Seeley Climate Wizard CW-6S Microcore User manual

INSTALLATION MANUAL
CW-6S Microcore Indirect Evaporative Cooler
Original English Instructions

i |

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 1
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS
Read And Save These Instructions For Future Reference. 2
Warning - To Reduce The Risk Of Fire, Electric Shock, Or Injury To Persons, Observe The Following: 2
For Australian Bushre Prone Areas 2
Employer And Employee Responsibilities 2
Installer And Maintenance Contractors - Risk Assessment 2
Some Points To Consider 2
Other Important Requirements 2
COOLER VIEWS 3
EXPLODED VIEW 4
COOLER CONTENTS 6
COOLER INSTALLATION COMPONENTS 6
INSTALLATION
On Arrival To Site 7
Cooler Method Of Installation 7
Assessment Of Roof Structure 7
Moving The Cooler 8
Access For Servicing And Maintenance 8
Cooler Location 8
Install The Heat/Cool Duct Switch 9
MagIQtouch Wall Controller 10
Combined Cooler And Heater With No Zones 10
Combined Cooler And Heater With A Common Zone And Up To 4 Zones 11
Combined Cooler And Heater With A Common Zone And Up To 10 Zones 12
Dropper Details 13
Preparing The Dropper And Transition 13
Mounting The Dropper Assembly 14
Flashing The Dropper 15
Preliminary Cable Installation 15
Weatherseal 16
Installing The Cooler 16
Lifting The Cooler 16
Crane Installation 17
ELECTRICAL REQUIREMENTS
Control Module Wiring Diagram 19
Field Wiring Diagram 19
WATER REQUIREMENTS 19
INSTALLING THE DRAIN VALVE 20
CONNECTION TO MAINS WATER 20
WATER HAMMER 20
MAINS CABLE CONNECTION 21
MAINS AND COMMUNICATION CABLE PATH 21
WALL CONTROL INSTALLATION
MagIQtouch Controller 22
Control System 22
Locating The Wall Control 22
Mounting The MagIQtouch Controller 22
CONTROL SCHEMES
Connecting The MagIQtouch / MagIQcool Controller 25
MagIQtouch Controller Operation 25
Building Management System (BMS) Interface (optional) 25
FAULT CODES INDICATED BY LED’s ON THE COOLER ELECTRONICS MODULE 26
COMMISSIONING COMPLETION CHECKLIST 27
ADJUSTING COOLER SETTINGS 28
TROUBLE SHOOTING 29
APPENDICES
Appendix – A Generic Structurally Engineered Roof Mounting Schemes: 30
Appendix – B ‘Piece By Piece’ Installation 37
NOTES 45
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.

2 |
IMPORTANT SAFETY INSTRUCTIONS
READ AND SAVE THESE INSTRUCTIONS FOR
FUTURE REFERENCE.
Means for all pole disconnection must be incorporated in the
xed wiring in accordance with the wiring rules.
If the supply cord is damaged, it must be replaced by the manu-
facturer, its service agent or similarly qualied persons in order
to avoid a hazard.
The following specications for the cooler water supply are
required:
Min Water Pressure 100kPa (15psi)
Max Water Pressure 800kPa (115psi)
New hose sets supplied with the appliance are to be used and
old hose-sets should not be re-used.
To x the cooler to its support:-
• screw the transition to the dropper
• level the dropper and screw to roof
• t 4 x T-washers into the transition
• place cooler onto dropper and secure with the 12 x 12g
screws supplied
Refer to installation section for details
WARNING - TO REDUCE THE RISK OF FIRE,
ELECTRIC SHOCK, OR INJURY TO PERSONS,
OBSERVE THE FOLLOWING:
a) Installation work and electrical wiring must be done by
qualied person(s) in accordance with all applicable codes
and standards, including re-rated construction.
b) When cutting or drilling into wall or ceiling, do not damage
electrical wiring and other hidden utilities.
c) Ducted fans must always be vented to the outdoors
d) Do Not Use This Fan With Any Solid-State Speed Control
Device.
FOR AUSTRALIAN BUSHFIRE PRONE
AREAS
WARNING If an evaporative cooler is installed in a BAL-12.5 to
29 area the evaporative cooler dropper duct and ashings shall
be adequately sealed at the roof to prevent gaps greater than
3mm. The dropper duct and ashings shall be non-combustible.
WARNING: This cooler is NOT APPROVED for installation
in any bushre zoned area/property (BAL-12.5 to BAL-FZ).
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?
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.

