Reznor AS3 User manual

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GENERAL INFORMATION
•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.
TABLE OF CONTENTS
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
Revision: OPT-AS3,4,5,8 (07-22) 160202-B
OPTION AS3, AS4, AS5, OR AS8 FOR MODELS ADF, ADFH, PGBL, RBL,
RGBL, RPB, RPBL, AND SSCBL
EVAPORATIVE COOLING MODULE INSTALLATION,
MAINTENANCE, AND TROUBLESHOOTING
Supersedes: OPT-AS3,4,5,8 (06-22) 160202-A

2OPT-AS3,4,5,8 (07-22) 160202-B
GENERAL INFORMATION—CONTINUED
NOTE: INDOOR INSTALLATIONS: DO NOT suspend the evaporative cooling module—it must be
mounted on a platform. If the installation location does not have a suitable platform that allows
the module to be installed directly to the cabinet, install the module on a separate platform with a
compatible field-fabricated transition duct between the module and the cabinet.
•Ensure that all components listed in Table 1 are available before beginning installation. These components are
shipped with the evaporative cooling module.
Figure 1. Dimensions
Weights
Table 1. Evaporative Cooling Module Installation Components
Item No. Component PN (Quantity) Application
1 End rail 107235 (2)
Base assembly2 Side rail 107227 (2)
3 Two-piece leg 107236 (4)
4 Front top cover 107228 (1) Cooling module
5 Duct top 107229 (1)
Transition duct
6 Duct side 107231 (2)
7 Duct bottom 107230 (1)
8 Screw, #10 × 1/2 11813 (AR)
9 Hex head bolt, 1/4-20 16246 (AR)
10 Nut, 1/4-20 16050 (AR)
11 Duct extension 107233 (2) BL models, unit sizes 500 and 600
12 107234 (2) BL models, unit sizes 700 and 1050
13 Bleed line fitting, 1-1/4 hose ID × 1/2 NPT*105945 (1) Cooling module connections
14 Bushing (Heyco #SR-7W-2) 16835 (2)
NOTE: AR = as required.
*Not used with optional timed metering AquaSaver® system.
Dimensions
Table 2. Weights
Option
AS3 AS4 AS5 AS8
Net Weight (Pounds (kg))*
379 (172) 431 (195) 420 (191) 514 (233)
*With wet media and full reservoir.

3
OPT-AS3,4,5,8 (07-22) 160202-B
INSTALLATION
Install the evaporative cooling module as follows. Item numbers in parentheses refer to Table 1.
⚠ CAUTION ⚠
• DO NOT mount the cooling module directly on soft tar roofs where the legs could sink and tilt
the cooling module. Provide a weather-resistant solid wood or metal base under the cooling
module support base.
• DO NOT install the cooling module and connecting duct while blowers are in operation.
NOTE: Before installation,make preparations for necessary supplies,tools,and manpower.
Pre-Installation Checklist
Ensure that installation complies with all local, utility, and federal building and safety codes and regulations.
Check module for shipping damage. If damage is found, document it with transporting agency and immediately
contact Distributor.
If module is being installed indoors (model SSCBL, PGBL, or ADF/ADFH 700/1200), outside makeup air must
be provided.
If optional shipped-separate equipment is required (i.e., drain and fill kit, freeze protection kit, moisture elimination
pads, and/or water hammer arrestor), check to ensure that these parts are available for installation.
Ensure that there is adequate clearance between bottom of reservoir and roof or platform to allow for drain and
overflow pipe connections (refer to Dimensions section).
Ensure that roof or platform is capable of handling additional load of cooling module with full reservoir (refer to
Weights section).
Ensure that mounting surface for cooling module is level and free of debris.
Assemble Base
Refer to Figure 2.
1. Assemble all four legs:
a. Secure each two-piece leg (3) together using four bolts (9) and nuts (10).
b. Top flange of assembled legs should be level with bottom of system cabinet. Adjust legs to proper height and
securely tighten bolts and nuts. Leg height is adjustable from 9–16 inches (229–406 mm).
c. 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 1)
3
2
1

