TECHNICAL MANUAL

888-2625-002
HE-II Pump Module

HE-II Pump Module

(Closed Loop)
Harris Broadcast

T.M. No. 888-2625-002 10 Apr 2013

© Copyright Harris Broadcast 2012 Revision A
All rights reserved
 Technical Assistance
Technical and troubleshooting assistance for Harris Broadcast products is available from Harris
Broadcast Field Service (factory location: Quincy, Illinois, USA) during normal business hours
(8:00 AM - 5:00 PM Central Time). Telephone +1-217-222-8200 to contact the Field Service
Department; FAX +1-217-221-7086; or E-mail questions to [email protected].
Emergency service is available 24 hours a day, seven days a week, by telephone only. 
Online assistance, including technical manuals, white papers, software downloads, and service
bulletins, are available at http://www.broadcast.harris.com (from there, click on Customer Support
Portal under the Services & Support tab drop down menu).
Address written correspondence to Field Service Department, Harris Broadcast, P.O. Box 4290,
Quincy, Illinois 62305-4290, USA. For other global service contact information, please visit: http://
www.broadcast.harris.com/contact.
NOTE: For all service and parts correspondence, you will need to provide the Sales Order number,
as well as the Serial Number for the transmitter or part in question. For future reference, record those
numbers here: ___________________/____________________
Please provide these numbers for any written request, or have these numbers ready in the event you
choose to call regarding any Service, or Parts requests. For warranty claims it will be required, and
for out of warranty products, this will help us to best identify what specific hardware was shipped.

Replaceable Parts Service

Replacement parts are available from Harris Broadcast Service Parts Department 7:00 AM to 7:00
PM Central Time, Monday through Friday, and 8:00 AM to 1:00 PM Central Time on Saturday.
Telephone +1-217-222-8200 or email [email protected] to contact the Service Parts
Dept. 
Emergency replacement parts are available by telephone only, 24 hours a day, seven days a week
by calling +1-217-222-8200.

Unpacking
Carefully unpack the equipment and perform a visual inspection to determine if any apparent
damage was incurred during shipment. Retain the shipping materials until it has been verified that all
equipment has been received undamaged. Locate and retain all PACKING CHECK LISTs. Use the
PACKING CHECK LIST to help locate and identify any components or assemblies which are
removed for shipping and must be reinstalled. Also remove any shipping supports, straps, and
packing materials prior to initial turn on.

Returns And Exchanges

No equipment can be returned unless written approval and a Return Authorization is received from
Harris Broadcast. Special shipping instructions and coding will be provided to assure proper
handling. Complete details regarding circumstances and reasons for return are to be included in the
request for return. Custom equipment or special order equipment is not returnable. In those instances
where return or exchange of equipment is at the request of the customer, or convenience of the
customer, a restocking fee will be charged. All returns will be sent freight prepaid and properly
insured by the customer. When communicating with Harris Broadcast, specify the Harris Order
Number or Invoice Number.

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 Manual Revision History

HE-II Pump Module

REV. DATE ECN Pages Affected

A 10Apr2013 P54855 Release

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 Guide to Using Harris Broadcast Parts List Information
The Harris Broadcast Replaceable Parts List Index portrays a tree structure with the major items being left most
in the index. The example below shows the Transmitter as the highest item in the tree structure. If you were to
look at the bill of materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the
Output Cabinet. In the Replaceable Parts List Index the Control Cabinet, PA Cabinet, and Output Cabinet show
up one indentation level below the Transmitter and implies that they are used in the Transmitter. The Controller
Board is indented one level below the Control Cabinet so it will show up in the bill of material for the Control
Cabinet. The tree structure of this same index is shown to the right of the table and shows indentation level
versus tree structure level.
Example of Replaceable Parts List Index and equivalent tree structure:

Replaceable Parts List Index Part Number Page

Transmitter
Table 7-1. Transmitter 994 9283 001 7-2 994 9283 001
Table 7-2. Control Cabinet 992 9244 002 7-3
Table 7-3. Controller Board 992 8344 002 7-6 Control Cabinet PA Cabinet Output Cabinet
Table 7-4. PA Cabinet 992 9400 002 7-7 992 9244 002 992 9400 002 992 9450 001
Table 7-5. PA Amplifier 994 7894 002 7-9
Table 7-6. PA Amplifier Board 992 7904 002 7-10 Controller Board PA Amplifier
Table 7-7. Output Cabinet 992 9450 001 7-12 992 8344 002 992 7894 002

PA Amplifier Board
992 7904 002
The part number of the item is shown to the right of the description as is the page in the manual where the bill for
that part number starts. Inside the actual tables, four main headings are used:
• Table #-#. ITEM NAME - HARRIS PART NUMBER - this line gives the information that corresponds
to the
• Replaceable Parts List Index entry;
• HARRIS P/N column gives the ten digit Harris part number (usually in ascending order);
• DESCRIPTION column gives a 25 character or less description of the part number;
• REF. SYMBOLS/EXPLANATIONS column 1) gives the Ref Des for the item (i.e., C001, R102, etc.)
that corresponds to the number found in the schematics (C001 in a bill of material is equivalent to C1 on
the schematic) or 2) gives added information or further explanation (i.e., “Used for 208V operation
only,” or “Used for HT 10LS only,” etc.).

Inside the individual tables some standard conventions are used:

• A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS col-
umn means that this item is used on or with C001 and is not the actual part number for C001.
• In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has pur-
chased and has not manufactured or modified. If the last three numbers are other than 000, the item is
either manufactured by Harris or is purchased from a vendor and modified for use in the Harris product.
• The first three digits of the ten digit part number tell which family the part number belongs to - for
example, all electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic
(can) capacitor is found to have a 9xx xxxx xxx part number (a number outside of the normal family of
numbers), it has probably been modified in some manner at the Harris factory and will therefore show
up farther down into the individual parts list (because each table is normally sorted in ascending order).
Most Harris made or modified assemblies will have 9xx xxxx xxx numbers associated with them.
The term “SEE HIGHER LEVEL BILL” in the description column implies that the reference designated part
number will show up in a bill that is higher in the tree structure. This is often the case for components
that may be frequency determinant or voltage determinant and are called out in a higher level bill
structure that is more customer dependent than the bill at a lower level.

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 Harris Broadcast Phone: 217-222-8200
PO Box 4290 PARTS ORDER FORM FAX: 217-221-7096
3200 Wismann Lane 62305 Shipping Information
Billing Information
Ship To (If different from billing information):
Customer Name: ________________________
________________________________
Address: ________________________________
Address: ________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Telephone: ______________________________
Telephone: ______________________________
FAX: ______________________________
FAX: ______________________________
Preferred
Preferred
Payment Method : ________________________
Shipping Method : ________________________
Frequency & Channel: ______________________
Guide for Ordering Parts: Please provide as much information as possible to facilitate part
Equipment Part Number:____________________ substitution as required. Equipment name, part number and serial number is found on a metal
ID plate on the rear of the unit. Describe the unit using the parts list if possible. Include
Equipment Serial Number:___________________ schematic information, schematic number, or number of next higher assembly. The next higher
assembly usually has a part number that begins with a 9xx-xxxx-xxx.
Item Used On -
Description of Part - Ref Des Assembly if Known e.g.
Part’s Name, Description, and e.g. C21, C21 used on 992-8025-001
Item Quantity Part Number Specification from Parts List R100, etc. & Schematic 839-8038-991 Comments
 ! WARNING:
THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS.
PERSONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUC-
TIONS AND REGULATIONS.

This manual is intended as a general guide for trained and qualified personnel who are aware
of the dangers inherent in handling potentially hazardous electrical/electronic circuits. It is not
intended to contain a complete statement of all safety precautions which should be observed
by personnel in using this or other electronic equipment.

The installation, operation, maintenance and service of this equipment involves risks both to
personnel and equipment, and must be performed only by qualified personnel exercising due
care. Harris Broadcast shall not be responsible for injury or damage resulting from improper
procedures or from the use of improperly trained or inexperienced personnel performing such
tasks. During installation and operation of this equipment, local building codes and fire
protection standards must be observed.

The following National Fire Protection Association (NFPA) standards are recommended as
reference:
- Automatic Fire Detectors, No. 72E
- Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10
- Halogenated Fire Extinguishing Agent Systems, No. 12A

! WARNING:
ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLO-
SURES, GATES, PANELS OR SHIELDS. ALWAYS USE GROUNDING STICKS
AND SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE
INTERNAL ADJUSTMENTS, PERFORM MAINTENANCE OR SERVICE WHEN
ALONE OR WHEN FATIGUED.

Do not remove, short-circuit or tamper with interlock switches on access covers, doors,
enclosures, gates, panels or shields. Keep away from live circuits, know your equipment and
don’t take chances.

! WARNING:
IN CASE OF EMERGENCY ENSURE THAT POWER HAS BEEN DISCONNECTED.

