Gohastings Com Ec 120 Users Manual ISEC 1 SERVICE
EC-40 ISEC-1 SERVICE MANUAL
2015-02-09
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ISEC-1 July 1997 INSTALLATION AND OPERATION MANUAL Evaporative Coolers EC-40, -80, -120, -160, -220, -300, -400, -500, -600, and -750 NOTICE Read These Instructions Before Installation Upon arrival, inspect the unit for shipping damage and completeness. If any part is missing or damaged, notify the carrier immediately. Always refer to the unit’s serial and model numbers located on the specification plate when making an inquiry regarding maintenance and parts. To insure unit integrity, use only Factory Authorized Replacement Parts. CONTENTS Precautions .………………………………………………………………………..................... Page 2 Specifications ………………………………………………………………………................... Page 3 Unit Installation ………………………………………………………………………………….. 1. Evaporative Cooler ……………………………………………………...................... Page 3 2. Wiring …………………………………………………………………………………... Page 3 3. Water connections ……………………………………………………………………. Page 4 Operation 1. Standard Unit ………………………………………………………………………….. Page 4 2. Unit with automatic Drain Kit …………………………………………….................. Page 5 3. Unit with Automatic Drain Kit and Freeze Protection ……………………………… Page 5 Service and Parts ………………………………………………………….................. Pages 6 and 7 Trouble Shooting ………………………………………………………………………………... Page 8 WARNING This equipment was designed and manufactured with safe operation as a priority. However, the very nature of any equipment having water and electrical connections presents hazards to personnel which cannot be completely safeguarded against. PRECAUTIONS 1. Read these instructions before installation and operation; save for future reference. This manual contains necessary information for safe operation and maintenance of the unit. 2. Shut off main power and lock it in the off position when making repairs or replacements of components. 3. Use extreme caution when making voltage tests with “live” circuits – follow the established safety procedures. 4. Electrical repairs should be performed by trained, qualified personnel only. (Failure to follow safe electrical procedures can result in series injury – or death.) 5. Do not attempt to operate unit by jumping, or otherwise bypassing, any circuit. 6. Keep evaporator reservoir clean. Do not allow fine sediments or scale to accumulate in reservoir, on filter media, or on other components. 7. Do not exceed water pressures recommended in this manual. -2- SPECIFICATIONS Model (EC) 40 80 120 160 220 300 400 500 600 750 Dry Weight 110 176 225 271 310 373 634 726 845 1067 Operation Weight** 335 560 650 825 880 1135 1680 1930 2085 2635 Pump Cap/GPH req.* 270 360 540 720 720 810 540+ 630+ 630+ 630+ Cap/GPH @ Lift* 387 1135 1135 1135 1135 1100 1080 1080 1060 1060 Pump Lift/ft. 3 4 4 4 4 5 6 6 7 7 * These figures do not include the 3 to 6 percent bleed-off rate required to reduce scaling for standard unit. **Unit in operation, media fully saturated. + Per pump EC = Evaporative cooler WATER CONNECTIONS ALL UNITS 1-1/2 FPT Overflow ½ MPT Bleed-off ¾ FPT Drain ½ FPT Float Valve ELECTRICAL SPECIFICATION Model (EC) 40 Pump Motor Model CP 1000 HP 1/50 Amperage 1.1 A Voltage EC = Evaporative Cooler 80 120 160 5 MSP 1/6 5.0 A 220 300 400 500 600 (2) 5 MSP 1/6 5.0 A 750 115 V APPROXIMATE BLEED-OFF FLOW RATE Model Per Minute EC-40 -80 ½ to 1 qt. EC-120 -160 1 to 2 qt. EC-220 -300 2 to 3 qt. EC-400 -750 2 (2-3 qt.) CONSTRUCTION AND MEDIA SPECIFICATION Maximum Water Temperature Maximum Air Temperature pH Range Cabinet Evaporator Reservoir Celdek 130ºF 300ºF 6-9 Glasdek 165ºF 300ºF 6-9 Aluminized Steel and Painted Stainless Steel and Painted INSTALLATION INSTRUCTIONS 1. 