SEELEY INTERNATIONAL Climate Wizard CW-80 User manual

INSTALLATION & OPERATION MANUAL
CW-80, CW-80S
INCLUDING STANDARD & HIGH CAPACITY FANS OPTIONS
(Dual Unit) (English)
Original English Instructions

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 3
TABLE OF CONTENTS
WARNING: Failure to install and commission the product in compliance with these instructions, or failure to do the job
properly and competently, may void the customer’s warranty. Further, it could expose the Installer and/or the Retailer to
serious liability.
Index
IMPORTANT SAFETY INSTRUCTIONS 4
COOLER CONTENTS 7
INSTALLATION COMPONENTS 7
OPTIONAL COMPONENTS 7
COOLER VIEWS 8
TOP 8
SIDE 8
BACK 8
FRONT 8
TECHNICAL DESCRIPTION 9
AIRFLOW 9
HEAT EXCHANGERS 9
TRANSPORT 10
ROAD TRANSPORT 10
SHIPPING CONTAINER 10
MOVING THE COOLER 11
LIFTING THE COOLER 11
INSTALLATION 12
COOLER LOCATION 12
ACCESS FOR SERVICING AND MAINTENANCE 12
VIBRATION ISOLATION 12
SUPPLY AIR DUCT CONNECTIONS 12
INTAKE AIR FILTERS 13
EXHAUST FANS 14
EXHAUST WEATHERSEALS 14
SUPERCOOL DRIP TRAY 15
ELECTRICAL REQUIREMENTS 16
ELECTRICAL SUPPLY INSTALLATION 16
HIGH LEAKAGE CURRENT 16
RESIDUAL CURRENT CIRCUIT BREAKER (RCCB) 16
FIRE TERMINALS 16
WATER REQUIREMENTS 17
WATER SUPPLY INSTALLATION 17
WATER SUPPLY ISOLATION 17
WATER SUPPLY FILTRATION 17
WATER HAMMER 17
WATER DRAIN INSTALLATION 17
COOLER CONTROL COMPONENTS 18
WATER MANAGEMENT SYSTEM 18
CONTROL COMPONENTS 19
INPUT AND OUTPUT TERMINALS 19
MULTI-MAGIC CONTROLS 20
MULTI-MAGIC PLC 20
CONTROL SCREEN 20
MONITOR SCREENS 21
SENSOR SCREENS 21
CONTROL METHOD OPTION 1 (W/C) 22
CONTROL METHOD OPTION 2 (MBS) 22
COMMUNICATION CABLE SPECIFICATIONS 22
COMMUNICATION CABLE CONNECTIONS 22
COMMUNICATION CABLE WIRING RULES 22
TERMINATING RESISTORS 23
DEVICE NODE ADDRESS 23
CONTROL METHOD OPTION 3 (BMS) 24
BMS FAULT OUTPUT 24
BMS CONTROL INPUTS 24
BMS FAN SPEED INPUT 24
BMS CABLING REQUIREMENTS 24
CONTROL METHOD OPTION 4 (LCL) 25
CHANGING COOLER SETTINGS 26
PRE-WET 26
FAN START DELAY & RUN OUTPUT RELAY 26
MESSAGE BAR CONTENTS 27
LED STATES 28
FAULT CODE DISPLAY 28
FAULT CODE RESET 28
FAULT CODE DESCRIPTIONS 29
COMMISSIONING 30
INSTALLATION CHECKLIST 30
SETUP MENU ACCESS 31
MULTI-MAGIC DEVICE TYPE 31
TEST MENU 31
WATER MANAGEMENT SYSTEM CHECKS 31
HEAT EXCHANGER FLUSH 31
SUPPLY FAN CHECKS 31
MULTI-MAGIC COOLER SETTINGS 32
MULTI-MAGIC CONTROL SETTINGS 32
CUSTOMER HANDOVER CHECKLIST 32
MAINTENANCE SCHEDULE 33
MAINTENANCE FREQUENCY 33
WINTER SHUTDOWN 33
MAINTENANCE CHECKLIST 34
MAINTENANCE INSTRUCTIONS 36
COOLER CONTROL 36
QUARTERLY INSPECTION PROCEDURES 36
WATER FILTER MAINTENANCE 37
PUMP MAINTENANCE 37
CHLORINATOR CELL MAINTENANCE 37
WATER MANAGEMENT PROBE MAINTENANCE 38
WATER RESERVOIR (TANK) 38
INLET AIR FILTERS 38
TROUBLESHOOTING 39
WARRANTY TERMS AND INFORMATION 41
APPENDIX A 45
EXAMPLE WALL CONTROLLER WIRING 45
APPENDIX B 47
EXAMPLE LOW VOLTAGE BMS WIRING 47
APPENDIX C 48
MODBUS REGISTERS 48

