Introduction: Technical Information: Motor Circuit Diagram: Installer Commissioning Instructions:...

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2 Contents Page Introduction: Technical Information: Cooler Circuit Diagram: Motor Circuit Diagram: Installer Commissioning Instructions: Installing Multiple Coolers: Installer Set-Up Programming: Cooler Operation: General Operation Networker Control in Auto Mode Networker Control in Manual Mode Wash Service Flush Service Operation N-E2 Electronic Controller Module Operation Fan Operation N-E2 Module Cooler Model Configuration Speed Feedback FAN_LIMP Mode - Networker Error DC Brake Axial Fan Impellor Checks and Adjustments Motor Failure - Networker Error Fan Will Not Operate Fan Will Not Operate - Flowchart Dismantling Fan and Fan Motor Removal Pump Operation Dismantling Procedure Pump Will Not Operate Electrical Checks Mechanical Checks Electrical & Mechanical Checks - Flowchart Water Inlet Solenoid Dismantling Procedure Water Inlet Solenoid Does Not Supply Water Into Tank Water Inlet Solenoid Does Not Turn OFF

3 Contents Page ServoSeal and Drain Valve Operation Dismantling Procedure ServoSeal Will Not Open / Drain Close ServoSeal and Drain Valve Diagnostic Checks ServoSeal Motor Circuit Diagram Trident Water Management Operation: Trident Operation Abnormal Operation Water Limp Modes Low Water Level Sensor - Networker Error High Water Level Sensor - Networker Error Drain - Networker Error Water Sense Failure - Networker Error Test Procedure and Service Checks FlushService Guide Table Dismantling Networker Service Parameters: Dealing With Problem Installations: Excessive Internal Noise From Unit Excessive External Noise From Unit Operation Noise Condensation Water Entering Building Service Maintenance: Pre Season Maintenance End of Season Maintenance Dismantling the Water Distribution System

4 Introduction Brivis introduces 2 new models to the Contour Series, for the season of The new L10 and L20 models, in a new smaller cabinet, replace the temporary L10T and L20T units. All models are available in 6 different colours. Beige, Slate Grey, Terracotta, Caulfield Green, Heritage Red and Chocolate. Brivis Contour Coolers use the Networker wall control exclusively, and employ N-E2 electronic control system, which operates on a 2 wire bus communication scheme with the Networker. This system is capable of handling multiple Coolers, as well as combined cooling and gas ducted heating control, when using Brivis MPS and Auto EMS heaters. The Contour Cooler not only has a revolutionary new design and shape, but its construction is also unique. Radiating from the strength and support of the dropper duct, Contour Coolers engage a triangulation suspension construction. The external panels and tank are colour co-ordinated in UV stabilised plastic, and the low profile base design has allowed Contour Coolers to achieve greater performance with less water storage. A motorised duct damper called a ServoSeal, is built into the Cooler's base. The ServoSeal is integrated with a tank draining system, known as the Auto Refresh Tube (A.R.T.), which is an improved form of the conventional principle of a dump valve. Contour Coolers also feature a new water management system, that electronically controls the water levels, and tank water quality. During operation, the Cooler flushes away water with any salt build up, at intervals relating to the current operating conditions. At the end of use the Cooler performs a tank wash operation. All these innovative Brivis Contour features bring true meaning to the term "seasonal maintenance". Apart from good looks and superior control functions, Contour Cooler's design has provided a special dry compartment to house most of the unit's controls, components and wiring circuits. 4

5 Introduction (cont.) The water circulation system of the Contour has been specially designed, by locating the Synchro-Drive pump in the dry compartment, with sealed piping to the pump's inlet and outlet. The pump itself has a magnetic coupling drive, and thermal protection on the motor windings. The N-E2 module controls the fan motor through a speed sensor circuit. This provides superior control of the motor's operation with smoother motor starts and speed adjustments, irrespective of duct resistance. The speed sensor also provides the motor with a DC voltage brake locking operation, to arrest the reverse rotation of the fan due to air up draught from within the building. The Contour N-E2 module has also been programmed to automatically engage Pre- Wetting of the filter pads, to ensure optimum performance of the Cooler. 5

6 Technical Information Contour L 10 Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 960 mm 740 mm 430 mm 960 mm 46 kg 56 kg Filter Pad Details Down Quantity 4 Thickness 75 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1 ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BNVA-A12 Capacity 20 L/minute Watts 315 Overflow size 40 mm Amps 2.8 Waste Outlet Size 40 mm R.P.M Tank Capacity 10 Litres Capacitor Size 8 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1450 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 7 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 485 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 5 RPM 500 Blade Angle 25 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 6

7 Technical Information Contour L 10T Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 1060 mm 800 mm 480 mm 1060 mm 52 kg 64.5 kg Filter Pad Details Down Quantity 4 Thickness 75 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BNVA-A12 Capacity 20 L/minute Watts 315 Overflow size 40 mm Amps 2.8 Waste Outlet Size 40 mm R.P.M Tank Capacity 12 Litres Capacitor Size 8 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1050 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 4 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 533 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 5 RPM 500 Blade Angle 25 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 7