! WARNING:
IF OIL FILLED OR ELECTROLYTIC CAPACITORS ARE UTILIZED IN YOUR
EQUIPMENT, AND IF A LEAK OR BULGE IS APPARENT ON THE CAPACITOR
CASE WHEN THE UNIT IS OPENED FOR SERVICE OR MAINTENANCE, ALLOW
THE UNIT TO COOL DOWN BEFORE ATTEMPTING TO REMOVE THE DEFEC-
TIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR
WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSE-
QUENT INJURY.
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viii 888-2625-002 5/10/13
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 FIRST-AID

Personnel engaged in the installation, operation, maintenance or servicing of this equipment

are urged to become familiar with first-aid theory and practices. The following information is
not intended to be complete first-aid procedures, it is a brief and is only to be used as a
reference. It is the duty of all personnel using the equipment to be prepared to give adequate
Emergency First Aid and there by prevent avoidable loss of life.

Treatment of Electrical Burns

1. Extensive burned and broken skin

a. Cover area with clean sheet or cloth. (Cleanest available cloth
article.)
b. Do not break blisters, remove tissue, remove adhered particles of
clothing, or apply any salve or ointment.
c. Treat victim for shock as required.
d. Arrange transportation to a hospital as quickly as possible.
e. If arms or legs are affected keep them elevated.

NOTE:
If medical help will not be available within an hour and the victim is conscious and
not vomiting, give him a weak solution of salt and soda: 1 level teaspoonful of salt
and 1/2 level teaspoonful of baking soda to each quart of water (neither hot or
cold). Allow victim to sip slowly about 4 ounces (a half of glass) over a period of
15 minutes. Discontinue fluid if vomiting occurs. (Do not give alcohol.)

2. Less severe burns - (1st & 2nd degree)

a. Apply cool (not ice cold) compresses using the cleanest available
cloth article.
b. Do not break blisters, remove tissue, remove adhered particles of
clothing, or apply salve or ointment.
c. Apply clean dry dressing if necessary.
d. Treat victim for shock as required.
e. Arrange transportation to a hospital as quickly as possible.
f. If arms or legs are affected keep them elevated.

REFERENCE:
ILLINOIS HEART ASSOCIATION
AMERICAN RED CROSS STANDARD FIRST AID AND PERSONAL SAFETY
MANUAL (SECOND EDITION)

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 Table of Contents

Section 1 - Introduction Section 5 -

Purpose of This Manual . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance & Alignments
General Description. . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transmitter Cooling System . . . . . . . . . . . . . . . 1-3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Cooling System Control Panel. . . . . . . . . . . . . 1-3 Miscellaneous Maintenance . . . . . . . . . . . . . . . . . .5-1
Pump Module. . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Cooling System Checks . . . . . . . . . . . . . . . . . . . .5-1
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Heat Exchanger Cleaning . . . . . . . . . . . . . . . . .5-1
PA Modules & Combiner Cold Plates . . . . . . . 1-5 Alternate Pumps. . . . . . . . . . . . . . . . . . . . . . . . .5-1
Glycol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Pump Module Strainer Cleaning . . . . . . . . . . . .5-1
General Specifications. . . . . . . . . . . . . . . . . . . . . . 1-5 Coolant Level Management: . . . . . . . . . . . . . . .5-3
Cooling System Maintenance Notes . . . . . . . . .5-3
Pump Module Operation Without Transmitter .5-4
Section 2 - Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section 6 - Diagnostics
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Pump Module Drawings. . . . . . . . . . . . . . . . . . . 2-1
Operating Environment and Placement. . . . . . . . . 2-1
AC Mains Requirements . . . . . . . . . . . . . . . . . . . . 2-2 Section 7 - Parts List
Surge Suppression Devices. . . . . . . . . . . . . . . . . 2-2
Ground Requirements. . . . . . . . . . . . . . . . . . . . . 2-3
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . 2-3
Charging Closed Loop Cooling Systems . . . . . . . 2-7
Charging Systems with Circulating Pump . . . . . . 2-9

Section 3 - Operation
Inverter Setup and Operation . . . . . . . . . . . . . . . . 3-1
Inverter Pre-programming . . . . . . . . . . . . . . . . . 3-1
Verify F700 Setting & Run Command. . . . . . . 3-2
Inverter Programming. . . . . . . . . . . . . . . . . . . . . 3-3
Identifying Parameter Type:. . . . . . . . . . . . . . . 3-3
Changing Basic Parameters . . . . . . . . . . . . . . . 3-3
Changing Extended Parameters: . . . . . . . . . . . 3-3
Clearing Inverter Memory . . . . . . . . . . . . . . . . . 3-4
Manual Fan Control . . . . . . . . . . . . . . . . . . . . . . 3-4
Adding Dip Switch Settings . . . . . . . . . . . . . . . . 3-5

Section 4 - Theory of Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Speed Of Electric Induction Motors . . . . . . . . . . . 4-1
Using An Inverter To Control Motor Speed . . . . . 4-2
Inverter Operated Pump and Cooler Modules . . 4-4

1
Table of Contents (Continued)

2
HE-II Pump Module

Section 1 - Introduction
1
1.1 Purpose of This Manual
This technical manual contains the information pertaining to the Harris HE-II Pump
Modules with part number 995-0333-004.
• Section 1, Introduction, provides general manual layout, equipment description,
block diagram and general specifications.
• Section 2, Installation/Initial Turn-On, provides physical and electrical installation
procedures for the pump module.
• Section 3, Operation, provides operational instructions for inverters.
• Section 4, Theory of Operation, provides detailed theory of operation for the pump
module and sub assemblies.
• Section 5, Maintenance and Alignments, provides preventative and corrective main-
tenance information and applicable field alignment procedures.
• Section 6, Diagnostics, provides detailed fault information and diagnostic proce-
dures.
• Section 7, Parts List, provides pump module replacement parts lists.

1.2 General Description

This section contains specifications, component locations and a general description of the
Harris HE-II Pump Module.

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Section 1 - Introduction HE-II Pump Module

Figure 1-1 Harris HE-II Pump Module - Isometric & Front Views

Figure 1-2 HE-II Pump Module - Rear & Left Views

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HE-II Pump Module Section 1 - Introduction

1.2.1 Transmitter Cooling System

Liquid cooled broadcast transmitters typically use 50/50 glycol/distilled water coolant to
move heat away from the transmitter. They may also use cabinet air flushing fans to
remove residual cabinet heat. A simplified block diagram of a typical liquid cooling
system is shown in Figure 1-3. The cooling system components normally consists of:
a. Pump Module/Cooling System Control Panel
b. Plumbing (hose or copper tube)
c. Heat Exchanger
d. Transmitter PA Modules and Combiner Cold Plates

Figure 1-3 Transmitter Liquid Cooling System

1.2.1.1 Cooling System Control Panel

The cooling system control panel is used to control the pump module and heat exchanger.
It also serves as the interface to the transmitter control system. The cooling system control
panel connects to the transmitter for monitoring/control and supplies AC to the heat
exchanger fans.
The control panel, shown in Figure 1-4, has local inverter controls on the front which
allow setup and activation of pump A and B and heat exchanger fans A and B.
It also contains the following controls and indicators:
• Pump A Inverter control
• Pump B Inverter control
• Fan A Inverter control
• Fan B Inverter control
• REMOTE/LOCAL Switch

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Section 1 - Introduction HE-II Pump Module

• Pump B ON/OFF Switch

• Pump A ON/OFF Switch
• Circuit Breakers: Inverters, Pump A & B and Fans A & B

Figure 1-4 Cooling System Control Panel

Status indications may also be sent to the transmitter for display or for use in remote
control operation.
When in Remote mode, the transmitter is responsible for control of the cooling system,
including ON/OFF, manual pump selection and automatic pump switching in the case of a
failure. Placing the control panel in Local mode allows manual switching of the pumps
using the pump ON/OFF switches on the cooling control panel.
The lower half of the control panel contains AC breakers for the pumps, fans and
inverters. The pump module should be installed with a customer supplied AC disconnect
that can be used to remove all AC power from the pump module. The control panel is an
integral part of the pump module assembly (see Figure 1-1) and normally installed within
view of the transmitter (usually next to the transmitter disconnect panel).

1.2.1.2 Pump Module

The pump module, shown in Figure 1-1, is a self-contained unit with integrated expansion
tank, pressure gauges, temperature sensor, inlet strainer and dual pumps (operating in
main/standby mode). The pump module is designed for indoor mounting. The pump
module can be configured for single phase 208-240VAC, three phase 208-240VAC, or
three phase 380-415VAC operation.

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HE-II Pump Module Section 1 - Introduction

1.2.1.3 Heat Exchanger

The heat exchanger, which is typically installed outside, contains 2 fans. The fans are
enabled when the pump module is under transmitter control. A thermistor (temperature
sensor) in the outlet side of the pump module controls the speed of both fans. See 4.3.1 for
additional information on fan control.
There are several heat exchanger models available with cooling capacities that vary from
12 -50 kW depending on model. Heat exchangers can be mounted vertically or
horizontally depending on model and configuration of mounting legs.

1.2.1.4 PA Modules & Combiner Cold Plates

Each transmitter PA module has an integrated liquid cooled cold plate which connects to
the cooling system with quick release connectors. There ay also be cold plates inside the
combiners or splitters to which internal combiner reject loads are attached.