4 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
IMPORTANT SAFETY INSTRUCTIONS
WARNING - TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK, OR INJURY TO
PERSONS, OBSERVE THE FOLLOWING:
a) Use this unit only in the manner intended
by the manufacturer. If you have questions,
contact the manufacturer.
b). Before servicing or cleaning unit, switch
power o󰀨 at service panel and lock the ser-
vice disconnecting means to prevent power
from being switched on accidentally. When
the service disconnecting means cannot be
locked, securely fasten a prominent warning
device, such as a tag, to the service panel.
c). Installation work and electrical wiring must
be done by qualied person(s) in accor-
dance with all applicable codes and stan-
dards, including re-rated construction.
d). When cutting or drilling into wall or ceiling,
do not damage electrical wiring and other
hidden utilities.
e). Do Not Use This Fan With Any Solid-State
Speed Control Device.
f). Ducted fans must always be vented to the
outdoors.
READ AND SAVE THESE INSTRUCTIONS
FOR FUTURE REFERENCE.
This appliance is not intended for use by
persons (including children) with reduced
physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they
have been given supervision or instruction
concerning use of the appliance by a person
responsible for their safety. Children should be
supervised to ensure that they do not play with
the appliance.
Means for all pole disconnection must be
incorporated in the xed wiring in accordance
with the wiring rules, adjacent to or on the
cooler cabinet. If mounting on the cooler
cabinet, take care not to puncture the water
reservoir.
If the supply cord is damaged, it must be
replaced by the manufacturer, its service agent
or similarly qualied persons in order to avoid a
hazard.
EMPLOYER AND EMPLOYEE
RESPONSIBILITIES
The installation and maintenance of evaporative
coolers at height has the potential to create
Occupational Health and Safety issues for
those involved. Installers are advised to ensure
they are familiar with the relevant State and
Federal legislation, such as Acts, Regulations,
approved Codes of Practice and Australian
Standards, which o󰀨er practical guidance on
these health and safety issues. Compliance
with these regulations will require appropriate
work practices, equipment, training and
qualications of workers.
Seeley International provides the following
information as a guide to contractors and
employees to assist in minimising risk whilst
working at height.
INSTALLER AND MAINTENANCE
CONTRACTORS - RISK ASSESSMENT
A risk assessment of all hazardous tasks is
required under legislation. A risk assessment is
an essential element that should be conducted
before the commencement of work, to identify
and eliminate the risk of falls or to minimise
these risks by implementing control measures.
There is no need for this to be a complicated
process, it just is a matter of looking at the job
to be done and considering what action(s) are
necessary so the person doing the job does not
injure themselves.
This should be considered in terms of:
• What are the chances of an incident
happening?
• What could the possible consequence be?
• What can you do to reduce, or better still,
completely get rid of the risk?