8 Page 8 Technical Information Contour L 20 Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 960 mm 740 mm 430 mm 960 mm 46 kg 56 kg Filter Pad Details Down Quantity 4 Thickness 90 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1 ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BQVA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Waste Outlet Size 40 mm R.P.M Tank Capacity 10 Litres Capacitor Size 25 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1450 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 7 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 485 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 10 RPM 500 Blade Angle 25 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 8

9 Technical Information Contour L 20T Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 1060 mm 800 mm 480 mm 1060 mm 52 kg 64.5 kg Filter Pad Details Down Quantity 4 Thickness 75 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BNVA-A12 Capacity 20 L/minute Watts 315 Overflow size 40 mm Amps 2.8 Waste Outlet Size 40 mm R.P.M Tank Capacity 12 Litres Capacitor Size 8 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1150 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 3 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 533 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 5 RPM 500 Blade Angle 25 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 9

10 Technical Information Contour L 30 Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 1060 mm 800 mm 480 mm 1060 mm 52 kg 64.5 kg Filter Pad Details Down Quantity 4 Thickness 75 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1 ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BQVA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Waste Outlet Size 40 mm R.P.M Tank Capacity 12 Litres Capacitor Size 25 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1150 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 3 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 533 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 10 RPM 500 Blade Angle 33 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 10

11 Technical Information Contour L 40 Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 1060 mm 800 mm 480 mm 1060 mm 52 kg 64.5 kg Filter Pad Details Down Quantity 4 Thickness 90 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1 ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BQVA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Waste Outlet Size 40 mm R.P.M Tank Capacity 12 Litres Capacitor Size 25 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1350 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 1 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 533 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 10 RPM 500 Blade Angle 33 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 11

12 Technical Information Contour L 50 Sizing Guide Reference Figure Cabinet detail Width Height front Height back Length Dry Weight Wet Weight 1060 mm 800 mm 480 mm 1060 mm 52 kg 64.5 kg Filter Pad Details Down Quantity 4 Thickness 110 mm Type CELDEK 5090 Duct Outlet Size Width Length Down 550 mm 550 mm Motor Pump/Water Distribution Type 240 V - 1 ph Type ASKOLL. Model BETTS Rating 240 V /.22 Amps 855BQVA-A14 Capacity 20 L/minute Watts 750 Overflow size 40 mm Amps 5.7 Waste Outlet Size 40 mm R.P.M Tank Capacity 12 Litres Capacitor Size 25 uf Coil Resistance 169 Ohm R.P.M Min Setting 500 Distribution Hose Size 20 mm CLEAR HOSE R.P.M Max Setting 1350 Inlet Valve Type Tech/Comp C202/89 Motor Selection No. Model 1 Inlet Valve Size 1/2" BSP (Male) Thread Inlet Valve Rating 240 V Amps Inlet Valve Capacity 12 L/minute Fan Impellor ServoSeal Motor Size 533 mm Type S.A.I.A Types AUSWING 92 Rating 240 V 50 Hz 0.23W Blades 10 RPM 500 Blade Angle 33 o TIP Resistor 100 nf Capacitor 470 Ohm Wall Controller Type Networker Water Connection Flexible Hose Connection with 1/2" BSP (Male) Thread Drain Connection 40 mm PVC 12

13 Cooler Circuit Diagram Internal Circuit Diagram MAINS SUPPLY WATER INLET SOLENOID FAN MOTOR SERVOSEAL DAMPER / DRAIN VALVE RESISTOR / CAPACITOR MOTOR CAM SWITCH RUN START COMMON SPEED SENSOR BLACK (OPEN) YELLOW YELLOW RED (CLOSE) A N N NETWORKER E CAPACITOR A N N-E2 TRIDENT WATER MANAGEMENT SYSTEM PUMP N - E 2 B a s e T e r m in a l C o n n e c to r M o u n tin g B ra c k e t B r o w n V a c a n t W h ite R e d B la c k P u rp le R e d V a c a n t D a r k B lu e L ig h t B lu e V a c a n t B r o w n 13

14 Motor Circuit Diagram Betts 315 Watt Motor 855BNVA-A12 BLUE(COMMON) BLACK (START) BROWN GREEN /YELLOW EARTH OVERLOAD START 38.8 MAIN

15 Motor Circuit Diagram (cont.) Betts 750 Watt Motor 855BQVA-A12 BLUE(COMMON) BLACK (START) BROWN (RUN) GREEN /YELLOW EARTH OVERLOAD START 15.8 MAIN 3.8 o R esistances at 20 C 15

16 INSTALLER COMMISSIONING INSTRUCTIONS Wiring the Cooler to the Networker The first step is to run a twin wire cable (i.e. figure 8 cable mm2) from the Cooler to the Networker. Next mount the Networker backing plate. Remove the backing plate from the Networker by unclipping it at the bottom. Be sure to draw the wires from the wall cavity, and feed them through the centre opening of the wall plate. Then mount the wall plate on the wall. Connect the cable to the Networker connection lead terminal block at the Cooler, and to the terminal block at the Networker. Networker If the Cooler is integrated with a Brivis MPS or Auto EMS heater(s), then simply connect the wiring in parallel with the heater's circuit to the Networker. N e tw o rker C o n tro l T W 2 T W 1 N ET W O RKER 16