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 3
COOLER VIEWS
Dimensions are in mm (inches in brackets).
ILL2679-A
ILL2676-A
TOP ISO
ILL2680-A
ILL2677-A ILL2675-A
FRONT SIDE
SERVICES UNDERSIDE
1160mm
(45 1/2”)
1160mm
(45 1/2”)
1020mm
(40”)
ILL2678-A
(8.3”) (8.0”)
570 (22.4”)
(suits
530
(20.9”)
dropper)
(suits 530 (20.9”) dropper)
565 (22.2”)
Inlet
Inlet
Drain
Drain
CW Logo
location
(13.6”)
212
346
212
230 (9.0”)

4 |
EXPLODED VIEW
ILL2982-A
INDEX PART No. DESCRIPTION QTY
1 562162 TANK MICROCORE GREY 1
2 562391 CLIP SIDE PANEL CW-6S 8
3 562438 CLIP SIDE PANEL TOP CW-6S (4) 4
4 562179 PANEL SIDE MICROCORE GREY 1
5 855879 FILTER CARTRIDGE 25”x14”x1” 8
6 562063 LID GRILLE EXHAUST MICROCORE 1
7 562223 LID SCREW GRILLE MICROCORE 8
9 562322 SUPPLY DRAUGHT FLAP 2
10 122328 DROPPER TRANSITION ASSY CW-6S 1
11 639381 T-WASHER CW-6S 4
12 562032 PLENUM INNER CW-6S 1
13 834660 PLENUM OUTER MICROCORE 1
21 122175 MOTOR ASSY 1PH INVERTER DRIVE 1
22 122182 MOTOR ASSY 1PH INVERTER DRIVE 1
23 562308 RING MOTOR LOCK MICROCORE 1
24 562046 VENTURI SUPPLY MICROCORE 1
25 562094 FAN SUPPLY MICROCORE 1
26 562186 MOUNT MOTOR SUPPLY MICROCORE 1
27 562056 VENTURI EXHAUST MICROCORE 1
INDEX PART No. DESCRIPTION QTY
28 122342 FAN EXHAUST CW-6S 1
29 562476 CAP FAN CW-6S (2)
30 863832 PLUG VENTURI MICROCORE 1
31 863665 STRAPS RETENTION MANIFOLD 1
32 866512 CHLORINATOR LARGE ASSY 1
33 560294 COVER CHLORINATOR MOUNT (2) 1
34 560287 FITTING ELBOW AIR-BREAK CW-6S 16
36 804415L O’RING BS128 38ID*2.6 N70 M51 1
37 865607 SOLENOID VALVE 12V DC 1
39 815978 WASHER RUBBER LCQ KITS 1
40 833835 PROBE WATER 3PIN 1.76M 1
41 116130 PUMP 230/50 TWIN OUTLET 1500 2
42 562339 OUTLET TWIN TORNADO PUMP 1 per pump
43 562346 STRAINER TWIN OUTLET TORNADO
48 122311 DRAIN VALVE ASSY CW-6S 12V MFG 1
49 535401 ^NUT 1.5” BSP 1
53 117928 CONTROL ASSY CW-6S 1
57 935898 >PUCK/CAP/UMBREL PRESSURE 1

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 5
INDEX PART No. DESCRIPTION QTY
14 117935 MICROCORE DIRECT ENCAPSULATION 1
15 122151 ENCAPSULATION INDIRECT RIGHT 1
17 122366 SPREADER SUB ASSY DIRECT CW-6S 1
18 122144 SPREADER SUB ASSY INDIRECT 1
19 562124 SPREADER ELBOW CLIP MICROCORE 1
20 863208 O RING BS112 2
ILL2982-A
EXPLODED VIEW

6 |
COOLER CONTENTS
Item Part
No.
Illustration Description QTY
1094298 MagIQtouch Controller Kit 1
2833880 Control Cable 20m (65”) 1
3859747 Instruction - Installation 1
4859748 Instruction - Operation, Maintenance 1
5850764 Flexible Water Inlet Hose 1
6583020 Grommet for Dropper 1
7639381 T-Washer 4
8101713 Adapter Drain Fitting Assembly 1
9639391 Solenoid Cover 1
10 122328 Dropper Transition Assembly 1
11 875392 Dropper TEK Screw Fasteners
Screw TEK, Hex, Steel, 12 Gauge, 30-35mm x 14TPI,
(20 for dropper + 2 for solenoid cover)
22
ILL2554-A
COOLER INSTALLATION COMPONENTS
ILL3397-A

