, an immediate signal is also sent to the cooler. Whenever the Networker sends an OFF or ON signal to the N-E1 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-E1 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. If the temperature changes by 2.50C or more within this 5 minute period, then the Networker will signal the N-E1 module to adjust immediately. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 16

17 Operation of the Cooler & Wall Controls (cont) Tekelek 461 Controls The Tekelek 485 Wall Control switches a low voltage on both the pump and fan circuits to the Tekelek 461 Module. On the fan circuit from the wall control, the voltage variation through the potentiometer, adjusts the fan speed minimum and maximum speed. The Tekelek 461 Electronic Control contain a minimum speed adjustment, to regulate the minimum voltage supplied to the motor when the operating at the minimum setting on the wall control. Check the Technical Information sheet for the model and voltage. Note: when replacing the Tekelek 461 or lid assemble, ensure the correct minimum voltage is set for the model. N-E1 Operation The N-E1 Cooler module is programmed to automatically Pre-Wet the filter pads when the pump is turned ON. In manual mode the fan may be operated without the pump working. If the pump is turned ON with the fan running, then the fan will be forced OFF for the Pre-Wet operation, then turn back ON again. The Pre-Wet time depends on how long the Cooler's pump has been OFF, drying out the filter pads, from a prior pump operation. If the pump has been OFF for more than 10 minutes (DryPadTime) then a 4 minute Pre-Wet will result. Extended Pre-Wet Time - 3 min. + Pre-Wet Time - 1 min. = 4 minutes If the pump has been OFF for less than 10 minutes (DryPadTime) then a 1 minute Pre-Wet will result. If an optional dump valve is fitted with the N-E1 module, then time is needed to fill the tank prior to commencing the Pre-Wet. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 17

18 Operation of the Cooler & Wall Controls (cont) Dump alve Operation (N-E1 models only) The N-E1 lid assembly has a potentiometer with a 5 position selection to be set according to the Cooler model type and dump valve configuration. When the Cooler is correctly configured for Dump valve operation, on the initial operation with a dry tank, the N-E1 has a programmed FillTime Delay of 4 minutes to prevent the pump operation and subsequent Pre-Wet, until sufficient water has entered the tank. If the unit has been turned OFF (i.e. pump and fan OFF) for longer than 45 minutes, the dump valve automatically isolates the water entry and dumps the tank water, leaving the trough dry (DryDumpDelay). Additionally if the cooler pump accumulates 35 hours of operation without performing a dump action, because the fan and pump have not been OFF for 45 minutes (DryDumpDelay), then a dump service action will occur. The DumpService sequence will turn OFF the pump and fill valve, then opens the dump valve for a period of 90 seconds, draining the tank water. The fan may continue to operate during this time if turned ON. The fill valve is then activated again, closing the dump valve, and filling the tank with water. The pump operation will resume after the FillTime (4 minutes) has expired. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 18

19 General Operation N-E1 Controls The selection potentiometer provides the facility to turn OFF or ON the Dump valve function, with a selection of alternative fan speed ranges. Model 5 (All Models) Dump OFF Fan minimum speed = 450 RPM Fan maximum speed = 1450 RPM Model 4 (All Models) Dump ON Fan minimum speed = 450 RPM Fan maximum speed = 1450 RPM Model 3 Dump ON Fan minimum speed = 1000 RPM Fan maximum speed = 1400 RPM Model 2 Dump ON Fan minimum speed = 450 RPM Fan maximum speed = 1050 RPM Model 1 Dump OFF Fan minimum speed = 450 RPM Fan maximum speed = 1050 RPM Fan Operation (N-E1 models) The N-E1 controls the level of voltage output to the fan determined within parameters of the Model Selection Potentiometer settings. The table above indicates the position the potentiometer to set for an alternative fan speed range, that may be required to suit specific installations. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 19

