BONAIRE B18 Owner's manual

INSTALLATION
,
OPERATION & M
A
INTENANCE
BONAIRE BSERIES
Commercial Evaporative
Air Conditioning
Bonaire B18 –B36
• IMPORTANT NOTICE •
Please leave this manual with the owner of this air conditioner.
Please keep this important manual in a safe place. It is the owner’s responsibility to ensure that regular servicing as
per the Bonaire Evaporative Air Conditioner service recording planner is carried out. Failure to complete and record
the periodic service work as outlined will void all guarantees beyond statutory and legal requirements.

INSTALLATION,OPERATION &MAINTENANCE
Table of Contents
INTRODUCTION _______________________________________________________ 3
Dealer Responsibility _____________________________________________________ 3
Before Commencing______________________________________________________ 3
UNIT INSTALLATION ___________________________________________________ 4
Unit Location Check List___________________________________________________ 4
Precautions_____________________________________________________________ 4
Location and Orientation___________________________________________________ 4
Duct Connection Details___________________________________________________ 5
Lifting the Unit___________________________________________________________ 6
Mounting the Air Conditioner _______________________________________________ 6
Ductwork System ________________________________________________________ 7
WATER CONNECTIONS _________________________________________________ 8
Unit Base Layout ________________________________________________________ 8
Water Installation _______________________________________________________ 10
Connecting the Water Supply___________________________________________________ 10
Drain______________________________________________________________________ 11
ELECTRICAL CONNECTIONS ____________________________________________ 12
Wiring Connections______________________________________________________ 12
Wiring – Important Notes _________________________________________________ 12
Wiring Diagram_________________________________________________________ 13
COMMISSIONING_____________________________________________________ 16
Water Levels___________________________________________________________ 16
Bleed-off Rate__________________________________________________________ 16
Distribution Flow________________________________________________________ 16
Fan Operation__________________________________________________________ 17
Controls ______________________________________________________________ 17
Customer hand Over ____________________________________________________ 17
Commissioning Check List ________________________________________________ 18
Unit_______________________________________________________________________ 18
Ductwork and general ________________________________________________________ 18
Site_______________________________________________________________________ 18
Customer Hand Over_________________________________________________________ 18
OPERATING INSTRUCTIONS _____________________________________________ 19
WARRANTY –AUSTRALIA ONLY _________________________________________ 21
SERVICE &MAINTENANCE _____________________________________________ 25

INSTALLATION,OPERATION &MAINTENANCE
Introduction
INTRODUCTION
Please take the time to fully read this Installation manual. Failure to follow these instructions
may result in injury to you and damage to the air conditioner or your customer’s property.
Installation of this Bonaire Evaporative Air Conditioner must conform to local building rules
and regulations, electrical and plumbing codes, Environmental Protection Authority (EPA)
regulations, and all applicable Australian Standards.
Should you not follow these instructions the unit warranty may be void. The cost of warranty
would then be a cost to the customer or the installer / dealer.
Refer to the tick box Commissioning Checklist to ensure you have covered all points when
the installation is complete.
DEALER RESPONSIBILITY
Training
•It is the responsibility of all dealers to adequately train their staff to ensure the
product is correctly sized and specified.
•It is the responsibility of all dealers to ensure their installation teams / sub-
contractors are trained in the correct installation techniques of both the product and
the ducting.
•Climate Technologies will provide technical assistance and training to the dealer /
installer. Ongoing training and professional development for staff and contractors is
the responsibility of the dealer.
Legal & Statutory obligations
•It is the dealer / installer responsibility to comply with all codes, statutory and legal
requirements, state and council / shire by laws.
Safety and O.H.&S. Requirements
•It is the responsibility of the dealer / installer to insure the environment is safe for the
installer to carry out the installation.
•It is the responsibility of the dealer / installer to ensure safe access to the unit can be
achieved for service.
•It is the responsibility of the dealer / installer to ensure the roof is provided with
access footings and platform where the pitch of the roof is greater than acceptable
standards
•It is the responsibility of the dealer / installer to ensure tethered restraint anchor
points are provided. See Australian Standard 1891.4:2000 Part 4 Selection use and
maintenance, Table 2.1.
BEFORE COMMENCING
•Packaging – check there is no damage before removing packaging.
•Have you got all the system components?
•Have you got the right unit?
•Is the System Design Correct?

