AdobeAir MC63, MC64B, HC64A, MC43B, MC44B Installation Use And Care Manual

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Page 1
INSTALLATION USE AND CARE
PARTS REPLACEMENT
Evaporative cooling works on the principle of heat absorption by moisture evaporation.
Your evaporative cooler draws outside air into specially made pads soaked with water, where the air is cooled by evaporation, then circulated into your home.
Your MasterCool evaporative cooler has been designed to provide more efficient, consistent cooling through use of a long-life MasterCool pad. It is a cellulose fiber treated with stiffening and wetting agents
to provide the most reliable evaporative pad ever devised. Your cooler has two modules - wet and dry - which may be separated for service and cleaning, and
incorporates the most reliable components for long, trouble-free life.
MODELS: MC43/44B HC43/44A MC63/64B HC63/64A
REQUIRED: A special MasterCool motor kit is necessary for installation.
NOTE! READ AND SAVE THIS MANUAL -
"IMPORTANT SAFETY INSTRUCTIONS"
Model Number Serial Number
The model and serial numbers for your unit are located on the data plate attached to your cooler.
Record this information in the space allotted above.
This product covered by City of Los Angeles Research Reports RR930224 (for all single phase applications), or RR930190 (for 3 phase applications) Electrical, and RR8141 Mechani- cal. Copies of these reports are available from the manufacturer upon request.
MasterCool" II, 1
Page 2
Installation and Start-Up ............................................................ ................................
Mounting and Securing ....................................................................... 3
Electrical Connections ........................................................................ 3
Grounding ............................................................. '.............................. 3
Installing Motor ................................................................................... 3
Installing Overflow Standpipe and Drain Line ...................................... 4
Connecting Water Supply ................................................................... 4
Faucet Use ......................................................................................... 4
Adjusting Water Level and Float Valve ............................................... 4
Installing Bleed-Off ............................................................................. 4
Installing Float Shield ......................................................................... 4
Maintenance Schedule
Annual Start-Up/Shut-Down ............................................................... 5
Required Exhaust Openings ............................................................... 5
Pre Start-Up Inspection ...................................................................... 5
Periodic Inspection ............................................................................. 5
Checklist ............................................................................................. 5
Cabinet Cleaning & Touch-Up ............................................................ 5
Scratches & Bare Metal ...................................................................... 5
Changing Pad ..................................................................................... 5
Adjusting Belt Tension ........................................................................ 6
Lubrication .......................................................................................... 6
Cleaning Water Pump ........................................................................ 6
Snugging Down Set Screws and Nuts ................................................ 6
Washing Pad ...................................................................................... 6
Parts Replacement
Motor .................................................................................................. 6
Pump .................................................................................................. 6
Float .................................................................................................... 6
Bleed-Off ........................................................................................... 6
Troubleshooting ........................................................................................................ 7
Getting the most from your cooler ...................... t................................................... 7
Maintenance ....................................................................................... 7
Add-On Coolers .................................................................................. 7
Insulation ............................................................................................ 7
Multi-Speed Motor .............................................................................. 7
Attic Vents .......................................................................................... 7
Thermostat Control .......................................................................... 3,7
2 MastetCooP II
Page 3
Installation. and Start-Up
Read carefully before =nstalhng your MasterCo'bl evaporative cooler.
To install the unit the following tools are needed:
5132" hax key allen wrench
Channel locks
Pliers
Adjustable wrenches Tubing cutter
Screwdrivers
Hammer 114"Socket wrench
7/16" Socket wrench
Before attempting to install the cooler, make sure the following preparations have
been made:
Assure that the mounting sudace is strong enough to bear the weight of the cooler when in use; remember that when the system fillswith water, the cooler will be much heavier than when
dry. The operating weight for MC units is 250 pounds, and for HC units is 295 pounds.
Make sure you have adequate means for liftingthe cooler in place.
Make sure the mounting sudt_ceis level
in all directions.
Make sure any ductworkandelectrical
needscomplywithlocal,state,county, and federalcodes.
Caution: Aft electrical in-
stallations must comply
with local buflding and safety codes, and must be performed by qualified personnel only. ,
Mounting
The blower module and the media module can be separated before mounting by re-
moving tour bolts and one sh_ppingscrew
-see drawing below.