20 General Operation (cont) Fan Speed Feedback (N-E1 models only) The fan motor is fitted with a speed sensor which signals the motor RPM back to the N-E1 Cooler control. The sensor is fitted to the special stub shaft provided on the new series motors 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-E1 doesn't receive any signal from the speed sensor, or looses the signal, the N-E1 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. In FAN_LIMP mode the fan speed is controlled to a phase angle, associated with the fan output level of the Tek 485 wall control, and therefore the fan can still vary in speed, whilst operating in LIMP mode. If the condition rectifies itself, and the speed sensor signal is restored, then the Cooler will resume normal fan operation. DC Brake Whenever the fan motor is required to operate, the N-E1 checks if the motor and fan are rotating (may be due to air up draught). The N-E1 will apply a brake to stop the rotation by energising the motor with DC oltage. 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. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 20

21 General Operation (cont) Using Multiple Coolers on the Network If more than one Cooler is connected to a single Networker, then all the Coolers will be wired in parallel to the Networker. Wiring Multiple Coolers. To ensure each Cooler is configured correctly to the Networker, see below. Networker Setting up Multiple Coolers on the Network. When more than one Cooler is installed on a Networker, each Cooler must be; (a) given a different specific Identification number, starting at No. 1. (b) designated to a zone. (refer to the Networker - Advanced Programming Manual). Each Cooler comes with the ID number 1. To give it a new number, first complete the installation and wiring of all the units, as described above. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 21

22 General Operation (cont) Changing an Identification Number To change the ID number, a Cooler must be powered and configured individually. Turn OFF the power to all the other Coolers and Heaters on the Network, and make the change to the specific Cooler at the Networker. Use the Installer Set-Up program as follows: 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: E 1 Parameter Parameter Cooler & alue Number Unit Number Rotate the circular dial to change the parameter value displayed at the top left of screen, to the unit number required for this Cooler: E 1 Parameter Parameter Cooler & alue Number Unit Number Press the Networker ON/OFF button and exit the program. Turn the power supply at the Cooler OFF, to save the new ID number. Repeat the sequence for each Cooler. Then follow the advanced programming instructions to allocate the Coolers to their respective zones. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 22

23 General Operation (cont) Networker Configuration Link The N-E1 module (post 1/11/98) has a new removable bridge link to configure the control to the correct message handling system of the version Networker. The Networker on original AD series Coolers was slightly different in the way the operation message signals between the controls were communicated on later Networker heater and Cooler products. When these later controls are required to operate with an older version Networker, the bridge link is required to be removed. Note: The bridge link is in the same location previously used with a solid wire link for multiple units set-up. N -E 1 N e tw o rk e r C o n fig u ra tio n B rid g e L in k M a n u a l w a ll c o n tr o l p lu g N e tw o r k e r te r m in a l b lo c k Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 23

24 General Operation (cont) Cabinet and Component Modifications The Askoll pump below the tank with inverted filter basket on AD models. The Philmac ball float valve with supply inlet filter New moulded Bleed tray with 19mm barb fitting / 40mm thread. Bleed tray Indicator Dry pad maximum level Dry pad minimum level Overflow pipe Tank base deepened at plumbing side. Base frame modified to accommodate new pump, dump, and float valve design. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 24

25 FUSED Service Diagnostics and Procedures Fan Motor Will Not Operate Page 25 Check the impellor is free to turn. Check the motor shaft is free to rotate and is not jammed. 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). Check minimum olt setting - Tekelek 461 module only. 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. Check for 240 olts at terminals MOTOR/- and MOTOR/COMMON- on the circuit board (max. fan speed selected). N-E1 Tekelek 461 LID CONNECTIONS GREY IOLET L1 MOTOR DUMP C1 COMMON EARTH LK1 C3 C2 1 SW1 MAS ACTIE OFF 240 OLTS IOLET ACTIE T400 SERIES SPEED CONTROL 7 6 COMMON COMMON / OUT 8 T200 SERIES SPEED CONTROL 9 12 / ALTERNATIE FAN WHITE ARISTOR SWITCH CONTROL GREY ACITOR FAN CONTROL ACTIE OUT ACTIE OFF 240 COMMON 1 WALL SWITCH MAS 10 A COM 10 A multimeter FUSED COM Multimeter Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 25