INSTALLATION,OPERATION &MAINTENANCE
Unit Installation
UNIT INSTALLATION
UNIT LOCATION CHECK LIST
•Place the unit well away from sources of smoke, dust and objectionable fumes so
that only clean, fresh outside air will be drawn into the unit. (Refer AS1668)
•Check the proposed location to ensure that building members are structurally
capable of supporting the operating weight of the air conditioner.
•Provide easy access to the unit(s) for service. It is the responsibility of the dealer
/ installer to ensure safe access to the unit can be obtained for servicing.
•Access to the unit and platform / safe roof area must be provided for safe
service.
•NOTE: The manufacturer and its agents reserve the right to refuse service
unless safety and accessibility to the unit can be guaranteed.
•The cost of any extra equipment required to provide access to the unit for
servicing is the responsibility of the owner.
EPA
Any issues with noise abidance on an installation that contravene local council or
EPA requirements will be the responsibility of the dealer / installer.
PRECAUTIONS
Please read this manual thoroughly as failure to do so could result in injury to you or
damage to the air conditioner and property.
Installation of the air conditioner must conform to local electrical, water supply and
environmental codes, rules and regulations and to applicable National Standards.
LOCATION AND ORIENTATION
Check the proposed unit location first to ensure that it is structurally capable of supporting
the weight of the unit. A level stand is required which must be capable of supporting the
operating weight of the unit, including wind loading. Check the technical data for
operating weight.
The preferred location for an evaporative air conditioner on a sloping or pitched roof is on
the side from which the prevailing winds come in the summer season.
Always locate the unit where it will receive a plentiful supply of fresh air and not in a
recess where it may be starved or where the air is polluted.
Keep the unit well away from exhaust fans and ducts. Never undersize the duct system.
Allow adequate access around the unit for maintenance. Provision must be made for
access to electricity, water supply and drains. High roofs need to be provided with
permanent access to carry out maintenance or warranty work.
NOTE: It is the owner’s responsibility to provide safe access to the unit. Climate
Technologies may refuse to do maintenance or warranty work if access is
unsafe. If any additional equipment is needed to provide access to the unit,
this will be provided (and paid for) by the owner.

INSTALLATION,OPERATION &MAINTENANCE
Unit Installation
DUCT CONNECTION DETAILS
B18
B23 - 36

INSTALLATION,OPERATION &MAINTENANCE
Unit Installation
LIFTING THE UNIT
When lifting the units with a crane, sling the units from the base. Always correctly
secure the product in the sling.
Where lifting with a forklift, ensure the lifting tines are long enough to reach right through
the bottom of the unit pallet. Extension fork tines may be required. Should you fail to do
so, the water reservoir may get damaged.
MOUNTING THE AIR CONDITIONER
1. A mounting stand must be provided with each
unit installed.
2. The stand must be designed to carry the
operating weight of the product. Where the units
are fitted on a roof, ensure the stand is installed
on a structurally sound section.
All installations must comply with the
relevant building codes, regulations and
engineering specifications for the building.
3. An insulator should be installed between the unit
base and stand to eliminate and possible
reaction between the metal stand and the
aluminium chassis.
4. Always ensure the unit is level.
5. Allow adequate access around the unit for
maintenance. Provision must be made for
access to electricity, water supply and drains.
High roofs need to be provided with permanent
access to carry out maintenance or warranty
work. It is the owner’s responsibility to provide
safe access to the unit. Climate Technologies
may refuse to do maintenance or warranty work
if access is unsafe. If any additional equipment
is needed to provide access to the unit, this must
be provided (and paid for) by the owner.
6. Down Discharge, Side Discharge and Top
Discharge units should have a minimum of
300mm from base of unit to bottom / ground level
for connecting plumbing.
7. Unit installation should have a minimum of
750mm clearance on all the service sides.

INSTALLATION,OPERATION &MAINTENANCE
Unit Installation
DUCTWORK SYSTEM
It is essential that water cannot enter the building as
a result of inadequate sealing (caulking or flashing) of
the fixings, the ductwork system, system pipes and
wiring.
All duct designs and airflows must be
calculated by a qualified air conditioning
consultant or contractor in accordance with
normal good ducting practices.
Discharge duct design critical to the air
performance of the product. See diagram
below.
Where flexible ductwork is used, all bends
must have a minimum radius of 1.5 times
the diameter. All joins must be taped
airtight.
The last bend to each ceiling register
must be a smooth radius so that airflow is
even into the room.

