Essick Air N55, N66D, N45S, N56, 5000 DD User Manual

...
0 (0)

C H A M P I O N • E S S I C K

Evaporative Cooler Manual

 

Models

3000 DD

N31D

3000 SD

N30S

4001 DD

N43/48D

4001 SD

N40/45S

5000 DD

N56/66D

5000 SD

N55/65S

Read carefully all of this manual before installing the unit.

Circle the model of your cooler and record the serial number below.

Encierre con un circulo el modelo de su enfriador y escribe el número de serie abajo.

Serial #

Número De Serie

Lea con cuidad todo este manual antes de instalar la unidad.

Read And Save These Instructions

Vea el Español en el interior

Safety Rules

1.Read instructions carefully.

2.Electrical hook up should be done by a qualified electrician, so that all electrical wiring will conform to your local standards.

3.Always turn OFF POWER and UNPLUG motor and pump inside the cooler before installing or performing any maintenance.

4.Your cooler will run on either 120V or 240V A.C., single phase, 60 Hz (cycle) current.

5.Motor and pump have a grounded, molded plug and an automatic thermal overload switch which will shut motor off when it overheats. The motor will restart automatically when it cools down.

6.Pump receptacle is for grounded evaporative cooler pump only. Do not plug anything else into receptacle.

WARNING: To reduce the risk of fire or electric shock, do not use this fan with any “solid-state fan speed control device.”

Evaporative Cooling

Evaporative cooling is nature’s way of cooling. When air is moved over a wet surface, water is evaporated and heat is absorbed. When stepping out of a swimming pool with the wind blowing, evaporative cooling makes you feel cool, even though the air may be warm. The human body itself is cooled primarily by the evaporation of perspiration.

This unit works on the same principle. Air is drawn across wet filter pads where the air is cooled by evaporation and then circulated throughout the building. It is this combination of cooled air and the movement of air over the skin which makes it feel cool.

Unlike refrigeration systems which recirculate the air, an evaporative cooler continually brings in fresh air while exhausting old air. You are completely replacing the air every 2 to 4 minutes by opening windows or doors or a combination of both. The air is always fresh, not stale, laden with smoke and odors as happens with refrigerated air conditioning.

Operation

For the best cooling performance, if the pads are dry, pre-wet the pads by running the pump for a few minutes before starting the blower.

These coolers may be used without water for ventilation purposes. When outside air is cool (for example, at night) or when humidity is high, the water pump can be turned off.

A cooler can also be installed with a thermostat and attic exhaust dampers to provide completely automatic operation.

Open Windows To Exhaust Air

An often misunderstood concept of evaporative cooling is the amount of air that should be exhausted. How much should you open your windows? The fact is that most people do not open their windows enough. The following two methods will help you determine the amount to open your windows.

CFM Method

You should allow an opening of at least 2 square feet (288 square inches) for each 1000 CFM rating of your unit. Example: At 3654 CFM, model 4001 DD with a 1/2 hp motor requires 7.3 square feet (1052 square inches) of opening (3654/1000 * 2 = 7.3). Multiply the number of windows by window width in inches and divide this into the number of square inches required for your size unit. This will give you the height to open windows. In this example, four 36 inch wide windows should be opened 7.3 inches each.

110503-1

www.championcooler.com

10-09

Essick Air N55, N66D, N45S, N56, 5000 DD User Manual

Champion Air Balancing Method

1.Take a piece of tissue paper and cut it lengthwise into 3 equal strips.

2.Turn your cooler on high cool.

3.Open one window at least six inches wide in each room that you want to cool.

4.Take the piece of tissue paper and put it up against the screen of the open window furthest from the cooler discharge opening. Let go of it. It will do one of three things.

IF

It falls down.

THEN

CLOSE all of the windows one inch and try step 4 again.

IF

It plasters itself to the screen.

THEN

OPEN all of the windows one inch and try step 4 again.

IF

It stays on the screen lightly.

THEN

PERFECT. You are done. Enjoy your cooler.

NOTES:

When switching to low cool, you must rebalance your home. Repeat step 4.

Once you balance your home you can cool some areas more than others by opening those windows more and closing the others by the same amount. Repeat step 4 to make sure your home is still air balanced.

