BONAIRE | VSS50 | Unit installation | BONAIRE VSS50 Unit installation

Bonaire Integra
Fresh Air Conditioning
Installation Instructions
VSS50, 55 VSM60, 65
VSL70, 75
Installation Instructions
Table of Contents
INTRODUCTION____________________________________________________ 3
Important Notes ____________________________________________________ 3
Dealer / Installer Responsibility ________________________________________ 3
Training ____________________________________________________________ 3
Legal & Statutory obligations ____________________________________________ 3
Safety and O.H.&S. Requirements________________________________________ 4
Before Commencing ________________________________________________ 4
UNIT LOCATION ___________________________________________________ 5
UNIT INSTALLATION ________________________________________________ 6
Installing the Dropper Duct ___________________________________________ 6
Installing the Enviroseal Duct Shutter ___________________________________ 7
Installing the Air Conditioner __________________________________________ 8
Installing the Duct Work _____________________________________________ 10
CONNECTIONS ___________________________________________________ 12
Water Management ________________________________________________ 12
Inlet Water _______________________________________________________ 12
Water Drain Connections____________________________________________ 13
Fitting the Float Valve_________________________________________________ 12
Connecting the Water Supply___________________________________________ 12
Fitting The Overflow Assembly__________________________________________ 13
Fitting the Enviroflow Water Conservation System___________________________ 14
Drainage provisions __________________________________________________ 14
Electrical ________________________________________________________ 18
Wiring – Important Notes ______________________________________________ 18
Wiring Connections __________________________________________________ 18
Wiring Diagram______________________________________________________ 19
COMMISSIONING _________________________________________________ 20
SERVICE (AUSTRALIA ONLY) ________________________________________ 23
Page 2
Installation Instructions
1.0 Introduction
Please take the time to fully read this Installation manual. Failure to follow these
instructions may result in injury to you and damage to the air conditioner or your
customer’s property.
Installation of this Bonaire Fresh Air Conditioner must conform to local building rules and
regulations, electrical and plumbing codes, Environmental Protection Authority (EPA)
regulations, and all applicable Australian Standards.
Should you not follow these instructions the unit warranty may be void. The cost of
warranty would then be the cost of the customer or the installer / dealer.
Refer to the tick box Commissioning Checklist to ensure you have covered all points
when the installation is complete. Please complete the Commissioning Checklist tick box
in the owner’s manual, as a completed. A signed and dated checklist will be required to
verify certain warranty claims.
1.1. Important Notes
All rights reserved. No part of this document may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including photocopying,
recording or by any information storage and retrieval system, without prior
permission in writing from Climate Technologies.
Climate Technologies is constantly researching and developing improved
product features and therefore reserves the right to change the
specifications without notice. E. & O.E.
1.2. Dealer / Installer Responsibility
1.2.1. Training
It is the responsibility of all dealers to ensure their staff are adequately
trained to ensure the product is correctly specified.
It is the responsibility of all dealers to ensure their installation teams / subcontractors are trained in the correct installation of product, duct& fittings
as well as relevant installation codes and OH&S requirements.
Climate Technologies will provide technical assistance and training to the
dealer as required. On going technical support will only be provided to
those dealers and installers who attend regular training provided by
Climate Technologies.
1.2.2. Legal & Statutory obligations
It is the dealer / installer responsibility to comply to all codes & standards,
statutory and legal requirements, state and council / shire by laws.
Relevant certificates of compliance for the installation must be issued.
Service may be refused or warranty may be void if the installation is not
Page 3
Installation Instructions
1.0 Introduction
1.2.3. Safety and O.H.&S. Requirements
It is the responsibility of the dealer / installer to insure the environment is
safe for the installer to carry out the installation. A risk assessment should
be carried out in conformance to state codes of practice. An industry guide
to “safe Work at Heights” is available from Climate Technologies.
It is the responsibility of the dealer / installer to ensure safe access to the
unit can be achieved for service and that the access conforms to the
relevant standards and codes.
It is the responsibility of the dealer / installer to ensure the roof is provided
with access footings and platform where the pitch of the roof is unsafe for
service access.
