evaporcool maintenance guide · evaporcool® system maintenance guide version ecsm.5.16 1...

EVAPORCOOL® SYSTEM MAINTENANCE GUIDE Version ECSM.5.16

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Evaporcool® Solutions, LLC

www.evaporcool.com

5100 Wilfong Road, Memphis, TN 38134 Phone: (901) 382-7809

Email: [email protected]

http://www.evaporcool.com/

mailto:[email protected]


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Congratulations on your purchase of a new Evaporcool® System! This guide is

intended for the person(s) responsible for maintaining the system, the building owner,

and the end-use customer.

Evaporcool® Systems, LLC patented system has incorporated 21st century computer

technology to design a state-of-the-art evaporative cooling system that makes efficient

use of water to help your rooftop HVACR equipment operate at its most efficient levels.

With care, your Evaporcool® system will extend the life of your air conditioning

equipment, while reducing electrical consumption and HVACR equipment maintenance

for years to come. Although there are just a few parts that need regular care, it is

important that you follow the instructions herein to maintain optimum performance, and

to protect your warranty.

Should you encounter any problems with your Evaporcool® System, please contact the

installing contractor or your HVACR service maintenance provider immediately. In the

event they are not available, please call us at (901) 382-7809, and our service staff will

be glad to help you.

Thank you again for your Evaporcool® purchase.


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CONTENTS

Introduction 4

What is the Evaporcool® System? 5

Routine Maintenance Checklist 7

Ordering Replacement Parts 8

Evaporcool® Seasonal Start-Up and Shut-Down Tips 9

EZ-Frame™ Maintenance 11

Screen Maintenance 15

Sprayer Maintenance 16

Replacing Evaporative Pad Media 20

Solenoid Valve Maintenance 23

In-Line Water Filter Maintenance 24

Water Softener Maintenance 28

Bladder Tank Maintenance 28

Booster Pump Maintenance 29


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INTRODUCTION This manual describes the various parts that make up the Evaporcool® System on your building. The Evaporcool® System always includes the following maintainable items:

In-line particulate water filter (Pentek® or Rosedale®)

Water pressure gauges (Wika®)

Evaporcool® control box (master or client)

Solenoid valve boxes

EZ-FrameTM assemblies with evaporative pad media

Spray nozzles located inside EZ-FrameTM assemblies

Transformers, fuses and fuse blocks

Insulated flexible water lines and water line connectors

Temperature sensors and humidity sensors

The Evaporcool® System may also include the following maintainable items:

Salt water softener system with backwash device (Kinetico®)

Booster pump

Expansion tanks

Water meter


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WHAT IS THE EVAPORCOOL® SYSTEM?

The Evaporcool® System is a proprietary evaporative cooling system that works with virtually any existing air-cooled condensing unit.

At the air conditioning unit, the Evaporcool® System is made up of the following components:

-EZ-Frames™

-Evaporcool® controller (master or client)

-Valve boxes

Figure 1. The Evaporcool® System: overview

EZ-Frame™: The EZ-Frame™ framing system provides a unique mechanism for protecting condensing coils, and creates a cool, moist micro-environment in which air temperature is lowered as it enters the air conditioning unit. This unique design consists of an inner and an outer filter separated by several inches of interior air space. Small spray nozzles are strategically placed within each frame to maximize coverage. EZ-Frames™ are magnetically attached around the condenser coils of an air conditioning unit. The frames contain small nozzles that spray water into the air before the air is drawn into the condenser coil area. This cools the air used to remove heat from the condenser coil. By cooling the air before it reaches the condenser coils, the Evaporcool® System makes the air conditioning unit perform as though the external air temperature is cooler than it actually is.


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Further, the EZ-Frame™ and filter media protect the coil from dirt and debris. As a result, the coils stay clean much longer. This helps in extending the life of the HVAC equipment and also reduces the energy consumption of the compressors.

Figure 2. Components of the EZ-Frame™ (front)

Figure 3. Components of the EZ-Frame™ (back)

Evaporcool® controller: The Evaporcool® control box is the brain of the Evaporcool® System. It monitors the external environment and the HVAC equipment in order to determine spray quantity and spray intervals to provide optimal amount of water to evaporate into the air, while minimizing runoff. For information on operating the Evaporcool® controller, refer to the Evaporcool® Operating Manual.


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ROUTINE MAINTENANCE CHECKLIST Monthly during Evaporcool® operational period and at seasonal start-up:

Check the evaporative/filter pad media for debris, dust and salt build up. Clean as necessary.

Put the system in test mode. Conduct a spray test. Check sprayers and all water line connectors for leaks.