17 INSTALLER COMMISSIONING INSTRUCTIONS (cont.) Wiring the Cooler to the Networker (cont.) If more than one Cooler is connected on the system to one Networker, then all the Coolers will be wired in parallel to the Networker as shown. Ensure each Cooler is then configured correctly to the Networker, using the instructions on page 18. Networker Cooler No. 1 Cooler No. 2 Cooler No. 3 17

18 Installing Multiple Coolers on the Network The Networker is capable of controlling multiple evaporative Coolers on the one system. When more than one Cooler is installed on a Networker, each Cooler must be given a different specific identification number, starting at No. 1, and each Cooler must also be designated to a zone (refer to the Networker - Advanced Programming Manual). First, complete the installation and wiring of all the units, as described on page 16-17, then proceed as follows: Each Cooler must be powered and configured individually, whenever any Cooler identification number is to be changed. Isolate the power from all other Coolers and Network appliances, other than the unit which the identification number is being changed, and proceed to make the change at the Networker wall control through the Installer Set-Up program as follows: Turn the Networker OFF (ON/OFF button). Press the Clock key to enter "Clock Set-Up" program. Now simultaneously press, and hold the 2nd & 4th keys for 3-5 seconds, until the screen changes to display: 1 07 E 1 P aram e te r V a lu e P a ra m e ter N u m b er C o oler & U nit N o. Rotate the circular dial to change the parameter value displayed at the top left of screen, to the unit number required for this Cooler i.e.: 2 07 E 1 P aram e te r V a lu e P a ra m e ter N u m b er C o oler & U nit N o. Press the Networker ON/OFF button and exit the program. Turn the power supply at the Cooler OFF, to save the new identification number. Repeat the sequence for each Cooler, then follow the Networker Advanced Programming instructions to allocate the Coolers to their respective Networker zones. 18

19 Installer Set-Up Programming Networker Wall Control Set-Up Parameters Example n1 Parameter Value Parameter Number Networker Wall Control Parameter Display Parameter Description Entry Reference 1 00 n1 Networker Wall control Not Adjustable 1 01 n1 Refrig Common Zone Refrig Unit No n1 Refrig Zone A Refrig Unit No n1 Refrig Zone A damper Damper Relay No n1 Refrig Zone B Refrig Unit No n1 Refrig Zone B damper Damper Relay No n1 Refrig Zone C Refrig Unit No n1 Refrig Zone C damper Damper Relay No n1 Refrig Zone D Refrig Unit No n1 Refrig Zone D damper Damper Relay No n1 Heating Common Zone Heater Unit No n1 Heating Zone A Heater Unit No n1 Heating Zone A damper Damper Relay No n1 Heating Zone B Heater Unit No n1 Heating Zone B damper Damper Relay No n1 Heating Zone C Heater Unit No n1 Heating Zone C damper Damper Relay No n1 Heating Zone D Heater Unit No n1 Heating Zone D damper Damper Relay No n1 Evap Common Zone Evap Unit No n1 Evap Cooling Zone A Evap Unit No n1 Evap Cooling Zone B Evap Unit No n1 Evap Cooling Zone C Evap Unit No n1 Evap Cooling Zone D Evap Unit No n1 Circulation Fan Operation (Heat) 1 = ON 0 = OFF 19

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

21 Cooler Operation (cont.) General Operation (cont.) If the pump has been OFF for less than 2 minutes (ShortDryPadTime), then no Pre-Wet will occur. If the pump has been OFF for less than 10 minutes (LongDryPadTime), but longer than 2 minutes (ShortDryPadTime), a 1 minute (ShortPrewetTime) will apply. If the pump has been OFF for longer than 10 minutes (LongDryPadTime) then a 4 minute (LongPrewetTime) will occur. If the power supply to the N-E2 has been interrupted, the first Pre-Wet will be 4 minutes (LongPrewetTime). Pump ON Pump OFF Pump ON Pump ON Pump ON Power Interruption Time interval from prior pump operation more than 2 mins and less than 10 mins Time interval from prior pump operation less than 2 mins (ShortDryPadTime) Time interval from prior pump operation more than 10 mins (LongDryPadTime) Pump ON 1 minute pre-wet (ShortPrewetTime) No pre-wet 4 minute pre-wet (LongPrewetTime) 4 minute pre-wet (LongPrewetTime) Fan ON If the unit is turned OFF (i.e. pump and fan OFF) for longer than 60 minutes (originally 20 minutes) (ServoCloseDelay), the N-E2 module will automatically isolate the water inlet solenoid, and drive ServoSeal closed, closing the dropper duct and draining the tank. 21