1.2.1.5 Glycol
Depending on application either ethylene or propylene glycol are suitable for use in the
HE-II pump module. Harris recommends a 50/50 mixture of glycol and distilled water for
normal operation. Follow all local and national regulations regarding use and disposal of
glycol. For additional information on glycol products refer to www.dowtherm.com or
www.dowfrost.com.

1.3 General Specifications

NOTE:
Specifications subject to change without notice.

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Section 1 - Introduction HE-II Pump Module

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HE-II Pump Module

Section 2 - Installation
2
2.1 Introduction
This section includes information for installation and initial turn on of the Harris HE-II
Pump Module.

2.2 Documentation
The following is a list of documentation that ships with the pump module. Locate and save
all documentation.
• Documentation Package 988-2625-002
The Document Package includes:
• This technical manual 888-2625-002
• Installation drawings, schematics and wiring diagrams

2.2.1 Pump Module Drawings

Review the drawing package to become familiar with the available information.
Information on installation and planning is given in the following drawings:
• Outline Drawing - Illustrates the connections for AC and control lines, and provides
overall mechanical dimensions
• Wiring Diagram - AC and control wiring requirements

2.3 Operating Environment and Placement

The selection of a proper installation location is essential for equipment longevity and
reliability. Do not install the pump module in places where it may be exposed to
mechanical shocks, excessive vibration, temperature, dust, water, salty air, or corrosive
gas.
Ambient temperature and relative humidity should always range between the following
limits at the installation location:
• Ambient temperature: -33 to +50oC
• Relative humidity: 5 to 95% non-condensing
An electrical control panel is integrated into the pump module assembly. The pump
module and electrical panel are specifically designed for indoor use only and should be
positioned near the transmitter so the pump module control panel can be readily viewed
and is easily accessible.
The pump module should be installed to allow access to the front for maintenance
purposes. Changing pump modules will require access to the front of the unit.

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Section 2 - Installation HE-II Pump Module

Approximately 1 meter of clearance is recommended at the front. AC mains connections

are on the sides of the unit.
Once in place, the pump module should be securely fastened to the floor using customer
supplied brackets and fasteners. 13.0 mm(1/2 inch) diameter mounting holes are located
on the bottom (front and rear) of the pump module rack.

2.4 AC Mains Requirements

The desired AC mains voltage must be provided when order is placed. The pump module
can be configured for single phase 208-240VAC, three phase 208-240VAC, or three phase
380-415VAC operation. The preceding three phase voltages are phase to phase values. A
neutral connection is needed for 380-415V configurations.
Upon receiving the pump module, measure the AC mains voltage to verify that the correct
version of pump module has been supplied.
Consult drawing 843-5607-530 sheet-2 for information on suggested wiring, fusing and
motor jumper requirements.

! WARNING:
DISABLE AND LOCK OUT PUMP MODULE PRIMARY POWER BEFORE AC MAINS
CABLES ARE CONNECTED TO THE EQUIPMENT. TURN OFF (OPEN) ALL
SWITCHES AND BREAKERS ON THE COOLING CONTROL PANEL, PUMP MODULE
AND HEAT EXCHANGER. THIS WILL ALLOW THEM TO BE TURNED ON (CLOSED)
ONE AT A TIME LATER TO CHECK FOR WIRING PROBLEMS.

! WARNING:
AN EXTERNAL CIRCUIT PROTECTION DEVICE (BREAKER OR FUSE) IS
REQUIRED. THIS IS PROVIDED BY THE CUSTOMER IN ACCORDANCE WITH PRE-
VAILING LOCAL SAFETY NORMS AND DRAWING 843-5607-530.

Install the AC mains wiring in a separate conduit from all control and small signal lines.

2.4.1 Surge Suppression Devices

Harris strongly recommends the use of surge protection devices on the incoming AC
mains lines. These devices protect against damages due to transients arising from both
natural and man-made sources. (e.g. lightning and inductive load switching). Clear
preference is to be given to “series” type surge protection devices -- featuring protection
by both a series inductance / shunt capacitor filter and shunt threshold device -- over
simple shunt-only clamping devices. The surge protector must be sized to handle the full
amperage of the load it is protecting (plus a nominal safety margin) and be connected to
the building ground system by short, direct connections. In the case where the shunt
protection elements are protected by a fuse, it is necessary to periodically check the
integrity of the fuse to ensure continued transient protection.

! CAUTION:
FAILURE TO FOLLOW THESE RECOMMENDATIONS MAY LEAD TO
SHORTENED EQUIPMENT LIFE AND REDUCED RELIABILITY.

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HE-II Pump Module Section 2 - Installation

2.4.2 Ground Requirements

The HE-II pump module requires an AC safety ground. The AC safety ground prevents an
electrocution hazard should a dangerous potential from inside the unit accidentally contact
the metal chassis. The AC safety ground works by providing a secure, uninterrupted path
for any wayward electrical current to return to the source: the secondary winding of the
local power-grid transformer (or generator). This ensures that any exposed metal parts will
not simply “float” to a voltage level dangerous to humans in the case of an accidental
contact with mains voltage and that sufficient fault current will be drawn to trip any circuit
protection devices.
The AC safety ground (green/yellow) wire from the pump module should terminate at a
suitable physical earth (PE) or (PEN) connection at the AC mains entrance/distribution
panel, or as otherwise dictated by safety norms. In those systems with only a direct earth
ground instead of a wired PE connection back to the power source, the use of special
ground-fault sensing circuit protection devices is indicated.
In addition to the equipment chassis, all metal enclosures and conduit pieces potentially
exposed to mains voltages in the case of a fault should have a secure, un-interrupted,
conductive path back to the PE terminal in the mains entrance.

2.5 Electrical Connections

! CAUTION:
AVOID RUNNING PUMPS WITHOUT COOLANT. RUNNING PUMPS DRY CAN
DAMAGE THEM IN AS LITTLE AS 15 SECONDS.

STEP 1 Install conduit and then connect the AC wiring between the AC mains panel and
pump module. Refer to AC Power Flow Diagrams and Electrical Installation
Diagrams that are part of the transmitter documentation package. A safety
ground wire must also be included and attached at the location noted in Figure 2-
1.

Figure 2-1 Pump Module Control Panel AC & Ground Terminals

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Section 2 - Installation HE-II Pump Module

STEP 2 Install conduit and then connect the AC wiring between the control panel and
heat exchanger fans. Refer to drawing 843-5607-530 in the pump module
documentation package. The rotation of the fans will need to be checked prior to
operation. Fan rotation is checked by momentarily activating them while
monitoring the direction of the fan blades as they slow down. If blade rotation is
opposite the arrow direction (Figure 2-2 on right) on the fan cover then swap two
of the AC lines feeding the fans. These connections are inside the control panel.
Remove control panel cover and relocate wires in the fan Wago block (see
Figure 2-1). Swap two of the wires (to each fan) to change direction of rotation.

NOTE:
If the transmitter is not available to provide control for the heat exchanger fans,
they must be turned on manually. Refer to Section 3.1.4 for instructions on man-
ual fan control.

Figure 2-2 Pump & Fan Rotation Arrows

Heat Exchanger Heat Exchanger

Fan AC Fan AC

Figure 2-3 Heat Exchanger Fan AC Connections

STEP 3 Install conduit and connect the control and status wires between the cooling
control panel and the transmitter with multi-conductor cable. These low
level signals are wired from connector J1 at the top of the transmitter to terminals
J3 or J4 in the cooling control panel. Refer to the transmitter External Wiring

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HE-II Pump Module Section 2 - Installation

Diagram for details.

Table 2-1 Inputs to Control Panel J3 or J4

Pin Wire Color Signal Conditions

1 BLK GROUND

2 RED NC

3 BLU PUMP INTLK From transmitter, active high. When high, the
transmitter’s RF output is muted and the pumps are
forced to OFF regardless of the LOCAL/REMOTE
setting in the pump cooling control panel. If this
interlock is active, the pumps can’t be turned ON
(even locally). This interlock is driven by the
transmitter or PA cabinet leak detector. If a leak is
detected, this interlock goes to high.

4 WHT PUMP RUN From transmitter, active high to turn on selected

pump.

5 BRN SWITCH PUMP From transmitter, pulsed active high to switch

between Pump A and Pump B.

6 GRY GROUND

7 TAN NC

8 PINK NC

9 ORG PUMP A Pump module output, transmitter input. Active

SELECTED when input is LOW.

10 YEL PUMP B Pump module output, transmitter input. Active

SELECTED when input is LOW.

11 GRN LOCAL STATUS Pump module output, transmitter input. Remote =

LOW, Local = HIGH

12 PUR GROUND

Table Note: NC = Not Connected

NOTE:
Condensation can occur in the conduit leading to the outside heat exchanger from
the control panel. This conduit and connectors should be caulked or sealed after
the system is tested and operational. The goal is to keep warm air from inside the
building out of the conduit which lies outside the building.

