Brivis Iceberg User manual

285 Issue 1 - Service Manual - Iceberg
Service Manual
Brivis Iceberg™
Service shall be carried out only by Authorised Personnel. This Service
Manual must NOT be left with the Owner, or distributed to other persons not
permitted to obtain this information by Brivis Climate Systems.

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Issue
Date
Description
1
March
2015
Release of the Iceberg cooler Model number:
XQ4 ICEBERG

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Table of Contents
1.0 Operation Overview................................................................................................................ 1
2.0 Component Overview............................................................................................................. 2
2.1 Evaporator Module ................................................................................................................. 2
2.2 Evaporator Module - Internal.................................................................................................. 2
2.3 Service Control Panel............................................................................................................. 3
2.4 Brivis Icecap™ - Components................................................................................................ 3
2.5 Component Overview:............................................................................................................ 4
3.0 Technical Data Sheet XQ4..................................................................................................... 5
3.1 Wiring Diagram....................................................................................................................... 6
3.2 Main Control board Connections............................................................................................ 7
4.0 Cooler Operation .................................................................................................................... 8
4.1 Cooler Operation – Manual Sequence ................................................................................... 9
4.2 Cooler Operation – Auto Sequence...................................................................................... 10
5.0 Installation Requirements..................................................................................................... 11
5.1 XQ4 Dimensions .................................................................................................................. 11
5.2 Platform & Service Clearance – With Module....................................................................... 11
5.3 Platform & Service Clearances – Without Module................................................................ 12
5.4 Electrical Power Supply to the Cooler .................................................................................. 12
5.5 Water Supply to the Evaporator Module............................................................................... 13
6.0 Inlet Connection ................................................................................................................... 13
7.0 Solenoid Valve ..................................................................................................................... 14
7.1 Water Inlet Solenoid Operation ............................................................................................ 14
7.2 Water Inlet Solenoid – Removal........................................................................................... 14
7.3 Water inlet Solenoid – Does not supply water into the tank when empty. ............................ 15
7.4 Water Inlet Solenoid – If power present and doesn’t open: .................................................. 16
7.5 Water Inlet Solenoid – If NO power: ..................................................................................... 16
7.6 Water Inlet Solenoid – Does not turn OFF ........................................................................... 17
8.0 Brivis Aquastop .................................................................................................................... 17
9.0 Circulation Pump.................................................................................................................. 18

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9.1 Pump Removal..................................................................................................................... 19
9.2 Circulation Pump – Electrical checks ................................................................................... 20
9.2.1 Pump will not operate........................................................................................................ 20
9.2.2 If power present:................................................................................................................ 21
9.2.3 If pump doesn't operate:.................................................................................................... 21
9.2.4 If NO power: ...................................................................................................................... 21
9.2.5 If Pump doesn’t operate: ................................................................................................... 22
9.2.6 Circulation Pump - Mechanical Checks............................................................................. 22
9.3 Drain Pump .......................................................................................................................... 22
10.0 Winter seal damper assembly ............................................................................................ 23
10.1 Dismantling......................................................................................................................... 24
10.2 Damper motor assembly will not open ............................................................................... 26
10.3 If power is present to the switch terminal, but not to the motor terminal:............................ 26
10.4 If power is present at the motor terminal: ........................................................................... 27
10.4.1 If damper motor assembly does not operate: .................................................................. 27
10.4.2 If motor operates: ............................................................................................................ 27
10.4.3 If NO power present at ServoSeal motor Active Open terminal:...................................... 28
10.4.4 If winter seal damper motor operates: ............................................................................. 28
10.4.5 If winter seal damper motor doesn't operate: .................................................................. 28
10.4.6 Damper blade will not close:............................................................................................ 29
10.4.7 Circuit Diagram:............................................................................................................... 29
11.0 Fan Motor Assembly .......................................................................................................... 30
11.1 Fan motor assembly removal ............................................................................................. 31
11.2 Fan Motor will not operate.................................................................................................. 32
12.0 Brivis Iceberg Wall Control ................................................................................................. 34
13.0 Dip Switches & Potentiometer............................................................................................ 37
13.1 Dip Switch Settings ............................................................................................................ 37
13.2 Potentiometer - Drain refill cycle count............................................................................... 38
14.0 Evaporator Module – Primary Drain ................................................................................... 39
14.1 Safety Tray – Secondary Drain .......................................................................................... 39
15.0 Final Checklist .................................................................................................................... 40
16.0 Iceberg Cooler Service....................................................................................................... 41