22 Cooler Operation (cont.) Networker Control in Auto Mode The following sequences are normal operation in Auto mode, with the Networker at a set comfort level, and the room temperature varying according to the Cooler's operation and load conditions. When the Networker is turned ON in Cooler Auto mode, an immediate signal is sent to the cooler to indicate if the unit is required to operate or not. If the comfort level setting is adjusted on the Networker when operating in Cooler Auto mode, an immediate signal is also sent to the cooler. Whenever the Networker sends an OFF or ON signal to the N-E2 module, both the pump and the fan will be turned OFF or ON, however, their operation may be delayed by the fill and Pre-Wet functions. The Cooler will be turned ON, if the room temperature is 0.50C. higher than the set comfort level, and OFF if the room temperature is lower. The ON fan signal from the Networker accompanies a fan speed signal, to determine the speed required according to the temperature differential between the room temperature and set comfort level. The fan will operate at minimum speed, when the room temperature is up to 10C. above the set comfort level, and is incremented to be at maximum fan speed, when the room temperature is 50C. or more above the set comfort level. During normal operation, at 5 minute intervals, the Networker updates the N-E2 module on the temperature differential between room temperature and the set comfort level, and if the temperature has varied by 0.50C. or more then the cooler is adjusted. However, if the temperature changed rapidly by 2.50C or more, within the 5 minute update interval, then the Networker will signal the N-E2 module to adjust immediately. If the room temperature is higher than the set point when the Networker is turned ON, then the fan will immediately operate at the speed according to the set point, following the normal ServoSeal, water fill and Pre-Wet operations. 22

23 Cooler Operation (cont.) Networker Control in Manual Mode When operating the Cooler in manual mode, the Networker screen changes to display a pump and fan button for manual selection. The rotary dial is used to select the constant fan speed. The Pre-Wet times apply to manual mode, in the same way described for Auto mode. However in manual mode, the Pre-Wet period can be extended by simply operating the pump longer without the fan. Fan only operation is available for air movement in high humidity climate conditions, or for ventilation and circulation. NOTE: Should the pump be turned ON whilst the fan is operating, then the fan will be forced OFF for the Pre-Wet period, then come back ON again automatically. 23

24 Cooler Operation (cont.) Wash Service When the Networker is turned OFF, at the end of use, or the pump and fan have been OFF for more than 60 minutes (originally 20 minutes), the ServoSeal closes and the drain valve lowers to drain the tank water. Following the ServoSeal closing, the Cooler will automatically perform a tank washing action, after the time delay allowed for closing the ServoSeal ServoTime (20 seconds). A further 45 second delay (WashWaitTime) allows time for the tank to be drained completely, and initially wash out any sediment from the tank. With the drain valve still in the lowered position, the water inlet solenoid is opened for 30 seconds (WashTime), allowing clean water to further flush sediments from the tank base. On completion of the wash, an additional 45 second delay applies, before any other (new) operation can be performed i.e. Networker turned back ON again. The Cooler then remains idle until the Networker is turned ON again, and calls for cooling. 24

25 Cooler Operation (cont.) Wash Service (cont.) Networker ON - No call for O peration Call for Fan Operation Call for Pump Operation with or without Fan ServoSeal opens ServoSeal opens Inlet Valve opens and Tank fills Delay = 15 seconds (S ervotim e) Delay = 20 seconds (ServoTim e) Water at low level Pump turns ON Fan turns ON Networker turned OFF or call for pump and fan to OFF Pre-Wet time starts Pre-Wet com plete Delay = 60 minutes (ServoCloseDelay) Fan turns ON if required ServoSeal Closes 15 seconds Delay = 45 seconds (WashWaitTime) Water Inlet Valve opens 30 seconds (WashTime) Delay = 45 seconds 25

26 Cooler Operation (cont.) Flush Service Operation The N-E2 module program performs a tank flush at regular intervals, to dilute any salt and sediment build up as the unit is operating. The flush service will not affect the normal pump, or fan functions of the Cooler. The flush service timing is determined by the number of times the water has filled to the Trident High Water Level Sensor, and then evaporated down to the Trident Low Water Level Sensor. After 15 tank re fills (originally 10), the Flush Service commences. Each sequence of 15 refills of the tank, will force another the flush service operation, although the time between each Flush Service can vary, according to the conditions and Cooler settings. When the water level evaporates down to the Low Water Level Sensor for the 15th tank re fill, the water inlet solenoid will open and fill the tank to the high water level, then remain open for a further 100 second (originally 75 seconds) period. The water level will continue to rise above the High Water Level Sensor, and over flow out the drain valve / overflow pipe. The action of the fresh water entering, mixing and overflowing out from the tank, dilutes the salt and sediment ratio back to the original supply water condition. 26

27 Cooler Operation (cont.) N-E2 Electronic Control Module Operation The N-E2 module controls all the Cooler's working operations, using the signals from the Networker sent on a 2 wire bus network. The N-E2 will communicate with the Networker about the status of the Cooler's operation, including malfunction errors. Note: Although this error reporting is available on models later than September 1998, it's initial introduction will be restricted to the Melbourne market. The N-E2 is universal to all Contour Cooler models, but may require configuring to the model type, using the service parameters accessed through the Networker. The power supply input and output terminals to the N-E2 module, are via the base terminal connection mounting bracket. The module is correctly located into the mounting bracket via side slide rails. The N-E2 module has a isolating switch, that isolates the output power supply to all components within the Cooler. WARNING: The incoming 240 Volt power supply is not isolated using the N-E2 switch, and therefore some terminals within the Cooler will remain energised, until the main power supply on the unit's 3 pin plug and lead, has been disconnected. Wiring connections direct to the N-E2 module are, the Networker connection loom, the motor speed sensor and water level control looms. All installer and service parameter access is done through the Networker wall control. M O T O R S P E E D S E N S O R L O O M N E T W O R K E R L O O M W A T E R L E V E L C O N T R O L L O O M A L T E R N A T IV E N E T W O R K E R C O N N E C T IO N P O IN T J 2 J 1 J 6 J 5 27