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Pump Module
Control Wiring
to Transmitter

Figure 2-4 Pump Module Control Panel Control Wiring (goes to transmitter)

To Pump Module
Control Panel

Figure 2-5 Transmitter Connection to Pump Module

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2.6 Charging Closed Loop Cooling Systems

The following instructions assume that the transmitter cabinet, plumbing for cooling
system, pump module and heat exchanger have all been properly installed per instructions
provided in the transmitter documentation package.

! CAUTION:
AVOID RUNNING PUMPS WITHOUT COOLANT. RUNNING PUMPS DRY CAN
DAMAGE THEM IN AS LITTLE AS 15 SECONDS.

STEP 1 Before charging the system with coolant or water use a tire gauge to check air
pressure on the on the expansion tank. Pressure can be checked by removing the
plastic cover on the end of the tank to expose a Schrader valve. The measured air
pressure in the tank should be 12 psi from the factory. If it is not 12 psi add or
release air to achieve 12 psi bladder pressure.

NOTE:
The 12 psi pressure level is acceptable if the pump module is going to be installed
at the same elevation as the heat exchanger. In situations where the heat
exchanger will be located above the pump module higher initial bladder tank air
pressures will be required.

The following instructions assume that the bladder tank pressure is 12 psi and the heat
exchanger and pump module are located at the same elevation.
STEP 2 Open automatic bleed vents to allow trapped air to bleed from system.
STEP 3 Close supply and return ball valves at transmitter bypass manifold. Open bypass
valve to allow coolant to flow through bypass assembly and prevent flow
through transmitter. Coolant flow through the transmitter is not desired until
system is clean.
STEP 4 Bypass flow through liquid cooled test load and or filter at this time. Flow
through these components is not desired until system is clean.
STEP 5 Charge the system with coolant (use charge pump or circulation pumps) to an
initial static pressure of 15psi. If this is the first fill the initial charge should be
pure water until integrity of system can be checked.

NOTE:
Static pressures are measured with pumps off.

NOTE:
If the circulation pump is to be used to charge the system see separate instructions
in "2.7 Charging Systems with Circulating Pump" on page 2-9.

STEP 6 Momentarily turn on pump A and monitor the rotational direction of the pump
motor fins as they slow down. If the direction is opposed to the indicator arrow
on the motor cowl swap two of the AC lines feeding the pump motor (after the
inverter, U/T1, V/T2 or W/T3 connections). These connections are inside the
inverter and can be accessed by opening the inverter cover and loosening the
terminal screws located at the rear on the right. The inverter controls the rotation
of the pump motors independent of the mains.

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STEP 7 Repeat this process for Pump B motor to verify that it is also rotating in the right
direction.

! CAUTION:
PURE WATER SHOULD BE USED FOR SHORT TERM INITIAL TESTING ONLY.
IF OUTSIDE TEMPERATURES ARE NEAR OR BELOW FREEZING AVOID
USING WATER IN THE SYSTEM FOR PERIODS OF TIME THAT WOULD
ALLOW IT TO FREEZE. FREEZING WATER IN THE COOLING SYSTEM WILL
DAMAGE COOLING SYSTEM COMPONENTS.

STEP 8 Turn on the circulation pump and monitor inlet and outlet pressures. When most
air is out of system the inlet pressure should be 5-15 psi (cold). If necessary
charge the system with additional coolant until approximately 15 psi static
pressure is noted.
STEP 9 Run the system for 30 minutes on one pump then switch to the opposite pump for
another 30 minutes. Add coolant as required to keep inlet pressure between 5-
15psi.

NOTE:
Inlet and static pressures may rise above 15 psi if the system coolant is hot.

STEP 10 If the system has been charged with distilled water the system should be drained
and the water should be checked for cleanliness. It the system is dirty it will need
to be flushed. See transmitter manual for flushing instructions. After cleaning
and flushing the system should be charged with coolant (50/50 mix of glycol/
distilled water).
STEP 11 If the system has been charged with coolant (50/50 mix of glycol/distilled water)
run the system for several hours while monitoring the sight glass (if used) for air.
A low level of coolant or bubbles in the sight glass would indicate air in the
system and coolant should be added.

NOTE:
Typically the sight glass is located at a high point in the system on the return side
of the transmitter. The air purger and sight glass traps air that is introduced during
transmitter maintenance.

STEP 12 Close system automatic air vents.

STEP 13 Restore flow through transmitter, filter and test load as required.
STEP 14 End of procedure.

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2.7 Charging Systems with Circulating Pump

Properly outfitted closed loop cooling systems can be charged using the system circulating
pump. A separate charge pump is not required.
STEP 1 Turn off the pump breakers A and B on the front of the control panel. Turn Pump
A and B local control switches to the OFF position. Set pump module system
control switch to Local mode. See Figure 1-4 on page 1-4 for location of
breakers and switches.

NOTE:
These actions prevent the pumps from starting before the system is properly
primed.

STEP 2 The pump B intake side must be primed with coolant or water prior to initial turn
on.
STEP 3 Use a 2-7/8" (73 mm) open end or adjustable wrench to disconnect the inlet
connector just below the inlet valve as noted in Figure 2-6. Remove the inlet
valve/strainer assembly.
STEP 4 Attach the fill valve hose shown in Figure 2-7 on page 2-11 and route the hose to
a reservoir containing coolant or clean water. The reservoir end of the hose
should have a screen strainer installed in the hose fitting.
STEP 5 Close the fill valve shown in Figure 2-7 on page 2-11.
STEP 6 Open the pump B inlet valve shown in Figure 2-7 on page 2-11.
STEP 7 Fill the inlet side of the pump module with coolant or with pure water if this is
the first fill (approximately 1/2 gallons, 1.9 liters).
STEP 8 Open the fill valve for a few seconds to allow coolant to flow through the fill
valve hose. When coolant flow from the hose is noted place the hose end below
the fluid level (near the bottom of the reservoir) and close the fill valve. This step
removes air from hose.
STEP 9 Refill the inlet side of the pump module to replace the coolant drained from the
fill hose.
STEP 10 Re-attach the inlet valve/strainer and tighten the fittings.

NOTE:
Water is used for the first fill (new system only) to check the system for leaks.
Once the system is leak free then the system should be drained and refilled
(flushed) as needed to insure that no dirt or debris is retained in the cooling sys-
tem. Finally, the system should be drained and refilled with 50/50% glycol/dis-
tilled water mix using this same procedure.

! CAUTION:
IN COLD ENVIRONMENTS WATER MUST NEVER BE ALLOWED TO STAY IN
THE SYSTEM LONG ENOUGH TO FREEZE. THE SYSTEM MUST BE DRAINED
OF WATER AND FILLED WITH 50/50 GLYCOL/DISTILLED WATER MIX
BEFORE BEING EXPOSED TO FRIGID TEMPERATURES FOR EXTENDED
PERIODS.

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NOTE:
Adding the water or coolant primer could be done before the pipe/hose is con-
nected to the pump module.

Figure 2-6 Top of Pump Module

STEP 11 Set up a 30 gallon (size varies with system) reservoir (bucket or drum) filled with
pure water (for first fill) or 50/50% glycol/distilled water mixture for the final
fill. If the initial fill of water is contaminated with dirt and debris several flushing
cycles may be needed to insure the system is clean. The strainer should be
cleaned after each flush. The strainer is cleaned with the pumps off and inlet
valve closed to prevent draining the entire system.
STEP 12 Attach a hose to the pump module strainer valve (see Figure 2-6) and route to the
reservoir. With this strainer valve open, air and coolant will be allowed to bleed
from the system into the reservoir as the system is being filled with coolant.
When the pump is first activated air bubbles will rise from strainer valve hose in
the reservoir. The flow from this hose will become a solid coolant stream after
air is purged from the system. Use adequate length to allow end of hose to extend
well below coolant level in reservoir.

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Figure 2-7 Fill Valve Hose Connection

STEP 13 Open the vent cap located on top of the pump module air separator. See Figure 2-
8. Also open the vent cap on the system air purger which is located near the
transmitter on the bypass manifold.

Figure 2-8 Air Seperator Vent

STEP 14 Open inlet and outlet valves on top of the pump module to allow coolant flow
when pump is activated.
STEP 15 Apply AC power to the pump module.
STEP 16 Turn on pump B breaker shown in Figure 1-4 on page 1-4.
STEP 17 Open the strainer valve and the fill valve.

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STEP 18 Fully close pump B inlet valve. This will force the system to draw water or
coolant from the reservoir via the fill hose.
STEP 19 Be prepared to monitor the pump module pressure gauges while charging the
cooling system.
STEP 20 Momentarily turn on pump B and monitor the rotational direction of the pump
motor fins as they slow down. If the direction is opposed to the indicator arrow
on the motor cowl swap two of the AC lines feeding the pump motor (after the
inverter, U/T1, V/T2 or W/T3 connections). These connections are inside the
inverter and can be accessed by opening the inverter cover and loosening the
terminal screws located at the rear on the right. The inverter controls the rotation
of the pump motors independent of the mains. Repeat this process for Pump A to
verify that it is also rotating in the right direction.
STEP 21 Turn pump B switch to the ON positions. Pump B should automatically start
running and begin to draw coolant from the reservoir into the cooling lines.
Allow the pump to continue running while monitoring the pressure gauges. Also,
monitor for any air bubbles that rise from the reservoir. The air is being vented
from the strainer bleed valve hose.
STEP 22 Use the pump B inverter potentiometer to speed up the pump for more suction.
STEP 23 Close the strainer valve when a steady coolant stream appears to flow and no air
bubbles rise from the hose into the reservoir.
STEP 24 When the inlet pressure reaches 15 psi, close the fill valve and open pump B inlet
valve. Leave hoses in the reservoir with the ends submerged. They will be used
later to add coolant.
STEP 25 Allow the cooling system to continuously run so any trapped air can be purged
through the air separator vent caps. Periodically switch between pumps to ensure
trapped air is evacuated from the system through the vent cap. The inlet pressure
gauge must maintain a positive reading to insure adequate coolant flow to the
pumps.
STEP 26 Allow the pump module to run continuously and periodically switch between
pumps.