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 7
INSTALLATION
ON ARRIVAL TO SITE
The CW-6S cooler will be delivered on a dedicated pallet and
will be wrapped in plastic lm with timber and foam supporting
members.
The cooler will be accompanied by a packout kit box containing
control items and other components that are required for
installation.
ILL2772-A
To correctly unpackage the cooler, follow the instructions below:
1. Inspect for transport damage prior to unpacking.
2. Remove the plastic lm, white foam packing blocks and
pallet strapping. Dispose of responsibly.
3. Remove the top horizontal timber support members and
vertical timber support members. Dispose of responsibly.
4. Leave the base pallet and foam supporting blocks in
position in 4 places, as shown. These are required for
lifting.
5. Remove pad frames to access the BMS Module packed
inside the cooler.
ILL2773-A
COOLER METHOD OF INSTALLATION
There are two possible methods of installation for the CW-6S
cooler:
1. Installation via crane (preferred) – cooler is lifted from its
pallet on the ground and slung onto the dropper.
2. Piece by piece assembly – cooler is disassembled on the
ground and reassembled on the dropper.
The ideal method of installation will be specic to each
assignment. To determine which method is best suited to your
installation, be sure to consider regulations, location, access
points, potential obstacles and safety.
Discuss the possible options with the customer.
ASSESSMENT OF ROOF STRUCTURE
THE CW-6S COOLER REQUIRES AN ADEQUATE ROOF
STRUCTURE TO BEAR THE LOAD OF ITS OPERATING
WEIGHT. IT IS LIKELY THAT MOST RESIDENTIAL
STRUCTURES WILL REQUIRE REINFORCEMENT.
Engineering designs of roofs, including the supporting
structure and cladding, should take into account whether the
work practices necessary to carry out the installation and
maintenance of the roof can be carried out safely.
Model Shipping Weight Operating Weight
CW-6S 175 kg
(386 lb)
240 kg
(529 lb)
It is the installers responsibility to verify the integrity of the roof
structure as well as determine and implement an adequate load
bearing structure to which the dropper and cooler is xed. The
roof structure in question must be in good condition (i.e. no
worn members or pre-existing damage) and compliant with one
of the structurally engineered roof mounting schemes provided
(Refer below).
If these generic schemes are not applicable to the customer
installation, it is the installer’s responsibility to seek the services
of a structural engineer or certied builder to ensure that the
installation is adequate and complies with local and national
building codes. Installation on inadequate structures will void
the warranty and could result in death or serious injury. If the
installer has any doubt in regards to the structural integrity or
condition of the customer installation, then a structural engineer
or building certier must be consulted.
Note: 4th Foam Block position obscured in this view
The following generic structurally engineered roof mounting
schemes have been provided (Refer to Appendix A):
1. Pre-manufactured roof truss, interior walls (non-load-
bearing):
a. 600mm nominal truss spacing
b. 1200mm nominal truss spacing
2. Interior load-bearing walls

8 |
INSTALLATION
MOVING THE COOLER
The CW-6S cooler can be moved either by fork-truck or pallet-
truck whilst it is resting on its dedicated pallet. Do not drag or lift
the cooler unless it is on its dedicated pallet.
If the cooler has been unpackaged as per the instructions in the
‘On Arrival to Site’ section, then ensure that the foam supporting
blocks are in place and transport carefully.
COOLER LOCATION
Check proposed cooler location to ensure it is structurally
capable of supporting the weight of the cooler. If the roof is
structurally inadequate, provide an alternate load bearing
structure.
The ideal location for the cooler is in a central position on the
roof (away from sleeping areas and where people spend most
of their time) so that the duct runs are of approximately the
same length. Carefully consider neighbouring residences and
noise levels when locating the cooler, if necessary talk to the
customer and the neighbour before carrying out the installation.
Always locate the cooler where it will receive adequate fresh air
and not in a recess where it may be starved for air or where the
air is polluted.
Ensure location is a minimum of:
• 3m (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,
• 5m (17’) from a sewer vent, and
• 600mm (2’) from a wall.
ILL2970-A
ILL2962-A
Allow adequate access to and around the cooler for
maintenance. Provision must be made for access to electricity,
water supplies and drains.
Note! Do you need to discuss the installation of items like
safety anchor points with the customer?
• The cooler must be mounted at least 3m (10’) (preferably
5m (17’)) away from any TV antenna or antenna cables.
Make sure the cooler is not between the antenna and the
transmission tower that is providing the television signal to the
home.
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 (> 3m 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 adjacent.
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.
ILL2987-A

