Installation and Operating ManualInstallation and Operating Manual
N A T U R A L L Y C O O L E R
N A T U R A L L Y C O O L E R
EXT Series
Evaporative Air Coolers
EXT Series
Evaporative Air Coolers
11
Index
INDEX
SAFETY.........................................................................................................1
Pre-Assembly Inspection...............................................................................2
Installation Details..........................................................................................3
Water Installation............................................................................................4
Electrical Installation.......................................................................................5
Wiring Diagrams.............................................................................................7
Maintenance.................................................................................................. 8
Trouble shooting ............................................................................................9
Installation Checklist......................................................................................11
Exploded View.& Parts List............................................................................12
SAFETY INSTRUCTIONS
Important Safety Instructions and
Warnings
WARNING: The warnings and safety
instructions in this manual must be
followed to reduce the risk of fire,
electric shock or injury, and to provide
reasonable safety and efficiency in
using this Evaporative Air Cooler. The
operator is responsible for following
the warnings and instructions in this
manual and on the cooler.
Read this entire manual before
proceeding to install the cooler.
Restrict the use of this cooler to
persons who read, understand and
can follow the warnings and
instructions in this manual and on
the cooler. NEVER ALLOW
CHILDREN TO OPERATE THE
COOLER.
Failure to observe these warnings
and instructions will void
manufacturer's warranties and will
discharge the manufacturer of all
liability.
CAUTION!
ALWAYS disconnect the cooler
from the power supply before
commencing maintenance
procedures.
During maintenance procedures,
NEVER use a naked flame for any
inspection or cleaning purpose as a
fire could be caused by a flame
coming into contact with the cooler
materials.
Avoid Dangerous Situations:
Protect the cooler from all sources
of ignition because polymers and
cooling pads will burn.
NEVER use a water hose to squirt
the interior of the cooler for cleaning
as residual water could damage
electrical components and create the
risk of fire and /or electric shock to
the user after re-assembly.
11
11
Safety
WATER PUMP
The water pump is supplied with this
cooler and is factory fitted into its
correct location.
Ensure that it is properly secured and
upright as intended.
There is no need to adjust the water
flow since the cooler is designed to
operate with maximum cooling at low
air velocities.
Water pump replacement
Factory authorized pumps are fitted
with thermal overload protection.
Water pumps may seize up and
overheat, creating a fire risk. Pumps
that have thermal overload protection
are designed to shut off the pump if the
motor overheats.
Factory Authorized water pump
Seeley "Tornado" pump (part no.
095851)
“Power Clean" Style Timed Pumps
Under no circumstances are "Power
Clean" style timed pumps to be
used in any Breezair evaporative air
cooler. Use of these devices or any
other non-approved device will cause
serious damage to the special safety
circuits of this cooler. Failure to follow
this instruction will VOID ALL
WARRANTY and may create severe
risk of electric shock and fire!
FAN MOTOR
This cooler is supplied with a fan motor
made by the cooler manufacturer.
USE ONLY THE AUTHORIZED FAN
MOTOR SUPPLIED.
Failure to follow this instruction will
VOID ALL WARRANTY and may
create severe risk of electric shock
and fire!
Factory Authorized Fan Motor
Seeley motors:
550W (3/4HP) motor part # 113043
The fan motor is equipped with inbuilt
overheating protection that will reset
automatically on cool-down to a safe
temperature. This may take up to 45
minutes.
CIRCUIT BREAKER
PROTECTION
This cooler is fitted with circuit breaker
protection for the fan motor and pump.
! Use only the power supply voltage
shown on the motor/cabinet
nameplate.
! Do not install or service the air
cooler during rain, high wind or severe
weather conditions.
! Keep children, bystanders and
animals at a safe distance, a minimum
of 30ft (10m) away from working
areas.
! Dress safely. Wear non-skid shoes
when working at high levels and roofs.
Do not wear loose clothing or personal
accessories while installing or
servicing the air cooler as they may
become caught in moving parts.
! Keep loose hair, loose clothing,
fingers and all other parts of the body
away from openings and moving
parts.
! Check the cooler for worn, loose,
missing, or damaged parts before
operation.