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 5
SOME POINTS TO CONSIDER
• What is the best and safest access to the
roof and working areas?
• If a worker is alone, who knows they are
there and if they get into di󰀩culty, how can
they summon help?
• (Call someone on the ground? Mobile
phone? etc.)
• What condition is the roof in? Should the
trusses, underside or surface be checked?
• Does the worker have appropriate foot
wear? (Flat sole jogger type is advisable)
• Are all power cables / extension leads safe
and appropriately rated?
• Are all ladders, tools and equipment suitable
in good condition?
• Where ladders are to be used, is there a
rm, stable base for them to stand on?
Can they be tied or secured in some way
at the top? Is the top of the ladder clear of
electricity supply cables?
• Is there a roof anchor to attach a harness
and lanyard to? If so, instruction should be
issued for the use of an approved harness
or only suitably trained people used.
• Are all tools and materials being used,
prevented from slipping and falling onto a
person at ground level? Is the area below
the work area suitably protected to prevent
persons walking in this area?
• Does the work schedule take into account
weather conditions, allowing for work to be
suspended in high winds, thunder storms/
lightning or other types of weather giving
wet, slippery surfaces?
• Is there an on-going safety check system of
harnesses, ropes, ladders and access/lifting
equipment and where they exist on roofs,
anchor points before the commencement of
work?
• Is there a system which prevents employees
from working on roofs if they are unwell or
under the inuence of drugs or alcohol?
• Are there any special conditions to consider
i.e. excessive roof pitch, limited ground
area, fragile roof, electrical power lines?
OTHER IMPORTANT REQUIREMENTS
• Never force parts to t because all parts are
designed to t together easily without undue
force.
• Never drill holes in the tank of the cooler.
• Check the proposed cooler location, to
ensure that it is structurally capable of
supporting the weight of the cooler, or
provide an adequate alternate load bearing
structure.
• Ensure the installation complies with all
local and national regulations with regards
to electrical, plumbing and bushre
construction requirements.
MAINTENANCE NOTE
As with any product that has moving parts
or is subject to wear and tear, it is VERY
IMPORTANT that you maintain your cooler
and have it regularly serviced. It is a condition
of warranty cover for your cooler that you
comply with all of the maintenance and
service requirements set out in this Manual.
Compliance with these requirements will
prolong the life of your cooler. Further, it is also
a condition of warranty cover that each item
in the Maintenance Schedule in the Manual is
lled out (by signing and dating it in the places
indicated) when the item is completed.
Any failure to carry out the required
maintenance and servicing, and any failure to
ll out the maintenance schedule, will void your
warranty.
IMPORTANT SAFETY INSTRUCTIONS

6 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 7
COOLER CONTENTS
INSTALLATION COMPONENTS
OPTIONAL COMPONENTS
Item Description QTY
1Exhaust Fan/Motors 4
2Exhaust Weatherseal Top 4
3Exhaust Weatherseal Bottom 4
4Air Filters 16
5Air Filter Housings 16
6M8 Screw & Washers Assembly 48
Item Seeley Part Description
1121956 Multi-Magic Wall Control Kit
2121963 Multi-Magic Room Air Sensor Kit
3121932 Multi-Magic Ambient Air Sensor Kit
4121925 Multi-Magic Duct Air Sensor Kit
ILL3803-A
ILL3709-A
ILL3709-A
ITEM 1 ITEM 2
ITEM 3 ITEM 4
ILL3867-A
ILL3803-A
M8 SCREW
ASSEMBLY“A”
M8 SCREW
ASSEMBLY“B”
ILL2221-A
M8 FLAT
WASHER
M8 SPRING
WASHER
M8 SCREW
Due to transport height and width limitations, exhaust fan/
motors, exhaust weatherseals, and air lter assemblies are
shipped on a separate pallet for on-site installation.
For multi-cooler shipments, this pallet may be packed on a
separate transport.
ITEM 1
ITEM 2
ITEM 3
ILL3512-A
ITEM 4
ITEM 5
ITEM 6

8 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
COOLER VIEWS
TOP
SIDE
BACK FRONT

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 9
TECHNICAL DESCRIPTION
AIRFLOW
The cooler has 2 sets of fans
2x Supply Air Fans
4x Exhaust Air Fans
All the fans work together to draw hot outside air through the 16
side-mounted air lters, through the dry channels of the 16 air-
to-air indirect evaporative heat exchangers and into the middle
of cooler.
From inside the cooler, the air is split into an exhaust ow and a
supply ow.
The 4 exhaust air fans draw the exhaust air through the
wet channels of the 16 air-to-air indirect evaporative heat
exchangers, and out 4 the exhaust ports on top of the cooler
back to atmosphere.
The 2 supply fans draw the supply air into the supply air plenum
and, if tted, over a secondary direct evaporative cooling stage,
before entering the customer's ductwork..
HEAT EXCHANGERS
Indirect Evaporative Cooling (IEC)
The cooler has 16 air-to-air indirect evaporative heat
exchangers, composed of alternating dry and wet channels
separated by a membrane.
Through evaporation and conduction, heat is transferred from
the air in the dry channels, across the membrane, and into the
air in the wet channels.
The air in the dry channels is progressively cooled, but gains no
additional moisture.
Direct Evaporative Cooling (DEC)
Supercool coolers are tted with a secondary direct evaporative
cooling stage.
The cooled air from the IEC stage passes over saturated
Chillcel® media, where, through evaporation it is cooled further
with an increase in moisture content.
SUPPLY FANS
(2)
DEC STAGE
(SUPERCOOL
COOLERS)
EXHAUST FANS (4)
IEC HEAT
EXCHANGERS (16)
SUPPLY AIR
EXHAUST AIR EXHAUST AIR