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Scope
This Service Manual contains information relevant to servicing a Brivis Iceberg Evaporative
Cooler. It is intended for Service personnel who have received adequate training on Brivis
Evaporative Coolers.
Brivis Iceberg Evaporative Cooler
The Brivis Iceberg™ evaporative cooler is a new design where the evaporation process takes
place beneath the roof line. The Brivis Icecap™™™ is an optional accessory located on the roof
of the home and is designed to provide the minimum ventilation requirement of 0.5m² to the
Evaporator Module installed within the roof space.
The model range as follows:
Model
XQ4 Iceberg™
The main sections covered include:
•Cooler Operation
•Troubleshooting
•Servicing
•Components Removal/Assembly Procedures
•Technical Specifications
Definitions
Shall
Indicates a mandatory requirement of this manual
Should
Indicates a recommended reauirement of this manual
Safety Warning
•DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE.
•DO NOT USE OR STORE FLAMMABLE MATERIALS NEAR THIS APPLIANCE.
•DO NOT MODIFY THIS APPLIANCE.

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1.0 Operation Overview
In February 2015 Brivis introduced a new style of evaporative cooler called the Brivis Iceberg.
The Evaporator Module is where heat transfer through evaporation takes place. The Evaporator
Module contains the Iceberg control system and water distribution system which supplies water
to the Hydrochill pads. The unit must be installed on the safety drain tray supplied by Brivis.
The Icecap™™ is an optional ventilation accessory. It is the installer’s responsibility to ensure
the minimum ventilation requirements of 0.5m² required by the Iceberg. 0.5m² may be achieved
with the use of roof vents, gable vents, eve vents or the Brivis Icecap™™.
There are 4 x fan motors installed on the unit. The fan module has 4 x duct connections. Each of
450mm diameter. Fresh air is drawn into the unit via the air inlet mesh when the damper
assembly (winterseal) has opened enabling air flow into the home.
The Iceberg Evaporator Module has 4 Hydrochill pads fitted. There are 2 pads on either side of
the module.
When the wall control is switched OFF after the cooling operation the unit will continuously run
for 6 min for pad drying time and then shut down. The damper assembly will close 2 minutes
after the fans shut off and after 45min and the drain pump will drain the water from the trough.

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2.0 Component Overview
2.1 Evaporator Module
2.2 Evaporator Module - Internal
Inlet MeshAcoustic
Cooling
Chamber
Acoustic
Cooling
Chamber
Hydrochill ™
Pads
Toggle
Clips
Control
Service
panel
Water
Inlet
Isolation
switch Primary Drain
Discharge
Discharge
pop
Fan assembly
Circulation
Pump
Drain
Pump
Pump
Outlet
Drain pipe
Water
distribution outlet
Water
distribution pipe

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2.3 Service Control Panel
2.4 Brivis Icecap™ - Components
Brivis Icecap™ (Plastic) BAL Icecap™ (Metal)
Mesh Screen
Note: For installation requirements refer to the Appendix for more detail.
2 x Fan Power
Supplies
Aquasave
Main Control
Board
Isolation
switch
Water Solenoid
Valve