2. When installing the evaporative cooler, special consideration should be given to the physical positioning of the unit, electrical power supply, the proper water supply, and the structural members to support the cooler at the operating weights. It is recommended that supports be placed within every four feet to distribute the weight evenly. Be sure the supports are level. After the unit is properly located, electrical connection may be made. If the Evaporative Cooler has been purchased separately, wiring from a 115 volt supply may be connected to the junction box supplied with the unit. Refer to the wiring schematic supplied in owner’s packet or, pages 4 and 5 of typical wiring schematics, and to drawings for standard unit, units with automatic drain kit, or units with automatic drain kit and freeze protection. When the evaporator cooler is purchased with a system exhaust blower and filter, most connections may have been made already. Refer to schematic with owner’s packets for any additional wiring to be done. -3- CAUTION: the electrical wiring must comply with all applicable local, state, or provincial and national ordinances and codes. 3. Water connections (refer to "Specifications') should, and must follow, local codes and ordinances. Connections are provided on each unit with standard pipe thread sizes. Refer to pages 4 and 5 for your system. For units with automatic drain kit and freeze protection, the minimum pressure should be 10 PSI so valves will operate properly; for other models, 10 PSI or less. 4. Set the float valve (FV) to allow fresh water to enter reservoir to a depth of 2 1/2" for models EC-40 through EC-750. By loosening the thumb screw, located on the float valve assembly, and setting the float until the valve shut off is at the designed depth, no other adjustment needs to be made. Do not forget to tighten the thumb screw securely. 5. You may now start your unit. Watch for the first few times that the media gets completely saturated and that all phases of operations (See "Operations") are working properly. If necessary adjust the pump discharge gate valve to avoid dry areas on the media. Water should be visible trickling down the flutes of the media. Watch also for excess foaming (See "Trouble Shooting") of the water and media. After a day of operation you will notice the water to be a shade of green. The media is the cause, and the reservoir should be drained and refilled a couple of times to correct this. 6. Now proceed to the "Operation" part of this manual and read about the unit that you have purchased. OPERATION Refer to the schematic piping and wiring while going through start-up procedure for the particular system you have purchased. STANDARD UNIT START UP PROCEDURE 1. 2. 3. 4. 5. 6. OPEN MANUAL SHUT OFF VALVE (WV). MANUAL DRAIN VALVE (DV) IS CLOSED. FLOAT VALVE (FV) ALLOWS FRESH WATER TO ENTER RESERVOIR. WATER PUMP (WP) WILL START AS SOON AS FLOAT SWITCH (FL) CLOSES. iF WATER IS TOO LOW PUMP WON'T RUN. WATER PUMP (WP) SHOULD BE WIRED SO THAT PUMP CANNOT RUN WITHOUT BLOWER MOTOR IN OPERATION. BLEED OFF (BO) TO PREVENT SCALE FORMATION. A BLEED-OFF AT THE RATE OF 3-6% IS REQUIRED. THE EXACT AMOUNT WILL DEPEND ON THE pH AND HARDNESS OF THE WATER, AND THE INTENSITY OF EVAPORATION. UNIT CAN BE USED WITH BLOWER ON, AND EVAPORATIVE COOLER PUMP OFF. 115 VOLT 1 PHASE BLEED OFF VALVE FLOAT VALVE FV 1/2 NPT 1 1/2 NPT RESERVOIR WATER LEVEL OVER FLOW OF WP 3/4 NPT DR UNIT SUPPORT BY OTHERS DV MANUAL DRAIN VALVE BY OTHERS ROOF LINE FRESH WATER SUPPLY TO CONTROL CONTACTS PUMP MOTOR CONTROL RELAY CONTACTS FL TO DRAIN BY OTHERS WATER VALVE BY OTHERS TO NEUTRAL GRN BLU NEEDS LEGEND WHT __ __ __ __ __ Field Wired ____________ Factory Wired __ _______ __ Field Piping PUMP MOTOR RED WV RED PUMP MOTOR CONTROL RELAY -4- SOLENOID & TIMED DRAIN VALVE WITH FREEZE PROTECTION START UP PROCEDURE 1. 