NOTE:
Recharge the coolant system if the inlet pressure falls below 5 psi. This can be
accomplished by switching to pump “B”, slowly closing pump B inlet and then
slowly opening the system fill valve. Monitor inlet pressure as outlined in STEP
24.

STEP 27 Close the air separator plastic vent cap once the gauge readings have stabilized
and air is no longer coming out of the vent.
STEP 28 Set the inverter low level (LL) to an initial value of 15 Hz using instructions
provided in 3.1.1 on page 3-1. The pump module ships with this value set to 45
Hz which may produce too much flow for smaller transmitters.
STEP 29 Set the transmitter cabinet to the recommended flow rate by adjusting the pump
inverter frequencies (use knob on inverters) one at a time.The recommended
flow rates are listed in Table 3-1 on page 3-2. Record the frequencies that
produce the desired cabinet flow. These frequencies will be used later to set up

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HE-II Pump Module Section 2 - Installation

the inverter low levels (LL) as described in 3.1.1 on page 3-1.

NOTE:
The flow rate (liters per minute) can be viewed on the transmitter System GUI
screen.

STEP 30 When the inlet and outlet pressure gauge readings hold steady, switch the active
pump OFF and select REMOTE operation. This should turn off the pump
module and the gauge readings will fall to the static pressure reading. Both
gauges will read the same pressure.
STEP 31 Close the pump module and system automatic air vent valves.
STEP 32 Continue to monitor the cooling system pressure readings for several weeks after
the transmitter is brought up to normal operations. You may need to add some
additional coolant by repeating STEP 27. Normally, the amount of coolant
required will be less than 1/2 gallon(1.89 liters).
STEP 33 End of procedure.

NOTE:
See Section 3 for inverter setup and operation.

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Section 2 - Installation HE-II Pump Module

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HE-II Pump Module

Section 3 - Operation
3
3.1 Inverter Setup and Operation
Inverters are used to control pump and fan motors. They control the speed of the motors as
required to achieve operational cooling parameters. The inverters must be properly
programmed prior to system operation. Typically, LL and F202 need to be set on site.

Figure 3-1 VF-S11 Inverter Control Panel

The plumbing/cooling system must be installed and filled with coolant before proceeding
with the following steps. In order to program the inverters the pump frequency needed to
achieve the recommended flow rate must be determined. The optimum pump operating
frequency will need to be determined and set up for each system. This value will then be
programmed to the and F202 parameters.

3.1.1 Inverter Pre-programming

The lower limit pump operating frequency is programmed at the factory to
45 Hz to satisfy larger cooling systems. The optimum pump frequency should be
determined for each system. This value must then be programmed to the parameters
and F202. Use the following procedure to determine the required pump
frequency.

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STEP 1 Make sure the pump module control switch is in LOCAL mode and both pumps
are off.
STEP 2 Set the basic parameter to 15 Hz. See 3.1.2.2 for instructions on
setting basic parameters.
STEP 3 Fully open the transmitter inlet and outlet coolant control valves allowing flow
through transmitter cabinet.
STEP 4 Turn one of the pumps on. The potentiometer dial on the inverter front panel will
be used to change the pump frequency.
STEP 5 Use the transmitter TCU GUI screens to determine actual coolant flow rate and
then use the inverter settings dial to adjust the pump frequency until the
recommended flow rate in Table 3-1 is achieved. Do not use frequencies below
15Hz. Record this value. The inverter will be programmed with this value using
the and F202 parameters.

NOTE:
The recommended flow rates given in Table 3-1 are lower than those given in the
transmitter outline drawing and technical manual. The settings here represent the
lowest recommended coolant flow. The HE pumps will increase speed automati-
cally at higher ambient temperatures and increase flow above these levels as
needed.

Table 3-1 Typical Transmitter Flow Rates

Quantity of PA Minimum Coolant Recommended Typical Pump

Modules Flow Rate Trip Point Coolant Flow Rate Frequency Range
(LPM) (LPM) (Hz)

2 10 23 15-20

3 19 29 15-20

4 23 34 20-25

6 31 46 25-30

8 38 57 30-35

10 46 68 35-40

12 53 80 40-45

16 70 103 50-55

3.1.1.1 Verify F700 Setting & Run Command

If the inverter has been previously programmed, inverter programming may be locked.
This setting prohibits parameter values from changing. To enable programming, set
extended parameter F700 to 0. To prohibit programming, set F700 to 1. See 3.1.2.3 for
detailed instructions on changing extended parameters.

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Many parameters cannot be changed while the inverter is receiving the RUN command.
This command can be disabled by unplugging the inverter control connector from the
pump control board. If the inverter has not been previously programmed, the RUN and
STOP keys on the inverter front panel are used to control the inverter. Simply press the
STOP key to cancel the RUN command. Verify that the motor has stopped.

3.1.2 Inverter Programming

Inverters for fans and pumps are programmed with different parameter values. Refer to
Table 3-2 for pump inverter settings. Refer to Table 3-3 for fan inverter settings. It is
recommended that the parameters be programmed in the order shown in Table 3-2 and
Table 3-3. Programming parameters in a different order will not affect the inverters
operation. The F700 parameter locks programming of parameters, and must be the last
parameter programmed.

3.1.2.1 Identifying Parameter Type:

Two types of parameters need to be changed for the inverter to interface properly with the
transmitter:
Basic parameters – parameters that are changed often. Basic parameter names typically
contain all letters. Basic parameters:

Extended Parameters – parameters that begin with F followed by three digits (F100 –
F999). Extended parameters are accessed by selecting in the basic
parameter menu. 

3.1.2.2 Changing Basic Parameters

Figure 3-1 shows the inverter control panel keys used to change parameter values.
Pressing the MODE key several times during programming will return to the initial
display.
Initial press of the MODE key once will display “AUH”.
Use the settings dial keys to select the desired basic parameter, such as
Press the Enter key. The current value of the selected basic parameter should be displayed.
Use the settings dial keys to select the desired new value for the parameter.
If the settings dial keys won’t change the parameter value, programming might be locked
on the inverter. See 3.1.1.1 to enable programming.
Press the ENTER key to save the new value. The parameter name and new value should
flash on the display.
Use the settings dial and ENTER keys to modify more basic parameters if needed.
Otherwise, press the MODE key several times until the display returns to 0.0 Hz.

3.1.2.3 Changing Extended Parameters:

Figure 3-1 shows the inverter keys used to change parameter values. Pressing the MODE
key several times will cause a return to the frequency display.

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Press the MODE key. The inverter should display “AUH”.

Use the settings dial keys to select the extended parameter list:
Press the Enter key. You should see the first extended parameter F100.
Use the settings dial keys to select the desired extended parameter such as F115.
Press the ENTER key. You will see the current value of the selected parameter.
Use the settings dial keys to change the parameter value to the desired value.
If the settings dial keys won’t change the parameter value, programming might be locked
on the inverter. See 3.1.1.1 to enable programming.
Press the ENTER key to save the new value. The parameter name and new value should
flash on the display.
You can use the settings dial and ENTER keys to modify more extended parameters if
needed. Otherwise, press the MODE key until the display returns to 0.0 Hz.

3.1.3 Clearing Inverter Memory

The basic parameter allows the inverter to be reset to factory default values.
If the inverter has been improperly programmed it may be useful to clear inverter memory
and then reprogram it.
To clear all inverter parameters, set the basic parameter to 3. All inverter
parameters will need to be reprogrammed. See 3.1.2.2 for detailed instructions for
programming basic parameters. See Table 3-2 or 3-3 for parameters.

3.1.4 Manual Fan Control

After the fan inverters have been properly programmed according to Table 3-3, frequency
setting (fan speed) will be controlled by a temperature sensor in the pump module. The
inverter settings dial will not change the fan motor speed.
Should it become necessary to allow manual frequency control (fan activation) via the
built in inverter potentiometers additional jumpers inside the inverter will be needed.
To enable the built in potentiometer for manual frequency control (manual fan activation):
STEP 1 Turn off the AC breaker going to the inverter.
STEP 2 Open the front panel of the inverter. To open the front panel the sliding lock
shown in Figure 3-1 needs to be turned counterclockwise.
STEP 3 Place a jumper wire between the S2 terminal and one of the CC terminals on the
inverter terminal board. This jumper allows potentiometer control.Ok to add
jumper to existing wire in terminal.
STEP 4 If there is no inverter enable signal is coming from the transmitter then another
jumper is needed to allow manual operation of the inverter. Place the additional
jumper between terminals F and CC. This jumper allows fan activation when
transmitter is not installed or can’t be activated.Ok to add jumper to existing
wire in terminal.