It is the responsibility of the dealer / installer to ensure harness anchorage
points are provided where units are located on a roof greater than single
story or if the pitch and roof construction do not allow safe access. See
Australian Standard 1891.4:2000 Part 4 Selection use and maintenance,
Table 2.1.
1.3. Before Commencing
Packaging – check there is no damage before removing packaging. Damaged
units should not be installed. Climate Technologies should be contacted prior to
Do not install damaged products. Contact your nearest Climate Technologies
office for further advice.
Installed damaged products will not be covered by warranty.
Have you got all the system components?
Have you got the right unit?
Does the system design conform to the minimum specification of Bonres
specification and as such fall in line with sound engineering design practices.
Page 4
Installation Instructions
2.0 Unit Location
2.1 Unit Location Check List
EPA - A correct installed unit will perform to specification on sound pressure
radiated noise. As an installer, you have a professional obligation to ensure that
every practical and reasonable effort is made to install this product to best
practice guidelines and ensures that any operational noise does not affect
neighbours. Complying with EPA / council bylaws for noise abatement is the
responsibility of the dealer / installer / owner.
Do not mount the unit on a section of roof that slopes towards a
neighbour’s property.
Place the unit well away from sources of smoke, dust and objectionable fumes so
that only clean, fresh outside air will be drawn into the unit. Reference should be
made to relevant gas codes and state plumbing regulations.
Check the proposed location to ensure that building members are structurally
capable of supporting the operating weight of the air conditioner. You may need
to consult the roof truss manufacturer.
The unit must be installed in a position that gives safe access for service. It is
the responsibility of the dealer / installer to ensure safe access to the unit can be
obtained for servicing the product.
Where roof height, pitch or construction will cause OH&S concerns as previously
mentioned, service footing supports / platform and or harness anchorage must
be provided for safe service.
NOTE: The manufacturer and its service providers reserve the right to
refuse service unless safety and accessibility to the unit can be
The providing of any extra equipment required to give access to the unit for
servicing or warranty repairs is the responsibility of the owner.
The unit should face into the customer’s back yard, as low as possible on the roof, with easy,
unobstructed access. Keep the unit away from chimneys, flues and vents that will pollute the
filter pads and the fresh air being drawn into the house.
Page 5
Installation Instructions
3.0 Unit Installation
3.1. Installing the Dropper Duct
All Bonaire Fresh Air Conditioners are designed to be fully supported by a metal
dropper duct. Metal dropper ducts must be designed, located and fixed to comply to
the relevant building codes. Plastic dropper ducts are not recommended for use.
Recommended Dropper Sizes
Dropper Duct Size
550mm x 550mm
550mm x 800mm
Dropper Duct Height - Roof
Roof Pitch
Clearance Height
165 mm
195 mm
3.1.1. Use the recommended dropper duct as advised above.
3.1.2. The dropper must be installed square and level.
3.1.3. It should not touch ceiling joists or other structural members that allow noise
and vibration to be transmitted into the building.
3.1.4. Ensure the dropper duct is installed so the unit does not touch the roof.
3.1.5. Fix the duct dropper to the roof structure so that it’s secure and vibration free.
3.1.6. All droppers must be fitted with a splitter pyramid in the base to ensure correct
3.1.7. All ductwork, electrical cables, water pipes and drains must be fully flashed
and sealed to prevent the entry of water into the building.
3.1.8. Plastic dropper ducts should not be used as these may void warranty.
Page 6
Installation Instructions
3.0 Unit Installation
3.2. Installing the Enviroseal Duct Shutter
Step 1
The Enviroseal duct shutter must be
installed a minimum of 150mm below the
top of the dropper duct. If the dropper duct
is fitted with insulation, remove insulation to
give the shutter free operation.
Step 2
Ensure the Enviroseal is secured
horizontally on both angles.
Step 3
Ensure electrical cables are not draped
across the top of the Enviroseal
Step 4
Ensure the Enviroseal is installed the correct way up. The Enviroseal flaps
must open downwards.
For more details refer to instructions in the Enviroseal kit.
Page 7
Installation Instructions
3.0 Unit Installation
3.3. Installing the Air Conditioner
3.3.1. Remove 4 Louvre panels from unit and place in a safe place to ensure no
damage. To remove Louvre:
STEP 1. Lift the Louvre assembly up approximately 15mm over the corner
post location.