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2.5 Component Overview:
2.1 Evaporator Module
The Evaporator Module is made of an insulating material and it is where the heat transfer
process through evaporation takes place.
2.2 Electronic Control Modules
The Main PCB controls the coolers working status using the signal sent from the wall control.
There are two Fan Power Supplies which control the 4 x 48VDC Fan motors. The Control board
converts the power supply from AC to DC. Both the Fan Control Boards control two fan motors
each which are located on either side of the unit.
2.3 Aquasaver water treatment module
Water management system known as the Aquasave water treatment module is designed to
reduce the requirement for flushing, thus saving water.
2.4 Trident Water Management System
The Trident Water Management System uses three stainless steel probes, to detect the water
level within the tank. There is a high and low level feedback to the PCB.
2.5 Winterseal Assembly
The Evaporator Module is fitted with a Winter Seal damper which opens when there is a call for
cooling and closes when the system is turned off.
2.6 Drain and Circulation pump
The Evaporator Module also consists of two pumps. One circulates the water around the unit,
wetting the Hydrochill pads for cooling. The other is used to drain and empty the Cooler's tank at
the end of use.
2.7 Brivis Icecap™™™
The optional Icecap™™™ is an accessory that is installed on the roof to assist with the
Iceberg’s ventilation requirements.
Further information on installation and operation of Brivis Iceberg Evaporative Coolers can
be obtained from the Cooling Installer’s Manual and Cooling Owner’s manual

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3.0 Technical Data Sheet XQ4
Type: Technical Data Base Date Updated: 4/03/2015
Category: Specification Sheet - Cooler
Subject: Iceberg™ XQ4
Sizing Guide Reference Figure 1400 - 2900
Cabinet detail
Width 1458mm
Length 982mm
Height front 811mm
Dry Weight 46kg
Wet Weight 62kg
Tank Capacity 12 Litres
Filter Pad Details Water Treatment Unit
Quantity 4 Type Aquasave
Thickness 100mm Rating 240 V / 50 Hz 10W
Type Hydrochill Amps 0.12
Air/Gas Flow Rate 1 L/minute minimum flow
Duct Outlet Size
Duct Connection 4 x 450mm Dia
Pump / Water Distribution
Fan & Motor Specification Pump and drain Type HAI BAO HB-D777
Type 48VDC - 1 ph Pump Rating 110 - 240 V
Model Fans-Tech Pump Capacity 30 L/min
DM075D3-DF0-32 Winding Resistance 122Ω
Watts 290W Amps 6
R.P.M.(Rated) 3480 Distribution Hose Size 20mm, 20DN pressure pipe
R.P.M Max Setting 3400
Current draw 8Amps@48Vdc
PCB Water Supply Solenoid
XQ4 Main PCB Inlet Valve Type ELBI E.V Type 329
Inlet Valve Rating 240 V - 0.03 Amps
Fan Power Supply Inlet Valve Capacity 5.5L/minute
Mean well HRP – 600 Coil Resistance 4.1 kOhm approx. @ 20
o
C
Inlet Valve Size 3/4" BSP (Male) Thread
Outlet Valve Size ½” Hose Barb
Fan Duct Connection .
Pop Size 18” / Ø450mm
Cooler Control Module
Dip Switch Settings (run mode)
1-0-0-0
Wall Controller
Water Connection Tek700 Iceberg Wall Control
Flexible Hose Connection with
3/4" BSPF (female)
Drain Connection
Evaporator unit size 20mm DN pressure pipe
Safety Tray outlet size 40 mm DWV

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3.1 Wiring Diagram

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3.2 Main Control board Connections
Fan Motor Supply Module
Earth
connection
Damper
Motor
Mains
supply from
Electronic
Filter
Common to
Fan modules
Motor power
supply to Fan
Modules
Trident water
Sensor
Speed Control
Signal
(0-10Volts)
Drain
Pump
Circulation
pump
Solenoid
valve
Not in use
Wall
Control Aqua Saver
Dips
Switches
Drain refill
cycles count
Fan Motor
(B) Neutral
Fan Motor
(A) Neutral
Earth
Neutral
Fan Motor
(A) Neutral
Fan Motor
(B) Neutral