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 9
INSTALLATION
STEP 2 - WIRING CONNECTION
Wire as per schematic diagram.
Mount a mains power supply socket in close proximity to the
heater in the roof space as the damper control enclosure
requires its own separate 240V/50Hz supply.
IMPORTANT! Do not connect until installation is complete.
Wall Controller cable (20m) must plug into enclosure marked
“HEATER”. The 20m Cooler communication cable must plug
into the enclosure marked “COOLER”. Both cables are routed
through the Communication In/Out cable gland.
Connect damper control cable (not supplied) to the output
24VAC on the circuit board. Ensure the damper cable is
restrained using the cable tie provided, then route through the
Damper Out cable gland.
Use the supplied screws to attach the damper control inside the
roof space either onto the dropper, on a nearby joist or near the
heater unit The Heat Cool Duct Switch must be within 20m of
the heater unit, but not on top of the unit.
Plug in the Heat/Cool Duct Switch power cable.
The Heat/Cool Duct Switch KIT contains;
Control Enclosure Assembly (inc. Power Cable/Plug), 20m
Communication lead, Screws Enclosure Mount, Cable Ties.
NOTE: Dampers & damper control cables (24VAC) are not
supplied. Use ONLY Belimo LM24A; LM24A-T; or LM24A-90-T
damper models.
STEP 1 - ASSEMBLE THE HEAT/COOL SWITCH
ENCLOSURE
Open the enclosure and take note of output positions on the
circuit board for 24V damper wiring (not supplied).
ILL2991-A
INSTALL THE HEAT/COOL DUCT SWITCH
OPERATION
The Climate Wizard CW-6S is available as a Stand Alone
cooling solution or as a Dual System heating and cooling
package (CW-6S Dual System) when combined with a Braemar
Ducted Gas heater. If installing a Dual System, the Heat Cool
Duct Switch (HCDS) is required to allow the cooler and heater
to share the same set of ducts and room outlets.
The Heat/Cool Duct Switch (HCDS) interacts with the
MagIQtouch Wall Control, the CW-6S Cooler and the Ducted
Gas Heater ducting dampers in the Dual System. The HCDS
automatically responds to switch the appliance ducting dampers
open and closed according to the Wall Control setting. If
Heating is selected, the dampers isolate the Cooler from the
duct outlets. If Cooling is selected, the dampers isolate the
Heater from the duct outlets.
The HCDS can be tted to any installation using MagIQtouch
controls. It has a programmable period that delays the start of
the fan motor to allow time for the 24VAC dampers to open and/
or for residual heat to dissipate from the ducting.
ILL3129-A
When Cooler is ON
Dampers C & D Closed
Dampers A & B Open
When Heater is ON
Dampers A & B Closed
Dampers C & D Open
ILL3131-A

10 |
INSTALLATION
ILL2992-A
STEP 3 - COOLER, HEATER, HEAT COOL DUCT SWITCH
AND WALL CONTROL CONNECTION
Connect the 20m communication cables to the cooler control
and wall control as per below.
Damper Control output rating: 24VAC 1.6A.
If the supply cord is damaged, it must be replaced by a Seeley
service agent or similarly qualied person in order to avoid
hazard. Stranded conductors shall not be consolidated by lead-
tin soldering where they are subject to contact pressure, i.e
on terminal block. Interconnection cable to dampers shall use
cable that comply with the requirement of supply cord.
For 24VAC output use H05VV-F, 3 x 1.0mm cable only.
CAUTION: The wall controller CONTROL IN and cooler
CONTROL OUT connections are SELV circuits and shall only
be connected to the corresponding SELV circuits on the wall
controller and heater control.
Wall Controller Options
Option P/N Description Qty.
A 094298 MagIQtouch Wall Control 1
B 118369 MagIQtouch Wi-Fi Smart App Controller & 20m Cable 1
AB
OR
CONTROLLER
(CABLE VERSION)
20M
CONTROLLER
(CABLE VERSION)
MAGIQTOUCH WIFI
SMART APP CONTROLLER
20M 20M
AB
HEAT COOL
DUCT SWITCH
HEATER
DAMPERS
COOLER
DAMPERS
CW-6S
ILL3072-B
ILL3075-B
COMBINED COOLER AND HEATER WITH NO ZONES
Step 1 - Press ‘SETTINGS’ menu. If not displayed press
‘MORE’ to reveal the extra menu items.
MAGIQTOUCH WALL CONTROLLER
ILL2785-A
ILL1563-A
Step 2 - Select ‘COOLER’ tab and activate ‘DAMPER DELAY
MODULE’ button. Access code 7378 to activate.
ILL3022-A
Step 3 - Switch Damper Delay function to ‘ON’ and select time
for delay. ‘SAVE’ and exit when complete.
ILL3023-A