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3.1.5 Adding Dip Switch Settings

VFS15 inverters have a dip switch that defines the type of control logic being used. This
switch must be set to the "SINK" position when used with Harris pump modules. Refer
to Figure 3-2 to locate this switch and ensure it is in the "SINK" position.

Figure 3-2 "SINK" Switch Position

Table 3-2 Pump Inverter Settings

Programming Parameter Setting Description Selection

Order

Command mode
1 0 Terminal board
selection

Frequency mode
2 0 Built-in potentiometer
selection

3 1 Acceleration time 10 seconds

See Section
4 Lower limit frequency Hz
3.1.1

5 1 V/F selection mode Variable torque

Input terminal selection Frequency command

6 F115 104 5 (S2) forced switching

VIA input point 1

7 F201 50 setting
50%

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Table 3-2 Pump Inverter Settings

Programming Parameter Setting Description Selection

Order

Set to same VIA input point 1

8 F202 value as LL. frequency
Hz

VIA input point 2

9 F203 100 setting
100%

Frequency setting mode

10 F207 1 selection 2
VIA

Auto-restart control Auto-restart after

11 F301 1 selection. momentary stop

Operation starting
12 F242 1 frequency (hysteresis)
1 Hz

13 F303 10 Retry selection 10 times

Panel operation
14 F733 1 prohibition (RUN/STOP Prohibited
keys)

Prohibition of panel
15 F734 1 emergency stop Prohibited
operation

Prohibition of change of
16 F700 1 parameter settings
Prohibited

Table 3-3 Fan Inverter Settings

Programming Parameter Setting Description Selection

Order

0 Command mode Terminal board

1 selection

1 Frequency mode VIA

2 selection

3 1 Acceleration time 10 seconds

4 10 Lower limit frequency 10 Hz

5 1 V/F selection mode Variable torque

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Table 3-3 Fan Inverter Settings

Programming Parameter Setting Description Selection

Order

104 Input terminal selection Frequency command

6 F115 5 (S2) forced switching

30 VIA input point 1 30%

7 F201 setting

10 VIA input point 1 10Hz

8 F202 Frequency

60 VIA input point 2 60%

9 F203 setting

0 Frequency setting mode Built-in potentiometer

10 F207 selection 2

10 Operation starting 10Hz

frequency. Turns
11 F241 inverter off when fluid
<30 o C.

1 Auto-restart control Auto-restart after

12 F301 selection momentary stop

10 Retry selection 10 times

13 F303
1 Panel operation Prohibited
14 F733 prohibition (RUN/STOP
keys)

1 Prohibition of panel Prohibited

15 F734 emergency stop
operation

1 Prohibition of change of Prohibited

16 F700 parameter settings

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Section 3 - Operation HE-II Pump Module

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HE-II Pump Module

Section 4 - Theory of
Operation 4
4.1 Introduction
Liquid cooling system pump and fan modules were previously operated with single speed
AC motors, which have two operating conditions, on or off.
The volume of coolant flow was determined by he the pump size and associated plumbing,
flow rate was determined by the worst case cooling requirements.
Cooling of the liquid was controlled by the heat exchanger, where single speed fans
sucked air across a chiller core. Cooling was controlled by two temperature settings,
which are as follows:
• Below the low temperature setting, both fans were off.
• When the temperature was between the low and high settings one fan
operates.
• When the temperature was above the high setting, both fans operate.
Pump, fan and core sizes were determined by the worst case cooling requirements
An alternate concept in cooling systems involves the use of variable speed induction
motors on pumps and fans to more adequately control coolant flow, temperature, and
reduce the cost of operation.

4.2 Speed Of Electric Induction Motors

In the past, a DC motor was the only convenient way to easily have a continuously
variable motor speed.
AC induction motor speed is determined by the AC line frequency, the number of field
coils, and the amount of speed reduction due to load (this is called the slip speed). For
example, an induction motor which operates on 60 Hz and has four field coils (2 pairs of
field coils) and has a slip speed of 50 RPM would have the following speed in revaluations
per minute (RPM).
F  60  2 60  60  2
RPM = ------------------------- – S = --------------------------- – 50 = 1750
N 4

Where: F = AC line frequency.

N = Number of poles.
S = Slip speed, which is the slowing of the motor speed due to its load.

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Section 4 - Theory of Operation HE-II Pump Module

The current drawn by an induction motor is determined by three factors, which are:
• The dc resistance of its coils.
• The inductive reactance, which is determined by the number of turns of the
coil and the amount of magnetic material in the frame and rotor.
• The back EMF (electromotive force) generated as a function of the motor’s
speed.
When the rotor of motor is locked, its line current is extremely high, being limited by the
dc resistance and inductive reactance (the impedance) of its coils. As the motor speed
increases, it generates a back EMF which is proportional to the motor speed. The back
EMF cancels part of the applied voltage, the difference voltage applied to the coil
impedance determines the AC current draw. When the slip speed is zero RPM, the motor
is rotating at its ideal speed, 1800 RPM in the above example, and the back EMF equals
the applied voltage.Therefore, the AC current of the motor is zero. In the real world even
an unloaded motor has some friction losses, therefore, it will have some slip speed and
draw some current.
A speed of a given induction motor can be reduced by lowering the applied AC frequency,
but, unless the motor was designed for such use, it would draw higher AC current at any
given load. This is due mainly to the decrease of back EMF generated due to its slower
operating speed and to a somewhat less effect because of its lower inductive reactance.
Both of these detrimental effects can be reduced by use ing more magnetic material in the
motor (heavier frame) and possibly increasing the number of turns of the coils.

4.3 Using An Inverter To Control Motor Speed

The heart of the variable speed induction motor is the high efficiency inverter module.
This module operates as follows. The incoming AC is rectified to DC and stored in large
capacitors. Solid state circuitry, using off/on switching, creates a simulated AC sine wave
at the desired voltage and frequency.
To reduce the AC current draw as the line frequency and motor speed are reduced, the
applied voltage is reduced in proportion to the line frequency. For example, a 240 Vac
motor designed for 60 Hz will require 40 Vac at 10Hz. This is calculated by the following
formula.
Rated AC Voltage 240
Applied Voltage = --------------------------------------------------  Applied Frequency = ---------  10 = 40 Vac
Rated AC Frequency 60

NOTE:
The applied voltage may be varied slightly to obtain optimum performance.

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HE-II Pump Module Section 4 - Theory of Operation

Figure 4-1 Three Phase Input Three Phase Output Inverter

Figure 4-2 Single/Split Input Three Phase Output Inverter

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Section 4 - Theory of Operation HE-II Pump Module

4.3.1 Inverter Operated Pump and Cooler Modules

Inverters and variable speed pumps and fans are used in the Harris liquid cooling systems.
Depending on inverter type these systems use either three phase or single phase AC
power.
The temperature of the pump module output coolant, which is the input coolant to the
transmitter, is monitored and changed to a control voltage which is proportional to the
temperature. This control voltage controls the output frequency of the inverters, which
controls the pump and fan speed. Two temperature thresholds are used.
Fans:
The range of the control voltage is 0 to 10 Vdc. At the low temperature threshold the
control voltage is approximately 3 Vdc, and at the high temperature threshold, the control
voltage is approximately 6 Vdc. When the control voltage is at or below 3 Vdc, the
inverters turn off. This reduces fan speeds which provides minimum air flow and cooling.
When the control voltage is  6 Vdc, the inverters output a 60 Hz frequency at the input
AC line voltage. This operates the fans at maximum speed which provides maximum
coolant flow and cooling. When control voltage is between 3-6vdc, frequency is variable.
Pumps:
Pumps operate at LL frequency for  5Vdc then begin to increase frequency.
The inverter, pump motor, and fan motor have two AC voltage ratings, which are 200 to
240 Vac or 380 to 500 Vac.
When the correct AC rotation is established between the inverter and the pump or fan
motors, The direction of rotation is independent of the rotation of the input three phase AC
power. Inverters that use three phase inputs will continue to produce three phase output
power if one phase of the AC input power is lost, however, long term operation with a lost
phase is not recommended and will reduce inverter life.

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HE-II Pump Module

Section 5 - Maintenance &

Alignments 5
5.1 Introduction
This section contains all of the maintenance and alignment procedures for HE pump
module and associated cooling system components. Consult the transmitter technical
manual for more detailed cooling system maintenance information.

5.2 Miscellaneous Maintenance

5.2.1 Cooling System Checks
Inspect the cooling system weekly for coolant leaks and check the coolant level.

5.2.1.1 Heat Exchanger Cleaning

The heat exchanger fins and pump motor housing fins should be examined for dust and
dirt buildup monthly. Clean as necessary with low pressure water hose, soft bristled brush
or compressed air.