Placement and Securing
The duct opening for the 63/64 units should be about 20" x 20"+ The cooler
discharge opening for these models is
19-3/4 x 19-3/4". For the 43/44 units the
duct opening should be about 18" x
15". The cooler discharge opening for
these models is 17-3/4" x 17-3/4".
If the cooler is to be mounted on the roof, construct a suitable roof stand to support
the entire weight of the cooler. (The roof
jack or ducting should NOT be used to support any weight ofthe unit). For models MC63 or MC64 our #785 leg kit,sold sepa- rately as an accessory, willadequately sup-
port the unit and secure it to the roof. For High-Performance models HC43. HC44. HC63 and HC64 we recommend that a full stand be constructed in such a manner as to support the entire perimeter of the
cooler. A leg kit only may not provide
adequate support forthese mode!s due to
their increased size and weight.
Place the cooler over the roof jack and
position so that it is level. Carefully seal the space between the roof jack and bot- tom of cooler with caulking compound, silicone, asphalt or industrial sealing tape to prevent air leakage, Then care- fully seal the roof jack to roof with asphalt or caulking compound to prevent air leak- age from cooler or rain water from leaking into mot. (See Figure 1). There should be 24 inches clearance on all sides of the cooler for maintenance.
For maximum cooling performance and even water distribution, the cooler must be level. The base of the cooler
at the drain fitting should have at least
4" clearance to allow drain installation.
Electrical Connections
For the convenience of thermostat con- trol, we recommend installing a
MasterStat TM Universal Cooler Control Kit, Model CC1000A. Complete installa-
tion instructions are furnished with the CC1000A Kit. For electrical connections
to a rotary wall switch, use the following instructions:
Locate the junction box installed inthe dry module. Junction box is to be installed
with the receptacle facing away from the pad. Make certain all electrical cords are clear of the belt, water, pulleys and blower wheel. Note that there ere two
plug-ins, one for the motor and one forthe pump. The building power supply must be connected to this iunction box to provide power to the motor and pump. The wiring diagram in Figure 1 shows how the junc- lion box receptacle should be connected to the power supply. Make sure contro switch and circuit breaker are in the OFF
position. Low voltage electrical supply (below 105 V) may cause insufficient water supply to pad,
®
Caution: Turn off afi elec- trical power to the cooler before attempting to in- stall, open, or service
your cooler.
Grounding
Install a ground wire to suitable ground
according to local codes.
Install Motor
NOTE: A special MesterCool motor kit
Is necessary for installation due to the custom designed receptacle In the
junction box.
1. Adjust motor cradle spacing.
2. Place motor in cradle (see Figure 2). 3, Place straps over each end, connect to
cradle and tighten.
4, Align sheave (motor pulley) with blower
pulley by moving sheave in and out on
motor shaft until visual alignment is
achieved. Tighten alignment set screw to 125 in-lbs. Do not adjust to the point
where the motor sheave comes in con-
tact withthe motor face plate (see Figure
2). Belttensionshould be ad usted so the beltwi defect 1/21o3/4 nchatthecenter
of the span per Figure 3. Re-adjust belt tensionafter any pulley adjustment. Re- place worn or damaged belts.
MOTOR STRAPS
_---'"-___U PPORT BRACKETS
AE_IUSTNENT
BRACKET
F/gure 3
Figure t
230 VOLT INSTALLATION
MasterCoot _ I/, 3
Page 4
Caution: Disconnect all electrical power to the
cooler and insure that belt is not rotating before ad-
justing belt tension. Do
not adjust belt tension by
changing dlamefer of ad-
justable sheave. Adjust
belt tension only by ad-
justing motor brackeL
Rotate blower wheel by hand to see that it moves freely without rubbing against housing.
Check motor mountinq to be sure all screws and nuts are tightened down.
If cooler is connected to ductwork, air
delivery and motor amperage will be de- creased due to increased duct resistance.
To compensate for this, the motor pulley is adjusted out or in. using an ammeter to check motor amperage. For maximum air flow check motor amperage with all ser- vice panels in place. To prevent overload-
ing of the motor, check amperage with all windows and doors open and all relief systems operating. Tighten pulley set
screw to 125 in-lbs. A qualified serviceman is required to ad-
just motor before start-up.