! If you work with power tools, wear
protective eyewear and gloves.
! Take care when lifting or raising the
air cooler to its final location. Use safe
equipment and never attempt to lift the
cooler alone. Always have assistance.
Otherwise you might damage the
cooler or the building or injure
yourself.
! Ground Fault Circuit Interrupter
(GFCI) protection should be provided
on the circuit supplying this air cooler.
Receptacles are available with built-in
GFCI protection.
! Air coolers installed on roofs must
not have the waste water directed
onto the roof as stains will occur.
Connect the cooler drain outlet to a
gutter or drain pipe using a suitable
hose.
! Always use the correct tools.
! WARNING! the packaging plastic
on this cooler can be a safety hazard.
Dispose of carefully.
! Never drill holes in the pan or walls
of the cooler.
! Avoid dangerous situations. Do not
use the cooler in the presence of
flammable liquids or gasses to avoid
creating fire or explosion. This air
cooler is NOT flame retardant. A fire
may result from contact with a flame
or from an electrical short.
! Use of wrong replacement parts
creates risk of severe electric shock
and fire which may result in serious
property damage, personal injury or
death.
INSTALLATION, REPAIR AND
OPERATION
! All installation and repair work
must conform to local electrical, water
supply and environmental codes,
rules and regulations and applicable
national standards.
! All installation, maintenance and
repair work must be done by a
licensed and qualified electrician
and/or a qualified, experienced
heating, ventilating, air
conditioning technician. All such
work must be effected with factory
authorized spare parts only.
! Disconnect electrical power at the
fuse or circuit breaker box before
installation commences. ALWAYS
turn OFF the isolating switch
(disconnect) located on the electronic
module inside the cooler BEFORE
commencing any maintenance
11
22
Pre-Assembly Inspection
PRE-ASSEMBLY INSPECTION
! Check that the correct cooler has been supplied. The cooler should have the following parts:-
(Check the parts are inside the cooler by removing a cooling pad frame.)
SLIDE UNIT ON ITS LID
TO AVOID DAMAGE TO
CUTOFF PLATE
ILL939-A
11
33
Installation Details
UNPACKING THE COOLER
Cut and remove the shrink wrap from
around the cooler. Using 2 people,
carefully lift the cooler up and away
from it’s skid (Fig 1).
REMOVING PAD FRAMES
Firstly remove the corner clips, which
are located above the top louvre and
third louvre from the bottom on all
corner joins. The clips will require a
screw driver to aid removal.
Each frame is clipped into the cooler
and is removed by use of a medium
sized screwdriver. Insert the
screwdriver into the small slots at the
top of the frame and lever upwards
until the clips disengage. The frame
is now free to be lifted out of the
cooler cabinet (Fig.2).
1
2
Keep the cooler away from heater
flues, exhaust vents (especially
kitchens) and sources of ignition.
Avoid dangerous situations.
Allow for adequate, SAFE access
around the cooler for maintenance,
especially for pad cleaning, water
connections, electrical connections,
drain connections.
It is mandatory that water cannot enter
the building as a result of poor sealing
(caulking or flashing) of the various
penetrations into the building (ducts,
necks, water pipes, electrical
conduits).
REPLACING PAD FRAMES
Ensure the pad frame is the correct
way up by checking that the louvres
face upwards. Fit the frame in at the
bottom along the edge of the pan and
rotate it in at the top. Take care not to
damage the Chillcel as the frame
approaches the plastic water
spreader under the top panel. Then
two sharp hits by hand should locate
the frame into its correct location
under the top panel. Replace the pad
frame clips at the corners
COOLER LOCATION
Check the proposed cooler location
first, to ensure it is structurally
capable of supporting the weight of
the cooler. Polymer coolers are lightweight but they require adequate
support. The largest cooler in the EXT
range is about 185 lbs (84 Kgs).
Always locate the cooler where there
is a plentiful supply of clean fresh air,
and not in a recess or close to the
ground where the air may be dusty or
polluted.
MOUNTING THE AIR COOLER
Handling and installing the cooler is
always much easier if you remove
the pad frames first.
New installation, roof jacks
Use 24 G or stronger metal roof jack.