10 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
TRANSPORT
SHIPPING CONTAINER
Remove the cooler from a shipping container by attaching a
chain to the integrated hook and pulling out with a fork-lift truck.
ILL2156-A



ILL2155-A
ILL2158-A
ILL2159-A
ILL2155-A
ILL2156-A
ILL2158-A
ILL2159-A
ILL2808-A
ROAD TRANSPORT
For road transport it is recommended to securely chain through
the front and rear fork-lift pockets
Use a fully enclosed curtain-sided truck or a heavy duty
tarpaulin to cover the open ports and protect the cooler surface
against transport damage.
As the cooler slides out, reposition the fork-lift truck and use
supporting timbers to ensure that the cooler does not drop onto
the ground.
Ensure that the cooler is dragged out parallel to the container
oor to ensure that damage to the top of the cooler does not
occur.
SUPPORTING
TIMBER
SUPPORTING
TIMBER
SUPPORTING
TIMBER

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 11
TRANSPORT
ILL2025-A
ILL2024-A
MOVING THE COOLER
The cooler can be moved by fork-lift truck using the inner pair of
fork-lift pockets.
LIFTING THE COOLER
The cooler may be lifted by crane with slings through the outer
fork-lift pockets.
Do not attempt to lift using any cabinet features or by retrotting
lifting lugs. The cabinet may be damaged and/or lift safety
compromised.
It is recommended to use a spreader bar on the straps or slings
and/or to protect the upper edges of the cooler with a corner
protector beneath the lifting straps to avoid any damage to the
cabinet during the lift.

12 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
ILL2209-A
CONCRETE SLAB
VIBRATION ISOLATION
A series of mounting holes are provided in the cooler chassis
base rails for use with vibration isolation mounts. Installers
should use a su󰀩cient number of suitably rated mounts to
support the operating mass of the cooler.
SUPPLY AIR DUCT CONNECTIONS
Vibration absorbing exible connections are recommended for
all duct connections to the cooler.
All ducts must be independently supported.
All duct direction changes must utilise a generous radial turn
with internal air directors to minimise turbulence and maximise
e󰀩ciency.
All ducts are to be suitably insulated to minimise temperature
losses.
INSTALLATION
COOLER LOCATION
Check the proposed cooler location to ensure that it is
structurally capable of supporting the weight of the cooler, or
provide an adequate alternate load bearing structure.
Model Operating Weight
CW-80 2700 kg / 4410 lb
CW-80S 2850 kg / 4630 lb
Always locate the cooler where it will receive a plentiful supply
of fresh air, NOT in a recess where it may be starved for air or
where the air is polluted. Provision must be made for access to
electricity, water supplies and drains.
Air exiting the exhaust outlets is warm and heavily laden with
moisture. Ensure the exhaust air will not cause corrosion or
damage to other nearby items. Do not allow exhaust air to re-
circulate into the air intake of the cooler.
Ensure that the location is a minimum of
• 3.0m (10’) from a solid fuel heater ue
• 1.5m (5’) from a gas ue
• 1.0m (3.5’) away from adjacent solar panels or similar roof
mounted xtures
• 6.0m (20’) from a sewer vent
• 3.0m (10’) (preferably 5.0m (17’)) away from any TV antenna
or antenna cables. Make sure the cooler is not between the
antenna and the transmission tower .
ACCESS FOR SERVICING AND
MAINTENANCE
The cooler should be installed in a position that allows adequate
access for installation, and future maintenance and servicing
activities. This should comply with installation guidelines and
any local, State and National regulations.
Consider the following for installation location:-
• Which has clear access to and around the cooler
• Which is clear of xtures in line with below clearances
• Which is clear of fall edges (> 3.0m (10') away)
• Which is structurally capable of supporting the weight of the
cooler and service technicians
Required clearances around the cooler for future maintenance
and servicing are shown below.
Extra service or warranty charges may apply for the cost of any
equipment or additional labour involved in accessing the cooler
if these guidelines are not met.
Note! Do you need to discuss the installation of items like
safety anchor points with the customer?