Check the water spray patterns for irregularities. Clean or replace the spray heads as necessary.

Check accuracy of temperature and humidity readings. Verify control inputs. Check all valves and water connections for leaks. Check filter frames for standing water, particulate build-up, residue, and organic

growth. Clean as necessary with a damp rag. Check the in-line filter gauges. Clean or replace in-line filter cartridge or bag if needed. Check the brine tank for salt (if applicable). Add pellet type solar salt as

necessary. Check booster pump operation (if applicable). Check expansion tanks (if applicable). Check water meter (if applicable).

Quarterly during Evaporcool® operational period: All of the above plus: Check air pressure in bladder tanks (if applicable).

Winterization:

Shut off all incoming water supply valves. Drain the supply water lines and clear with compressed air/nitrogen/etc. Drain the water lines to each Evaporcool system component and clear with

compressed air/nitrogen/etc. Remove the screen. Remove the lowest sprayer or undo the lowest tubing fitting in each frame and

allow all water to gravity drain. Replace the sprayer or tubing, and then replace the screen. Open all valve boxes, remove the solenoid valve drain plug, and let water drain

out. Replace the valve drain plugs and reinstall the valve box covers. Turn the power switch to “OFF” position on all Evaporcool® Master and Client

controllers. Latch closed and screw the controller cover tight. .


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ORDERING REPLACEMENT PARTS When worn or broken parts need to be replaced, or if spare parts are desired, please contact Evaporcool® in Memphis for pricing and availability:

Phone: (901) 382-7809




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EVAPORCOOL® SEASONAL START-UP AND SHUT-DOWN TIPS Seasonal Start-Up: Tips Before inspecting the system for functionality, follow the installation guide procedure for flushing the water system.

CAUTION! Before turning the water on to the system, FLUSH ALL LINES THOUROUGHLY! Failure to do so can cause debris to clog strainers in solenoid valves and orifices in the sprayer heads inside the EZ-Frames™.

Before flushing the system, become familiar with the “Test Spray” mode on the controller. To enter “Test Spray” mode:

1) Ensure the water supply and power to the controller are turned on.

2) Press and hold the button on the right side underneath the controller for 10 seconds.

3) Press the button momentarily to cycle to the second channel.

4) To cancel “Test Spray” mode immediately, momentarily press the button,

otherwise the spray will shut off after 60 seconds.

Perform the following procedure to flush the system: 1) Connect the tubing to the main water supply.

2) Open the main water supply valves and flush for 2 minutes.

3) Close the main water supply valves and connect the tubing from the main water

supply to the solenoid valves.

4) Connect the tubing from the solenoid valves to the EZ-Frames™, stopping short of the final connection to the EZ-Frame™ inlet.

5) Open the main water supply valves and set the Evaporcool® controller to “Test

Spray” (see above).

6) Allow the water to run for 2 minutes on each channel.

7) Exit the “Test Spray” mode and close the main water supply valves.


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8) Make the final connections to the EZ-Frame™.

Next, re-enter “Test Spray” mode and visually inspect the condition of the screen and EZ-Frame™, all plumbing/tubing for leaks, and the condition of the spray pattern from each nozzle as outlined elsewhere in this guide.

Seasonal Shut-Down: Tips

Follow the “Winterization” guidelines on page 7 of this guide. Ensure that any low spots in the tubing or building outdoor plumbing system are not trapping any water which may freeze during the cold season. Blowing out lines with compressed air is the preferred method of draining the tubing/plumbing system. After ensuring all water has been drained from the entire system, proceed to re-connect all fittings before leaving the job site. Failure to do so may result in insects, dust, or foreign object debris collecting in the fittings in the ensuing cold season. Upon the system start-up, this debris may clog the sprayers.


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EZ-FRAME™ MAINTENANCE

Cleaning the Evaporative Pad Media Under normal conditions, routine cleaning of the evaporative pad media can be performed while

the EZ-Frame™ is attached to the unit. Pressure washing is NOT recommended and may

damage the screen, evaporative pad media, or the EZ-Frame™. Lightly rinse the media with

water. Beginning from the top of the EZ-Frame™, use a hose and apply water with a side to

side motion at a 45 degree angle through the screen and into the evaporative pad media (Figure

4. Cleaning the screen with a hose (front of the EZ-Frame™)). Once the media has been rinsed

thoroughly make sure the soiled water at the bottom of the EZ-Frame™ drains clear through the

drain holes.