The cooler may then be attached
directly to the jack.
Replacement installation, roof
jacks
Roof Jack recommended wall
thickness should be 24 G steel or
stronger. The supplied roof jack
adaptor may be required to attach the
cooler to the existing roof jack.
For assembly of the roof jack adaptor,
see Fig. 3.
4
5
RAISING COOLER TO IT’S FINAL
LOCATION
HANDLE WITH CARE. DO NOT DROP.
For lifting or pulling the cooler, always
apply the ropes around the full cabinet
or the fan housing and NEVER tie
them to any of the four corner posts.
WARNING! Take care when moving
the cooler that nothing is allowed to
penetrate into the discharge
opening (such as the end of a
ladder), as damage may occur to the
internal cooler components. If a
ladder is used as a slide for the
cooler to be pulled onto a roof or
platform, we strongly recommend
the cooler be turned upside-down
first. Protect the lid from scratching.
After placing the cooler on the roof jack
check that water spreaders and other
internal components are all securely in
place.
Attach the cooler to the roof jack from
inside the cooler (Fig. 6), using 1¼"
long self-tapping screws. Use a
minimum of six (6) screws. In high
wind areas or when not using leg
supports use a minimum of eight (8)
screws, 3 per side and 2 at the front.
3
NOTE! It is recommended that a strip
of foam or sealant is applied to the
upper flange on the roof jack before
securing the cooler to provide an
airtight seal.
Ensure that the top of the roof jack is
level, then check the lip of the pan for
level when the cooler is in position on
the roof jack. (Fig. 4)
6
The sump of the pan is designed to
be located on the low side of the roof
(Fig. 7)
44
Installation Details
SECURING LEG SUPPORTS
After levelling and securing the cooler
onto the roof jack you are ready to fix
the four leg supports. The telescopic
leg supports (with feet attached) slide
up and down inside the four cooler
corner posts.
By removing the screw from the lower
end of the corner post you enable the
leg support to slide down to roof level.
Refer figs 8, 9 & 10 for the procedure
for adjusting and securing the leg
supports.
8
9
If freezing conditions can occur at
any time, a drain down facility must
be provided at the lowest point of
the water supply pipe.
Install a manual water shut-off valve
near the point of entry of the water
supply to the cooler, in the permanent
water supply. In areas subject to
winter freezing, install a drain down
feature.
DO NOT FIT SHUT OFF VALVES
DIRECTLY ONTO THE FLOAT
VALVE NIPPLE.
WARNING!
Flush foreign matter from water supply
pipe before final connection to avoid
damage to the float valve.
Overflow & Bleed Off Feature
A special "bleed-off" fitting is supplied
with the cooler. It has a 3-fold function:
it acts as an overflow, a drain and a
bleed-off.
If the water level gets too high the
excess water overflows into the fitting
and away to waste. If the user wants
to drain the pan he can lift the fitting
out of the drain hole and the pan water
will run away to waste.
The bleed function must always be
commissioned, except in areas where
it is illegal to run water to waste. The
continuous bleeding of a small amount
of water to drain forces fresh water to
enter the cooler and reduces the rate
at which salt and scale build up on the
pads.
7
10
The support legs are not full weight
bearing and are only intended for
additional support in case of high
winds, etc.
WATER INSTALLATION
A permanent water supply is required
to be connected to the float valve that
is factory fitted inside the cooler. The
float valve controls the water level in
the pan automatically.
The water connection point is located
underneath the pan where the ½" float
valve nipple protrudes .(Fig. 11)
11
The bleed-off fitting is inserted into the
large hole already formed in the pan.
(Fig. 12). Screw the tank nut firmly
under the pan by hand.
12
Make sure the fitting is located
correctly in relation to the pads and
that the large O-ring is on before
placing the fitting into the hole in the
pan Secure with clips provided. (Figs.
12 & 13)
13
The drain adaptor allows the
attachment of a ¾" drain hose to run
water to a waste point. Attach it to the
bleed fitting underneath the pan by
using the drain nut. (Fig. 14)
14
1/2” BSP
1/2” or 1/4”
Water Inlet
55
Electrical Installation
15
16
The bleed rate can be varied
according to local conditions. With all
the plastic plugs removed from the
tray, minimum bleed will occur.