Installation

NOTE: The pump comes installed. The belt, motor pulley, and motor cord and float are included in the cabinet, the motor is shipped separately.

CAUTION: Make sure that the mounting surface is strong enough to support the operating weight of the cooler when in use. (For operating weight, see Specification Table.)

CAUTION: Never plug in cooler until installation is complete and unit has been tested for rigidity.

Install Duct Adapters. If desired, a 4 piece duct adapter is available as an optional accessory. Call 1-800-643-8341 to obtain these from the factory. Align the holes in the duct adapter to the holes in the blower opening and attach using the provided screws (see Fig. 1). Repeat for all four sides. Note: All 4 pieces are identical except for models 5000SD & N55/65S which have an offset piece which attaches to the bottom of the outlet. To install this offset piece, remove the screws holding the cut-off plate and slide the offset duct adapter between the blower opening and the cutoff plate. You may need to loosen other screws to do this. Line up the holes and secure with the screws previously removed.

Motor Installation

Install motor cord. For typical 120V operation, connect motor cord to motor using the following color code: Black - Hi, Red - Low, White - Com., Green - Ground. (See Wiring Diagrams)

Mount motor. Install blower motor in the motor mount yokes, adjusting the yoke if necessary. Fasten with the provided mounting clips (see Fig. 2).

Install pulley. Install the adjustable motor pulley so that it aligns with the blower drive pulley (see Fig. 3) and tighten set screw.

Electrical Installation

Duct Adapter

Cut-Off Plate

Fig. 1

Motor

Clips

 

Adjustable

Fig. 2

Yoke

 

 

Motor

 

Pulley

Blower

Blower

Housing

 

Pulley

Fig. 3

 

WARNING: Disconnect all electrical service that will be used for this unit before you begin the installation.

Remove junction box. The elec-

Screws

Junction Box

trical junction box is located in the

 

 

upper inside corner of the cooler

 

 

cabinet. Remove the two screws

 

 

and remove the junction box (Fig.

 

Clip

4). Slide receptacles into slots in

 

junction box.

 

Fig. 4

 

 

Hook up electrical. Electrical hook up should be done by a qualified electrician, so that all electrical wiring will conform to your local standards. This unit is suppled with a 120V pump. For 240V pump operation, a 240V pump must be purchased. The fan and pump receptacles will support both 120V and 240V installations. See the wiring diagrams for 120V and 240V installations. Note: Clip pump cord onto cord clip located on the bottom of the junction box to keep cord our of the water.

IMPORTANT: When a single speed motor is used, do not use the red lead on the receptacle and motor plug wiring. Tape off end of both of the red leads.

CAUTION: Pump receptacle is for grounded evaporative cooler pump only. Do not plug anything else into receptacle. WARNING: Make sure the cooler cabinet is properly grounded to a suitable ground connection for maximum safety.

Wiring Diagrams

120 Volts

 

 

Blue/Black

Pump

 

 

White

 

 

 

Brown

 

Pump

 

Orange

 

 

Green

To Switch

Motor

 

 

Black

 

 

Hi

 

 

Red

Lo

 

Black

White

Com.

Hi

Orange

 

Lo

Red

Green

Ground

White

 

 

Com.

 

 

Green

 

= Wire Nut

Ground

 

Blower Motor

 

 

 

 

240 Volts

 

 

Blue/Black

 

 

 

White

Pump

 

 

Brown

Pump

 

Orange

 

 

Green

To Switch

Motor

 

Black

 

 

Hi

 

 

Red

Lo

 

Black

White

Com.

Hi

Orange

Lo

Red

Green

Ground

Orange

 

 

Com.

 

 

Green

 

= Wire Nut

Ground

 

Blower Motor

 

 

 

Fig. 5

 

 

 

Water Connection

Install overflow assembly. Place drain nipple through the hole in the pan, with the rubber washer between the pan and the head of the drain nipple (Fig. 6). Screw on nut and draw up tight against bottom of pan. Insert the overflow pipe in the nipple to retain water. The overflow pipe may be removed to drain the pan when necessary. A garden hose may be screwed on the drain nipple to drain water away from your unit.