4OPT-AS3,4,5,8 (07-22) 160202-B
INSTALLATION—CONTINUED
Assemble Base—Continued
2. Connect base rails to legs:
a. Position side rails (2) on inside of top flanges on assembled legs (3). Secure rails to top three holes on legs
located just below top flange using bolts (9) and nuts (10). Repeat on three remaining legs. Tighten nuts securely.
b. Position end rails (1) on inside of top flanges on assembled legs (3). Secure rails to top three holes on legs
located just below top flange using bolts (9) and nuts (10). Repeat on three remaining legs. Tighten nuts securely.
Install Evaporative Cooling Module on Base
Refer to Figure 3.
1. Carefully lift cooling module with both ends supported and place it on base assembly. Ensure that module is level
and that all base assembly bolts are secure.
2. Install top front cover (4) and secure using 13 screws (8)—three per side and seven across top.
Assemble Transition Duct
Refer to Figure 3.
1. Secure duct top (5) to duct sides (6) using eight screws (8)—four per side.
2. Secure duct bottom (7) to duct sides (6) using eight screws (8)—four per side.
NOTE: If the packaged heating system is a unit size 500, 600, 700, or 1050 BL model, duct exten-
sions (11 or 12) must be installed on the transition duct.
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).
Figure 3. Evaporative Cooling Module and Transition Duct (Refer to Table 1)
COOLING MODULE
4
5
6
7
11
OR
12

5
OPT-AS3,4,5,8 (07-22) 160202-B
Connect Transition Duct to Blower Cabinet
Refer to Figure 4.
1. Remove and save screws from along top rear lip of blower cabinet panel.
2. Slide transition duct flange underneath blower cabinet top edge and loosely insert two existing screws through
top edge, through transition duct flange, and into cabinet end panel.
3. If transition duct has duct extensions (11 or 12), insert duct extension mounting flanges into slots on blower
cabinet end panel.
Figure 4. Evaporative Cooling Module, Transition Duct, and Blower Cabinet (Refer to Table 1)
Connect Transition Duct to Evaporative Cooling Module
Refer to Figure 4.
1. With transition duct connected to blower cabinet, carefully tilt transition duct upwards to clear cooling module
reservoir pan and slide cooling module underneath catch pad mounting trough.
2. Squeeze cooling module and transition duct assembly into blower cabinet until tight fit is obtained.
3. Align holes in cooling module corner leg (3) with holes in transition duct sides and secure transition duct sides to
cooling module using screws (8)—five per side.
4. Secure transition duct flange to front top cover (4) using seven screws (8).
5. With cooling module and transition duct properly positioned on blower cabinet, tighten two screws that have been
loosely inserted. Re-insert and tighten existing screws in remaining holes along top edge of cabinet.
NOTE: It may be easier to connect the transition duct to the blower cabinet with the media pads
removed. If optional moisture elimination pads are included, media pads will have to be removed
to complete the installation (refer to Installation/Replacement of Media Pads section).
6. If there are no duct extensions (11 or 12) on transition duct, reach inside cooling module and secure module to
back of blower cabinet end panel using six screws (8). If there are duct extensions, reach inside cooling module
and secure duct extensions to back of blower cabinet end panel using four screws (8).
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.
COOLING MODULE
TRANSITION DUCT
FLANGE
BLOWER CABINET
11
OR
12
CATCH PAD
MOUNTING TROUGH
4

6OPT-AS3,4,5,8 (07-22) 160202-B
INSTALLATION—CONTINUED
Installation/Replacement of Media Pads
NOTE: Option ASA1 moisture elimination pads are shipped separately for field-installation.
Install/replace media pads and/or moisture elimination pads as follows:
1. Remove media pads (see Figure 5):
a. Remove three screws that secure top pad retainer and release top pad retainer from cooling module.
b. Remove three screws that secure bottom pad retainer and release bottom pad retainer from cooling module.
c. Disengage screen retainers from sides of media pads.
d. Disengage inlet screen from media pads and remove media pads from cooling module.
e. Slide all media pads horizontally away from cooling module until clear of bottom reservoir pan.
Figure 5. Media Pad Assembly
2. Install moisture elimination pads if required (see Figure 6):
a. Install two catch pad clamps to one side of cooling module’s front legs and secure clamps through legs into
clamp using four screws (8).
b. Assemble catch pads together using three screws (8).
NOTE: The screen part of the catch pad assembly should always be facing the attached air mover.
c. Guide catch pad assembly through inlet of cooling module and place bottom of lower pad into catch pad mounting
trough (see Figure 4). Slide catch pad assembly into two slots located in catch pad clamps installed in step 2a.
d. With pads in place, slide one of two remaining clamps over middle seam where assembled catch pads meet.
Slide other clamp over top catch pad frame and secure both clamps to cooling module leg using screws (8).
⚠ CAUTION ⚠
IMPORTANT: Cooling media is made up of two different sheets of cooling material, each with
its own unique angle. 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.