28 Cooler Operation (cont.) N-E2 Electronic Control Module Operation (cont.) The N-E2 controller is fitted with an internal 8 Amp fuse to protect the PCB circuitry. The 8 Amp fuse will protect the N-E2 controller from short circuit and/or high current draw, on the following circuits: Pump Water inlet solenoid Fan motor PCB relays Important Note: The N-E2 internal 8 Amp fuse does not protect the control against short circuit on the ServoSeal / drain valve motor circuit. The N-E2 controller will maintain a minimum voltage on the output to the water inlet solenoid in the OFF cycle. Originally the N-E2's OFF cycle voltage was 60 Volt, and was later reduced 10 Volt. The N-E2 version with the 10 Volt OFF cycle voltage can be recognised by the inclusion of a 3rd (smaller) capacitor on the PCB (view through the case opening). N-E2 modules on models later than October 1998 have a new design plastic housing, which can be unclipped to access the PCB. 28

29 Cooler Operation (cont.) N-E2 Electronic Control Module Operation (cont.) Service Checks N-E2 not operating: Check for power supply to into the unit at the power point and Active - Neutral incoming supply terminals. Check if the N-E2 power indicator LED is illuminated. Check the N-E2 is correctly located in the base terminal connector and mounting bracket. Check the N-E2 is set to the correct Network ID number. Check if the N-E2 internal 8 Amp fuse is in circuit or is open circuit. If fuse NOT open circuit: Check the Servoseal / Drain valve wiring loom, motor and switch mechanisms for short circuit. If fuse IS open circuit (blown): Check the pump motor and wiring loom for short circuit. Check the water inlet solenoid and wiring loom for short circuit. Check the fan motor and wiring loom for short circuit. Replace 8 Amp fuse and re test. 29

30 Cooler Operation (cont.) Fan Operation N-E2 Module Cooler Model Configuration The N-E2 module is capable of being set for up to 7 different Cooler models. This setting relates to the Cooler's motor capacity and the appropriate RPM range for correct operation. The minimum RPM setting is 500 RPM for all models, and the maximum RPM varies by the model setting selected (see table below). N-E2 Model Minimum Maximum Contour Models Number RPM RPM Model L30, L40, L50 Model Model L30, L20T Model L10T Model Model Model L10, L20 Fan Operation The N-E2 controls the level of voltage output to the fan and this is determined within parameters of the Model Selection settings. The fan speed will vary on a linear scale between the minimum and maximum settings, even if the differential is minimal. Other service adjustments can be made within the Model No. range, and are discussed in the section regarding special adjustments using the Networker. 30

31 Cooler Operation (cont.) Fan Operation (cont.) Speed Feedback The fan motor is fitted with a speed sensor which signals the motor RPM back to the N- E2 Cooler control. The N-E2 must have a speed sensor fitted and operating or the unit will operate in a FAN LIMP mode. The sensor is fitted to the special stub shaft provided on the motor and uses a light beam across the shaft flat section to register the revolutions of the motor's shaft. The purpose of the sensor is to: Detect if the fan motor (impellor) is rotating when the power is first applied to the fan motor. Detect if the fan motor is locked. Detect if the fan motor is not rotating within the correct operating range. If the N-E2 doesn't receive any signal from the speed sensor, or looses the signal, the N-E2 will adopt a FAN LIMP mode operation. Initially, when the motor is required to run and the speed signal is lost, the fan will immediately be driven to the maximum power (speed) for 60 seconds. Then the FAN_LIMP mode will commence, however, there will be a 4 minute delay before the error is displayed on the Networker (where available). If the condition rectifies itself, and the speed sensor signal is restored, then the Cooler will resume normal fan operation. 31

32 Cooler Operation (cont.) Fan Operation (cont.) FAN_LIMP Mode - Networker Error 30 FAN_LIMP mode is displayed at the Networker as Error 30 whilst this condition is current (only on models later than Sept. 1998). Service In FAN_LIMP mode the fan speed is controlled to a phase angle, associated with the fan output level of the Networker, according to its mode and/or comfort setting. Therefore the fan can still vary in speed, whilst operating in LIMP mode and the user may not even notice any difference in the unit's operation. Service Check List Check the speed sensor wire loom for damage, and plug connection into the N-E2. Check the speed sensor is correctly located in the hub of the motor end plate. Remove speed sensor from motor end plate and check; That no foreign matter has entered the sensor cap The sensor PCB is firmly secured within the sensor cap. The 2 sensor probes on the PCB are vertically aligned. The wiring circuit within the speed sensor and the PCB is not damaged. Check the motor start winding is not open circuit. Check the motor capacitor - replace and retest. Check the N-E2 is not faulty - replace and re test. 32