26 FUSED Service Diagnostics and Procedures (cont) Fan Motor Will Not Operate (cont) If 240 olts Present Check for olts at terminals MOTOR/COMMON- and MOTOR/-. Replace capacitor and test again. Replace fan motor. NE-1 Tekelek 461 DUMP EARTH LK1 C2 SW1 IOLET ACTIE ARISTOR T400 SERIES GREY SPEED CONTROL CONTROL SWITCH LID CONNECTIONS IOLET L1 MOTOR C1 C3 COMMON 1 MAS ACTIE OFF 240 OLTS 7 6 COMMON COMMON / FAN OUT WHITE T200 SERIES SPEED CONTROL / ALTERNATIE FAN CONTROL 13 GREY 14 ACTIE OUT ACITOR ACTIE 240 OFF 10 A COMMON 1 WALL SWITCH MAS 10 A COM COM multimeter FUSED Multimeter Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 26

27 FUSED Service Diagnostics and Procedures (cont) Fan Motor Will Not Operate (cont) If No olts Present Check if motor runs: Isolating power, remove N-E1 or Tekelek 461 LID- wire from board, remove MOTOR/- wire and place on LID- terminal, switch ON power and check if motor runs. or Bridging terminals MOTOR - and MAS-ACTIE using a multimeter set on Amps (check current for motor - refer motor specs). N-E1 Tekelek 461 DUMP EARTH LK1 C2 SW1 T400 SERIES SPEED CONTROL IOLET ACTIE CONTROL ARISTOR SWITCH LID CONNECTIONS GREY IOLET C1 C3 L1 COMMON MOTOR 1 MAS ACTIE OFF 4.7 AMPS 7 6 COMMON COMMON / OUT 8 T200 SERIES SPEED CONTROL 9 12 / ALTERNATIE FAN WHITE GREY FAN CONTROL ACTIE OUT ACITOR ACTIE 4.7 AMP OFF 10 A A COMMON 1 WALL SWITCH MAS Amp 10 A multimeter COM FUSED COM Multimeter If Motor Runs Replace N-E1 or Tekelek 461 lid and test again. Replace Wall control &/or loom and test again. If Motor Doesn't Run Replace capacitor and test again. Replace motor. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 27

28 Service Diagnostics and Procedures (cont) Pump Operation 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 - Askoll Pump Check that the tank water level is correct. Check the water distribution piping is not blocked. Dismantle the pump and 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. Dismantling the Askoll Pump Isolate the 240 olt power supply to the pump. Drain the tank of water and remove the pump assembly. 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. 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. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 28

29 FUSED Service Diagnostics and Procedures (cont) Pump Operation (cont) Electrical Checks Check the pump motor winding is not open circuit. Isolate the electrical supply and use a multimeter on Ohm's setting check the circuit resistance at terminals - and - Askoll pump = 170 OHM JRM (50 L) pump = 34 OHM NE-1 DUMP EARTH SW1 Tekelek 461 LK1 C2 IOLET ACTIE ARISTOR LID CONNECTIONS GREY IOLET L1 C1 C3 COMMON 1 ACTIE 44 OHMS T400 SERIES SPEED CONTROL 7 6 COMMON COMMON 5 OUT 8 T200 SERIES SPEED CONTROL 9 12 / ALTERNATIE FAN WHITE CONTROL GREY SWITCH MOTOR MAS OFF / FAN CONTROL ACTIE OUT ACITOR ACTIE 169 Ohm OFF 10 A COMMON 1 WALL SWITCH MAS 10 A FUSED COM multimeter Multimeter COM Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 29