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 11
INSTALLATION
Major Appliances:
Appliance Included With Appliance Qty.
Gas Ducted Heater 20m Cable 1
Indirect Evaporative CW-6S Cooler 20m Cable 1
Wall Controller Options
Option P/N Description Qty.
A 094298 MagIQtouch Wall Control 1
B 118369 MagIQtouch Wi-Fi Smart App Controller & 20m Cable 1
ILL3074-B
20m
A
B
OR
CONTROLLER
(CABLE VERSION)
20M
CONTROLLER
(CABLE VERSION)
MAGIQTOUCH WIFI
SMART APP CONTROLLER
20M 20M
AB
HEAT COOL
DUCT SWITCH
HEATER
DAMPERS
COOLER
DAMPERS
CW -6S
ILL3074-A
COMBINED COOLER AND HEATER WITH A COMMON ZONE AND UP TO 4 ZONES
Additional Kits Required
P/N Description Cable
Inc. Qty.
094939 MagIQtouch Zone Control, Board Only (24V) 0.2m 1
094915 MagIQtouch Zone Control, in Enclosure (24V) 20m 2

12 |
INSTALLATION
COMBINED COOLER AND HEATER WITH A COMMON ZONE AND UP TO 10 ZONES
Major Appliances:
Appliance Included With Appliance Qty.
Gas Ducted Heater 20m Cable 1
Indirect Evaporative CW-6S Cooler 20m Cable 1
Wall Controller Options
Option P/N Description Qty.
A 094298 MagIQtouch Wall Control 1
B 118369 MagIQtouch Wi-Fi Smart App Controller & 20m Cable 1
Gas Ducted Heater (+ Optional Cooling)
ILL3075-B
20m
AB
OR
CONTROLLER
(CABLE VERSION)
20M
CONTROLLER
(CABLE VERSION)
MAGIQTOUCH WIFI
SMART APP CONTROLLER
20M 20M
AB
20m
HEATER
DAMPERS HEAT COOL
DUCT SWITCH
COOLER
DAMPERS
CW-6S
ILL3075-A
Additional Kits Required
P/N Description Cable
Inc. Qty.
094939 MagIQtouch Zone Control, Board Only (24V) 0.2m 1
094915 MagIQtouch Zone Control, in Enclosure (24V) 20m 2

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 13
INSTALLATION
DROPPER DETAILS
Cooler is supported by a 530 x 530mm (20 7/8” x 20 7/8”)
dropper with a minimum metal thickness of 1.0mm (20 gauge).
The dropper duct must have a raw edge or safe edge at the top.
Do not fold in a ange as this may interfere with the transition
and/or the Weatherseal
Refer to Appendix B for dropper dimensions and detail.
ILL2774-A
Cut a 50mm diameter cable exit hole in the dropper then t and
screw the cable grommet into position. Locate the hole so the
cables will not interfere with the operation of the Weatherseal.
ILL1646-A
PREPARING THE DROPPER AND TRANSITION
The cooler will be accompanied by a separate kit box containing
the dropper transition assembly, ttings and all associated
fasteners.
Begin by dismantling the dropper transition assembly on the
ground. For accessibility purposes, it is best to temporarily
remove the Weatherseal as shown.
ILL2775-A
Fit the transition onto the dropper as shown. Ensure that it is
orientated correctly, as shown by the engraved detail on the
transition.
Fix the transition to the dropper by drilling 6x of the supplied
dropper transition fasteners into the dropper. There are 2x
pilot holes on each side and a single hole on the front and rear
(centre) of the transition. The following fasteners may be used
as a secondary alternative or spare for securing the transition to
the dropper:
• Screw TEK, Hex, Steel, 12 Gauge, 30-35mm x 14TPI,
Category 3-5 (Depending on local regulations), Neoprene
seal.
ILL2776-A
Transport the transition and dropper assembly to the roof.
ILL2971-A