STEP 2. Tilt the Louvre back from the top of unit and remove.
3.3.2. The venturi / fan assembly can be removed to assist in carrying the unit on the
roof. To remove the fan / venturi assembly:-
STEP 1. Disconnect the motor loom from the control box in unit.
Caution: Ensure motor wires are reconnected correctly otherwise
the product warranty may be void.
It is also possible to remove the electrical control box and
pump assembly to avoid disconnecting the electrics.
STEP 2. Remove fan / venturi assembly by releasing the venturi from the
location notches lifting vertically. (There are 4 location notches holding the
venturi in place.)
STEP 3. Carefully remove fan from the cabinet, not bumping the fan
Page 8
Installation Instructions
3.0 Unit Installation
NOTE: Handle the fan/venturi assembly with care, as the fan blade is
not protected by the venturi once removed.
3.3.3. Store the fan / venturi assembly in a
safe area until final installation to
ensure no damage. Store the fan
upside down (on the motor) ensuring
no damage to the fan assembly. (Do
not store in the gutter.)
NOTE: Warranty claims for damaged motors, impellers or venturis will
not be recognised if the motor / venturi has been damaged during
3.3.4. Lift unit chassis onto the roof. When locating the unit onto the dropper duct,
ensure the water reservoir is on the low roof side of the dropper duct.
3.3.5. Fit the unit level on the dropper duct to ensure even water distribution.
3.3.6. Check the unit is located correctly on the dropper duct. Locate the unit on the
correct chassis duct location points for the appropriate dropper duct size. The
unit should be central on the dropper duct.
3.3.7. Fix the unit into position with self-tapping type screws by screwing through the
unit duct adaptor flange and into the dropper duct. A minimum of 4 screws
should be used on each accessible side of the unit.
Page 9
Installation Instructions
3.0 Unit Installation
3.3.8. Lift the fan deck onto the roof and reinstall into the unit. Ensure the venturi is
correctly rotated for the motor wiring loom and has snapped into the location
notches. Spin fan blade by hand to ensure that the blade does not touch the
inlet ring.
3.3.9. Reconnect the fan loom to the control box.
3.3.10. Connect the 24-volt water solenoid cable to the control (where fitted).
3.3.11. Connect communication cables to the control box
3.3.12. Feed the communication cable and the 240-volt plug and cable set through
the 50mm electrical entry drilled into the dropper duct. Ensure the 50mm
rubber grommet supplied is used to ensure an electrical hazard is not created.
3.4. Installing the Duct Work
3.4.1. Use only insulated ductwork to a thermal resistance of
insulation minimum of R0.6, designed and installed to
‘BONRES’ System Design guidelines. All bends must have a
minimum radius of 1.5 times the diameter. All joins must be
taped airtight.
3.4.2. Flexible ductwork connected to the dropper duct must be designed and
installed to the ‘BONRES’ System Design Guide in conjunction with industry
based best guidelines.
3.4.3. Cut flexible duct to the correct length to ensure no excess duct is left in the
system. This will insure minimum system resistance and maximum air flow.
3.4.4. All duct work should be streamlined. Avoid sharp angles that will reduce
3.4.5. The minimum bend radius is 1.5 times the duct diameter
3.4.6. The last bend to each ceiling register must be a smooth radius so that airflow
is even into the room.
3.4.7. Do not squash duct work to fit through small openings, as airflow will be
restricted. Find a better location.
3.4.8. If more than 6 metres of flexible duct work are required in one length, the next
size up flexible duct must be used.
3.4.9. All duct work in ceiling spaces or hot areas must be well insulated.
3.4.10. All external exposed duct work must be weatherproofed.
3.4.11. All duct work must be taped airtight.
Page 10
Installation Instructions
3.0 Unit Installation
The last bend to each ceiling register must be a smooth radius
so that airflow is even into the room
Page 11
Installation Instructions
4.0 Connections
All water connections must be carried out by a licensed plumber. A plumbing certificate of
compliance is required.
Correct water management in an evaporative air conditioner is vitally important to the
operation and longevity of the product. If the water management is not set correctly by the
installer to the local water condition, warranty will be void. Maintaining correct water
management is the responsibility of the owner of this appliance and warranty will also be
void if correct settings are not maintained.