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OPT-AS3,4,5,8 (07-22) 160202-B
Figure 6. Elimination Catch Pad Assembly
3. Reverse procedure in step 1 to replace media pads. Media must be installed in orientation shown in Figure 7.
Figure 7. Airflow Direction Through Media Pads
Pump/Junction Box Assembly Installation
NOTE: To avoid damage during shipping, the pump/junction box assembly is secured to the top
of the side panel.
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.

8OPT-AS3,4,5,8 (07-22) 160202-B
INSTALLATION—CONTINUED
Pump/Junction Box Assembly Installation—Continued
Figure 8. Pump/Junction Box Assembly
Electrical Connections
PUMP/JUNCTION
BOX ASSEMBLY
OPERATING
LOCATION
Figure 9. Evaporative Cooling Module Factory-Installed Wiring
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)

9
OPT-AS3,4,5,8 (07-22) 160202-B
⚠ WARNING ⚠
Disconnect power to the unit.
NOTES:
• Line voltage wiring must be field-installed between the blower junction box and the evaporative
cooling module junction box. The tubing-encased wires are factory-connected in the cooling
module junction box.
• Models ADF/ADFH have optional 115V evaporative cooling module pumps. A transformer is
included on the unit.
• The two snap strain relief bushings, which must be used to prevent water from leaking into the
cabinet, are shipped in the bottom pan of the cooling module.
1. Remove compartment door panels, electrical compartment cover, and service panel in line with hole in cooling
module.
2. Drill 7/8-inch hole in cabinet end panel in line with hole in cooling module junction box.
3. Pull tubing-encased wires through hole in blower cabinet. Place one strain relief bushing around tubing and insert
bushing into hole.
4. Route wires across cabinet bottom. If there are any filters, run wires through slot in bottom filter rack. If there are
inlet dampers, take care to ensure that wires do not interfere with damper controls.
5. Run wires up to electrical compartment, remove plug from one bottom entrance hole, and push tubing-encased
wires into electrical compartment. Place other strain relief bushing around tubing and insert bushing into hole in
electrical compartment.
6. Connect wires to terminal blocks in accordance with wiring diagram provided with heater. If there is excess tubing
and/or wiring, trim before making connections.
7. Before unit is operated, replace all door panels and fasten all latches.
Piping Connections
⚠ CAUTION ⚠
On outdoor systems, the water reservoir must be drained and the pump motor must be turned off
when the outside temperature falls below 32°F. The pump must never be operated without water
in the reservoir.
Float Valve Connection
•In a cooling module with pump and float controls, a float valve (see Figure 10) maintains the appropriate water
level in the reservoir.
•Connect the fresh water supply to the float valve inlet using a field-supplied 1/4-inch diameter tubing with compression
nut and tubing ferrule. Place the nut and ferrule over the tubing and insert the tubing into the float valve stem.
Tighten the nut securely.
Figure 10. Float Valve Connection
COMPRESSION NUT AND
TUBING FERRULE
1/4-INCH TUBING
CABINET SIDE PANEL
FLOAT VALVE ROD

10 OPT-AS3,4,5,8 (07-22) 160202-B
INSTALLATION—CONTINUED
Piping Connections—Continued
Optional Fill and Drain Kit Installation
An optional automatic fill and drain kit will automatically release supply water to the cooling module when a call
for cooling is made and will drain all water from the reservoir when the cooling switch is deactivated or a cooling
thermostat is satisfied. Install the optional fill and drain kit as follows:
NOTE: Follow instructions included in the valve packages for connecting valves to the water line
only. The remainder of the installation instructions with the valves do not apply to this type of ap-
plication.
1. Connect water line (see Figure 11):
a. For supply (three-way valve) connections, connect water supply line to B (normally closed), connect water
drain line to A (normally open), and connect middle outlet to supply water to cooling module reservoir.
b. For drain (two-way valve) connections, connect drain pipe from reservoir to A and connect outlet side to B and
connect into drain lines from cooling reservoir and supply valve.
2. Connect wiring (requires black and white 14-gauge wire):
⚠ WARNING ⚠
Risk of electrical shock. Disconnect the power.
NOTE: Refer to the wiring diagram provided with the furnace. If the kit is not ordered with the
system, connections will not be shown on the diagram.Terminal connections are specific to each
system. Contact the factory for terminal connections. Be prepared to provide all model information.
a. Run field-supplied black wire from electrical compartment (terminal on wiring diagram) of evaporative cooling
module and connect to black wire on three-way and two-way valves.
b. 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