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 13
INTAKE AIR FILTERS
16 o󰀨 Air Filters and Air Filter Housings are supplied loose.
Remove the protective covers from the cooler's air intake ports.
Slip the Air Filter inside the Housing, take care to note the
airow direction arrow on the lter label.
ILL2030-B
INSTALLATION
ILL2212-A
ILL2212-A
TOP
MOUNTING
PLATE
TOP
FLANGE
FILTER
HOUSING
Push the bottom of the Filter Housing in against cooler and
then push down so that the anges on each side of the Filter
Housing are engaged behind the bottom mounting plates on
both sides.
ILL2213-A
ILL2214-A
ILL2213-A
ILL2214-A
FILTER
HOUSING
SIDE FLANGE
BOTTOM
MOUNTING
PLATE
With the Air Filter sitting inside, position top ange of the Filter
Housing behind the top mounting plate and push upwards.

14 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
INSTALLATION
EXHAUST WEATHERSEALS
Weatherseals shroud the exhaust fans, acting as a safety
device, preventing outside air from entering the cooler, and
ensuring exhaust air is directed away from the inlets.
Use 4 o󰀨 M8 Screw & Washer assemblies to fasten the.
"Weatherseal Top Assembly" to the "Weatherseal Bottom
Assembly".
ILL2302-A
WEATHERSEAL TOP
ASSEMBLY
WEATHERSEAL
BOTTOM ASSEMBLY
ILL2304-A
Position the complete weatherseal over exhaust fans and
secure with 4 o󰀨 M8 Screw & Washers assemblies
ILL2304-A
ILL2223-A
ILL2223-A
M8 SCREW &
WASHERS
EXHAUST FANS
4 o󰀨 Exhaust Fan/Motors are supplied loose. They are pre-
wired with power and control plugs.
IMPORTANT! Risk of injury. Ensure power to the cooler is
isolated before working with exhaust fans.
The power and control sockets are positioned inside the cooler
during shipment to avoid damage. To access, remove the
exhaust port protective covers, reach inside the cooler and push
through the grommets on the cooler lid.
ILL2296-B
EXHAUST
PORTS (4)
Lift the Exhaust Fans to the roof and orientate so that the plugs
are aligned correctly with the sockets.
IMPORTANT! Exhaust Fan/Motor weigh 23kg (50lb). Use
the appropriate mechanical aids and lifting technique to avoid
injury..
Connect plugs to sockets, taking special care that the key on
the plug aligns with the key slot on the socket.
ILL2222-A
M8 SCREW &
WASHERS
Use 4 o󰀨 M8 Screw & Washer assemblies to fasten each
Exhaust Fan to the cooler.
POWER & CONTROL
SOCKETS GROMMETS (16)
ILL2219-A
POWER
PLUG
POWER
SOCKET
CONTROL
PLUG
ILL2220-A
CONTROL
SOCKET

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 15
INSTALLATION
SUPERCOOL DRIP TRAY
Coolers tted with a Direct Evaporative Cooling (DEC) stage
have a drip tray on the supply outlet. The drip tray is locked in
the up position for transport and needs to be lowered before the
supply air duct is installed.
SUPERCOOL DRIP TRAY
Unscrew the M8 bolts at either end of the drip tray. Lower into
position and secure with the same M8 bolts

