Bonaire Integra & Summer Breeze Fresh Air Conditioning

1. Introduction

Please read this Installation Manual carefully. Failure to follow these instructions may result in injury or damage to the air conditioner or customer property. Installation must conform to local building rules, electrical and plumbing codes, Environmental Protection Authority (EPA) regulations, and applicable Australian Standards. Failure to comply may void the warranty.

Refer to the Commissioning Checklist to ensure all installation points are covered. A signed and dated checklist is required for certain warranty claims.

1.1. Important Notes

• TEXT AND ILLUSTRATION COPYRIGHT CLIMATE TECHNOLOGIES 2007. All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means without prior written permission from Climate Technologies.
• Climate Technologies reserves the right to change product features and specifications without notice.

1.2. Dealer / Installer Responsibility

1.2.1. Training

• Dealers must ensure their staff are adequately trained for correct product specification.
• Installation teams/sub-contractors must be trained in correct installation, duct & fittings, and relevant codes (including OH&S).
• Climate Technologies provides technical assistance and training; ongoing support is for trained dealers/installers.

1.2.2. Legal & Statutory Obligations

• Dealers/installers must comply with all codes, standards, statutory and legal requirements, and council by-laws.
• Compliance certificates for installation must be issued. Service may be refused or warranty void if installation is non-compliant.

1.2.3. Safety and O.H.&S. Requirements

• Installers must ensure the environment is safe. A risk assessment is required, following state codes of practice. An industry guide to "safe Work at Heights" is available from Climate Technologies.
• Safe access for service must be ensured, conforming to relevant standards and codes.
• Roof access footings and platforms must be provided where roof pitch is unsafe for service access.
• Harness anchorage points are required for units on roofs higher than a single story or where safe access is compromised by pitch or construction. Refer to Australian Standard 1891.4:2000 Part 4.

1.3. Before Commencing

• Check packaging for damage before removal. Do not install damaged units; contact Climate Technologies. Damaged products installed will not be covered by warranty.
• Verify all system components are present.
• Confirm the unit is the correct model.
• Ensure the system design conforms to minimum specifications and sound engineering practices.

2. Unit Location

2.1. Unit Location Check List

• EPA Compliance: Ensure the installed unit performs to specification regarding sound pressure radiated noise. Installers must make reasonable efforts to ensure operational noise does not affect neighbours, complying with EPA/council bylaws for noise abatement.
• Avoid mounting the unit on a section of roof that slopes towards a neighbour's property.
• Position the unit away from sources of smoke, dust, and fumes to draw in clean, fresh outside air. Refer to relevant gas codes and state plumbing regulations.
• Verify building members are structurally capable of supporting the unit's operating weight. Consult the roof truss manufacturer if necessary.
• The unit must be installed in a position providing safe access for service.
• Where roof height, pitch, or construction poses OH&S concerns, provide service footing supports, platforms, or harness anchorage.
• NOTE: The manufacturer and service providers reserve the right to refuse service if safety and accessibility are not guaranteed.
• The owner is responsible for providing any extra equipment needed for access for servicing or warranty repairs.

The unit should face the customer's back yard, positioned as low as possible on the roof with easy, unobstructed access. Keep the unit away from chimneys, flues, and vents that could pollute filter pads or the fresh air intake.

3. Unit Installation

3.1. Installing the Dropper Duct

All Bonaire Fresh Air Conditioners require support from a metal dropper duct. Metal dropper ducts must be designed, located, and fixed according to building codes. Plastic dropper ducts are not recommended.

Recommended Dropper Sizes

Dropper Duct Height - Roof

Follow these steps for dropper duct installation:

1. Use the recommended dropper duct size.
2. Install the dropper square and level.
3. Ensure it does not touch ceiling joists or other structural members that could transmit noise and vibration.
4. Ensure the dropper duct is installed so the unit does not touch the roof.
5. Fix the duct dropper securely and vibration-free to the roof structure.
6. Fit a splitter pyramid in the base of all droppers for correct airflow.
7. Flash and seal all ductwork, electrical cables, water pipes, and drains to prevent water entry.
8. Plastic dropper ducts must not be used as they may void the warranty.

3.2. Installing the Enviroseal Duct Shutter

Follow these steps for Enviroseal installation:

1. Install the Enviroseal duct shutter a minimum of 150mm below the top of the dropper duct. If the dropper duct has insulation, remove it to allow free shutter operation.
2. Secure the Enviroseal horizontally on both angles.
3. Ensure electrical cables are not draped over the Enviroseal mechanism.
4. Install the Enviroseal with the flaps opening downwards.