2. 3. 4. 5. 6. OPEN MANUAL SHUT OFF ALVE (WV). WHEN EVAPORATIVE COOLER IS ACTIVATED IT CLOSES DUMP VALVE (DV). 3 WAY VALVE (TV) OPENS AND ALLOWS FRESH WATER TO FLOAT VALVE. WATER PUMP (WP) WILL START AS SOON AS FLOAT SWITCH (FL) CLOSES. WATER PUMP (WP) SHOULD BE WIRED SO THAT PUMP CANNOT RUN WITHOUT BLOWER MOTOR IN OPERATION. FLOAT VALVE (FV) ALLOWS FRESH WATER TO ENTER RESERVOIR. TIMER (TM) BREAKS CIRCUIT TO DUMP VALVE (DV) N.O. FOR DAILY SEDIMENT REMOVAL. 3 WAY VALVE (TV) WILL NOT ALLOW SUPPLY SUPPLY WATER TO FLOAT VALVE (FV) DURING CYCLE. TIMER IS SET FOR 1 1/2 HOUR MINIMUM FOR DRAINING RESERVOIR. FREEZE STAT (FZ) PROVIDES FREEZE PROTECTION BY AUTOMATICALLY DRAINING RESERVOIR THRU DUMP VALVE (DV), AND DRAINING COLD WATER SUPPLY FROM FLOAT VALVE (FV) THRU N.O. PARTS OF 3 WAY VALVE (TV). UNIT CAN BE USED WITH BLOWER ON AND EVAPORATIVE COOLER PUMP OFF. 115 VOLT 1 PHASE TIMER TM FREEZE STAT FS FL 1/2 NPT FLOAT FV VALVE RESERVOIR WATER LEVEL 1 1/2 NPT OVER FLOW OF NP 3/4 NPT DR UNIT SUPPORT BY OTHERS ROOF LINE COLD WATER SUPPLY SOLENOID DUMP VALVE N.O. DV WV A B TV WATER VALVE BY OTHERS TO CONTROL CONTACTS SOLENOID 3 WAY VALVE, A N.C., C N.O. DV TO 115 VOLT SUPPLY TM1 BLK RED FZ TV TO NEUTRAL YEL NEEDS LEGEND WHT BLK TIMER MOTOR TM BLK PUMP MOTOR CONTROL RELAY CONTACTS GRN RED FL __ __ __ __ __ Field Wired ____________ Factory Wired __ _______ __ Field Piping WHT BLU PUMP MOTOR TERMINALS IN EVAPORATIVE COOLER. TO BLDG. DRAIN BY OTHERS WP WHT RED PUMP MOTOR CONTROL RELAY 115 VOLT 1 PHASE SOLENOID & TIMED DRAIN VALVE KIT START UP PROCEDURE 1. 2. 3. 4. 5. OPEN MANUAL SHUT OFF VALVE (WV). WHEN EVAPORATIVE COOLER IS ACTIVATED IT OPENS WATER CONSERVATION SOLENOID VALVE (SV), CLOSES N.O. DUMP VALVE (DV). WATER PUMP (WP) WILL START AS SOON AS FLOAT SWITCH (FL) CLOSES. WATER PUMP (WP) SHOULD BE WIRED SO THAT PUMP CANNOT RUN WITHOUT BLOWER MOTOR IN OPERATION. FLOAT VALVE (FV) ALLOWS FRESH WATER TO ENTER RESERVOIR. TIMER (TM) BREAKS CIRCUIT TO DUMP VALVE (DV) N.O. FOR DAILY SEDIMENT REMOVAL. WATER CONSERVATION SOLENOID VALVE (SV) N.C. WLL NOT ALLOW SUPPLY WATER TO FLOAT VALVE (FV) DURING CYCLE. TIMER IS SET FOR 1 1/2 HOURS MINIMUM FOR DRAINING RESERVOIR. UNIT CAN BE USED WITH BLOWER ON AND EVAPORATIVE COOLER PUMP OFF. TIMER TM FL OF WP DR 3/4 NPT UNIT SUPPORT BY OTHERS ROOF LINE WATER CONSERVATION SOLENOID VALVE - N.C. DV SV MANUAL SHUT OFF VALVE WITH DRAIN PLUG COLD WATER SUPPLY TO CONTROL CONTACTS OVER FLOW FLOAT FV VALVE RESERVOIR WATER LEVEL 1 1/2 NPT 1 1/2 NPT SOLENOID DUMP VALVE N.O. WV TO DRAIN BY OTHERS WATER VALVE BY OTHERS FILL VALVE TO 115 VOLT SUPPLY TM1 BLK BLK TIMER MOTOR TO NEUTRAL DV YEL WHT TM BLK TERMINALS IN EVAPORATIVE COOLER PUMP MOTOR CONTROL RELAY CONTACTS BLU PUMP MOTOR RED FL NEEDS LEGEND GRN WHT WP WHT RED PUMP MOTOR CONTROL RELAY -5- __ __ __ __ __ Field Wired ____________ Factory Wired __ _______ __ Field Piping SERVICE AND PARTS Evaporative cooler media may be removed from the rear for cleaning or replacement, as required, by removing the upper rear panel. Use only standard garden hose variety, with minimal water pressure, to avoid damaging the filter media when cleaning. It would be advisable to replace evaporative cooler media every five years on units that are subject to contaminated atmospheres, or where water has a high mineral content. Installation of evaporative media requires the 45 deg. angle flutes to slope down toward the air entering the pad. Use care in handling the pad to avoid damage. MEDIA INSTALLATION DETAIL Cover Pipe PVC Distribution Pipe Distribution Pad 45 Flute Air Flow 15 Flute Red Dot Indicates Position in Unit -6- -7- 1ST HOLE SMALLER DIA THAN THE OTHERS UNIT SIDE PLATE 3/4 CLEAR PLASTIC TUBING 1" MALE ADAPTOR PVC 76-24-0015-12 (FIT INTO PUMP 79-31-0001-10) 