Connect water supply line. Find the closest supply of water. Use a saddle valve (Fig. 7) to connect 1/4” tubing to the cold water supply or use a Sillcock and water valve connected to an outside faucet (Fig. 8). Place the nut and ferrule on the tubing and tighten the nut until water tight. IMPORTANT: Do not connect the water supply to any soft water applications. Soft water will cause corrosion and decrease the life of the cooler.

Overflow Pipe

Nipple

Rubber Washer

Bottom Pan

Nut

Fig. 6

1/4” Tubing

Saddle

Valve

Cold

Water

Pipe

Fig. 7

2

110503-1

Pump Hose
Bleeder Tee Bleeder Tubing
Restrictor
Overflow
Fig. 11

Install float and attach water line to

float. The float may be installed in either the corner post or bracket (see Fig. 9). If you have model 3000DD/N31D then the float should be mounted to the bracket. Refer to figure 10 for installation instructions. Insert the float (1) thru the hole in the corner post or bracket. Install the washer (2) and nut (3). Tighten to keep the float from turning. Place the nut (5) and ferrule (4) on the water supply line. Connect to float fitting and tighten until water tight.

Fill pan. Allow water to fill to within 1” of top of pan and adjust

float to maintain this water level. This can be accomplished by bending the float rod.

Level water troughs. Operate pump until pads are saturated. Check each trough to see if water is evenly dispersed in the trough. If they are not, loosen adjustment bolts and level trough. Retighten bolts. Check to see that all pads are saturated with water and that there are no dry spots or openings in the pads.

SupplyWater

Valve Ferrule Nut

Faucet

 

Sillcock

Fig. 8

Corner

Post Bracket

Float

Fig. 9

6 4 5

2 3

1

Fig. 10

Bleed-Off

Installation of the bleed-off kit is recommended to increase the life of the cooler. A bleed-off system is designed to prevent scale build up by continually removing a small percent of the water in the pan.

Install Bleeder Tee and Tubing.

Refer to figure 11. Cut the pump hose and insert the barbed ends

of the bleeder tee into each cut end. Insert one end of the bleeder tubing onto the bleeder tee and run the other end out of the cooler through the overflow pipe. Note: A

restrictor clamp is provided which, if desired, may be installed onto the

bleeder tubing to restrict the amount of water being bleed off. The amount of water to bleed off depends on the quality of the water in your area. Start with 1-2 gal/hr and increase if needed.

Amperage Draw And Belt Tension

This unit is equipped with an adjustable motor drive pulley for adjusting the blower wheel speed to the proper loading on different duct systems. It is important that the motor drive pulley is adjusted to correct size to assure maximum air delivery without damage to the motor. Be sure to follow these instructions carefully.

Adjust drive pulley. After the unit is completely installed, adjust the drive pulley to the least diameter and adjust belt tension. See the maintenance section for adjusting belt tension.

Start cooler. Install all pad frames, start pump, and allow to operate until pads are wet.

Check amperage. With pads wet and unit started, check amperage draw with an amperage meter.

Adjust pulley if necessary. If amperage

draw is less than motor rating, turn off elec-

Decrease

trical power and remove pad frame. Unplug

Amperage

motor inside cooler, this will protect you

 

from someone turning on unit while you are

 

working inside. This should be done for your

Fig. 12

 

safety. Adjust pulley to a larger diameter and readjust belt tension, plug motor in, install pad frame, and retest amperage draw. Repeat this process until correct amperage draw is attained. Increasing motor pulley diameter increases amperage draw. Decreasing motor pulley diameter decreases amperage draw (see Fig. 12).

CAUTION: Do not operate cooler with larger amperage draw than specified on motor plate.

NOTE: No attempt should be made to completely install this unit without the aid of an electrician or someone familiar with testing amperage draw. Failure to comply with these instructions may void your warranty.

Maintenance

WARNING: Before doing any maintenance be sure power is off. At the time you remove a pad frame be sure to unplug motor and pump. This is for your safety.

Spring Start-Up

Clean pump. Cleaning the pump is necessary once a year at start-up. For your safety, turn unit off and unplug motor and pump. Remove the pump from the mount slot. Remove the base of the pump (Fig. 13). Clean the pump and turn the impeller to ensure free operation. Remove the pump spout and check for any blockage.

After cleaning, reinstall the base

Remove

onto the pump. Press firmly to

Base

make sure it is secure. Reattach

 

the pump to the mount in the cooler

 

using the plastic retainer to ensure

 

that the pump will not overturn. Do

Impeller

not forget to replace the spout and

water delivery tube onto the pump

Fig. 13

outlet.