4.1. Water Management
The definition of hard water is 300 ppm or greater.
Water bleed rates or the dump cycle times must be set to a rate
appropriate to the local supply water conditions. No scaling should be
evident where the dump cycle / bleed rates are set correctly. This will
ensure maximum cooling and filter pad life, reduced opportunity for scaling
and therefore less regular maintenance.
Where water quality is of high mineral content e.g. bore
water, bleed off will be required in conjunction with a regular timed
dumping cycle.
4.2. Inlet Water
4.2.1. Fitting the Float Valve
STEP 1. Remove nut from float valve assembly.
STEP 2. Ensure rubber washer is fitted inside the tank
on the float valve. Fit float valve assembly in
STEP 3. Fit the nut to the valve on the underside of
the tank. Do not over tighten.
NOTE: In areas of low water pressure it
may be necessary to remove the water
flow restrictor from the inside of the
valve. Minimum water pressure required
to operating the float valve is 100 kpa.
STEP 4. Fit elbow supplied to the float valve.
STEP 5. Fit the 24-Volt AC water solenoid valve to the elbow.
STEP 6. Fit Flexible Connector to solenoid valve
4.2.3. Connecting the Water Supply
The water supply pipe work and connection to the air conditioner must be
installed by a licensed plumber and conform to AS 3500, state & local
plumbing regulations.
Ensure water pressure to the appliance does not exceed the maximum
static pressure of 500kPa (50 m head) as per AS 3500 (section 3.3)
Page 12
Installation Instructions
4.0 Connections
Unit water connection a ½” BSP female flexible connection. Use the
flexible connector supplied for the connection between the isolating cock
and the solenoid / float valve.
In areas where water pipes freeze, a low level drain tap or
pressure expansion control valve provision will be needed to drain
the water piping to prevent damage to the air conditioner. The
customer should also be advised on its operation by the dealer /
Ensure the approved water supply pipe is of the correct length and is
secured to prevent tension on the solenoid / float valve fittings.
The supply pipe should be 12mm copper pipe or similar approved. A ¼
turn ball isolating valve must be installed on the supply pipe near the unit
for ease of maintenance. Do not use duo or non-return valves of any kind
including stop taps with jumper washer.
NOTE: Non return type valves can have an effect on the operation of
the water solenoid valves. Lock up and damage can be caused. Non
return valves are not required as the product conforms to MP52 Spec
101:2001 Plumbing safety licence.
Before connecting the supply pipe flush
it of any swarf or debris that may cause
the float valve or solenoid to leak.
NOTE: Failure of the Solenoid valve
or Ball Float due to debris or swarf
will not be covered by warranty and
is therefore the responsibility of the
installer / owner.
4.3. Water Drain Connections
4.3.1. Fitting The Overflow Assembly
The overflow fitting connection size is 50mm BSP.
STEP 1. Remove nut and rubber washer from
over flow assembly.
STEP 2. Place rubber washer inside the tank and
fit overflow assembly.
STEP 3. Fit the nut to the overflow fitting on the
underside of the tank and tighten
ensuring no leaks.
Page 13
Installation Instructions
4.0 Connections
4.3.2. Fitting the Enviroflow Water Conservation System
– (This does not replace the Overflow Fitting)
The Enviroflow water conservation system uses water pressure to close the
dump valve. There is a requirement for a minimum of 100kpa water pressure
to maintain the dump valve mechanism closed.
STEP 1 Remove nut from the dump valve.
STEP 2 Fit the dump valve into the 40mm hole in the tank and tighten nut
from the underside of the tank ensuring no leaks.
STEP 3 Fit the 24-volt cable between the
solenoid and the control box
routing it through the overflow
fitting. Connections are not
colour specific.
STEP 4 Fit pressure hose between the
solenoid valve and the top of the
dump mechanism routing it
through the over flow fitting and
trim to length. Fit all wiring
pressure hose in a professional
4.3.3. Drainage provisions
The discharge pipe must have an internal diameter of no less than the internal
diameter of the unit connection provision supplied by the manufacturer.
Provided is both a 40mm and a 20mm fitting for the dump valve
The following diagrams are typical and provide guidance for evaporative
cooler installers on the permitted ways to discharge the drains from
evaporative coolers in accordance with the Plumbing Standards Regulations.