14 |
INSTALLATION
MOUNTING THE DROPPER ASSEMBLY
WARNING! The roof must have an adequate load bearing
structure that is su󰀩cient to bear the load of the cooler
along with any other dead/live loads (such as cladding
and personnel etc.) prior to mounting the dropper. Please
refer to the ‘Assessment of Roof Structure’ section. The
following instruction assumes an adequate roof structure
is in place.
A dropper height template has been provided to accurately set
the height of the dropper such that it is ideally positioned for
tment of the sloped tank and accessories pack. The template
is a 25mm x 25mm x 3mm piece of steel angle bar with length
of 750mm.
ILL2778-A
The following method of height-setting is only applicable
for roof angles between 15 and 30. Roof angles outside this
range of angles will need to be manually set for height via
another method.
Install back-ashing into the dropper roof opening. Place a thin
sheet of rigid material (i.e. ashing, sheet metal, MDF board or
similar) onto the rear of the roof opening as shown to stop the
height tool from falling into the crevices of the corrugated iron/
tiles and to prevent it making rubbing or scu󰀩ng marks on the
roof.
ILL2977-A
ILL2978-A
Once in place, begin lowering the dropper into the opening in
the orientation shown (this may require two personnel). Adjust
the position of the dropper such that the height tool rests on the
piece of rigid material.
Level the dropper, with a spirit level placed across the top of the
transition in both directions.
Once level, secure the dropper to the roof structure with a
preliminary fastener (these are not provided - use a regular
fastener i.e. a single nail or TEK screw) to assist with holding
the dropper in place. Recheck the position of the dropper using
the spirit level and the height template. Adjust the preliminary
fasteners if necessary.
Once level, begin properly securing the dropper to the roof
structure using roong screws. These are not provided.
DO NOT USE THE PROVIDED TEK SCREWS – THESE ARE
FOR USE ELSEWHERE.
Insert 5x fasteners per side to be spaced at 100mm intervals in
the centre of the timber support members. Refer to Appendix A.
Ensure the top of the dropper is level in both directions.
The installer must ensure the dropper is secured adequately
for wind conditions at the site. Additional restraints may be
required if the cooler is more than 200mm (8”) higher than the
roof timbers, or design wind velocity at the site exceeds 43m/s
(141fps). In very high wind areas or areas subject to hurricanes/
windstorms, or where the cooler is located more than 8m (26’)
above the ground, seek advice from a structural engineer.
Remove the height template by sliding it through the front
keyhole of the transition.
ILL2979-A
ILL2980-A
Insert the dropper height template into the keyed opening and
feed through until it sits ush against the opposite side of the
transition as shown. A section of the height template should
protrude from the rear of the dropper transition (high roof side).

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 15
PRELIMINARY CABLE INSTALLATION
Your installation kit includes a mains power cable and a control
cable. It also includes a Heat/Cool Duct Switch module which
requires a separate mains socket outlet. This outlet is best
located near the socket outlet supplying power to the installed
gas heater, as the Heat/Cool Duct Switch needs to be within 20
metres of the heater because of the communications cables.
For Australia Only
The control cable will be routed through the corner recess slot
in the transition (as shown below) by the installer.
This cable must be routed through this corner recess prior
to the cooler being mounted to the dropper.
ILL3116-A
ILL3029-A
INSTALLATION
Insert the four (4) T-Washers and push them down into the
transition piece as shown. The T-Washers should be facing
outwards and will be sitting inside the dropper.
MOUNTING THE DROPPER ASSEMBLY
ILL2782-A
ILL2783-A
FLASHING THE DROPPER
The dropper may now be ashed to the roof. Make sure there is
no chance of water entering the roof space.
IMPORTANT! Each T-Washer has three (3) holes in it. Once
in position, use each of the three holes in the T-Washers to
pre-drill three (3) pilot holes outwards through the dropper
that are 4mm in diameter. This must be completed before
lifting commences.
DO NOT DRILL ANY OF THE PROVIDED 12g TEK SCREWS
INTO THE DROPPER AT THIS STAGE – THESE ARE FOR
USE LATER IN THE INSTALLATION.
Pass the non-taped end of the control cable up into the dropper
duct, through the grommet. Pull the cable through and position
it in the transition slot where the sticker markers are. Leave
excess length of the cables (1.5m or 60” each) hanging out of
the roof dropper and not inside the dropper.
The socket end of the mains power cable must also be
installed. This is located (and restrained) within the tank of
the cooler. Pass the power socket end of the mains cable
through the rear access hole (RHS) in the tank and then pull
the remainder of unrestrained mains cable through such that it
protrudes out of the underside of the tank.
If installing manually, the mains power cable must be
installed BEFORE the cooler is secured to the dropper
Refer to appendix C (Steps 15-16). If installing by crane,
a section of the power cable must be routed through the
corner recess slot of the dropper transition whilst the
cooler is suspended above the dropper (Refer Step 8 of
installation).
To assist this process, bunch the loose power cable up and tape
it to an exterior panel on the side of the cooler for easy access
during installation. Do this whilst the cooler is on the ground.
Refer appendix C, steps 2 to 6.