! CAUTION:
TAKE CARE NOT TO DAMAGE THE FINS. DO NOT CLEAN WITH HIGH
PRESSURE WATER, WIRE BRUSH OR OTHER METHODS THAT MIGHT
DAMAGE THE FINS.

5.2.1.2 Alternate Pumps

Every two months select the opposite pump in order to keep both pumps in a proper
working state. Switching the pumps can be accomplished via the GUI screen (with pump
module in REMOTE mode) by pressing SYSTEM then press the GUI button to select the
inactive pump. This may also be a good time to manually operate (open and close them
several times) all valves to assure proper movement and closure.

NOTE:
See the cooling system drawings, manufacturers component manuals, transmitter
technical manual for additional details.

5.2.1.3 Pump Module Strainer Cleaning

The strainer is shown on Figure 5-1 which shows a ball valve above the strainer and
additional ball valves at the pump inputs. The strainer is located on the pump module in
the return line. The strainer should be inspected several times during the start up process
and cleaned following the final flush. The frequency of inspection after initial installation
may vary depending on site conditions but in most cases annual inspection and cleaning of

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Section 5 - Maintenance & Alignments HE-II Pump Module

the cooling system strainer is recommended. The strainer must be disassembled and
cleaned when the transmitter is off the air since the coolant flow must be disrupted prior to
opening the strainer assembly. Follow the steps that follow to clean the strainer:
a. Turn off the transmitter and pump module.
b. Close the ball valves on both sides of the strainer.

! CAUTION:
WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN
REMOVING THE STRAINER CAP. LOOSEN THE CAP SLOWLY SINCE THE
COOLANT MAY BE UNDER PRESSURE. THE COOLANT MAY ALSO BE HOT.

c. Remove strainer housing cap.

StrainerAssy.

Screen

Plug/Drain.

Figure 5-1 Pump Module Strainer

NOTE:
A small amount of liquid will still be present in the pipe and strainer housing, and
a receptacle (bucket) will be necessary to contain the spillage.
d. Pull strainer screen
e. Inspect and clean strainer as needed
f. Replace the strainer, and perform the above steps in reverse order to restore the
cooling system to normal operation.

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HE-II Pump Module Section 5 - Maintenance & Alignments

5.2.1.4 Coolant Level Management:

The HE pump module is used in a closed (pressurized) cooling system. The system
contains a pressurized expansion tank with a bladder that separates the system coolant
from pressurized air. The expansion tank is pressurized (with air) at the factory and should
not need pressurization on site. The coolant level is checked by viewing the coolant
passing through the sight glass located on the air purger at the highest point in the cooling
system. The presence of air bubbles or lack of fluid in the sight glass is an indication that
the system needs to be charged with additional coolant.

Air
Purger
Sight
Glass

Figure 5-2 Air Purger and Sight Glass

5.2.1.5 Cooling System Maintenance Notes

5.2.1.5.1 Coolant Checks:

The pH level of the 50/50 glycol/water mixture should be above 8.0. A PH level that is
below 8.0 indicates that the inhibitors in the glycol are ineffective. Should the PH level of
the mixture drop below 8.0 either additives must be added or the coolant should be
changed. The PH level should be checked regularly with either pH paper or with a pH
meter. If these test items are not available a sample of the coolant can be sent to an
independent service provider for analysis. The pH level should be checked at three month
intervals.
The 50/50 glycol/water mixture should be checked at three month intervals as well. Drain
a sample of coolant from the system and check the 50/50 mixture. Use a conventional float
hydrometer and jar (for ethylene glycol only) or a MISCO DFR 200 or equivalent digital
refractometer to verify the 50/50 mixture (for ethylene or propylene glycol).

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Section 5 - Maintenance & Alignments HE-II Pump Module

5.2.1.5.2 Changing Pumps:

a. Turn off the transmitter and pump module (if possible). Turn off all breakers and
switches on the pump module (if possible). If the transmitter must remain on air
during the pump change turn off the breakers for the bad pump.
b. Close the ball (isolation) valves on either side of the pump that is to be changed.
c. Disconnect the fittings on either side of the pump.

NOTE:
A small amount of liquid will still be present in the pipe and pump housing, and a
receptacle (bucket) will be necessary to contain the spillage.

! WARNING:
WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN REMOV-
ING. LOOSEN THE CAP SLOWLY SINCE THE COOLANT MAY BE UNDER PRES-
SURE. THE COOLANT MAY ALSO BE HOT.

d. Remove and replace the pump. Take care to install the pump so flow is main-
tained in the proper direction.

! CAUTION:
USE PIPE JOINT COMPOUND OR TEFLON TAPE ON MALE THREADED
FITTINGS AS REQUIRED PRIOR TO REINSTALLATION OF PUMP. USE JOINT
COMPOUND SPARINGLY TO AVOID CONTAMINATION OF COOLANT. IF
FITTINGS WITH O-RING SEALS ARE USED THE O-RINGS SHOULD NOT BE
REUSED. USE A NEW O-RING AND LUBRICATE IT LIGHTLY WITH SILICON
GREASE.

e. Perform the above steps in reverse order to restore the cooling system to normal
operation.
f. Once pump operation is restored check the sight glass to be sure that air bubbles
are not present and that the level of coolant is adequate. Charge system as
required to maintain coolant level.

5.2.1.6 Pump Module Operation Without Transmitter

The pump module can be operated independently, without being attached to the
transmitter, by selecting the LOCAL mode on the pump module/heat exchanger cooling
control panel.

! CAUTION:
SELECTION OF LOCAL WILL ALSO ALLOW THE PUMP MODULE/HEAT
EXCHANGER TO BE OPERATED FROM THE CONTROL PANEL AS LONG AS
THE PUMP INTERLOCK IS NOT ACTIVE.

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HE-II Pump Module

Section 6 - Diagnostics
6
6.1 Inverter
The ToshibaVF-S15 industrial inverter display a wide range of error and failure codes that
may aid in troubleshooting. Refer to the Toshiba Inverter Technical Manual which
contains tabulated fault listings and troubleshooting help.This manual ships with the pump
module and is also available on line.

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Section 6 - Diagnostics HE-II Pump Module

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HE-II Pump Module

Section 7 - Parts List

7
ASSY, PUMP MODULE, HE II 50/60HZ, 208-240V/308-415V - - - - - - 995 0333 004 (A) 2
ASSY, PUMP MODULE, BASIC HE II - - - - - - - - - - - - - - - - 981 5607 004 (D) 2
KIT, AUX. PUMP MODULE PARTS - - - - - - - - - - - - - - - - - 971 5607 015 (A) 2
DP, PUMP MODULE HE II - - - - - - - - - - - - - - - - - - - - - - 988 2625 002 (A) 3
SPK, ULX/VLX HI EFFICIENCY PUMP MODULE, HE II - - - - - - - 990 0160 014 (B) 3

For table above and in tables that follow in this section the (X) or (XX) after the table
title part number is the revision level of that bill of material and is for reference only.

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Section 7 - Parts List HE-II Pump Module

Table 7-1 ASSY, PUMP MODULE, HE II 50/60HZ, 208-240V/308-415V - 995 0333 004 (A)
Harris PN Description Qty UM Ref Des
981 5607 004 ASSY, PUMP MODULE, BASIC HE II 1 EA
988 2625 002 DP, PUMP MODULE HE II 1 EA
817 2350 172 SPEC, INVERTER PROG INSTR 0 DWG
880 0333 000 TP, HE PUMP MODULE 0 DWG
990 0160 014 SPK, ULX/VLX HI EFFICIENCY PUMP MODULE, HE II0 EA
9950333001GWI WI, ULX/VLX HIGH EFFICIENCY PUMP MODULE0 DWG

Table 7-2 ASSY, PUMP MODULE, BASIC HE II - 981 5607 004 (D)
Harris PN Description Qty UM Ref Des
000 0000 010 BOM NOTE: 0 DWG
021 7510 002 HOSE, 1/2'' ID, BLUE 2.5 FT
021 7510 004 HOSE, GEN PURP EPDM 1.25ID RED 1.25 FT
299 0014 000 TAPE, PVC VINYL CLOSED RL
336 1254 000 *HOSE CLAMP, (MINI) SST, SAE-6 2 EA
354 0190 000 NUT, WIRE YEL 18-12 AWG 600V 8 EA
358 1036 000 *HOSE CLAMP, SST, SAE-152 1 EA
358 1316 000 HOSE CLAMP, SST, SAE-24 8 EA
358 3025 000 HOSE BARB, 0.50H X 0.50MPT 1 EA
359 1154 000 BUSHING, 1/2 X 1/4 MALE TO 1 EA
359 1617 000 VALVE, BLOWDOWN BALL 2 EA
359 1619 000 VALVE, PRESSURE RELIEF 75 PSI 1 EA
359 1621 000 VALVE, AUTOMATIC AIR VENT 1 EA
359 1625 000 CROSS, FXFXFXF 0.500 BRZ/BRASS 1 EA
359 1631 000 ELBOW BRS 90DEG 0.500F X 0.500M 2 EA
359 1632 000 ADAPTER, FXM 0.250 X 0.250 BRASS 2 EA
359 1634 000 ELBOW 1.25"ID HOSE X 1.25"MNPT 2 EA
359 1635 000 HOSE BARB, 0.50H X 0.50FPT 1 EA
629 0202 000 GAUGE, PRESSURE 0-100 PSI 2 EA
646 1683 000 LABEL, SAFETY GROUND 2 EA
778-225-003 HOLE BUNG DP-1000 2 EA
817 2150 037 GROUNDING PLATE 1 EA
843 5607 462 SKID, PUMP MODULE 0 DWG
943 5607 436 BACK 1 EA
943 5607 437 BASE 1 EA
943 5607 449 ASSY, INPUT PLUMBING, PUMP MODULE, HE 1 EA
943 5607 450 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE1 EA
943 5607 463 BRACKET, TANK 1 EA
943 5607 631 LABEL KIT, PUMP MODULE 1 EA
971 5607 015 KIT, AUX. PUMP MODULE PARTS 1 EA
359 1620 000 TANK, EXPANSION IN-LINE 2 GAL 1 EA
708 0061 020 MOTOR PUMP 126, 2HP 2 EA
971 5607 014 ASSY, CONTROL UNIT, PUMP MODULE HE II 1 EA