Refer to the Enviroseal kit for more details.

3.3. Installing the Air Conditioner

3.3.1. Louvre Panel Removal

Remove 4 Louvre panels from the unit and store them safely to prevent damage. To remove a Louvre:

1. Lift the Louvre assembly approximately 15mm over the corner post location.
2. Tilt the Louvre back from the top of the unit and remove.

3.3.2. Fan / Venturi Assembly Removal

The venturi/fan assembly can be removed to aid in carrying the unit on the roof. To remove it:

1. Disconnect the motor loom from the control box. Caution: Ensure motor wires are reconnected correctly to avoid voiding the warranty. The electrical control box and pump assembly can also be removed without disconnecting electrics.
2. Release the venturi from the location notches and lift vertically to remove the fan/venturi assembly (4 location notches hold it in place).
3. Carefully remove the fan from the cabinet, avoiding damage to the fan assembly.

NOTE: Handle the fan/venturi assembly with care, as the fan blade is unprotected once removed.

Store the fan/venturi assembly in a safe area, upside down (on the motor), until final installation to prevent damage. Warranty claims for damaged motors, impellers, or venturis will not be recognized if damaged during installation.

3.3.4. Unit Placement and Securing

• Lift the unit chassis onto the roof. When positioning the unit on the dropper duct, ensure the water reservoir is on the low roof side.
• Fit the unit level on the dropper duct for even water distribution.
• Check the unit is correctly located on the dropper duct, aligning with the appropriate chassis duct location points for the dropper duct size. The unit should be central.
• Fix the unit in position using self-tapping screws through the unit duct adaptor flange into the dropper duct. Use a minimum of 4 screws on each accessible side.

3.3.8. Fan Deck Reinstallation

Lift the fan deck onto the roof and reinstall it into the unit. Ensure the venturi is correctly rotated for the motor wiring loom and has snapped into place. Spin the fan blade by hand to confirm it does not touch the inlet ring.

3.3.9. Electrical Connections

• Reconnect the fan loom to the control box.
• Connect the 24-volt water solenoid cable to the control (if fitted).
• Connect communication cables to the control box.
• Feed the communication cable and the 240-volt plug/cable set through the 50mm electrical entry in the dropper duct. Use the supplied 50mm rubber grommet to seal the hole and prevent electrical hazards.
• Electrical leads must not be draped over the fan deck or loosely around the unit; they must be fastened securely.

3.4. Installing the Duct Work

• Use only insulated ductwork with a minimum thermal resistance of R0.6, designed and installed per 'BONRES' System Design guidelines.
• All bends must have a minimum radius of 1.5 times the duct diameter. All joins must be taped airtight.
• Flexible ductwork connected to the dropper duct must be designed and installed according to the 'BONRES' System Design Guide and industry best practices.
• Cut flexible duct to the correct length to avoid excess, ensuring minimum system resistance and maximum airflow.
• All ductwork should be streamlined, avoiding sharp angles that reduce airflow.
• The minimum bend radius is 1.5 times the duct diameter.
• The last bend to each ceiling register must be a smooth radius for even airflow into the room.
• Do not squash ductwork to fit through small openings; find a better location.
• If more than 6 metres of flexible ductwork are required in one length, use the next size up.
• All ductwork in ceiling spaces or hot areas must be well insulated.
• All external exposed ductwork must be weatherproofed.
• All ductwork must be taped airtight.

An illustration shows insulated ductwork with airtight joints and a diagram illustrating the minimum bend radius (1.5 x diameter) and the requirement for a smooth radius on the last bend to the ceiling register for even airflow.

4. Connections

All water connections must be performed by a licensed plumber, requiring a plumbing certificate of compliance. Correct water management is vital for the operation and longevity of the product. Incorrect water management settings, not adjusted for local water conditions, will void the warranty. The owner is responsible for maintaining correct water management.

4.1. Water Management

• Hard water is defined as 300 ppm or greater.
• Water bleed rates or dump cycle times must be set according to local supply water conditions to prevent scaling, ensure maximum cooling, filter pad life, and reduce maintenance.
• For high mineral content water (e.g., bore water), bleed-off is required with a timed dumping cycle.