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4.0 Cooler Operation
The Evaporator Module is where heat transfer through evaporation takes place. The Evaporator
Module contains the Iceberg control system and water distribution system which supplies water
to the Hydrochill pads. The unit must be installed on the safety drain tray supplied by Brivis.
The optional Icecap™™ is a ventilation accessory. It is the installer’s responsibility to ensure the
minimum ventilation requirements of 0.5m² required by the Iceberg Evaporation Module. 0.5m²
may be achieved with the use of roof vents, gable vents, eve vents or the Brivis Icecap™™.
There are 4 x fan motors installed on the unit. The fan module has 4 x duct connections each of
450mm diameter. Fresh air is drawn into the unit via the air inlet mesh when the damper (winter
seal) assembly has opened. Enabling air flow into the home.
The Iceberg Evaporator Module has 4 Hyrdrochill pads fitted. There are 2 pads either side of the
module.
When the wall control is switched off after cooling mode the unit will continuously run for
6 min for pad drying time and then shut down. The damper assembly will shut 2 min after
the fans have shut off and 45min the drain pump will be turned on and the water will be
drained out of the system.
The following will occur:
•When the wall control is turned OFF the Iceberg Cooler will drain the water after a 45min
delay time. The pump will then turn on and continuously run for 10min. During this 10 min
on-time the solenoid will open for 30sec to back wash any sediments left in the unit
•When the wall control is turned ON in Cooler mode, no function will occur until the wall
control signals the Cooler to operate, i.e. the unit will remain closed and the tank empty.
•The water inlet solenoid will energise, and the tank will begin to fill with water. The Main
PCB module will not permit the pump to run, until the water has reached the high water
level on the Trident water management system.
•The Trident water sensor will operate the pump and maintain the tank water level.
The Cooler pump will automatically Pre-Wet the filter pads when the pump is turned ON,
either in manual or auto mode settings.
•Just before the fan operates, the Winter Seal will open and the fan will operate to the set
control speed.
•This is to ensure in all circumstances the filter pads reach full saturation and optimum
cooling potential when the fan starts.

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4.1 Cooler Operation – Manual Sequence
Start-up Sequence
Shut down sequence
Wall control is turned
on in Manual mode
40 Sec the Solenoid
opens
2 min Pump starts
(Solenoid turns off).
Solenoid opens 45 sec
later.
Solenoid turns off after
90 seconds.
Fan turns on and
operates at its set
speed. (4 min Cycle)
Damper (winterseal)
will open
Wall control has been
turned off
Fan runs down and
then increases to a set
speed for 6 min to dry
pads, fan will then stop.
45 min later the drain
pump starts operating
2 min later the Solenoid
opens for 5sec.
The drain pump
operates for 7 min 30
sec then stops.
Unit stops
(10
min
cycle)

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4.2 Cooler Operation – Auto Sequence
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-E6 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 0.5
0
C. 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 1
0
C,
above the set comfort level, and is incremented to be at maximum fan speed,
when the room temperature is 5
0
C, or more above the set comfort level.
During normal operation, at 5 minute intervals, the Networker updates the N-E6
module on the temperature differential between room temperature and the set
comfort level, and if the temperature has varied by 0.5
0
C. or more then the cooler
is adjusted.
However, if the temperature changed rapidly by 2.5
0
C, or more within the 5 minute
update interval, then the Networker will signal the N-E6 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.

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5.0 Installation Requirements
The below section provides an overview of the platform installation requirements; for more detail
refer to the Iceberg™ Installation manual.
5.1 XQ4 Dimensions
5.2 Platform & Service Clearance – With Module

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2290 Min
Platform &
Service
Clearance
1750 Min
750 Min
Safety Tray
550 600 Min
600 Min
600
Location holes (x6) in “Safety
Tray” top hat for “Evaporator
Safety
Tray
Cable tie to secure water
supply braided hose
5.3 Platform & Service Clearances – Without Module
5.4 Electrical Power Supply to the Cooler
The Cooler is pre-wired with a 3-pin plug and lead, and should be plugged into a standard 10
Amp - 240 Volt power socket located within the roof space, in close proximity to the Evaporator
Module. The power socket should be wired back to the meter box on a dedicated power circuit.
IMPORTANT: Switch OFF the power and unplug the Cooler before touching any internal cooler
breaker wiring. If any internal electrical wiring is damaged, it must be replaced by the
manufacturer, its service agents or an electrically qualified technician, in order to avoid a hazard.
The electricity supply must be 240 Volt / 50 Hertz, and from an authorised power supplier.
Generators should never be used, as their output may be incompatible with or damage the
Cooler’s electronic control system.
Cable tie to Secure Water
supply braided hose