Table 7-3 KIT, AUX. PUMP MODULE PARTS - 971 5607 015 (A)
Harris PN Description Qty UM Ref Des
335 0489 000 FILTER, 304 SST, 20 MESH 1 EA
358 3185 000 PLUG WHT 1.093/1.125 HOLE 4 EA
359 1638 000 WASHER, FILTER GARDEN HOSE BRS 2 EA
424 0677 000 HOSE, RUBBER 6' W/3/4" CPLGS 2 EA

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HE-II Pump Module Section 7 - Parts List

Table 7-4 DP, PUMP MODULE HE II - 988 2625 002 (A)

Harris PN Description Qty UM Ref Des
843 5607 072 LAYOUT, TYPICAL PLUMBING 1 CABINET MAXIVA ULX XMTR0 DWG
843 5607 530 OUTLINE DRAWING / WIRING DIAGRAM, HE II PUMP MODULE0 DWG
888 2625 001 TM, PUMP MODULE 0 DWG

Table 7-5 SPK, ULX/VLX HI EFFICIENCY PUMP MODULE, HE II - 990 0160 014 (B)
Harris PN Description Qty UM Ref Des
021 7510 002 HOSE, 1/2'' ID, BLUE 2 FT
021 7510 004 HOSE, GEN PURP EPDM 1.25ID RED 2 FT
335 0487 000 O-RING, UNION 1-1/2" VITON 4 EA
335 0488 000 GASKET, UNION 1-1/2" EPDM 2 EA
335 0489 000 FILTER, 304 SST, 20 MESH 1 EA
336 1254 000 *HOSE CLAMP, (MINI) SST, SAE-6 2 EA
354 0190 000 NUT, WIRE YEL 18-12 AWG 600V 8 EA
358 1036 000 *HOSE CLAMP, SST, SAE-152 1 EA
358 1316 000 HOSE CLAMP, SST, SAE-24 9 EA
359 1617 000 VALVE, BLOWDOWN BALL 1 EA
359 1619 000 VALVE, PRESSURE RELIEF 75 PSI 1 EA
359 1620 000 TANK, EXPANSION IN-LINE 2 GAL 1 EA
359 1621 000 VALVE, AUTOMATIC AIR VENT 1 EA
424 0677 000 HOSE, RUBBER 6' W/3/4" CPLGS 2 EA
606 1232 150 CKT BRKR 15 AMPS 2P 240VAC 4 EA
629 0202 000 GAUGE, PRESSURE 0-100 PSI 2 EA
638 0075 000 SENSOR, THERMISTR NTC 100K OHM 1 EA
708 0061 020 MOTOR PUMP 126, 2HP 1 EA
708 0061 072 KIT, EPDM-CARBON/SILICON SEAL 1 EA
736 0498 000 INVERTER DRIVE, 240V 1PH 1HP 1 EA
736 0499 000 INVERTER DRIVE, 240V 1PH 2HP 1 EA
9010227101T PWA, PUMP CONTROL, TESTED 1 EA

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Section 7 - Parts List HE-II Pump Module

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HE-II Pump Module

Appendix A Remote Placement of Control Panel

A.1 Introduction

The 9950333005 HE Pump Module Conversion Kit facilitates remote placement of HE

control panel on 9950333001G, 9950333002G, and 99500333004G HE pump module
assemblies.

Note: The HE pump module control panel is designed for indoor use only. The pumps can
be used outdoors if cover (included in remote mounting kit) is installed as described in
Installation Drawing 843-5607-072 (sheet 7)

Tools:
• #2 Phillips Screwdriver
• Diagonal cutter
• Wire stripper
• Pliers
A.2 Procedure

Figure A-1 Front Cover Mounting Screws

STEP 1 Remove covers from pump module control panel by removing (6) screws.
STEP 2 Disconnect thermistor wire WAGO connector (Figure A-2); use WAGO extractor
tool to remove wires, then place WAGO connector back on board (for later reuse).

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 HE-II Pump Module

Figure A-2 Thermistor Wire

STEP 3 Disconnect the wires feeding each pump at the inverter output terminals. These
wires will attach to a motor disconnect switch once the control panel has been
removed.
STEP 4 Trace thermistor wires to rear of unit and use diagonal cutter to remove tie wraps.
STEP 5 Remove thermistor wire clamp and pad (Figure A-3); retain for later reuse.

Figure A-3 Thermistor Wire, Sensor, Pad, and Clamp

Figure A-4 Cooling Control Panel Conduit Fittings

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HE-II Pump Module

STEP 6 Remove control panel conduit lock nuts from both pump AC supply lines (Figure
A-4) allowing conduits and AC wiring to pull free of control panel when removed.

Figure A-5 Control Box Mounting Screws

STEP 7 Use a #2 Phillips to loosen the top two control box mounting screws on each side
of the control panel (Figure A-5).
STEP 8 Use a #2 Phillips to remove the lower mounting screw on each side of the control
panel (Figure A-5).
STEP 9 Remove control panel assembly from pump module chassis.
STEP 10 Refer to installation drawing 8435607072 (sheet 7). Mount the cooling control
panel indoors, in a dry location, preferably within sight of the transmitter. M8 (5/
16”) hardware is suitable for mounting the control panel. Drill holes as required in
the cooling control back panel to facilitate wall mounting. Mount the panel to
allow ventilation on all sides. Unistrut sections (supplied by customer) can be
mounted to the wall and the back of the control panel can be affixed to unistrut
sections.
STEP 11 Install pump A and B isolator switches (provided in kit) on the pump side of the
pump module chassis opposite, and in-between, the copper supply and return line
pipes. Use self tapping screws to mount the switches; take care not to screw into
the rigid copper tubes that lie on the opposite side of the mounting partition.
STEP 12 Install the AC mains conduit and wiring from the customer mains panel or
disconnect to the remote cooling control panel.

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 HE-II Pump Module

STEP 13 Install the pump module AC conduits and wiring from the remotely located control
panel to the isolator switches. Attach the AC supply wires and safety grounds to
the isolator switches. Attach the existing pump AC wires and conduit to the
isolator switches.
STEP 14 Install the fan AC conduits and wiring between the cooling control panel (inside
the building) to the customer supplied AC fan disconnects (located outside) near
the heat exchanger fans.
STEP 15 Install the fan AC conduits and wiring between the AC disconnect (outside the
building) to the heat exchanger isolator switches on the heat exchanger chassis.
STEP 16 Affix the thermistor wire and temperature sensor on the pump module return side
copper pipe or on the transmitter copper bypass assembly (transmitter inlet side)
inside the building. Route the thermistor wire (use customer provided conduit)
back to the control panel and attach the thermistor wires to the WAGO connector
(previously used).

NOTE:
50’ of audio wire and connectors (used to connect thermistor to control panel con-
nector) are provided in the remote control panel kit (see Figure A-6). The tempera-
ture sensor is non-polar and can't be hooked up backwards. Shield and drain wire
in audio cable are not used.

Figure A-6 Thermistor Sensor, Wire and Connectors

STEP 17 Route and install the cooling control wires between the transmitter (pump module
connector on top of cabinet) and the control board inside the cooling control panel.
Use customer provided conduit. Wiring is described in the pump module manual
888-2625-002 (Section 2) and in the external wiring diagram (843-5601-705
single cabinet, 843-5601-296 dual cabinet, or 843-5601-305 three cabinet)
supplied with the transmitter documentation package.

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HE-II Pump Module

NOTE:
Do not run control and monitoring wires in the same conduit as AC supply.

STEP 18 Install HE pump cover (provided with kit). The extension panel attached to the top
cover should be removed and reversed to cover the isolator switches. Insert the
hold down pin in each side of the cover to keep it in place on the pump module
chassis.

NOTE:
Refer to the transmitter ULX TM 888-2628-001, VLX TM 888-2610-001 and HE
pump module manual 888-2625-002 for instructions on cooling system installa-
tion, charging, and operation.

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 HE-II Pump Module

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