Insert plugs to increase the bleed rate
to suit your salt build up experience.
See heading Operating Adjustments
for further details.
In those areas where draining of
bleed-off water is illegal, the bleed
must be disabled.
WARNING! In cases where bleed-off
is not used the pads will require
frequent inspection and replacement.
Failure to do so may cause water to
leak into the building or onto the roof,
which may enter electrical
components creating an electric
shock or fire hazard. Where this
condition is allowed to exist, Seeley
International (Americas) accepts no
responsibility for any damage or injury
that might occur.
WATER LEVEL ADJUSTMENTS
Water level:
The water level in the cooler is
important. Adjust the level at the float
valve inside the cooler. Rotate the
large plastic float CCW or CW to
change the level. CW will lower the
level; CCW will raise the level. (Fig.
15)
NEVER ADJUST THE WATER
LEVEL WITH THE COOLER
RUNNING because the residual
water in the pads and pipes will cause
the water to over flow when it runs
back into the pan.
Water level should be about ¼" above
the float valve support shelf. (Fig. 16)
ELECTRICAL INSTALLATION
WARNING! When retro-fitting the
cooler to an existing installation
always turn off the electrical power at
the source of the wiring. DO NOT
TAKE RISKS! Turn off and tape over
the circuit breaker or remove the fuses
and keep them with you until the job is
complete. Set cooler, isolator switch,
wall switch, motor and pump to "off".
Be sure to tell other occupants of the
building what you are doing.
WARNING! Check to be sure that the
voltage rating of the cooler matches
your electrical system voltage.
The electrical installation must be
carried out by a licensed and qualified
electrician.
Wiring to the cooler must be rated at
cooler rated amperes or higher, and
must be protected by a suitable fuse
or circuit breaker. Cables are to be
double insulated all the way into the
cooler junction box.
Ensure that all electrical connections
are tight. Loose connections will cause
overheating that may lead to machine
damage or fire.
Replace all covers on completion of
the work, using only the screws
supplied.
Do not tamper with factory wiring.
Before leaving the job, a trained,
licensed technician must check that
the cooler is operating correctly, and
must set the motor full load amps
using a clip-on ammeter. Make this
adjustment at the motor pulley
(sheave). See later detail under
heading "Operating Adjustments".
The Power Pack fitted in this cooler
contains a junction box with main
power supply termination box
attached. (Fig. 17)
ILL813-A
A screw is required to lock the junction
box into position. (Fig. 18)
ILL814-A
17
18
The main power termination box is
made in two sections to facilitate easy
wiring connections. Knock-outs are
provided for ½" conduit. A hole must be
drilled for ¾" conduits. (Fig. 19)
19
Connect the power supply and control
cables inside this termination box as
shown on wiring diagram/s on page 7.
The junction box is factory sealed;
do not attempt to open it; there are
no field serviceable parts inside.
The junction box contains plug
receptacles for fan motor, water pump,
and other optional features if used.
Fan motor amperes must be adjusted
before closing the termination box
using a clip-on ammeter on the power
wires.
20
66
MOTOR POWER (AMPS)
Important: Install all the pad frames
except the one on the motor side.
Ensure that all intended doors,
windows or other means of exhaust
are open in the building, and that all
outlet grilles are open fully.
WARNING:
Beware of rotating fan, belt and
pulleys whilst making adjustments
to motor speed, pulley or belt
tension settings. Ensure the cooler
is switched OFF via the junction
box’s isolation switch whilst
working inside the cooler.
Set the cooler running at the highest
speed for about 10 minutes, or until
the motor has reached its normal
operating temperature (hot!).
Motor load must be checked
without the pump running.
Clip your ammeter onto the free cable
in the main termination box. (Fig. 21)
This should be done by a trained
licensed electrician.
For convenience, the rated motor
current, in amps, is printed on a
small label attached near the cable
fork (in addition to the normal
motor nameplate label located at
the back of the motor).
Check the measured amps against
the motor nameplate amps.