In extreme conditions, the EZ-Frame™ may need to be pulled from the unit and the screen

removed. Starting on the back side of the EZ-Frame™, lightly rinse using a side to side motion

at a 45 degree angle toward the bottom of the assembly (Figure 5. Cleaning the evaporative pad

media with a hose (rear of the EZ-Frame™)). Turn the EZ-Frame™ around and repeat the rinse

from the front side making sure the soiled water drains clear through the drain holes at the

bottom of the assembly.

The above procedure needs to be done in regular intervals during Evaporcool operation. Local

conditions will ultimately dictate frequency: typically, cleaning is performed once per month. Do

not let material continually build up on the media, as it is harder to remove if allowed to

accumulate.


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Figure 4. Cleaning the screen with a hose (front of the EZ-Frame™)

Figure 5. Cleaning the evaporative pad media with a hose (rear of the EZ-Frame™)


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Removal of the EZ-Frames™ From the HVACR Unit Occasionally it may become necessary to repair or replace nozzles or evaporative pad media. To perform this maintenance, you will need to know how to access the sprayers and the evaporative pad media. Before removing EZ-Frames™ for maintenance, you will need to shut down the Evaporcool® System controller.

1) Open the Evaporcool® controller. In the lower left corner you will see an ON/OFF toggle switch. Flip the switch to the OFF position.

Figure 6. Power switch and Test Spray button locations (Master Controller)

2) Shut off the water supply at the HVACR unit.

3) Decouple the flexible water line that leads to the filter you are servicing. Do this by

pushing the releasing collar on the fitting on top of the EZ-Frame™ and then pull the hose from the fitting.

4) Remove the EZ-Frame™ by grabbing one corner and pulling the magnets free from the

HVACR unit. Once you have removed the EZ-Frame™ from the HVACR unit you can begin working on the interior media, nozzles, interior fittings, etc.

5) Slide the front screen out from the top of the EZ-Frame™. Removal of the front screen will provide access to the sprayers and interior of the EZ-Frame™.


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Figure 7. Removal of the screen

Reattachment of the EZ-Frames™ to the HVACR unit Reverse the steps listed above, ensuring the water supply and the power to the controller are both turned on.


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SCREEN MAINTENANCE DAMAGED SCREENS: Upon removal of the pre-filter screen, inspect for damage of the screen material and the screen frame and crossbar (if present). If there are any holes in the screen or any bent framing, they will need to be replaced. Standard nylon screen material and aluminum screen framing hardware (both available at most home improvement stores) is used to repair the screen. HARD WATER SCALING BUILDUP: Perform a visual inspection of the screen, both front and back. Water scaling should be clearly visible if present. Follow the cleaning procedure using water from a hose first. If that does not remove the scaling, take the flat side of a carpenter’s blade (or pocket knife) and gently scrape both sides of the screen where the scaling is present. Follow up by cleaning the screen with a hose.


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SPRAYER MAINTENANCE The sprayer assembly consists of three parts; (1) sprayer body, (2) flutter valve and (3) sprayer (Figure 8. Components of the sprayer assembly). Figure 2 shows the flutter valve placed in the

sprayer before insertion into the sprayer body (Figure 9. Sprayer body with flutter valve installed).

The sprayer fits into the sprayer body with a 90 degree turn (Figure 11).

Figure 8. Components of the sprayer assembly

Figure 9. Sprayer body with flutter valve installed


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Figure 10. Spray angle embossed on facade (80 degree shown)

Figure 11. Inserting sprayer into sprayer body


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Sprayer Maintenance: Methods

CAUTION! Never touch the orifice of the sprayer or attempt to service the sprayer by inserting any object into the orifice. Doing so may damage the sprayer and require purchase of a replacement.

NOTICE: Sprayers wear with use! A visual inspection of spray pattern and the sprayer orifice is generally enough to determine if the orifice is pitted or worn away. In this case, the sprayer must be replaced.

NOTICE: Three different angle sprayers are used in the Evaporcool® System (see Figure 10). The angle of sprayer must be noted when ordering replacement parts. If the angle of the sprayer to be replaced is unknown, Evaporcool® can assist in determining which type it is.

INCOMPLETE SPRAY PATTERN: After observing the spray pattern from each sprayer during normal operation or a Test Spray, turn off the water supply to the Evaporcool® System. Remove any sprayer that is not “fanning” a spray fully. Remove the flutter valve and check the sprayer for any blockage. Unblock the blockage using a reverse spray of water from a hose and nozzle through the face of the sprayer. Replace the flutter valve and the sprayer into the EZ-Frame™. Re-enter Test Spray mode or observe normal operation to verify the sprayer has been unclogged. If the blockage remains, redo the cleaning process of the sprayer, and reinstall. If a second attempt at cleaning does not solve the issue, contact Evaporcool® to order replacement parts. There are three different angle sprayers used in the Evaporcool® System: 80, 95, and 110. Note the sprayer angle imprinted on the front of the sprayer when ordering replacement sprayers (see Figure 10).