Caution: Do not exceed
maximum amperage out- put as stamped on the mo-
tor specification plate or motor can overload. Only
qualified persons with proper electrical equipment and knowledge should ad-
just variable pitch sheaves. Do not allow
water to get on the motor, as it will burn
out the windings.
Note on multi-speed switches: A switch with separate terminals for the pump is
recommended.
Install Overflow Standpipe and Drain Line
Install overflow drain bushing in bottom
wet section onthe rightside. Screw plastic overflow standpipe into the drain bushing
and tighten snugly. Slide rubber washer over drain bushing, push through bottom of cooler, and tighten nut, Connect a per- manent drain (copper/pvc/garden hose) to the drain bushing for draining the unit and overflow protection. Drain should be in accordance with local plumbing codes.
FTgure4
WASHER
4 MesterCooP II
Connect Water Supply
Connect water line to cooler as follows:
A water valve should be installed at a
convenient location, to allow the water supply to be turned onand off. 1/4"tubing
is used to provide water to the cooler. A water connector kit, availubte from your dealer provides the necessary items.
Install float valve in the side panel of the
wet section opposite the pump.
Place tube nut and ferrule over end of tubing.
Insert tube into float valve, and tighten to
Secure.
qOTE: Soft water equipment should not be mttached to any water lines going "to a
ooler. "Soft Water" will cause corrosion
md decrease effective life of cooler.
Figure $
COMPRESSION NUT
FERRULE _.
_RULE___
Fasten 1/4 inch water supply line to cooler
stand using tubing clamp and self-drilling screw. Locate tubing clamp 18 inches or
less from water supply line entry intocabi- net. (See Figure 5A)
f
SI_LF-DRtLUNG
SCREW
1/4" WATER
SUPPlyLINE
Faucet Use
Connect water line to water supply, as fol- lows (refer to Figure 6).
Install a sillcock and water valve on
faucet, as shown. Place tubing nut and ferrule on tube end and insed in valve. Tighten nuts on valve and tube.
l( faucet is not to be used for water supply, installvalve on water lineto be used. Follow instructions above for securing tubing to valve.
Figure6 .,_,_ |t_--TUBING FROM
FAUCET , "
F.nau.E
vW',v .
SILLCOCK
Adjusting Water Level and Float Valve
Fillreservoir as follows:
Turn water supply on. Check for good pressure and flow from float valve.
When float valve shuts off. check water level. Water level should be from 1/2 to
1 inch below top edge of overflow standpipe. It may be necessary toadjust float valve by bending the rod (refer to Figure 5).
Check reservoir and all connections for leaks.
Install Bleed-Off
A bleed-off system is provided with your MastsrCoo| cooler. We recommend the
bleed-off be installed and maintained while operating this unit. Its purpose is to eliminate a small quantity of water from
recirculatlon thus reducing scale build-up.
Rgure 7
Install bleed-off as
follows:
Install 1/4" black
plastic tubing into pump as shown in
Figure 7.
Insert smaller
black plastic
tubing into 114" tubing as shown
in Figure 7.
Adjust bleed-off by shortening smalltube to get the proper bleed rate shown below.
Disposal ofbleed-off water shouldcomply with local codes. Use of chemical additives
or any water treatment otherthan bleed-off
isnot recommended forthiscooler. Failure
to use the bleed-off with MasterCool pad
greatly increases the mineral deposits and reduces the expected life of the MasterCool pad. and could result in early replacement of pad at your expense.
SECONDSTOFILLA 12OZ.CAN
Model MC43/44 MC43/44 HC43144
HC43/44
MC63;64
MC63/64
HC63/64 HC63/64
Motor Hp Seconds to fill
1/2 100
3/4 80
1/2 80 3/4 65 3i4 70 1,0 60 314 60
1.0 50
Install Float Shield
Installshield overfloat valve as shown in
F)gure 8.
Loop of cotter pin fits into hole in shield.
Cotter pin loop and hole must face
MasterCool pad.
IEIIT'_p R PIN
Page 5
Required Exhaust Openings
Using standard CFM ratings, a common [[_.L_ method of determining how much to open doors or windows for proper exchange is:
2 square feet per 1000 CFM.
Pre-Start-Up Inspection
Assure that:
Cooler mounting is level; duct is sealed.