If the measured amps are less than
the nameplate amps the adjustable
motor pulley sheave must be altered
to increase the fan speed, thereby
delivering the full capability of the
cooler to your installation.
The measured amps must be equal
or close to, but never more than
the nameplate amps. (see heading
"Pulley (Sheave) Adjustment")
If the measured amps are greater
than the motor nameplate amps the
fan MUST be slowed down by
adjusting the motor pulley sheave in
the opposite manner. Failure to do
this will cause overheating in the
motor and may cause the motor’s
thermal protector to trip.
Replace all covers when adjustments
are completed using the screws
provided
PULLEY (SHEAVE)
ADJUSTMENT
The motor pulley is adjustable in order
to set the motor amperes at the
correct (nameplate) level, and thus
provide the owner with full machine
cooling capacity.
DO NOT USE THE PULLEY
ADJUSTMENT TO SET BELT
TENSION.
The adjustment is made with the
cooler switched OFF. Never attempt
this procedure with the cooler
operating.
Remove the drive belt.
To increase the fan speed (and
therefore the motor amps), the two
halves of the pulley must be closer
together, ie:turn the adjustable half
clockwise. (Fig. 22)
To decrease the fan speed (and
therefore the motor amps), the two
halves of the pulley must be further
apart, ie: turn the adjustable half
counter-clockwise. (Fig. 22)
A = Fixed Sheave
B = Grub Screw
C = Adjustable Sheave
D = Locking Cap
E = Locking Cap Screw
22
BELT TENSION
Belt tension is important. If it is too
tight there will be excessive belt and
bearing wear. If it is too loose there will
be belt slip, excessive belt wear and
loss of cooler performance.
There are two adjuster bolts with
locking nuts attached to the motor
mounting.
The tension should be adjusted so that
the deflection on one side of the belt is
5/8" to 13/16". To make the
adjustment, loosen the locking nuts
and screw the bolts in or out as
required to change the belt tension.
Re-tighten the locking nuts.
It is important to recheck the motor
amps again after re-setting the belt
tension.
Correct belt tension ensures the belt
will not slip. Check the temperature of
the belt by hand after each adjustment,
by turning off the cooler and holding
one side of the belt in your hand. If the
belt is warm to touch, it is slipping!
Continue to tighten until it runs cool.
(Fig. 23)
23
The outer half of the pulley is on a
thread and can be moved in or out by
removing the locking cap and then
turning the outer half by hand in the
desired direction.
When an adjustment is made, replace
the locking cap, aligning the screw
hole with the nearest hole in the
adjustable half. Lock it into place with
the securing screw. Refit the belt,
reset the belt tension, then run the
cooler and check the amps. Repeat
the process until the amp level is set.
You can start and stop the cooler for
this procedure by using the isolating
switch inside the cooler.
21
BLEED OFF
See previous heading "Overflow and
Bleed-Off feature" under "Water
Installation".
Adjusting the bleed rate is necessary to
reduce the salt deposit on the pads.
Salt deposit can NEVER be entirely
eliminated, only the rate of deposit can
be changed. The bleed feature causes
some salt concentrated water in the
pan to be drained away. Fresh water
enters the cooler automatically as the
salty water exits.
The rate of bleed will vary according to
water quality, but should be set to a
minimum rate as set out below:-
EXT155 (small cabinet): 0.08 gpm
EXT265 (large cabinet): 0.13 gpm
NOTE! Bleed adjustment cannot be
precise as operating conditions vary
continually.
NOTE! Previous warning about running
coolers without bleed-off.
Electrical Installation
WIRING DIAGRAMS
Wiring Option 1
Fig. 24 shows the field wiring for a 2
speed cooler WITH LINE SUPPLY
WIRED FIRST TO THE COOLER (not
first to the wall control).
NOTE! the cooler must be connected
in this way for successful operation of
the optional Salinity Manager/AutoDrain feature, as it requires a constant
source of power.
Wiring Option 2
Fig. 25 shows the field wiring for a 2
speed cooler WITH LINE SUPPLY
WIRED FIRST TO THE WALL
CONTROL (not first to the cooler).
NOTE! Option 2 will not support the
optional Salinity Manager/Auto-Drain
feature.