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SPRAY ANGLE INWARD/OUTWARD: A proper spray angle will send the mist directly between the screen and the pad when the HVACR unit is in operating mode. If any part of any individual sprayer is spraying directly onto the screen or onto the pad, it needs to be realigned. While firmly gripping the metal sprayer bracket (do NOT apply force to the white plastic sprayer itself), bend or torque the sprayer so that the mist is properly aligned. To rotate the sprayer, a wrench of appropriate width can be used on the gray plastic body. Never attempt to change a sprayer angle by manipulating the white sprayer itself.

SPRAYER POST-ACTIVATION DRIP: A sprayer should nearly immediately stop dripping after the valve box closes, courtesy of the flutter valve. If a sprayer is continuing to stream water at low pressure after the valve box closes, a flutter valve may have become dislodged (or was not installed). Remove the offending sprayer and inspect the flutter valve. Clean the flutter valve (if present) and install it in the sprayer, then replace the sprayer in the sprayer body.


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REPLACING EVAPORATIVE PAD MEDIA Retrofitting EZ-Frames™ to Velcro™ Media Attachment Evaporcool® utilizes two methods of attaching the evaporative pad media to the EZ-Frames™: rivets (on older models), and Velcro™ strips (on newer models). Below is the procedure to install the Velcro™ strips to hold the media in place, either as a replacement to the rivets, or to repair existing Velcro™ strips. The installation procedure can be performed in the field, with the EZ-Frame™ removed from the HVACR unit and placed flat on a workable surface. Velcro™ Installation: Method

1) Remove existing media, taking precaution not to disconnect water lines going to sprayer brackets. Remove any rivets that held pads or Velcro™ in place (on older models) and any loose/damaged Velcro™ strips.

2) Clean the plastic thoroughly where you will be attaching the Velcro™ (use a scraper to remove any adhesive from the frame, if present). Then use a rag moistened with rubbing alcohol and wipe clean the perimeter mounting flange along with the crisscross support flange for the media.

3) Place two pieces of the supplied Velcro™ in each corner, 1.5” from each edge in the

vertical as well as horizontal (Figure 12). Try and keep the edge of the Velcro™ as close to the outside edge as possible ensuring 100% surface adhesion of the rectangular piece of Velcro™.

Figure 12. Close-up of Velcro™ on the edge of the frames

4) On the crisscross section, orient the Velcro as close to the edge as possible on the stiff side of the angle. Place one piece in the center of all support sections, as seen in the example below.


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Figure 13. Close-up of the Velcro™ on the cross members of the frame

5) On the top and bottom of each EZ-Frame™ add two more pieces equally spaced

between the two corner pieces.

6) On each side, place one piece centered as close as possible between each sprayer. IMPORTANT: The adhesive on the Velcro™ needs 24hrs for optimum adhesion. The evaporative pad media can be installed shortly after the Velcro™ is installed, but the frames should not be placed back on the HVACR unit for at least 24 hours. Not allowing this time for the adhesive to cure can result in the Velcro™ not properly adhering to the EZ-Frame™ and coming loose prematurely.

Evaporative Pad Media Installation: Method

1) Roll up the media, keeping the sides as square as possible.

2) Starting from the top of the EZ-Frame™, orient the rolled media so the sides are in line with the sides of the EZ-Frame™, and the top is parallel to the top of the frame with ¼” to spare.

3) Start by pushing the media down gently in the center and then moving to each corner.

Don’t completely seat the media to the Velcro™ yet.

4) Roll the media out over the EZ-Frame™ and position the sides down each side of the EZ-Frame™. At the bottom of the EZ-Frame™, ensure the media is square to the bottom and in each corner.

5) Make your way back up each side pulling the media taught. Try not to seat, tear off and

reseat repeatedly as the media will become worn.


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6) After the media has become adequately taught, push down on each piece of Velcro™ within the EZ-Frame™ to finally seat the media.


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SOLENOID VALVE MAINTENANCE The valve box contains an all brass, 24v, continuous duty, normally closed solenoid valve. Water connections are made through either side of the box (inlet and outlet), as specified on labels on either side. Each solenoid valve box is secured to the AC unit via magnets mounted to the back of the box at the factory. NEMA enclosures may vary.