33 Cooler Operation (cont.) Fan Operation (cont.) DC Brake Whenever the fan motor is required to operate, the N-E2 uses the motor speed sensor to checks if the motor is rotating. This rotation of the fan and motor, may be due to air up draught in the dropper duct, whilst the unit was not running. The N-E2 will apply a brake to stop the rotation by energising the motor with DC Voltage. This is to ensure the fan motor will not be energised and driven in the reverse direction. DC power will only be applied to the motor, if at the time the fan motor is powered, the motor has not been previously powered for a least 10 seconds, and that rotation is detected above the minimum RPM requiring the brake. The DC brake will then remain ON until the motor speed sensor registers the fan motor has slowed to a RPM not requiring the brake, before powering the motor for a normal start. The rate that the DC brake is applied, is a factory setting, and cannot be field modified. If the fan is operating in FAN_LIMP mode, then the DC brake will not be applied. Allow for the 4 minute delay period to register the error on the Networker, before the DC brake is disabled. 33

34 Cooler Operation (cont.) Fan Operation (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. An incorrect blade angle setting may result in the following: - Too high current draw to the fan motor (especially at maximum speed). - Excessive operation and air noise. - Reduced airflow output from the fan (especially at maximum speed). - Reduced variation of fan speed selection or function. The fan impellor is designed to be located flush at the top of the fan motor shaft. The blade tips should be positioned centrally within the bell housing. This position has been determined to give the optimum performance of the unit, without generating excessive levels of noise. The fan impellor retaining bracket bolts are required to be tightened to the minimum tension of 8 Nm torque, to ensure the fan impellor is securely held in position. 34

35 Cooler Operation (cont.) Fan Operation (cont.) Axial Fan Impellor Checks and Adjustments (cont.) The Auswing fan impellor has a notch indicator on the hub adjacent to the blade. The diagram below shows the approximate notch setting, refer to the Technical Information sheets for the blade angle required for the model. 25 o 33 o Reference Points Fan Blade 35

36 1000V V Cooler Operation (cont.) Fan Operation (cont.) Motor Failure - Networker Error 60 Should the motor circuit and or the Coolers motor main winding be open circuit, the N-E2 module will lockout and display the error at the Networker Service This error condition requires a power up reset to restore the Coolers operation. Refer to motor diagnostics for check list. Fan Motor will not Operate Turn the fan ON in manual mode and make sure the motor is not in an operation delay period i.e. Servoseal open time. Check the impellor is free to turn. Check the motor shaft is free to rotate and is not jammed. Remove the N-E2 and check the motor wiring terminals are correctly positioned on the circuit board and that the connections are good. Check the motor winding resistance (refer Motor Circuit Diagram and Technical Information Sheet). MOTOR/RUN-BROWN MOTOR/COMMON-BLUE OFF OHMS V 10 A V COM FUSED MOTOR/START-BLACK Multimeter 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. 36

37 1000V V 1000V V Cooler Operation (cont.) Fan Motor will not Operate (cont.) Check for 240 Volts at terminals MOTOR/RUN-BROWN and MOTOR/COMMON-BLUE on the motor supply loom terminals, located on the service compartment back wall (max fan speed selected). MOTOR/RUN-BROWN MOTOR/COMMON-BLUE OFF 240 V VOLTS 10 A V COM FUSED Multimeter 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. MOTOR/COMMON-BLUE 240 VOLTS OFF V MOTOR/START-BLACK 10 A FUSED V COM Multimeter 37

38 1000V V Cooler Operation (cont.) Fan Operation (cont.) Fan Motor will not Operate (cont.) If no Volts present: Bridge terminals MOTOR/RUN-BROWN and MAINS/ACTIVE-IN using a multimeter set on Amps (check current for motor - refer motor specs). NOTE: Because the start winding is not in circuit, the motor may need to be manually turned to start. MOTOR/RUN-BROWN 4.7 Amps MAINS ACTIVE-IN OFF V A 10 A V COM FUSED Multimeter If motor runs: Check the motor wiring loom and all terminals. Check minimum RPM setting (see section - Service Adjustments using the Networker. Check the N-E2 internal 8 Amp fuse is not open circuit. Replace N-E2 and test again. Check that the ServoSeal has been driven open, indicating Networker signal operating correctly. If ServoSeal not open Replace Networker and test again. If motor doesn't run: Replace motor. 38

39 Cooler Operation (cont.) Fan Operation (cont.) Fan Motor will not Operate - Flowchart Fan Checks Check if the impellor and motor shaft are free to rotate and are not jammed. Check the incoming power supply is ON and is the correct polarity. Check for 240 Volts at terminals Motor/Run - Brown & Motor/Common - Blue on the motor supply loom terminals located on the service compartment back wall. If 240 Volts Present If NO Volts Present Check for 240 Volts at terminals Motor/Common - Blue and Motor/Start - Black Bridge terminals Motor/Run - Brown and Mains/Active - In Replace capacitor and test again. If motor runs If motor doesn't run Replace fan motor Check the motor wiring loom and all terminals Replace motor Check minimum RPM setting Check the N-E2 8 Amp fuse is open circuit Replace N-E2 and test again Check that the ServoSeal has been driven open, indicating Networker singnal operating correctly If ServoSeal not open - Replace Networker and test again 39