16 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
ELECTRICAL REQUIREMENTS
ELECTRICAL SUPPLY INSTALLATION
INSTALLATION OF THE COOLER MUST CONFORM
TO LOCAL ELECTRICAL RULES, REGULATIONS AND
STANDARDS.
It is a requirement of Seeley International that all coolers be
wired with a dedicated circuit and circuit breaker/fuse at the
distribution board.
A mains isolation switch, with all pole disconnection, shall be
furnished by the contractor and installed adjacent to the cooler.
IMPORTANT! There are specic models for regional voltages
and frequencies which are not interchangeable. Specically, the
fan motor(s), transformer(s) and pump(s) may be unique to the
voltage/frequency of supply.
See the cooler rating label for the correct electrical data. Before
connecting the device, make sure the power supply matches
the cooler voltage and frequency.
Electrical Supply Specication:
3~, 380-480V, 50/60Hz, 10kA SCCR
No Neutral is required
IEC Current Ratings (380V)
IEC Standard Fans 26A
Supercool Standard Fans 27A
IEC High Capacity Fans 29A
Supercool High Capacity Fans 30A
UL Current Ratings (440V)
IEC Standard Fans FLA 23A, MCA 24A, MOPD 25A
Supercool Standard Fans FLA 24A, MCA 25A, MOPD 25A
IEC High Capacity Fans FLA 25A, MCA 27A, MOPD 30A
Supercool High Capacity Fans FLA 26A, MCA 28A, MOPD 30A
Mains power terminals are provided inside the electrical cabinet
with gland plate provided for cable entry.
HIGH LEAKAGE CURRENT
IMPORTANT! High leakage current. Earth connection
essential before connecting supply.
The cooler utilises fan motors with built in inverter drives. To
comply with EMC regulations, these drives adopt EMC lters
that connect to the motor earth terminals. Across a total of
6 fan motors, the normal lter leakage current to earth may
accumulate to a total leakage current in excess of 10mA. . For
asymmetrical power systems or if a phase fails, the leakage
current can increase to a multiple of the nominal value.
To comply with regulations and to prevent electric shock, this
leakage current must be properly addressed.
In particular, both earth terminals (PE1 and PE2) at the mains
power point of connection must be properly connected and
earthed. Power must not be applied until this is correctly
completed.
Warning labels have been installed inside the electrical
enclosure door and adjacent to the incoming power cables.
ILL2867-A
3~ MAINS
TERMINALS
FIRE TERMINALS
A pair of terminals labelled "FIRE" are provided for integration
with a building re management system.
These terminals provide power to the controls PLC and are
supplied with a bridge.
To use with a building management system, remove the bridge
and connect the terminals through a NORMALLY CLOSED
relay which opens in a re event.
Interrupting power to the PLC will immediately stop all cooler
components, including fans.
RESIDUAL CURRENT CIRCUIT BREAKER
(RCCB)
The cooler utilises a fan motor with a built-in variable speed
drive (VSD). If local electrical standards require the use of a
residual current circuit breaker (RCCB), only AC/DC-sensitive
residual current devices (type B) are permissible. If incorrectly
selected and/or sized, when the cooler power supply is
switched on, pulsed charging currents from the capacitors in the
integrated EMC lter can lead to the instant tripping of RCCB.