30 FUSED Service Diagnostics and Procedures (cont) Pump Operation (cont) Electrical Checks Check that the pump is switched ON and that there is 240 olt output to the pump at the - (common) and - terminals on the circuit board. N-E1 DUMP EARTH SW1 LK1 C2 GREY C1 C3 L1 COMMON 1 LID CONNECTIONS IOLET MAS MOTOR ACTIE OFF 240 OLTS Tekelek 461 ARISTOR T400 SERIES SPEED CONTROL SWITCH CONTROL 7 6 COMMON COMMON / IOLET OUT 8 T200 SERIES SPEED CONTROL 9 12 / ALTERNATIE FAN WHITE ACTIE GREY ACITOR FAN CONTROL ACTIE OUT ACTIE 240 OFF COMMON 1 WALL SWITCH MAS 10 A COM 10 A multimeter FUSED COM Multimeter Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 30

31 FUSED Service Diagnostics and Procedures (cont) Pump Operation (cont) Electrical Checks If 240 olts Present Check - Pump Mechanical checks. Replace pump. If No 240 olts Present Check if pump runs: Isolating power, remove N-E1 or Tekelek 461 LID- wire from board, remove the - wire and place on LID- terminal, switch ON power and check if motor runs. Or Bridge terminals - & MAS -ACTIE using multimeter set on Amps. If Pump Functions Replace wall control and reset. Replace N-E1 or Tekelek 461 and re-test. N-E 1 Tekelek 461 LID CONNECTIONS GREY IOLET L1 MOTOR DUMP C1 COMMON EARTH LK1 C3 C2 1 SW1 MAS ACTIE OFF.34 AMPS IOLET ACTIE T400 SERIES SPEED CONTROL 7 6 COMMON COMMON / OUT 8 T200 SERIES SPEED CONTROL 9 12 / ALTERNATIE FAN WHITE ARISTOR SWITCH CONTROL GREY ACITOR FAN CONTROL ACTIE OUT ACTIE 0.22 AMP OFF COMMON 1 WALL SWITCH MAS 10 A Amp COM 10 A A multimeter FUSED COM Multimeter Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 31

32 Service Diagnostics and Procedures (cont) 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. The blade tips should be positioned centrally within the bell housing. 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. The Auswing fan impellor has a Notch indicator on the hub adjacent to the blade. AD Coolers Impellor Hub Bracket positioned at top of motor shaft 18 o o o o 27 Fan Impellor Reference Points Motor Motor Bracket Fan Blade 20mm Motor End Plate Motor Bracket positioned 20mm above motor end plate Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 32

33 Service Diagnostics and Procedures (cont) Fill alve Service Procedures Fill alve Will Not Open Check the wall control is turned ON (pump), and the Cooler power supply is turned ON. Check the N-E1 lid potentiometer is set to the correct position (normally #4) for Dump valve operation. Check the wiring and terminals to the fill valve are in the correct position and are good connections. Check for 240 olts at terminals DUMP- and DUMP- on the N-E1 circuit board. IMPORTANT NOTE: when the fill valve is not switched ON the dump terminals will have approximately 10 olts (0.03 A) present. DUMP EARTH LK1 SW1 C2 GREY LID CONNECTIONS IOLET L1 MOTOR C1 C3 COMMON 1 MAS ACTIE OFF 240 OLTS 10 A FUSED COM Multimeter Check the incoming water pressure does not exceed the maximum operation pressure of 1000 kpa. Check the incoming water pressure does not exceed the minimum operation pressure of 300 kpa. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 33

34 Service Diagnostics and Procedures (cont) Fill alve Service Procedures Fill alve Will Not Open Check the resistance on the fill valve solenoid at terminals DUMP- and DUMP- (6 K Ohm). DUMP EARTH LK1 SW1 C2 GREY LID CONNECTIONS IOLET C1 C3 L1 COMMON MOTOR 1 MAS ACTIE OFF 6 k OHMS 10 A FUSED COM Multimeter Check the fill valve plunger and valve seat for damage. Remove the 4 screws around the solenoid base and separate the solenoid from the valve body. Remove and check valve seat and plunger. Service Manual 21 Cooler AD CC 5 Series NE-1 & TEK 461 Approved Issue 1 Printed 2/13/ :49:29 AM 34