40 Cooler Operation (cont.) Fan Operation (cont.) Dismantling - Fan and Fan Motor Removal Remove thumb screws from roof panel. Remove the 4 filter pad frames and support tube brackets. Isolate power supply on service access cover switch. Close the ServoSeal / Drain valve and drain tank of water. Remove the 2 screws from the service access panel and open cover. Unplug the Trident loom plug from the N-E2 control. Remove the pump inlet lock nut from the tank base. Remove the 4 screws that secure the tank to the coolers sub frame, then lift up and remove the tank assembly. Remove motor wire loom terminals on the motor supply loom terminal block located on the service compartment back wall. Feed back the wiring into the fan motor assembly area and disconnect the cable ties from the motor bracket Disconnect the speed sensor loom from the N-E2 circuit board, and feed back the wiring loom to the motor assembly. Loosen and remove the nuts on the fan impellor retaining bracket bolts. Place a 50mm or larger socket fitting or similar, over the motor shaft and fan impellor retaining bracket, so that it seats on the fan impellor hub body. Use a mallet to hit the 50mm socket fitting, to release the tapered bracket cone from the hub, loosening the impellor on the motor shaft. Remove impellor. Support the motor's weight, then loosen and remove the 2 nuts and washers on the bolts, that secure the fan motor mounting bracket around the motor's case. Lower fan motor down and out of the mounting bracket. 40

41 Cooler Operation (cont.) Pump Operation The Contour Cooler's pump has a synchronous motor with thermal protection, and a magnetic coupling drive to the pump impellor. The pump impellor may be driven in either rotation direction, which lessens the likelihood of the pump blocking. The pump base is integrated into the tank base and should not require removal. The pump will be turned OFF for 10 seconds at 15 minute intervals, to allow the water head in the feed tube to the distribution spreader to back flush the pump, and keep it clear of blockages. Additionally, if the pump had an air lock, this pump stoppage will allow water into the pump, to resume normal operation again. All servicing and maintenance can be done through the service access compartment. Dismantling Isolate the 240 Volt power supply to the pump (N-E2). Open service access compartment cover. Drain the tank of water. Disconnect the wiring terminals on top of the pump motor. Remove 3 screws on the perimeter of the pump upper housing. Separate the upper pump housing from the base, which remains plumbed in the tank. Unclip the motor winding cover. Slide the winding and lamination plate assembly up and off the pump housing centre. Slide the winding coil out from the lamination plates. 41

42 1000V V Cooler Operation (cont.) Pump Operation (cont.) Pump will not operate Check that the pump is switched ON and that the pump is not in an operation delay period i.e. water contact across Trident probes or Servoseal open time. Check for 240 Volt output to the pump, at the PUMP-NEUTRAL and PUMP-ACTIVE terminals on the pump. PUMP - NEUTRAL OFF 240 V VOLTS 10 A V COM FUSED PUMP - ACTIVE Multimeter 42

43 1000V V Cooler Operation (cont.) Pump Operation (cont.) Electrical Checks If power present: Check the pump wire loom and connections. Refer to mechanical pump checks on page 45. Check the pump motor winding is not open circuit. Isolate the electrical supply and use a multimeter on the Ohm's setting to check the circuit resistance at terminals PUMP-NEUTRAL and PUMP-ACTIVE (169 Ohms +/- 200C.) Replace pump winding assembly. PUMP - NEUTRAL 169 Ohms OFF V A 10 A V FUSED COM PUMP - ACTIVE Multimeter If pump doesn't operate: Refer to mechanical checks. Replace pump. 43

44 F U S E D 100 0V V Cooler Operation (cont.) Pump Operation (cont.) Electrical Checks (cont.) if NO power: Check the Cooler's operation is not in a delay period preventing the pump from functioning. Check the power supply is turned ON and is the correct polarity and voltage (MAINS/ACTIVE-IN and NEUTRAL terminals). Check the N-E2 module is turned ON and is correctly located in the mounting plug. Bridge terminals PUMP-ACTIVE and MAINS/ACTIVE-IN using multimeter set on Amps. If pump functions: Check the pump loom and all terminals. Check the N-E2 internal 8 Amp fuse is not open circuit. Replace N-E2 and re-test. Replace Networker and re-test..22 A m ps M A IN S A C T IV E -IN O F F V A 10 A V C O M P U M P - A C T IV E M u ltim e te r If pump doesn't operate: Refer to mechanical checks. Replace pump. 44

45 Cooler Operation (cont.) Pump Operation (cont.) The following checks are required if the pump has power, but will not operate, or is not pumping sufficient water to the filter pads. Mechanical Checks Check that the tank water level is correct. Check the water distribution piping is not blocked. Dismantle the pump as per the instructions on page 47. Check and clear the lower pump housing of any obstruction. Check the pump impellor is not damaged, and can rotate within the upper pump housing. Replace upper pump housing assembly, if impellor damaged or jammed. 45