Cabinet issecurely fastenndto mounting.
Cooler cabinet is grounded. Electrical connections are safe and secure.
Motor, pump, and float installed. Motor
and pump plugged into junction box.
Pump impeller turnsfreely. Remove pump
and basket. Remove impeller cover (see FigurelO and spin the impeller to assure free rotation).
Water line connectedsecurelywithout
leaks.Water supplyturnedon.
Floatadjusted forproperwaterlevel.
Blower, shaft, collar, and pulley set bolts
are snug (do not overllghtan pulley boll).
Pulley alignment okay; belt tension okay
(see page 3 for instructions).
Blowerbearingsarelubricated.Filloilcup witha goodgrade SAE2OWor30W oil
Pad is pre-soaked. Check to see that
pump starts and pad is evenly Wet.
Open windows or vents in house.
In case of trouble in any oi these stag_,
refer to the Troubleshooting Chad on page 7.
Caution: Never operate unit with service panels, pad
or inlet _ter removed This will result In am overloaded €ondition and may damage the blower motor.
Periodic Inspection
In addition to the planned maintenance schedule, regular inspection of your MasterCool cooler willenhance the chance
for longtrouble-free service life.
Checklist
Check for leaks
0 Is cooler level?
0 Are there dry spots on the pad when
cooler is in operation?
CI Does blower turn freely? 0 Isthere 25 Ibs.tension (models 63/64)
20 It=. tension (models 43/44) on drive belt?
0 Are bolts, nuts, and set screws snug?
0 Is float set correctly? 0 Iswater pan clean?
Cabinet Cleaning and Touch-up
The cabinet and all internal parts except blower and drives are fumlehed with a hard
appliance-type Polybond coating. This
surface ishighly resistantto scale and cor-
rosion.A softcloth, warm water, and a mild
cleanser will bdng all surfaces back to like
new appearance. Avoidsteel wool or sand- paper in normal cleaning ofthe cabinet.
Scratches and Bare Metal
In the unlikely event that scratches or bare
metal areasoccur, sand orrub the area with steel wool to prepare the finish. Paint with standard paint or touch-up paint available through your dealer.
Changing Pad
This should be done after 5 years or if passages are clogged.
NOTE: Hosing off inlet face of pad can
unclog passages of dust, and minerals ac- cumulated there. Light ecrapinge of the in- take edges of the pad will not harm its
openings and will remove more stubborn
scale.
Caution: Avoid splashing
water on blower motor.
Remove wet section top.
Remove water distdbutor assembly, disconnecting hose.
Lift out used pad sections.
Replace wllh new MastarCool pad only, available from your dealer. Aspen and other evaporative pads WILL NOT WORK.
Maintenance Schedule
Regular maintenance isa key to long successful service ofyour MasterCool cooler. The selvice schedule willhelp you maintain an efficient unit with good appearance.
MAINTENANCE REQUIREMENTS ANNUAL ANNUAL (LOCATION IN MANUAL) START-UP SHUT DOWN
Changing pad (p. 5) At beginning of6th
year or ifpassages
are blocked. Cleaning & touch-up (p. 5) X Cleaning water pump (!o.6) X Lubrication (p. 6) X Adjusting bell tehsion (p. 6) X As needed
Periodic inspection (p. 5) Duringcoolingseason Duringcoolingseason
Snugging downset screws & nuts(p. 6) X Adjustingblend-off(p.4) X Washing down pad withhose (p. 6) X
Drain allwater lines to and fromthe
cooler to prevent freezing X
NOTES: DO NOT UNDERCOAT THE WATER RESERVOIR.
Your MastarCoolIIcooler'swater reser- voirisfinishedwitha Polybond®appliance
type finish. It is so hard, asphalt type coolerundercoatwillnotstickto it.Under-
coat willbreak free and clog pump and
waterdistributor.
Do not use cooler cleaners, cooler treatments, or other additives in this evaporative cooler. The use of any of these products will void your warranty and may impair the
life of your evaporative cooler.
MasterCooP II* 5
Page 6
Adjust Belt Tension
Each time you inspect your cooler, be sure to check belt tension on motor/blower assem-
bly. Check belt condition and replace it if frays or defects appear: Check alignment of blower pulley with motor pulley.