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 17
WATER REQUIREMENTS
WATER SUPPLY INSTALLATION
The cooler requires a permanent water supply to be
connected. A built-in Inlet Solenoid Valve, controlled by the
water management system, allows water into the cooler when
required.
INSTALLATION OF THE WATER SUPPLY MUST CONFORM
TO LOCAL PLUMBING RULES, REGULATIONS AND
STANDARDS.
The following specications for water supply are required:
Water Connections:
3/4" BSP male connection supplied suitable for a compression
tting.
Water Supply:
100kPa (15psi) - 1000 kPa (145psi)
20 L/min (5.3 gal/min) MINIMUM
25 L/min (6.6 gal/min) RECOMMENDED
Water Supply Temperature:
40°C (105°F) MAXIMUM
Water Supply Salinity:
100 to 1150μS/cm
Important! Water supply pressures which are lower than
100kPa (15 PSI) may prevent the inlet solenoid valve from
opening.
Water pressures which are higher than 1600 kPa (230 PSI) and/
or water temperatures which are higher than 60ºC (140ºF) risk
inlet solenoid valve failure.
If the water pressure exceeds this maximum specication then
a pressure reducing valve is required and must be supplied and
tted by the Installer.
If a non-return valve is installed in the water supply line, it
is recommended that a suitable pressure relief valve is also
installed between the cooler and non-return valve to limit the
pressure rise associated with the heating e󰀨ects of ambient
temperature and solar radiation.
WATER SUPPLY ISOLATION
The cooler is provided with a manual 1/4 turn ball type shut o󰀨
valve. This allows the water supply to be isolated whenever
work needs to be done on the cooler.
In areas where temperatures can cause water supply pipes
to freeze, a drain down facility should be provided during the
installation. This drain down facility must be activated prior to
freezing conditions, to avoid possible damage to the cooler
components.
WATER SUPPLY FILTRATION
The cooler is provided with a an inlet water lter in the water
supply line to prevent any debris from entering and damaging
cooler components.
Important! Flush the water pipe to remove any contaminants
(swarf, lings or dirt) before nal tting. Contaminants can
lodge in the inlet solenoid valve, preventing it from functioning
correctly.
The cooler's water management system is designed to use
water that is suitable to be classied as ‘potable’ and t for
human consumption. If alternative water (including rain water) is
to be used that contains unusually high or low levels of salinity,
hardness, acidity or chemical contaminants, then additional
ltration or treatment systems should be employed to render the
water ‘potable’.
WATER HAMMER
Not all installation pipe work is the same, and some may require
additional prevention against water hammer.
If water hammer is a problem, it is the responsibility of the
Installer to t an appropriate water hammer arresting device
external to the cooler.
WATER DRAIN INSTALLATION
The cooler requires a permanent water drain to be connected.
A built-in Drain Valve, controlled by the water management
system, releases water from the cooler when required.
INSTALLATION OF THE WATER DRAIN MUST CONFORM
TO LOCAL PLUMBING RULES, REGULATIONS AND
STANDARDS.
Drain Connections:
50mm (2") Flexible Coupling
Drain Rate:
40 L/min (10.5 gal/min)
Important! Water drained from the drain valve is high in salinity
and must be carried away to a suitable discharge point on the
building or property. Never drain the water directly onto the roof
WATER INLET WATER DRAIN

18 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
WATER MANAGEMENT SYSTEM
The cooler contains multiple parts to supply, distribute and
manage the water needed for the heat exchangers.
Water Inlet Solenoid Valve
The inlet solenoid valve allows water into the water reservoir. It
is open during the following phases.
• Initial Tank Fill
Trigger: Entering IEC or DEC mode.
• IEC Tank Fill
Trigger: Indirect Watering Cycle = TANK FILL.
• DEC Only Tank Fill
Trigger: Low Probe = WET.
Once open, the inlet solenoid valve will remain open until the
water high probe has detected water for at least 30 seconds.
If the water drain valve is open, the inlet solenoid valve will
remain closed.
Indirect Pump Control (IEC Watering Cycle)
The indirect pump moves water from the reservoir to the 16
indirect heat exchangers. The heat exchangers are split into 4
groups of 4 and an indexing valve is used to sequentially water
each group in turn.
The indirect heat exchangers do not require continuous
watering and the pump runs on the following cycle
• Tank Level OK - Water lled to high probe and waiting for
next IEC pump cycle to start.
• Indirect Pump Running (60 seconds).
• Core Drain - IEC pump stopped and excess water is
draining back to the reservoir (15 seconds)
• Tank Fill - IEC pump stopped and inlet solenoid valve open
and re-lling to high probe (75 seconds)
Total IEC pump on time = 60 seconds
Total IEC pump o󰀨 time = 100 seconds
The indexing valve automatically rotates each time the indirect
pump starts.
COOLER CONTROL COMPONENTS
Direct Pump Control (Supercool coolers only)
The direct pump moves water from the reservoir to the Chillcel®
media. When running in DEC mode the direct pump runs
continuously. Excess water from the Chillcel® media drains
back to the reservoir.
Water Salinity Control
As water evaporates from the heat exchangers, the salinity of
the remaining water naturally increases.
The water management system uses the 3-pin water probe to
measure water conductivity as a proxy for salinity. The probe
can sense conductivity down to 9 µS (about 4ppm) .
Water conductivity is updated every time water reaches the high
probe and, when it exceeds the upper set point, a salinity drain
cycle will start.
Chlorinator Control
The chlorinator is a pair of specially treated plates. When
energised and submerged in water, electrical current ows
between them generating chlorine which is known to kill
bacteria in water supplies.
The chlorinator is active when the cooler is in IEC mode, AND
the water level is above the bottom probe AND the water
conductivity is >1500 µs/cm.
If the water conductivity remain <1500µs/cm for 24 hours a
clean tank drain cycle will start.
Water Tank (Reservoir) Drain Valve
The drain valve will automatically open when power is rst
applied to the cooler. It will close again when IEC or DEC mode
is enabled.
During a salinity drain cycle, the drain valve opens until the
water level falls below the low probe, then the drain valve
closes immediately, and inlet solenoid valve opens to rell the
reservoir with fresh water.
During a clean water drain cycle, the drain valve remains open
for 10 minutes, after which the inlet solenoid valve opens to rell
the reservoir with fresh water.
The drain valve will open if it has been 3 days since IEC or DEC
mode was last run.

CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B | 19
COOLER CONTROL COMPONENTS
CONTROL COMPONENTS
Cooler logic and controls are handled by a PLC in conjunction
with a Water Manager PCBA, both located in the controls
enclosure.
INPUT AND OUTPUT TERMINALS
A series of input and output terminals are located in the middle
of the controls enclosure.
See MULTI-MAGIC CONTROLS for terminal functions.
PLC
WATER
MANAGER
PCBA
INPUT & OUTPUT
TERMINALS

20 | CW-80 INSTALLATION, OPERATION & MAINTENANCE MANUAL 859723-B
MULTI-MAGIC CONTROLS
MULTI-MAGIC PLC
ILL3622-A
10
61
2
3
4
5
7
8
9
Item Description Item Description
1
UP – moves cursor up to next
variable or increase value in
edit mode
6 Green LED – Power Status
2
DOWN – moves cursor down to
next variable or decrease value
in edit mode
7
Red LED – Fault Status.
Number of ashes indicates
fault code
3RIGHT – opens the next page 8Yellow LED – Chlorinator
Status.
4LEFT – opens the previous
page 9
Green LED – Flashes if wall
control/MODBUS master is
connected
5 OK (ENTER) – select/edit value 10 USB Type A for USB memory
stick
ILL3622-A
Use the navigation LEFT/RIGHT buttons to switch between the
“CONTROL”, “MONITOR” and “SENSORS” screens.
To return to the previous menu screen long press the LEFT
button
CONTROL SCREEN
This screen allows the user to select the cooler's primary input
control method, including controlling the cooler manually from
the PLC.
For all PLC screens:
• Use the navigation UP/DOWN buttons to scroll through the
options
• Push the OK button to edit the option.
• Use the UP/DOWN buttons to change the value of the option.
• Push the OK button again to conrm the selection and exit
edit mode.
ILL3624-B
Item Description Item Description
1Message Bar. Shows current
cooler status. 5 PLC Software Revision
2
Selects Primary Input Control
Method;
W/C = Wall Controller
BMS = Low Voltage BMS
LCL = Local Control
MBS = High Level Modbus
4
Displays status of VENT mode
If Control Method = LCL; Sets
Vent Mode ON/OFF
When Vent mode is turned ON,
IEC and DEC will automatically
turn OFF.
3
Displays status of Indirect Cool
Stage
If Control Method = LCL; Sets
Indirect Cool Mode ON/OFF
5
Displays Fan Speed Output
0-100% (BMS / MBS)
Displays Fan Speed Output
0-10 (W/C)
If Control Method = LCL; Sets
Fan Speed 0-10
4
Displays status of Direct Cool
Stage
If Control Method = LCL; Sets
Direct Cool Mode ON/OFF
SUPERCOOL COOLERS
ONLY
6 Displays Fault Code number.
IMPORTANT! The cooler can only accept control inputs from
the one primary control method selected on the CONTROLS
screen.
Control outputs are available across all methods.
For example, when W/C is selected, the cooler will only accept
inputs (e.g. Fan Speed) from a Multi-Magic Wall Controller,
whereas outputs (e.g. Drain Valve status) can be read by a 3rd
party Modbus device.