1" PIPE PVC 76-18-5001-15 1" UNION PVC 76-24-0014-19 1" PIPE PVC 76-18-5001-15 1" 90 DEG. ELL PVC 76-24-0013-16 1/2 CONDUIT NUT 78-14-0051-15 1/2 PIPE PVC 76-18-5000-12 1/2 MALE ADAPTOR PVC 76-24-0011-10 1/2 90 DEG. ELL PVC 76-24-0012-13 1/2 PIPE PVC 76-18-5000-12 SIDE PLATE 1/2 CONDUIT NUT 78-14-0051-15 3/4 PLASTIC PLUG 76-24-0019-14 FOR DRAIN 1/2 MALE ADAPTOR PVC 76-24-0011-10 1/2 PLASTIC GLOBE VALVE 76-24-0016-15 1/2 NIPPLE (TBE) PVC 76-24-0010-17 UNIT SIDE PLATE 1 1/4 FEMALE ADAPTOR 76-24-0017-18 STANDARD BLEED OFF KIT 94-1000-13 (OTHER OPTIONS AVAILABLE) 1" TO 1/2" REDUCER BUSHING PVC 76-24-0009-15 1" COUPLING PVC 76-24-0008-12 1" PIPE PVC 76-18-5001-15 1" TEE PVC 76-24-0007-19 1" PIPE PVC 76-18-5001-15 "TYPICAL INTERNAL PIPING DIAGRAM" 1" PIPE PVC 76-18-5001-15 1" PVC GATE VALVE 76-24-0045-19 1" PIPE PVC 76-18-5001-15 1" 90 DEG. ELL PVC 76-24-0013-16 1" PIPE PVC 76-18-5001-15 1" PIPE PVC 76-18-5001-15 USED WHEN BLEED OFF KIT NOT USED 1 1/4 TO 1 REDUCER BUSHING 76-24-0006-16 1 1/4 90 DEG. ELL 76-24-0005-13 UNIT HEADER PIPE (HOLES IN TOP) 1 1/4 PVC (POSITION HOLES CORRECTLY) 1 1/4 PLASTIC PLUG 76-24-0018-11 FLOAT VALVE DETAIL FLOAT BALL 76-24-0003-17 STEM 76-24-0002-14 1/2 FLOAT VALVE 76-24-0001-11 TROUBLE SHOOTING GUIDE TROUBLE CHECK-OUT PROCEDURE AND CORRECTION Green Water……………………….. 1. Usually occurs the first few days of operation; media is being rinsed. Drain reservoir and refill with fresh water. After a couple of operations, green should disappear. The 3 to 6 percent bleed-off, for standard units, will maintain your clear water also. 2. If unit has been in service for a while, algae can grow on the media. It will not cause deterioration or rot, but may clog the passages and inhibit the air flow. A commercial algaecide will control the growth when caught in the early stages. Foaming Occurs………………….. 1. Some foaming is natural if maintained in the reservoir. If foaming of the medial occurs after a couple of days of operation, a defoamer should be added. The exact amount will depend on the severity. After one application, you will be able to judge how much additional defoamer to use (see instructions on bottle). Scaling Occurs……………………. 1. Be sure you have a 3 to 6 percent bleed-off rate (See “Bleed Off Flow Rates.”) for unit size. If the frost-like scale does appear, increase water flow by adjusting pump discharge gate valve until it disappears. The exact amount will depend upon the pH and hardness of the water and the intensity of evaporation. Clean and flush distribution header on a regular basis. Water depositing into Transition and Reservoir Not Draining…….. 1. Reservoir float valve (FV) improperly adjusted (See “Installation Instructions,” note 4.) 2. Float valve bad, not shutting off. Replace. 3. Check overflow and drain valves for blockage. On models with timed drain valve, check time clock setting or solenoid valve (DV). Replace if bad. 4. After initial start-up, look for foaming of the media. If the blower is pulling foam bubbles off the media into transition, a static pressure or CFM problem is eminent. (Contact your service or unit representative.) Reservoir Dry……………………… 1. Check the manual shut-off valve. Is it open? 2. Is the float valve opening? If not, then readjust float level or replace valve. 3. Units with conservation water solenoid should be checked. Replace if bad. Water Out the Backside of Evaporative Cooler……………….. 1. Water pump is running without the blower running. 2. Damaged media. Replace. 3. If these problems, contact your service or unit representatives: A. Lack of CFM. B. Improper static pressure. P.O. Box 669 · Hastings, Nebraska 68902-0669 Phone (402) 463-9821 · Fax (402) 462-8006 www.hastingshvac.com E-mail: sales@hastingshvac.com
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