Lubrication
Blower shaft bearings need periodic lubri-
cation. The oil cups on the blower shaft
bearings should be filled with a good grade
SAI= 20W or30W oilwhen necessary. Under
normal use, oiling is required every three months of operation. DO NOT OVER OIL.
The pump and blower motor do not require
lubrication.
Four
Rgure 9
tabs
Cleaning Water Pump
Disassemble and clean water pump as
follows:
Disconnect pump from electrical box.
Remove pump
To Prevent breakage, carefully release
the four snap-out tabs, and lift impeller base plate from the pump body.
Using a mild detergent solution, wash all deposits from inside around impeller
and impeller base plate.
Spin impeller to dislodge any foreign material.
Rinse and reinstall impeller base.
Reinstall pump.
Make sure to usa a pump screen or
basket. Check to sea if old one needs replacing due to clogging
®
Caution: Do not allow pump to topple over and become
submerged; water will
damage pump motor.
Snugging Down Set Screws and Nuts
Location of set screws and hardware that
should be snugged down.
Pulley set screw (150 in-lbs)
Blower set screws (150 in-lbs)
Wet and dry module connection bolts
Washing Pad
Annually, mineral a.ccumulation and dust should be washed off the intake sudsce of the pad. Use garden hose and nozzle. A
paint scrapper may be used to remove hard- ened scale from edges of intake passages in pad.
Parts Replacement
Motor
Removingold motor
Disconnectpowertocooler
Unplugfromjuncflonbox-4 pinplug
Loosenalignmentset_:mw on motorpuney(onmotorsideofpulley)
andmmevebaitand motorpulley,
Flemovemotorstrap6.
Pul motorfrombrackets,
Replacing motor
Reverseproceduretoinstall
new motor,
Pump Removing old pump
Disconnectpowerto cooler.
Unplugfromju_ box(3pinping),
Unscrewpumpbracket.
Liftoutpump.
Replacing pump
Remove impeller base plate at
bottom or pump by releasing tour tabs,
Spin impeller to assure free rotation.
Reinstall impeller base plata.
Clean old pump basket or replace.
Race pump in basket.
Attach bracket to cabinet.
Connect pump plug to junction
box (3 pin receptacle).
Connect pump hose to hose
fitting.
Bleed-off
Removal of old bleed-off
Replacebleedlineif necessary.
Installation of bleed-off assembly
To installbleedline topumpsee
Rgere7.
Bleedllneshouldfilla 12ounse beveragecanasindicatedinchart
onpage4.
Adjustblasd rate byshoriening smallbleedtuba.
Float Removing old float
Removefloatshield
Removenutand ferrulefrom
waterline.
Removelockwasherand nutfrom valve.
Liftfloatout o!cabineL
Replacing or installing float
valves:
Secure nutand lockwasher
holdingfloatto cabinet.
Placetubanutandferruleoverend oftubing.
Inserttubeintofloat valveand
tightentosecure.
Turnon lauoatallowingwaterto
enterthroughvalve,
Fill from1/2 to I inchbelowtop edgeof overflewstandpipe.
Adjustfloatballby bandingthe float armwitha pairol pliersto
achieve correctangle.
Reinstallfloatshield.
Page 7
Troubleshooting
Symptom Possible Causes
Unit fells to Itart of deliver NO elactrlcal power io unit
Ilr Fuse blown
_N breaker_ed
Co_s) damagedor
unplugged
Bel toolooseortootlgnt
M_ cve_ andfrozen
_t_m
Blowerwileelbeadngsd_y
Meleeoverloaded
Fauly wiriogm _lofts
Remedy
Checkpower
Replacetuse"
Resetbreaker"
ffcondition_s, can
eleclrk_n
PlugInco_ or replaceIf
damaged
Adjust_n ten_
Replace motor
Adjustbel tensionor replace
Lubdc=sblowerbearlr_s
Us_g =nm_ef, adlua rnolcrio lull bad amps(see motetnamep_e).
cal einctddan
Unit lUlrts but eir delivery Inidequete
_ _ s_e_ U exheu_
Motor Be4ioo bose
MamrCo¢padp_
alum windows or doors to
Increaseventkellon
Usingamm_er,aclu_ motorto lull_ (seemotornamep_e) AdJu_be#lanslonm replaceN needed
R_seormp_cepad
I_dequete cooling
_lao ex_uM In house,
Alrreg_siers_robe_
pos_oned.