Note: Discharge water must be managed in accordance with State and
Local Government statutory requirements and local by laws.
For water conservation purposes, the waste water from the evaporative unit
could be stored and used at a later date and used for watering pot plants.
Page 14
Installation Instructions
4.0 Connections
OPTION 1. A discharge point to a
roof gutter pop outlet,
providing the downpipe
is not used for the
collection of water for
potable use.
OPTION 2. Direct to downpipe via
a tundish, providing
the downpipe is not
used for the collection
of water for potable
OPTION 3. A surface stormwater drainage
system. Provided the surface is
graded away from the building
and ponding does not occur,
and the discharge does not
present a safety risk to
pedestrians (eg. across a
Page 15
Installation Instructions
4.0 Connections
OPTION 4. A sanitary drainage system via a tundish in one of the following
forms in accordance with AS/NZS 3500.2.2 - 1996 clause
& 11.22.
ii) To a floor waste gully
iii) Direct to sanitary drain
Page 16
Installation Instructions
4.0 Connections
OPTION 5. An absorption pit. Provided the following conditions can be met:
Only permitted where no sanitary or surface water drainage is
The pit can only be constructed in permeable ground
Of a size appropriate for the volume of discharge
Located so the discharge water will not cause damage to
buildings by changing moisture conditions.
OPTION 6. To a suitable water spreader.
Tiled roofs only
Spreader design should be such that water will not spill over the
Providing the roof is not
used for the collection of
water for potable use.
Spreaders should not be
used on tiles that are
Page 17
Installation Instructions
4.0 Connections
4.4. Electrical
4.4.1. Wiring – Important Notes
A LICENSED ELECTRICIAN must carry out 240-volt connection
wiring to the unit. It is the responsibility of the LICENSED
ELECTRICIAN that the unit is connected as per AS3000 (Wiring rules)
and any local regulations and statutory or legal requirements. A
compliance certificate is required for any new electrical connections.
It is the recommendation of Climate Technologies that a dedicated
circuit be fitted from the distribution board with a separate circuit
breaker. This may be an electrical authority requirement in some
states, and is precautionary in other states for future additions where
an existing circuit is used.
Do not use an extension cord to reach the GPO. This is illegal and
unsafe. An Electrician must relocate the GPO if the plug and cable
does not reach.
4.4.2. Wiring Connections
Have a licensed Electrician install a dedicated circuit from the distribution
board with a separate circuit breaker and a 10 Amp GPO (generalpurpose outlet) within 600mm of the dropper duct.
Page 18
Installation Instructions
4.0 Connections
Drill a 50mm (2”) hole in the dropper to bring the service lead and
controller cable into the ceiling space. The rubber grommet fitted to the
service lead is used to seal the hole in the dropper from the inside.
Connect the controller and solenoid cables into the control box. Refer to
Controller installation and commissioning instructions
Plug the pre-wired service lead into the GPO.
Electrical leads must not be draped over the fan deck or loosely
around the unit and must be fastened securely.
4.4.3. Wiring Diagram
Page 19
Installation Instructions
5.0 Commissioning
5.1. Water Levels
5.1.1. Turn water on to unit and allow unit to fill. The water should be 65mm to
70mm from the top of the overflow.
5.1.2. If a Enviroflow Water Conservation System is fitted, turn the unit on and set
the pre-cool function. This will activate the solenoid valve and allow time to
check the float valve setting.
5.1.3. Adjusting the float valve arm: while the float valve arm is factory set some
adjustment may be required. Adjust with care.
5.1.4. Fit Louvre panels and check for even wetting of the filter medium.
5.2. Dialflow Settings
5.2.1. Filter Rate – Outer Knob
Ensure the filter knob is opened
to get water flow to the
distributor. Turn Filter anti
clockwise to increase water flow.
If water lift off is noticed, the flow
rate can be adjusted. Turn anti
clockwise to reduce the flow to
the distributor.
5.2.2. Bleed-off Rate – Inner Knob
Always set the bleed rate after the
flow rate has been determined.
To set the bleed rate, hold the filter
flow knob at its current setting while
adjusting the bleed rate.
All evaporative air conditioners need some water bleed-off to prevent build-up
of mineral deposits in the system. The correct setting of the bleed rate will
ultimately govern the life of the unit.
