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EVAPORATIVE COOLING MODULE INSTALLATION,
MAINTENANCE, AND TROUBLESHOOTING
OPTION AS3, AS4, AS5, OR AS8 FOR MODELS ADF, ADFH, PGBL, RBL,
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemble Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install Evaporative Cooling Module on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble Transition Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connect Transition Duct to Blower Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connect Transition Duct to Evaporative Cooling Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation/Replacement of Media Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump/Junction Box Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Float Valve Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Optional Fill and Drain Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AquaSaver Timed Metering Control System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Shutoff and Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bleed Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filling and Adjusting Water Level in Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjusting Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust Water Flow with Float and Pump Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust Water Flow with AquaSaver Timed Metering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Media Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flushing Water Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Water Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• The optional evaporative cooling module for packaged indirect-fired system models RGBL, RPBL, SSCBL, PGBL,
blower cabinet model RBL, and direct-fired makeup air models ADF/ADFH 700/1200 is factory-assembled but
requires field-installation.
• The evaporative cooling module is available in the following options:
Option AS3: includes 6-inch rigid cellulose media
Option AS4: includes 12-inch rigid cellulose media
Option AS5: includes 6-inch rigid glass fiber media
Option AS8: includes 12-inch rigid glass fiber media
• The base parts for supporting the evaporative cooling module and the transition duct for connecting it to the unit
are shipped with the module for field-assembly and installation. If optional moisture elimination pads, a drain and
fill kit, and/or a water hammer arrestor are to be included in the installation, they also require field-installation.
• All evaporative cooling modules require outside air.
DO NOT DESTROY. PLEASE READ CAREFULLY. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
RGBL, RPB, RPBL, AND SSCBL
TABLE OF CONTENTS
GENERAL INFORMATION
Revision: OPT-AS3,4,5,8 (07-22) 160202-B
Supersedes: OPT-AS3,4,5,8 (06-22) 160202-A
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Page 1: Table Of Contents
Supersedes: OPT-AS3,4,5,8 (06-22) 160202-A EVAPORATIVE COOLING MODULE INSTALLATION, MAINTENANCE, AND TROUBLESHOOTING OPTION AS3, AS4, AS5, OR AS8 FOR MODELS ADF, ADFH, PGBL, RBL, RGBL, RPB, RPBL, AND SSCBL TABLE OF CONTENTS GENERAL INFORMATION ................1 Dimensions . -
Page 2: Dimensions
NOTE: AR = as required. Not used with optional timed metering AquaSaver® system. Dimensions Figure 1. Dimensions Weights Table 2. Weights Option Net Weight (Pounds (kg)) 379 (172) 431 (195) 420 (191) 514 (233) With wet media and full reservoir. OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 3: Installation
Position four assembled legs approximately 2 feet (610 mm) from air inlet side of cabinet in rectangular pattern corresponding to size of cooling module. Check again to ensure that top of legs are level with bottom of makeup air system cabinet. Figure 2. Base Assembly (Refer to Table OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 4: Install Evaporative Cooling Module On Base
3. Secure duct extensions (11 for unit size 500 or 600 or 12 for unit size 700 or 1050) to transition duct assembly using fourteen screws (8). COOLING MODULE Figure 3. Evaporative Cooling Module and Transition Duct (Refer to Table OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 5: Connect Transition Duct To Blower Cabinet
7. Secure bottom of transition duct to blower cabinet end panel using seven screws (8). 8. Ensure that all screws are in place and seal all corners of transition duct assembly using waterproof silicone sealant to prevent moisture from entering cabinet. OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 6: Installation/Replacement Of Media Pads
When replacing the cooing media, BE CERTAIN that the 45° angle slopes downward toward the incoming outside air. If the media is not installed properly, water blowoff from the media pads will occur. OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 7: Pump/Junction Box Assembly Installation
1. Support pump/junction box assembly and remove and save four screws that secure assembly in its shipping location. 2. Install pump/junction box assembly in its operating location (see Figure 8) and secure using existing screws. OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 8: Electrical Connections
Figure 8. Pump/Junction Box Assembly Electrical Connections BL MODELS WITH 115/230/1/60 OR 230/460/575/3/60 (HEATER OPTIONS AK3, AK6, AK7, OR AK8) AND MODELS ADF/ADFH 700/1200 SYSTEMS WITH 208/1-3/60 (HEATER OPTION AK2 OR AK5) Figure 9. Evaporative Cooling Module Factory-Installed Wiring OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 9: Piping Connections
Place the nut and ferrule over the tubing and insert the tubing into the float valve stem. Tighten the nut securely. 1/4-INCH TUBING COMPRESSION NUT AND TUBING FERRULE CABINET SIDE PANEL FLOAT VALVE ROD Figure 10. Float Valve Connection OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 10: Optional Fill And Drain Kit Installation
Run field-supplied white wire from electrical compartment (terminal on wiring diagram) of evaporative cooling module and connect to white wire on three-way and two-way valves. Figure 11. Fill and Drain Kit Connections OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 11: Aquasaver Timed Metering Control System Connections
The hose barb protrudes from the air inlet side of the module cabinet (see Figure 12). Connect a 1/4 ID hose to the barb and run to the nearest drain. BLEED LINE CONNECTION Figure 12. Bleed Line Connection OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 12: Maintenance
3. If water is flowing off entering side of media, turn system off, disconnect power, and adjust ball valve to reduce entering water flow. BALL VALVE Figure 13. Ball Valve OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 13: Adjust Water Flow With Aquasaver Timed Metering Control System
(1245–1829 mm) (305–914 mm) MEDIA HEIGHT Figure 15. AquaSaver Microprocessor 3. Check reservoir for any water leaks. Reservoir was tested, but if any small leaks are present, drain reservoir and apply waterproof silicone sealer around corners and welds. OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 14: Media Maintenance
6. Carefully remove basket and snap-on base cover plate from bottom of pump and wash all deposits from inside pump using mild soap solution. 7. Remove all debris from impeller. 8. Reassemble pump, replacing parts in exact reverse order and ensuring that everything is returned to its proper position. OPT-AS3,4,5,8 (07-22) 160202-B... -
Page 15: Troubleshooting
Install moisture elimination (over 600 FPM) pad (refer to Installation/ being pulled from Replacement of Media Pads section) reservoir 3. Water level not 3 inches Refer to probable causes and remedies for symptom B above (pump and float control system) OPT-AS3,4,5,8 (07-22) 160202-B... - Page 16 Specifications and illustrations subject to change without notice or incurring obligations. Latest version of this manual is available at www.reznorhvac.com. ©2022 Nortek Global HVAC LLC, O’Fallon, MO. All rights reserved. OPT-AS3,4,5,8 (07-22) 160202-B...
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