Figure 14. Valve Box (NEMA enclosure shown may vary)

Each solenoid valve should be checked periodically for leaks and that the wire connections are sound. In areas where freezing temperatures are either possible or common, your Evaporcool system will need to be winterized. When winterizing, the drain plug should be removed, water allowed to drain, and then reinstalled. Be mindful of not losing the internal metal filter screen while removing the drain plug. Refer to page 7 of this guide for instructions on winterizing.


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IN-LINE WATER FILTER MAINTENANCE Maintaining the Pentek® In-Line Filter (if equipped): Put all Evaporcool® systems on the rooftop in the 120-second spray test mode, or open the bleed valve nearest the in-line filter (on the discharge side). Just prior to and just after the in-line filter you will find water pressure gauges. Check both water gauges. If the leaving water gauge is 15 psi less than the entering water gauge, shut off water lines and check the Pentek® filter compartment. The 5 micron filter cartridge is located inside the filter housing. This filter is designed to capture larger particulate matter within the water line. Maintenance of the in-line filter is as follows:

1) Remove the Pentek® filter cartridge from the housing as shown below.

2) Rinse out casing.

3) Check filter for wear and debris. If the filter supplied is reusable, clean with high pressure water and reinstall. If the filter is not reusable and visibly worn, replace with new. Make note of filter model number for future replacements.

Figure 15. FS10B-1 10" Single Filter

Figure 16. FS20B-1 20" Single Filter


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Figure 17. "Big Blue" Filter Cartridges

Figure 18. In-line filter system on roof

Figure 19. In-line filter pressure gauges

Examine the in-line filter pressure gauges. If the pressure differential is less than 15 psi, no action is needed.


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If the pressure differential is more than 15 psi, remove the filter housing and replace the interior cartridge filter (see Figure 20 - Figure 22).

Figure 20. Filter removal step 1



Remove the Pentek® filter housing. If it is too tight to remove by hand, remove with a filter wrench or a strap wrench. In addition to replacing the cartridge filter, check the O ring on the filter cap. If this is worn or shows evidence of water leaks, replace the O ring as you replace the filter cartridge. Note both the filter cartridge model and O ring size for future replacements.


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Maintaining the Rosedale® In-Line Filter (if equipped): Put all Evaporcool® systems on the rooftop in the 120-second spray test mode, or open the bleed valve nearest the in-line filter (on the discharge side). On the side of the Rosedale® filter housing, you will find two water pressure gauges. Check both water gauges (see Figure 23). If the outlet water gauge is 5 psi less than the inlet water gauge, shut off water lines, open ball valve on top of housing to release pressure and open the Rosedale® housing. The 5 micron bag filter is located inside the filter housing. This filter is designed to capture larger particulate matter within the water line. Maintenance of the in-line filter is as follows:

1) Remove the filter bag from the housing.

2) Rinse out the casing.

3) Check the filter for wear and debris. If the filter is reusable, clean with high pressure water and reinstall. If the filter is not reusable and visibly worn, replace with a new bag filter (part number: PE-5/3-P2S).

Figure 23. Rosedale™ filter and gauges


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WATER SOFTENER MAINTENANCE See the manual included with the Kinetico® softener provided by Evaporcool®.

BLADDER TANK MAINTENANCE Required maintenance of the Flexlite® bladder tank is simply a quarterly check of the air pressure on the air bladder. The procedure for this process is as follows:

1) Isolate the bladder tank from the water supply.

2) Drain the water from the bladder tank.

3) Remove the cap on top of the bladder tank (Figure 24).

4) Using an air pressure gauge, check the air tank’s pressure.

5) Insure that the tank’s air pressure is 2 PSI below incoming water pressure.

6) Close the drain down valve.

7) Slowly turn on the water supply.

Figure 24. Bladder tank


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BOOSTER PUMP MAINTENANCE See the manual included with the pump provided by Evaporcool®.

IMPORTANT: The Evaporcool® System and any associated air-conditioning equipment may generate, use and radiate radio frequency energy and, if not installed and used in accordance with the Evaporcool® System Installation Manual and Evaporcool® Systems Maintenance Guide, may cause radio interference. DISCLAIMER: Neither Evaporcool® Solutions, LLC nor any of its members, employees or affiliates shall be responsible for the interpretation of the information contained in the Evaporcool® System Installation Manual and Evaporcool® System Maintenance Guide, nor shall such parties assume any liability in connection with the use of such information. Content within this manual is subject to change without notification or incurring any obligations.


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Evaporcool® Solutions, LLC

www.Evaporcool.com

5100 Wilfong Road, Memphis, TN 38134 Phone: (901) 382-7809


Download the latest version of this installation manual by scanning the above QR code

http://www.evaporcool.com/


evaporcool maintenance guide · evaporcool® system maintenance guide version ecsm.5.16 1...

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