4.2. Inlet Water

4.2.1. Fitting the Float Valve

1. Remove the nut from the float valve assembly.
2. Ensure the rubber washer is fitted inside the tank on the float valve. Fit the float valve assembly into the tank.
3. Fit the nut to the valve on the underside of the tank; do not overtighten.
4. NOTE: In low water pressure areas, the water flow restrictor may need removal. Minimum water pressure required is 100 kPa.
5. Fit the supplied elbow to the float valve.
6. Fit the 24-Volt AC water solenoid valve to the elbow.
7. Fit the flexible connector to the solenoid valve.

4.2.3. Connecting the Water Supply

• Water supply pipework and connection must be installed by a licensed plumber, conforming to AS 3500 and local plumbing regulations.
• Ensure water pressure does not exceed the maximum static pressure of 500kPa (50 m head) as per AS 3500 (section 3.3).
• Use a 1/2" BSP female flexible connection for the unit water connection.
• NOTE: In areas prone to freezing, a low-level drain tap or pressure expansion control valve is needed to drain piping and prevent damage. Advise the customer on its operation.
• Ensure the water supply pipe is the correct length and secured to prevent tension on fittings.
• The supply pipe should be 12mm copper or similar. Install a 1/4 turn ball isolating valve near the unit for maintenance. Do not use duo or non-return valves.
• NOTE: Non-return valves can affect solenoid valve operation, potentially causing lock-up and damage. They are not required if the product conforms to MP52 Spec 101:2001 Plumbing safety licence.
• Before connecting the supply pipe, flush it to remove swarf or debris that could cause leaks.
• NOTE: Failure of the solenoid valve or ball float due to debris is not covered by warranty and is the installer/owner's responsibility.

4.3. Water Drain Connections

4.3.1. Fitting The Overflow Assembly

The overflow fitting connection size is 50mm BSP.

1. Remove the nut and rubber washer from the overflow assembly.
2. Place the rubber washer inside the tank and fit the overflow assembly.
3. Fit the nut to the overflow fitting on the underside of the tank and tighten to ensure no leaks.

4.3.2. Fitting the Enviroflow Water Conservation System

(This does not replace the Overflow Fitting)

The Enviroflow system uses water pressure to close the dump valve, requiring a minimum of 100kPa to keep it closed.

1. Remove the nut from the dump valve.
2. Fit the dump valve into the 40mm hole in the tank and tighten the nut from the underside, ensuring no leaks.
3. Fit the 24-volt cable between the solenoid and the control box, routing it through the overflow fitting. Connections are not colour specific.
4. Fit the pressure hose between the solenoid valve and the top of the dump mechanism, routing it through the overflow fitting and trimming to length. Ensure all wiring and pressure hoses are installed professionally.

Diagrams show the dump valve, solenoid valve, connection cable, and water pressure pipe.

4.3.3. Drainage Provisions

The discharge pipe must have an internal diameter no less than the unit's connection provision. Fittings for the dump valve are provided in 40mm and 20mm sizes.

Diagrams provide guidance for permitted drain discharge methods in accordance with Plumbing Standards Regulations.

• Note: Discharge water management must comply with State and Local Government statutory requirements and by-laws.
• For water conservation, waste water can be stored for later use, such as watering plants.

Illustrations show various drainage options:

• Option 1: Discharge to a roof gutter pop outlet (downpipe not used for potable water).
• Option 2: Direct to downpipe via a tundish (downpipe not used for potable water), with a 25mm air gap.
• Option 3: To a surface stormwater drainage system, graded away from the building, ensuring no ponding and no safety risk to pedestrians.
• Option 4: To a sanitary drainage system via a tundish, either to a floor waste gully or direct to a sanitary drain, with appropriate air gaps and trapped waste pipes.
• Option 5: To an absorption pit in permeable ground, sized appropriately, and located to prevent moisture damage to buildings.
• Option 6: To a suitable water spreader on tiled roofs, designed to prevent spillage and not used on porous tiles, provided the roof is not used for potable water collection.

4.4. Electrical

4.4.1. Wiring – Important Notes

• A LICENSED ELECTRICIAN must perform all 240-volt connection wiring, ensuring compliance with AS3000 (Wiring rules) and local regulations. A compliance certificate is required for new connections.
• Climate Technologies recommends a dedicated circuit from the distribution board with a separate circuit breaker. This may be an electrical authority requirement or a precautionary measure.
• 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 do 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 within 600mm of the dropper duct.
• Drill a 50mm (2") hole in the dropper to bring the service lead and controller cable into the ceiling space. Use the supplied rubber grommet to seal the hole.
• Connect controller and solenoid cables to the control box (refer to control installation instructions).
• Plug the pre-wired service lead into the GPO.
• Secure electrical leads properly; do not drape them over the fan deck or loosely around the unit.