INSTALLATION,OPERATION &MAINTENANCE
Water Connections
WATER CONNECTIONS
UNIT BASE LAYOUT
B18
B23

INSTALLATION,OPERATION &MAINTENANCE
Water Connections
B33
B36

INSTALLATION,OPERATION &MAINTENANCE
Water Connections
WATER INSTALLATION
A permanent water supply is required to be connected to the unit. Units have been type
test certified to MP52, Spec101. Certificate No.8663.
Connecting the Water Supply
•The water supply pipe work and connection
to the air conditioner must be installed by a
licensed plumber and conform to AS 3500,
state & local plumbing regulations.
•Ensure water pressure to the appliance does
not exceed the maximum static pressure of
500kPa (50 m head) as per As 3500 (section
3.3)
•The ball valve connection is inside the unit.
Ensure the copper inlet pipe is secured to
prevent movement of the float valve.
•The supply pipe should be 12mm copper pipe or similar approved. A ¼ turn ball
isolating valve must be installed on the supply pipe near the unit for ease of
maintenance. Do not use duo or non-return valves of any kind including stop taps
with jumper washer.
NOTE: Non return type valves can have and effect on the operation of the
water solenoid valves. Lock up and damage can be caused.
•Fit water supply tap close to the unit to assist in routine servicing.
•Before connecting the supply pipe flush it of any swarf or debris that may cause the
float valve to leak.
NOTE: In areas where water pipes freeze, provisions will be needed to drain
the water piping to prevent damage to the air conditioner.
Page 10

INSTALLATION,OPERATION &MAINTENANCE
Water Connections
Dump Valve (Optional)
•To fit a dump valve a 40mm hole will be
required in the lowest section of the tank
using the optional sump dump well.
Note:- the overflow assembly is still
required.
•Where a Dump Valve is to be fitted, the
solenoid MUST be installed in series on the
unit side of the water-isolating tap.
•Fit the black pressure tube between the
dump valve and the solenoid valve.
•The 24V solenoid will be supplied with an
in-line transformer for 240V connection.
•Connect the 240V solenoid transformer
leads in parallel with the pump
terminations.
Or
Connect to a timed / delay independent
circuit supplied by the installer.
•The tank in the unit will only fill once power
has been applied to the solenoid valve
transformer via the pump or an alternate
dump timing circuit. The water pressure
through the black tube then closes the
dump valve.
Drain
The combination drain/overflow pipe outlet must
be connected to a drainpipe, which has
sufficient capacity to take the discharge of
water from the reservoir. The pipe must
connect to a suitable drain or gutter.
Note: Refer to local regulations to ensure
discharge of drain / overflow water is
in accordance with statutory
requirements.
Page 11

INSTALLATION,OPERATION &MAINTENANCE
Electrical Connections
ELECTRICAL CONNECTIONS
WIRING CONNECTIONS
•Have a licensed Electrician install a dedicated circuit from the distribution board with a
separate circuit breaker for each unit installed.
•Unit isolating switch is provided on the control box in the unit.
Isolate the mains supply at the circuit breaker before conducting any electrical
connect work.
•Circuit breaker selection and cable size must be made relevant to the current rating of
the motor and the circuit breaker motor Kw specifications.
•Where 3 phase units are being with frequently stop / started on high speed, a delay
timer must be fitted to the low speed control circuit by the installer to start the unit on
the low speed. This will reduce the level of maintenance required to belts and pulleys.
•Electrical connections must be easily accessible for service and maintenance.
•Check to see if the voltage of the air conditioner is compatible with your electrical
system voltage. Check that there will not be excessive voltage drop, which will cause
the unit to run inefficiently or even cause motor burn out. ±5% of the motor
nameplate voltage is usually acceptable by motor manufacturers.
•Prior to completing the installation an electrician must check that the air conditioner is
operating correctly, and that the fan is rotating in the correct direction.
•Replace all lids and covers.
•The manufacturer advises that they will not be held responsible for replacement of
parts or labour costs on electrical components which fail as a result of incorrect
wiring.
WIRING –IMPORTANT NOTES
•A LICENSED ELECTRICIAN must carry out all electrical connection wiring to
the unit. It is the responsibility of the LICENSED ELECTRICIAN that the unit is
connected as per AS3000 (Wiring rules) and any local regulations and statutory
or legal requirements.
•Where 3 phase units are clustered using a single wall control for multiple units,
the unit control box must labelled indicating live wires inside. There will be
voltage in the control circuit if all units in the cluster are not isolated in the
multiple connections.
Page 12