FOR INFORMATION CONCERNING
OTHER WIRING CONFIGURATIONS
CALL BREEZAIR TECHNICAL
DEPARTMENT. (800) 926-6824
HIGH
FIELD WIRING
HIGH
VENT
OFF
LOW
LOW
COOL
GROUND/EARTH
TERMINAL BOX
WALL
CONTROL
HOT WIRE/LINE VOLTAGE
USA WIRING DIAGRAM - 2 SPEED
SINGLE PHASE 115V (LINE VOLTAGE
WIRED TO COOLER)
COMMON/NEUTRAL
MOTOR CURRENT (AMP)
TEST POINT
FAN
CONTROL
PUMP
CONTROL
PUMP
HOT WIRE TO WALL CONTROL
GROUND/EARTH
COMMON/NEUTRAL
FACTORY WIRING (DO NOT DISTURB)
ILL1026-A
Wiring Option 1
HIGH
FIELD WIRING
HIGH
VENT
OFF
LOW
LOW
COOL
GROUND/EARTH
TERMINAL BOX
WALL
CONTROL
HOT WIRE/LINE VOLTAGE
USA WIRING DIAGRAM - 2 SPEED
SINGLE PHASE 115V (LINE VOLTAGE
WIRED TO WALL CONTROL)
COMMON/NEUTRAL
MOTOR CURRENT (AMP)
TEST POINT
FAN
CONTROL
PUMP
CONTROL
PUMP
GROUND/EARTH
COMMON/NEUTRAL
FACTORY WIRING (DO NOT DISTURB)
ILL1027-A
Wiring Option 2
24
25
77
Wiring Diagrams
Reset Pump Circuit Breaker 2 speed
Coolers ONLY:
(1) Disconnect power supply at the
main panel.
(2) Remove the junction box from the
blower housing.
(3) Invert the junction box and locate
the circuit breaker.
(4) Press the button until it "clicks" and
remains in. (Fig 26).
(5) Reposition the junction box on the
blower housing (ensure locking screw
is reinstalled. Fig 28).
Should a 2 speed motor overload, one
of the circuit breakers will trip, showing
a white button. To reset, press this white
button until it "clicks" and remains in.
26
ILL536-B
EXT COOLER
PUMP
CIRCUIT BREAKER
ILL813-A
28
27
11
88
Operating & Maintenance Instructions
In-season Maintenance
! Turn off the power supply to the
cooler.
! Remove pad frames
! Turn off the isolating switch inside
the cooler.
! Inspect the pads and clean or
replace as required (see previous
instructions under "Pre-season
Maintenance").
! Check water level and adjust if
necessary.
! Turn on the cooler isolating switch.
! Put the pad frames back on the
cooler.
! Restore main power supply and run
cooler according to the previous
instructions under "Operation of
Cooler".
End-season Maintenance
! Turn off the power supply to the
cooler.
! Remove pad frames
! Turn off the isolating switch inside
the cooler.
! Remove pad frames. Clean them by
hosing them with clean water, but do
not use excess pressure because you
might create holes in the pad media.
! Remove and clean the special water
"spreader" plates located under each
edge of the top panel. Do not
disconnect from water hose. When
replacing them, check underneath to
see that the spreaders are correctly
located in the notches under the top
panel.
! Drain all the water from the cooler
by removing the bleed tray. Do NOT
put it back until next season. Do not
lose the O-ring seal.
! Disconnect the water supply pipe
from the pan. Make sure no water is
left in the float valve. Leave pipe
disconnected and draining for winter to
prevent freezing and splitting.
! Clean the bottom pan thoroughly.
! Replace pad frames.
! Cover the cooler for winter if desired.
MAINTENANCE INSTRUCTIONS
Pre-season Maintenance:
NOTE! All maintenance must be done
by a trained, licensed technician.
! Turn off the power supply to the
cooler.
! Remove pad frames
! Turn off the isolating switch inside the
cooler.
! Fit new pads if necessary.
The life of Chillcel pads is generally
longer than traditional Aspen pads.
However the life depends on running
hours, quality of environment, weather
and water quality.