16 |
INSTALLATION
For Rest of the World
Pass the taped end of the wall control cable through the main
conduit and leave 1.5m (60”) of cable hanging out of the top
of the conduit. A sticker will mark point on the cables. Take
the power cable and pass the non-plug end down through the
conduit. Be sure to leave at least 1.5m (60”) of power cable
length hanging out of the conduit also.
Important! Pass the wall control cable through the conduit
rst.
Terminate the power cable in a junction box installed nearby.
The xed wiring must be tted with an isolation switch that
breaks the active (hot) and neutral (common) in accordance
with local wiring rules. We recommend the junction box be
located and installed on the duct.
Do not penetrate the duct near the Weatherseal.
Note! The maximum length for the wall control cable to travel
alongside the power cable is 10m (33’).
WARNING! Do not let cables, cable ends, or the control box
get wet. Position the cables in the dropper so they will be
accessible from inside the roof space.
WEATHERSEAL
Reinstall the Weatherseal into the dropper as shown. Ensure
they open all the way and do not interfere with the dropper or
any screws.
The aps should move freely through 70º without interference.
ILL2964-A
Important! There must be no obstructions to the Weatherseal
opening fully as it will adversely a󰀨ect the performance of the
cooler.
ILL2983-A
INSTALLING THE COOLER
The following sections assume that all aforementioned roof
structure reinforcement and dropper mounting preparatory
work has been completed, transition/dropper holes for the
“T” washers have been pre-drilled and communication
cable is protruding from the dropper 1.5m (60”).
The ideal method of installation will be specic to each
assignment. To determine which method is best suited to
your installation, be sure to consider regulations, location,
access points, safety and potential obstacles. Discuss with the
customer.
LIFTING THE COOLER
The CW-6S cooler may be lifted by crane via slinging only.
Slinging points for lifting the cooler have been provided. It is the
responsibility of the rigger to determine the appropriate method
and equipment for lifting the cooler.
Before the load is lifted:
• Inspect the cooler to make sure it is in good condition (i.e.
outer surfaces are undamaged). Ensure all exterior panels
and clips are rmly in place. Contact the dealer if any exterior
components appear to be structurally damaged.
• Inspect the structural integrity of the foam support blocks
to ensure they are in good condition (i.e. not damaged or
crushed).
• Ensure the foam support blocks and cooler have not moved
from their dedicated positions in transit. To check this, make
sure the foam support blocks are rmly inserted upwards into
the female openings in the tank.
• Ensure the power cable socket outlet has been passed
through the rear access hole and is taped to an exterior panel
on the side of the cooler.
To correctly lift the CW-6S cooler:
1. Remove the top section of the shipping crate frame (Ref
Pg 8). Remove the 2x rear foam supporting blocks from
underneath the cooler. This will allow the cooler to rock
back and forth such that the slings can be placed.
2. Ensure the large foam supporting blocks are rmly inserted
into the female openings in the underbody of the tank.
This secures the foam supports to the tank for lifting and
provides retention channels for slings.
ILL3026-A
ILL2773-A