Page 20
Installation Instructions
5.0 Commissioning
With normal town water supply, bleed rate should be adjusted so that the
discharge is not less than 10 litres per hour. Increased water hardness may
require a higher bleed rate and increased maintenance.
It is recommended to plumb the bleed off hose through the overflow fitting and
to waste as the discharge may cause unsightly stains.
NOTE: It is the responsibility of the installer / owner to set a correct bleed
rate to suit local water conditions and ensure that rate is maintained.
5.3. Dump Valve Settings
Correct water management in an evaporative air conditioner is vitally important to
the operation and longevity of the product. If the water management is not set
correctly by the installer to the local water condition, warranty will be void.
Maintaining correct water management is the responsibility of the owner of this
appliance and warranty will also be void if correct settings are not maintained.
Where a dump valve is fitted and is set up for regular timed dumping periods
during operation, the bleed may not need to be set. Check the level of
dissolved solids in the water supply to make this determination. Dump valves
are required where water hardness is greater than 300ppm.
Dump times available on RF / LV Programmable and the Touchpad controls.
Dump cycle times available are 0, 1, 2, 4, 8, 12 and 24 hour.
Where a dump valve is only used for the purpose of a dry sump when not in
use, the bleed rate will have to be set for the conditions of operation.
NOTE: It is the responsibility of the installer to set the correct dumping
period to suit local water conditions.
5.4. Fan Operation
Set the fan running and check the fan is clear of the venturi.
Check that the air is being evenly distributed through the ductwork.
Make adjustments, as required, to any manual air dampers that may be fitted.
5.5. Controls
• Refer to your control installation and commissioning instructions.
5.6. Customer hand Over
5.6.1. Instruct the customer in the use of the product.
Bleed off
Venting the air via the side of the home the wind is not blowing from.
Maintenance Requirements
5.6.2. Hand over of the customer’s operational manual.
Page 21
Installation Instructions
5.0 Commissioning
5.7. Commissioning Check List
You must complete, date and sign the ‘tick box’ checklist in the owner’s
manual. Use this copy to check the installation prior to completing the
owner’s documentation.
All equipment ordered by the customer is installed.
The unit is level and secure.
The tank is free of foreign matter and debris and the water isolating tap
is turned ON.
Water drainpipe work is completed and sealed.
The water basin fills with water and the float valve closes correctly when
the water level is 65-70mm below the overflow level.
The water pump operates correctly when turned ON at the controller.
The dump valve cycle times and / or dialflow water bleed rate are set to
suit local water conditions.
The Enviroflow Water Conservation System. The tank drains correctly
when unit turns off.
The fan deck is correctly located and the fan blade spins freely.
The mains and control wiring are complete and the circuit breaker and
GPO are turned ON.
The fan operates through the entire speed range.
The minimum fan speed is correctly set.
The water supply line has been flushed to clear swarf and debris and is
free of leaks.
Water distribution is even with the filter pads fitted and the air
conditioner operating pump and fan.
All Controller functions for the appliance operate.
Page 22
Installation Instructions
5.0 Commissioning
Ductwork and general
The Enviroseal functions correctly with the shutters opening downwards
at 90°
All roof penetrations are fully sealed and watertight.
All ductwork is completed to plan, correctly supported and airtight, with
no bend less than 1.5 x the ductwork diameter.
Air distribution checked, dampers are adjusted and all outlets correctly
adjusted and wiped clean.
Man hole cover replaced.
All rubbish has been removed from inside and on the roof.
Customer Hand Over
You have explained the following to the customer.
The operation of the Controller.
The need to open windows and doors for the correct operation of Fresh
Air Conditioning
The operation of the bleed or dumping system and it’s importance to
operate all the time
Stick the Serial Number Label of the unit in the owners manual
Maintenance requirements
6.0 Service
A qualified service technician should conduct any service work carried out on this ducted
cooling product. It is important that periodical service is carried out on the product to
ensure the customer receives the efficiency benefits the product provides.
Only an authorised Climate Technologies service provider can carry out warranty service.
Page 23
Manufactured by
Climate Technologies
ABN 13 001 418 042
26 Nylex Avenue
Salisbury, SA 5108
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