The pads supplied have been
selected to give the highest possible
cooling performance. WHEN
REPLACING PADS DO NOT USE
ALTERNATIVES. The manufacturer is
not responsible for the performance,
damage to, or safety of the air cooler
when alternative pads are used.
Using poor quality or incorrect pads
may cause water carry-over that
might enter electrical components
creating an electric shock or fire
hazard.
If the pads are re-used they can be
easily cleaned by hosing them with
clean water, but do not use excess
pressure because you might create
holes in the pad media.
! Replace the Bleed-off fitting. (This
should have been removed at the end
of last season. Ref. End Season
Maintenance).
! Reconnect the water supply line and
turn on the water supply.
! Check the float valve for correct
operation and check water level.
! Inspect and clean the pump filter and
impellor housing.
(To remove pump from filter)
Press release button on filter, twist the
pump body with button depressed, lift
pump body out of filter base.
! Check belt tension and adjust if
necessary.
! The main blower shaft bearings are
sealed for life and do NOT require oiling
or greasing.
! Turn on the cooler isolating switch.
! Put the pad frames back on the
cooler.
!Restore main power supply and run
cooler according to the previous
instructions under "Operation of
Cooler".
OPERATION OF COOLER
Using your Cooler:
Evaporative air coolers always function
on 100% fresh outside air.
Therefore you must either open doors
and windows, or, provide exhaust
outlets in the building. FAILURE TO
PROVIDE ADEQUATE EXHAUST
OPENINGS WILL CAUSE A BUILD UP
OF HUMIDITY INSIDE THAT WILL
BECOME VERY UNCOMFORTABLE.
Start up
! Turn on the water supply and make
sure the shut off valve at the cooler is
also on.
! Turn on electrical power supply.
! Wait a few minutes for the water to fill
the cooler pan.
! Turn on "cooling" at the wall control to
start the pump and pre-wet the pads.
! Turn on the fan to High or Low speed
as desired.
! In humid weather you may feel more
comfortable by turning off the cooling to
run the fan only.
! You can create your own pattern of
air flow in the building by adjusting the
outlet vents and doors and windows to
direct the air where you want it.
11
99
Troubleshooting
PROBLEM PROBABLE CAUSE SUGGESTED REMEDY
Under-sized cooler.
Replace with larger cooler.
Replace with larger ducts.Under-sized ducts.
Clean or replace pads.
Clogged or dirty cooling pads.
Check water distribution system for
possible obstruction in hoses. Check
pump.
Tighten belt by re-adjusting the motor
position. Replace belt if worn.
Dry pads or lack of water while cooler
is operating.
Belt slipping
Make sure there is adequate provision
for exhausting stale air from building
(open windows and doors).
Check motor amps. If below
nameplate amps, re-adjust motor
pulley to increase fan speed.
Insufficient air discharge openings or
inadequate exhaust from building,
causing high humidity and discomfort.
Fan running too slow.
Remove backdraft damper and
substitute manual slide damper.
Excessive resistance from poorly
located backdraft damper.
On days during summer when
ambient humidity is high the cooler will
not reduce the temperature as much
as on drier days. There is no remedy
except to shut off the pump.
Excessive ambient humidity (see also
item above re inadequate exhaust).
Inadequate Cooling
Air distribution system creating too
much back pressure, or changes of
direction too sudden, or grilles too small.
Have contractor re-evaluate his design;
use bends instead of elbows; change
grille sizes.
Fan out of balance due to dirt. etc. Clean the fan.
Noisy cooler.
Pump motor failure.
Pump fails to operate.
Pump circuit breaker tripped. Check pump for faults. Replace if
necessary.
Replace pump.
Fan fails to start.
Replace motor.
Check and tighten pulley and belt
Replace belt
Consult with power supply authority.
Replace controller.
Check fault condition via the tri-colour
LED on electronic module.
Rectify fault as indicated and restart the
cooler. (Refer Pg. 15-16)
Main power circuit breaker tripped or
fuse blown.
Fan motor burned out.
Belt or pulley loose
Belt broken
Check cause of overload. Reset circuit
breaker or replace fuse. Adjust motor
amp setting if necessary.