INSTALLATION,OPERATION &MAINTENANCE
Electrical Connections
WIRING DIAGRAM
Single Phase B18, B23
Single Phase B33
Page 13

INSTALLATION,OPERATION &MAINTENANCE
Electrical Connections
Three Phase B36
Page 14

INSTALLATION,OPERATION &MAINTENANCE
Electrical Connections
Variable Speed
Single Phase B18, B23
Page 15

INSTALLATION,OPERATION &MAINTENANCE
Commissionin
g
COMMISSIONING
WATER LEVELS
•Turn water on to unit and allow the reservoir to fill. The water should be 65mm to
70mm from the bottom of the tank.
•If a dump valve is fitted, turn the pump (or dump circuit) on to activate the solenoid.
Water pressure will be applied to the dump valve plunger via the black pressure pipe,
cause it to close allowing the reservoir to fill.
Note: the dump valve has minimum and maximum operational pressures of 100 kPa
to 1000kPa. Where pressures are below 100 kPa, the dump valve may not
close and the reservoir will not fill.
•Adjust float valve arm as required to set the water level (65 – 70mm).
•Fit Louvre panels and check for even wetting of the filter medium
BLEED-OFF RATE
•All evaporative air conditioners need some
water bleed-off to prevent build-up of mineral
deposits in the system. The correct setting of
the bleed rate will ultimately govern the life of
the unit.
•Recommended bleed rates should be set at
approximately 5 litres per hour per 1000 litres
of air. Increased water hardness will require a
higher bleed rate and increased maintenance.
•It is recommended to plumb the bleed off hose
through the overflow fitting and the bleed-off
away to a downpipe in situations where the
discharge may cause unsightly stains.
•To control the bleed-off rate rotate the bleed
dial clockwise for more water and anti-
clockwise for less water.
NOTE: It is the responsibility of the installer to set a correct bleed rate to suit
local conditions.
•If a dump valve is fitted and is set up for regular timed dumping periods during
operation, the bleed may not need to be set subject to water quality.
•If a dump valve is fitted and is only to be used for the purpose of a dry sump when not
in use, the bleed rate will have to be set for normal operation.
DISTRIBUTION FLOW
Generally the flow rate to the water distributors will be set to full. However there will be
some circumstances where water carry-over may occur. To stop water carry over where
there appears to be an excess of water on the filters, adjust the outer knob of the Dialflo
to clockwise to reduce the amount of water to the filters.
Note: Hold the bleed knob while adjusting the distribution flow, as this may go
out of adjustment when turning the distribution flow knob.
Page 16

INSTALLATION,OPERATION &MAINTENANCE
Commissionin
g
FAN OPERATION
•Check that pulleys are correctly aligned.
•Check the belt tension is correct. Nominally 15
– 20mm depression.
•Check bearings are tight on shaft
•Set the fan running and check.
•Check that the air is being evenly distributed
through the ductwork.
•Make adjustments, as required, to any manual
air dampers that may be fitted.
•Fan Motor Current. Check the motor
operating current is not greater the rating plate
value.
oFor systems with high statics and
non standard drive check motor
current. Where required, review
pulley requirements relative to the
system static. Where variable pitch
pulleys are fitted adjust accordingly.
oFor systems with minimal static eg
straight dropper and plenums,
check motor current. A smaller
motor pulley to standard may be
required.
CONTROLS
Check all control functions are working
CUSTOMER HAND OVER
Instruct the customer in the use of the product.
•Controls
•Bleed off
•Venting the air via the side of the premises the wind is not blowing from.
•Maintenance Requirements
Hand over of the customer’s operational manual.
Page 17