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5.5 Water Supply to the Evaporator Module
The Evaporator Module’s water system is designed to operate with a water supply pressure
between 300 kPa and 1000 kPa. If the supply pressure is excessive, a field-supplied pressure-
reducing regulator will be required. If the pressure is insufficient the Cooler’s operation will be
compromised. In areas subject to water pipes freezing the primary drain should be insulated to
prevent damage to the cooler.
• Ensure the supply piping has been flushed before connecting it to the Cooler.
• A registered licensed plumber must install the water supply piping and connection to the
Cooler in accordance with the local water supply regulations.
• An isolating valve on the supply pipe must be placed and secured in the Safety Tray
beside the Evaporator Module so that it does not dislodge. This must be provided to
facilitate isolation of the water or to disconnect the water supply piping when servicing.
• Non-return isolating valves on the water supply are not recommended as they may cause
damage or lock up the Cooler’s inlet mechanism where high lock-up pressures or freezing
water in pipes may occur.
• For the owner’s convenience, an additional isolating valve may be provided at ground
level to isolate the water supply.
• The water supply pipe must be supported and secured so as not to place strain on the
Cooler’s water connection fittings or cause water hammer noise.
• Water quality should be checked and filtration fitted where necessary e.g. tank or bore
water.
• The connection size to the Evaporator Module is 1/2” BSPF.
• Flow stop valve is fitted on the water line.
6.0 Inlet Connection
The water inlet connection point is on the “Evaporator Module” within the roof space. The
connection size is 3/4” BSPF and is located on the Aquastop, a device secured to the end of the
braided hose. A bi-directional water isolation valve is required at the unit for servicing and it
shall be connected directly to the Aquastop. After connection the ball valve shall be secured
inside the safety tray, a position and cable tie has been made available for this, refer to Diagram
Aquastop at the
Water tap end of the
braided line is ¾”
BSPF.
Note:
The
3/4
”
BSPM thread on unit is plastic, be careful not to cross thread.

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7.0 Solenoid Valve
7.1 Water Inlet Solenoid Operation
The Iceberg Cooler has a 240 Volt water inlet solenoid which is located at the front of the service
compartment.
The water inlet solenoid has a filter within and attached is a flexible hose or braided line, which is
terminated with a ½” BSP female fitting.
The water inlet solenoid has a supported external to the service controls compartment which has
a slide in brace. The one piece wiring loom to the water inlet solenoid is concealed from the
service compartment runs down to the solenoid chamber.
Note: The water inlet solenoid uses the water supply pressure to activate the 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.
7.2 Water Inlet Solenoid – Removal
•Power supply
•Turn off the water
•Care must be taken when disconnecting the water supply as to not break the solenoid coil
of the body of the valve.
•To access the filter, remove the water supply hose, remove filter basket with pin nose
pliers.
Slide the Solenoid
upward so the solenoid
has been removed
away from the brace.
Pull the solenoid away
from the unit so that the
electrical components
are exposed including
the outlet connection.

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7.3 Water inlet Solenoid – Does not supply water into the
tank when empty.
•Check that the Cooler is turned ON is calling for Cooling (pump operation) and is not in an
operation delay period i.e. Damper motor delay.
•Check the water supply tap is turned ON.
•Check that the water supply pressure is within the operation range (300 KPa – 1000
KPa).
•Checks that (both the High and Low Level Sensors are open Circuit) are not current.
•Check that the water inlet solenoid is energised (240 Volt), at the water INLET
SOLENOID- ACTIVE and INLET SOLENOID – NEUTRAL terminals.
Neutral Active
Check if 240 Volts Present