Low system voltage.
Controller failed.
11
1010
PROBLEM PROBABLE CAUSE SUGGESTED REMEDY
Float valve adjustment not correct.
Adjust float valve.
Continuous overflow of water.
Insufficient water in pan.
Adjust float level.
Pump runs but no water circulation.
Pump runs but pads lack water.
Water hoses blocked. Check and clean out blockage.
Pump strainer blocked.
Clean pump strainer.
Troubleshooting
Heavy pad deposits.
Clean or replace pads.
Pads not fitted correctly into pad
frames.
Make sure pads properly installed.
Water level too low, causing pump to
create fountain that is being sucked
into air stream.
Increase water level.
Incorrect or damaged pads fitted.
Replace with manufacturer's
recommended pads.
Loosen water hose connections.
Tighten all connections.
Water being blown into the
building.
Water hose broken.
Cover not fitted on float valve.
Replace any cracked or broken hoses.
Install correct cover on float valve to
prevent spray.
Unpleasant odour.
New cooler pads.
Cooler located near source of
unpleasant odour.
Algae in pan water.
Pads remain wet after shut down.
Heavy pad deposits.
Drain pan, refill, run pump for a while.
Remove source of odour or relocate
cooler.
Drain pan, clean thoroughly with strong
cleansing agent, refill, change pads.
Run fan on "vent" for 10 minutes after
cooling cycle to dry pads out.
Clean or replace pads.
Belt slipping or wearing
excessively.
Belt loose.
Pulleys out of line.
Worn belt.
Worn or warped pulleys.
Moisture on belt.
Tighten belt.
Align pulleys.
Replace belt.
Replace and re-align pulleys.
Stop any water leaks.
Cooler level and secure.
All roof work properly sealed.
Ductwork and air distribution checked and outlets correctly set.
All wiring complete.
Control switch correctly installed.
Motor and pump correctly plugged into sockets.
Drain/overflow fitting correctly installed.
Water level and float adjustment checked.
Pump runs and water evenly distributed to all cooling pads.
All control functions checked.
Owner instructed on correct operating procedure and supplied with
operating instructions.
Signed by Installer: …………………………………………………
Dated: ………………………………………………………………
SERVICE ENQUIRIES:
Contact your local Dealer or Installer
for assistance.
Owners Name:______________________
__________________________________
Telephone:_________________________
Address:___________________________
__________________________________
__________________________________
Dealer:____________________________
__________________________________
Installer:___________________________
__________________________________
Date Installed:_______________________
Model No.:__________________________
Serial No.:__________________________
Motor Type:_________________________
Motor Power:_________________________
11
1111
Installation Checklist
11
1212
Exploded View
PAD RETAINING PIN
PAD RETAINING WASHER
BLEED FUNNEL ASSEMBLY
PAN (Tank)
HOSE 1/2” ID, PVC - Water
BELT ADJUSTING ASSEMBLY
HOSE 3/4” ID, PVC - Water
1
1
4
4
8 or 16
8 or 16
1
1
1
DESCRIPTION
POST, CORNER
J-NUTS & SPEED NUTS
3
FLOAT VALVE
2
1
ITEM
SCROLL (Blower Housing)
4
5
7
6
8
9
10
11
12
PUMP - Water Circulation
SUPPORT - Leg Foot
SUPPORT - Leg Extension
SPREADER - Water Distribution
LID
BRIDGE
PULLEY, MOTOR - Adjustable
4-WAY DISTRIBUTOR (Water)
2
QTY
1
4
1
4
1
4
1
4
1
1
1
13
ITEM
14
15
16
17
18
DESCRIPTION QTY
19
20
21
22
23
V-BELT
JUNCTION BOX
PAD FRAME
CHILLCEL COOLING PAD
US 0710838724-D
Evaporative Air Cooling Manual. Seeley International Pty Ltd, Adelaide, South Australia. ACN 054 687 035.
As the policy of the company is one of continuous product improvement, all specifications are subject to change without notice.
Seeley International (Americas)
Phone: 602-353-8066
Fax: 602-353-8070
Toll Free: 1-800-926-6824
www.convaircooler.com
TM
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