INSTALLATION,OPERATION &MAINTENANCE
Commissionin
g
COMMISSIONING CHECK LIST
You must complete, date and sign the ‘tick box’ checklist in the owner’s
warranty card. Use this copy to check the installation prior to completing the
owner’s documentation.
Unit
All equipment ordered by the
customer is installed.
The unit is level and secure.
The water supply line has been
flushed to clear swarf and debris and
is free of leaks.
The tank is free of foreign matter and
debris and the water isolating tap is
turned ON.
Water drainpipe work is completed
and sealed.
The water basin fills with water and
the float valve closes correctly when
the water level is 65 -70mm from the
bottom of the tank.
The water pump(s) operates correctly
when turned ON at the controller.
The Dialflo water bleed rate is
adjusted to suit local water
conditions.
The Dump Valve (option). The tank
drains correctly when unit turns off.
The fan deck is correctly located and
the fan blade spins freely.
The mains and control wiring are
complete and the circuit breaker is
turned ON.
The fan operates correctly on all
speeds.
Water distribution is even with the
filter pads fitted and the air
conditioner operating pump and fan.
All Controller functions for the
appliance operate.
Fan motor current draw.
Ductwork and general
All ductwork is completed to plan,
correctly supported and airtight.
Air distribution checked, dampers are
adjusted and all outlets correctly
adjusted and wiped clean.
All roof penetrations are fully sealed
and watertight.
Man-hole cover replaced.
Site
All rubbish has been removed from
inside and on the roof.
Customer Hand Over
You have explained the following to the
customer.
The operation of the Controller.
Adequate exhaust is required for the
effective cooling. Air exit areas
should be at least 0.5 square meters
per 1000 litres of air.
The operation of the bleed or
dumping system and it’s importance
to operate all the time
Maintenance requirements
Page 18

INSTALLATION,OPERATION &MAINTENANCE
O
p
eratin
g
Instructions
OPERA
USING YOUR AIR CONDITIONER
TING INSTRUCTIONS
The principal of your unit is to introduce fresh air, which is washed through the filter pads to
provided cool fresh air. The air is exhausted taking with it any heat loading on the space.
Evaporative Air Conditioners must always function on 100% fresh outside air.
Exhaust / Air Relief
Evaporative air conditioners require you to open or provide exhaust outlets in the space
being cooled. Such outlets may be provided by the opening of doors and/or windows in
various rooms or sections. They may also be provided by the installation of special exhaust
grilles through doors, walls or into the ceiling (attic) space of the building. Air exit areas
should be at least 0.5 square meters per 1000 litres of air.
Where the building does not allow such easy exhaust provisions, there must be some kind
of mechanical ventilation installed, such as an exhaust fan which can extract approximately
80% of the air that the air conditioner is discharging.
Never allow conditioned air to exhaust into a closed space, it must always be allowed to
exhaust to the outside.
When deciding on an exhaust point using doors, windows or louvred vents, always keep the
opening options closed on the windward side of the building.
General Operation
Generally, the higher the relative humidity, the higher the air quantity required from the air
conditioner. You should therefore control the speed of your air conditioner accordingly. On
very dry days the air conditioner will give maximum cooling and this will decrease as the
humidity increases.
The air distribution system in your building has been fitted with air outlet grilles and they
probably have adjustable louvre blades. You can adjust the blades yourself to create your
own pattern of air distribution in the space.
If you close the louvres too much you may get undesirable air noise.
Page 19

INSTALLATION,OPERATION &MAINTENANCE
O
p
eratin
g
Instructions
OPERATING INSTRUCTIONS –2SPEED CONTROLS
Turn on the water supply at the source and
make sure that the water isolation valve at
the unit is also turned on.
Turn on the electrical power at the source
and make sure that the isolating switch in
the unit is turned on.
Cool / Pump Operation
Turn COOL switch on.
It is recommended that you wait 10 minutes
for the pump to saturate the filter pads. A
longer period may be required where a
dump valve is fitted.
Fan Operation
Select LOW fan speed, using the switch on
the control panel inside the building, then
switch unit ON. (It is recommended to start
the unit on LOW speed, and then switch to
HIGH if required).
At times, when the outside humidity is very
high, you may feel more comfortable using
ventilation system only. For ventilation
system only, turn the COOL switch off and
run the fan only. The fan speed can be
selected as described above.
Follow the above instructions about providing exhaust opening in the building. This is very
important. When unit is turned OFF the COOL switch should also be turned OFF as the
pump is independently switched.
OPERATING INSTRUCTIONS –OPTIONAL VARIABLE SPEED CONTROLS
For variable speed motors, refer to the owners manual supplied for unit operation details.
Page 20