A diagram shows the 10 Amp GPO, 50mm hole with rubber grommet for electrical and communication cables, and a detailed wiring diagram for the unit's components (fan motor, pump, dump valve, etc.).

5. Commissioning

5.1. Water Levels

• Turn on the water supply and allow the unit to fill. The water level should be 65mm to 70mm from the top of the overflow pipe.
• If an Enviroflow Water Conservation System is fitted, turn the unit on and set the pre-cool function to activate the solenoid valve and check the float valve setting.
• Adjust the float valve arm carefully if factory settings require modification.
• 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 open to allow water flow to the distributor. Turn the knob counter-clockwise to increase water flow.
• If water lift-off occurs, adjust the flow rate by turning the knob counter-clockwise to reduce it.

5.2.2. Bleed-off Rate - Inner Knob

• Set the bleed rate after determining the flow rate.
• To set the bleed rate, hold the filter flow knob at its current setting while adjusting the bleed rate.
• All evaporative air conditioners require bleed-off to prevent mineral deposit build-up; the correct bleed rate setting is crucial for unit longevity.
• For normal town water, the bleed rate should discharge at least 10 litres per hour. Increased water hardness may require a higher bleed rate and more frequent maintenance.
• It is recommended to plumb the bleed-off hose through the overflow fitting to waste to prevent unsightly stains.
• NOTE: The installer/owner is responsible for setting and maintaining the correct bleed rate for local water conditions.

5.3. Dump Valve Settings

Correct water management is vital for operation and longevity. Incorrect settings void the warranty. The owner is responsible for maintaining correct water management.

• If a dump valve is fitted for timed dumping, bleed may not be necessary. Determine this by checking dissolved solids in the water supply. Dump valves are required for water hardness above 300ppm.
• Dump times are available on RF/LV Programmable and Touchpad controls (0, 1, 2, 4, 8, 12, 24 hours).
• If a dump valve is used only for dry sump when not in use, the bleed rate must be set for operating conditions.
• NOTE: The installer is responsible for setting the correct dumping period for local water conditions.

5.4. Fan Operation

• Run the fan and check it is clear of the venturi.
• Verify air distribution is even through the ductwork.
• Make adjustments to any manual air dampers as required.

5.5. Controls

Refer to your specific control installation and commissioning instructions.

5.6. Customer Hand Over

5.6.1. Instruct the customer on product use:

• Controls
• Bleed off
• Venting air away from the side of the home where wind is not blowing.
• Maintenance Requirements

5.6.2. Hand over the customer's operational manual.

5.7. Commissioning Check List

Complete, date, and sign the checklist in the owner's manual. Use this copy to verify installation before completing owner documentation.

• All ordered equipment is installed.
• The unit is level and secure.
• The water supply line is flushed and leak-free.
• The tank is free of foreign matter, and the water isolating tap is ON.
• Water drainpipe work is completed and sealed.
• The water basin fills correctly, and the float valve closes at the 65-70mm water level.
• The water pump operates correctly when turned ON at the controller.
• Dump valve cycle times and/or dialflow bleed rate are set for local water conditions.
• The Enviroflow Water Conservation System tank drains correctly when the unit turns off.
• The fan deck is correctly located, and the fan blade spins freely.
• Mains and control wiring are complete, and the circuit breaker and GPO are ON.
• The fan operates through the entire speed range.
• The minimum fan speed is correctly set.
• Water distribution is even with filter pads fitted and the unit operating.
• All controller functions operate correctly.

Ductwork and general

• Enviroseal functions correctly with shutters opening downwards at 90°.
• All roof penetrations are fully sealed and watertight.
• Ductwork is completed to plan, supported, and airtight, with bends not less than 1.5 x ductwork diameter.
• Air distribution is checked, dampers adjusted, and outlets cleaned.
• Manhole cover replaced.

Site

• All rubbish has been removed from inside and on the roof.

Customer Hand Over

• Explain the following to the customer:
• Operation of the Controller.
• The need to open windows/doors for correct Fresh Air Conditioning operation.
• Operation of the bleed or dumping system and its importance.
• Stick the Serial Number Label in the owner's manual.
• Maintenance requirements.

6. Service

Any service work on this ducted cooling product should be conducted by a qualified service technician. Periodical service ensures the product's efficiency benefits are maintained. Only an authorized Climate Technologies service provider can perform warranty service.