Insufnclari w_. liow Io pad. pad r_o(weA.
:Pad
_'_n h_ _
Loose¢o_¢fk_ In _ler
mm
_ b_fl w_
O_oen w_dows or door to
InceNse ventliollon.
AdJusl to direct air as _slmd.
Check water Q_n wstem
Rinse orrep_ce pad
C_ _Ins
U_ pump.Cban Im_Uer _ ofaNfo_ m_er
Check for leeksand corre_
Rasel orreplacebleed-offkit
Cio;mbasket
.ot_ cycles on and off Exceesk,e b_dllenslon
Blow_•heirtighto_frozen
Meleeoverloaded Incormd sheaveadjustment
P_eys mba_gned _panels, padorInio_liter
Adjustbelttension
Lubrk:atebk)werbeadngsand rotatesha_by hand(poweroff)
Correct-donot exceedname plataamps. Servlcernanshouldadjust Ct_eckaNgnment Neveroperateu_t withsauce paneb,pador'_et flllarremoved.
INs wiNresultIn anevade•bed €o_dl_ andmaydamagemeier.
Wear dmlnl_ from FIO_[arm Improperly Ad_sl
overflow standpipe e_Justed
,_-_eatio IInatvalveleak_g *_ lanai',_ve
_r_t_ ._e_
Knocking or banging Bearings dr/ Lubd_e blowerbea/_lgs
sound Wbeelrul_r,gt_v,w * Irebedblowxabet.eol_,
hous_orro_k_o_beJ_ce _ e_ puky.N_vner_an_
L_ R_o_ _d
Blower shakes or rattles Bck or pulley loose Inspectbelland ad_ I needed.
,,wt_ben_-rit_acepuny.
Excessive humldl_ In _a_e e_lau_ Op_ _x_ Or_ la
harms vengei_on.
i Mu_y or unpleasant odor _ain _ s_ wal_ In _oir Dm_ Ilushand dean re_wo_
Pad_ldewed or clogged Checkbleed-_ seeing
Pad notcomplatel)'v_t beiore D_ypadanclbogotapan
coolerIsturnedon *Turnonwale_beioms_adlngu_
Newpad * NOTE:Themwillbea sl_l ode€" noticedonInNlaJs_-up. Tbeodo¢
wEdlsappeaJ-vAhhthe11mtk_v dayso_opera_bnI bleedolfIs used.
Getting the most
from your cooler
Your evaporative cooler is a finely crafted, eco- nomically operating unit built on decades of know-how and reseamh. It serves as the head of
an overall air cooling and moving system for your
home. Butthere are a number of ways you can maximize the comfort, efficiency, economy and convenience of your total cooling system.
Maintenance
Regular maintenance as recommended in this manual, isessential for cooling comfort, extend- ingthe life of yourcooler, and avoiding unneces- se_/pads replacements. Start-up and shutdown
servicing should never be ovedooked.
Add-On Coolers
Coolers come in a wide array of sizes, horse- power, and capacities, suitableforpatio, garage,
guestroom, and so fodh, More than one coolerin a single home improves the cooling effective- ness of the system. Owners of refrigerated air
conditioning have found that the addition of an evaporative cooler vastly reduces their electric
bills.
Insulation
Once your cooler forces cooled air into your home and pushes the hot air out, good insulation around your ductwork will keep the air as cool as possible. Whola-house insulation will prevent heat from seeping in and will also improve cool-
ing comfort.
Multi-Speed Motor
The cooling rate can be controlled by increasing
and reducing the amount of cooled air blowninto
your home. Two-speed motors allow youto use
higher speeds during the hottest pad of the day, lower speeds for milder temperatures.
Attic Vents
By exhausting cool air through the attic, you can reduce the temperature ofthis hotspot and make your home more comfodable.
Thermostat Control The addition of automatic control makes your
system convenient and efficient. We recommend the MasterStat TM, Model CC1000A, Universal
Evaporative Cooler Thermostat and Control Kit.
MasterCooP I1.7
Page 8
AdobeAir, Inc. * 500 S. 15th Street Phoenix, AZ85034
L411004A 1/96
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