CW-6S INDIRECT COOLER INSTALLATION MANUAL | 17
CRANE INSTALLATION
Important! Two people are required to guide the cooler
onto the dropper.
Lifting the Cooler
1. Prepare the cooler for lifting as per the ‘Lifting the Cooler’
section.
2. Ensure that the transition has been secured to the dropper
as per the ‘Preparing the Dropper & Transition’ section.
3. Ensure that the dropper is mounted as per the ‘Mounting
the Dropper’ section.
4. IMPORTANT! Ensure that the control cable has been
installed as per the ‘Preliminary Cable Installation’ section.
5. Carefully lift the cooler to the dropper location.
Marrying the cooler and transition
6. Important! Position the cooler above the dropper and
stabilize. Carefully lower the cooler very slowly until it
sits approximately 100mm (4”) above the transition. Stop
lowering the cooler at this point.
7. Check the orientation of the cooler to make sure it is in the
correct position. As shown, the branding on the front of the
cooler should be positioned toward the front of the dropper.
8. When the cooler is suspended slightly above the dropper,
remove the tape restraining the power cable and allow it
to dangle loosely. Using the height template tool, guide
the mains power cable into the corner recess slot on the
transition and down into the dropper. CAUTION: Avoid
placing hands and body parts underneath the cooler
whilst it is suspended. Once this is complete, check to
make sure that the white dropper transition straps are
visible (as shown). These straps are ared outwards and
should be protruding out from the tank as shown. The
(black) foam packaging/sling guides beneath the tank have
been designed to guide the (white) transition straps into
their positions outside the dropper without fouling on the
transition.
ILL3028-A
ILL3030-A
ILL3036-B
INSTALLATION
3. Place the slings underneath the cooler and through the
dedicated recess channel in the foam supporting blocks
as shown. Rocking, lifting &/or blocking up the front of the
cooler will be required to pass slings beneath cooler while
it sits on the pallet. Consider using parts of the packaging
to aid with this process. Care must be taken not to damage
cooler tank. Ensure appropriately rated slings are used.
The slings must also comply with Australian (or local)
Standards. Suggested sling length is 6m (19’ 7”). Once
properly slung and fastened, the cooler is ready for lifting.
Suitability of the lifting method is the riggers responsibility.
ILL2785-A
DO NOT LIFT USING ANY CABINET FEATURES,
ALTERNATE SLING LOCATIONS OR BY RETRO-FITTING
LIFTING LUGS.
The cabinet may be damaged and/or lift safety may be
compromised.
DO NOT ATTEMPT TO LIFT THE COOLER WITHOUT THE
FOAM SUPPORTING BLOCKS.
The foam supporting blocks are essential for lifting. If they are
missing or damaged, contact the dealer and/or resort to the
‘piece-by-piece’ method of installation.
DO NOT ATTEMPT TO LIFT THE COOLER ON THE PALLET.
It is not possible to install the cooler via crane if the pallet is
used to sling the cooler.
ILL3027-A

18 |
INSTALLATION
9. Important! Stabilise the cooler to ensure that it is not
rocking around whilst suspended.
10. When the cooler is stable and in position carefully begin
lowering the cooler onto the transition. The dropper
transition straps should fall outside the edges of the
dropper and transition, but may need to be guided onto
the outside surface of the transition and the dropper when
the cooler is being lowered. Be extremely careful not to
damage the transition straps, communication or mains
cables during this process.
WARNING! BE EXTREMELY CAREFUL NOT TO TRAP
HANDS IN BETWEEN THE COOLER AND TRANSITION.
DO NOT USE YOUR HANDS TO GUIDE THE TRANSITION
STRAPS.
DO NOT POSITION ANY PART OF YOUR BODY
UNDERNEATH THE COOLER WHILE IT IS SUSPENDED BY
CRANE.
ILL2786-A
11. Once the cooler has been safely placed on the transition
piece, remove the crane slings and dispose of the foam
lifting blocks thoughtfully.
ILL3031-A
Securing to the dropper
12. Ensure cooler is not hung-up on the edge of the transition
anywhere. The cooler may need to be adjusted while
sitting on dropper to achieve this. Care must be taken in
maneuvering cooler not to dislodge unit or damage any
parts of cooler. Ensure the communications or mains cables
are not trapped or pinched between the dropper and tank.
Align the dropper transition straps with the pre-drilled holes
in the dropper/T-washers. Some transition straps may need
to be pulled down to meet with pilot holes in the dropper.
This can be achieved with a small screwdriver inserted into
strap holes.
13. Begin securing the cooler to the dropper using the
dropper transition fasteners provided. A total of 12x
screws are required. Only use the screws provided. If an
alternative screw is used, ensure it is the same length and
specication (as follows):
Screw TEK, Hex, Steel, 12 Gauge, 30-35mm x 14TPI,
Category 3-5 (Depending on local regulations), No seal.
Once the transition straps have been secured to the
dropper, the major cooler installation is complete.
CRANE INSTALLATION
ILL2787-A
IMPORTANT! If the pilot holes have not been drilled as per
the instruction on Page 16, abort the lift and ensure this
is completed now, before proceeding any further with the
installation.