46 Cooler Operation (cont.) Pump Operation (cont.) Electrical & Mechanical Checks - Flowchart P u m p E le ctrica l & M e ch a n ica l C h e cks. C h e ck th a t th e p u m p is sw itch e d O N a n d th a t th e re is V o lt o u tp u t to th e p u m p a t th e P U M P -N E U T R A L & P U M P -A C T IV E te rm in a ls. P u m p w ill n o t o p e ra te. If N O p o w e r If p o w e r p re se n t C h e ck th e C o o le r's o p e ra tio n is n o t in a d e la y p e rio d p re ve n tin g th e p u m p fro m fu n ctio n in g. C h e ck th e p u m p w ire lo o m a n d co n n e ctio n s. R e fe r to M e ch an ica l P u m p ch e cks. C h e ck th e p o w e r su p p ly is tu rn e d O N a n d is th e co rre ct p o la rity a n d v o lta g e C h e ck th e p u m p m o to r w in d in g is n o t o p e n circu it. C h e ck th a t th e ta n k w a te r le ve l is co rre ct. C h e ck th e N -E 2 m o d u le is tu rn e d O N a n d is co rre ctly lo ca te d in th e m o u n tin g p lu g. B rid g e te rm in a ls P U M P -A C T IV E & M A IN S -IN. If p u m p fu n ctio n s: C h e ck th e p u m p lo o m a n d a ll te rm in a ls C h e ck th e N -E 2 in te rn a l 8 A m p F u se is n o t o p e n circu it R e p la ce N -E 2 a n d re -te st. If p u m p d o e sn 't o p e ra te : Iso la te th e e le ctrica l su p p ly, a n d ch e ck O h m 's a t P U M P -N E U T R A L & P U M P -A C T IV E te rm in a ls. R e fe r to m e ch a n ica l ch ecks. R e p la ce p u m p. R e p la ce p u m p w in d in g a sse m b ly If p u m p d o e sn 't o p e ra te : R e fe r to m e ch a n ica l ch e cks. R e p la ce p u m p. C h e ck th e w a te r d istrib u tio n p ip in g is n o t b lo cke d. D ism a n tle p u m p a s p e r in stru ctio n o n P a g e 4 7 C h e ck a n d cle a r th e lo w e r p u m p h o u sin g of a n y o b stru ctio n s. C h e ck th e p u m p im p e llo r is n o t d a m a g e d a n d ca n ro ta te w ith in th e u p p e r p u m p h o u sin g. R e p la ce u p p e r p u m p h o u sin g a sse m b ly if im p e llo r is d a m a g e d. R e p la ce N e tw o rke r a n d re -te st. 46

47 Cooler Operation (cont.) Water Inlet Solenoid Operation The Contour Cooler has a 240 Volt water inlet solenoid on the under side of the base, at the high side of the roof. The water inlet solenoid has a flexible hose attached with a filter inserted in the hose connections at each end. A 3/4" to 1/2" BSP nipple is provide for the installer for a convenient connection to the hose. The water inlet solenoid is assembled in a bracket to support the pipe connection and the outlet discharge, which is direct to a fitting moulded into the Cooler base on the high roof side. The wiring loom to the water inlet solenoid is concealed under the base, and feeds back into the service access compartment. Note: The water inlet solenoid uses the water supply pressure to it's diaphragm in the closing action of the valve. Ensure the solenoid closes within 5 seconds of turning the 240 Volt power OFF to the water inlet solenoid. Dismantling Turn OFF the water and disconnect the water supply pipe. Remove the screw on the water inlet solenoid support bracket. Slide the assembly across and out to disconnect the wire loom. Retract the pipe from the base tank fitting and remove inlet solenoid assembly. Remove the water inlet solenoid screws, and remove water inlet solenoid. OR Unscrew pipe fittings from the water inlet solenoid. To access filter, remove the inlet nipple from solenoid, remove filter insert from the inlet opening of the solenoid. 47

48 1000V V Cooler Operation (cont.) Water Inlet Solenoid Operation (cont.) Water inlet solenoid does not supply water into the tank (empty): Check that the Cooler is turned ON calling for cooling (pump operation) and is not in an operation delay period i.e. Servoseal delay. Check the water supply tap is turned ON. Check that the water supply pressure is within the operation range (300 kpa kpa). Check that an Error 50 (both High and Low Level Water Sensors are open circuit) is not current. Check that the water inlet solenoid is energised (240 Volt), at the water INLET SOLENOID-ACTIVE and INLET SOLENOID-NEUTRAL terminals, on the service compartment back wall. INLET VALVE - NEUTRAL 240 VOLTS OFF V 10 A V COM FUSED INLET VALVE - ACTIVE Multimeter 48

49 1000V V Cooler Operation (cont.) Water Inlet Solenoid Operation (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 (3.9 kohms). INLET VALVE - NEUTRAL 3.9 kohms OFF V 10 A V COM FUSED INLET VALVE - ACTIVE Multimeter Check if the water inlet solenoid is blocked. Replace water inlet solenoid. 49

50 1000V V Cooler Operation (cont.) Water Inlet Solenoid Operation (cont.) if NO power: Check the Cooler's operation is not in a delay period preventing the water inlet solenoid from functioning. Check the power supply is turned ON and is the correct polarity and voltage (Mains Active In and Neutral terminals). Check the N-E2 8 Amp fuse is not open circuit. Check the N-E2 module is turned ON and is correctly located in the mounting plug. Bridge power supply using a multimeter in series on Amp setting between MAINS/ACTIVE-IN and WATER INLET SOLENOID-ACTIVE terminals. Amps MAINS ACTIVE-IN OFF V A 10 A V FUSED COM INLET VALVE - ACTIVE Multimeter If water inlet solenoid operates: Replace N-E2 module, and check for output voltage to the water inlet solenoid. If water inlet solenoid doesn't operate: Check wiring terminals & loom. Check water inlet solenoid is not blocked or jammed. Replace water inlet solenoid. 50