Oil bearings. The blower bearings and cooler motor in this unit should be oiled with a few drops of non-detergent 20/30 weight oil once each year. The motor does not need oil if it has no oil lines for oiling. Motors that have no lines are lifetime oiled at the factory and require no further oiling for the life of the unit.

CAUTION: Do not over oil. Over oiling can cause motor burn out, due to excessive oil getting into motor winding.

Change Pads. The pads should be replaced once or twice a season, depending upon the length of the season. At the beginning and at mid season a clean pad is more absorbent and efficient and will deliver substantially more cool air.

Check belt tension. A 3 lb. force should

3 Lb.

3/4 Inches

deflect the belt 3/4 inches (see Fig. 14).

Readjust belt if needed.

 

Check bleed-off valve to be sure it is

 

not clogged.

Fig. 14

WINTER SHUT DOWN

Drain water. Always drain all of the water out of the cooler and water supply line when not in use for prolonged periods, and particularly at the end of the season. Keep the water line disconnected from both the unit and water supply so that it does not freeze.

Unplug motor and pump. When cooler is not used for extended periods, unplug the motor and pump from inside cooler.

Cover unit. To protect the life of the finish, a cover for the unit is suggested in extended periods of non use.

By following the operating, installation, and maintenance suggestions as outlined, you can get many years of efficient and satisfactory service from your cooler. In the event additional information is desired, your dealer will be more than glad to assist you in every possible way.

110503-1

3

Troubleshooting

Problem

 

Possible Cause

 

Remedy

 

 

Problem

 

Possible Cause

 

Remedy

 

 

 

 

 

Failure to

1.

No electrical power to

1.

Check power

 

 

Motor cycles

1.

Low voltage

1.

Check voltage

start or no air

 

unit

 

 

 

 

 

on and off

2.

Excessive belt tension

2.

Adjust belt tension

delivery

• Fuse blown

• Replace fuse

 

 

 

3.

Blower shaft tight or

3.

Oil or replace bearings

 

• Circuit breaker tripped

• Reset breaker

 

 

 

 

locked

 

(Unplug unit)

 

• Electric cord unplugged

• Plug in cords or

 

 

 

4.

Bearings dry

4.

Oil bearings

 

 

or damaged

 

replace if damaged

 

 

 

5.

Motor pulley diameter

5.

Adjust pulley so full

 

2.

Belt too loose or tight

2.

Adjust belt tension

 

 

 

 

too large causing motor

 

load ampere rating of

 

3.

Motor overheated

3.

Determine cause of

 

 

 

 

overload

 

motor is not exceeded

 

 

 

 

overheating

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Belt too tight

• Adjust belt tension

 

 

Noisy

1.

Bearings dry

1.

Oil bearings

 

• Blower bearings dry

• Oil blower bearings

 

 

 

2.

Wheel rubbing blower

2.

Inspect and realign

 

• Motor pulley diameter

• Adjust pulley to cor-

 

 

 

 

housing

 

(Unplug unit)

 

 

too large

 

rect diameter

 

 

 

3.

Loose parts

3.

Tighten loose parts

 

4.

Motor locked

4.

Replace motor

 

 

 

 

 

 

 

 

Musty or

1.

Stale or stagnate water

1.

Drain pan and clean

 

 

 

 

 

 

 

 

Inadequate

1.

Insufficient air exhaust

1.

Open windows or

 

 

 

 

unpleasant

 

in cooler

 

pads

air delivery

 

 

 

doors to increase air

 

 

odor

2.

Pads mildewed or

2.

Replace pads

with cooler

 

 

 

flow

 

 

 

 

clogged

 

 

running

2.

Belt too loose

2.

Adjust belt tension or

 

 

 

3.

Pads not wetting prop-

3.

Check water distribu-

 

 

 

 

replace if needed

 

 

 

 

erly

 

tion system

 

3.

Pads plugged

3.

Replace pads

 

 

 

• Trough holes clogged

• Clean

 

4.

Motor underloaded

4.

Adjust pulley to full

 

 

 

• Pump not working

• Replace or clean pump

 

 

 

 

load ampere rating of

 

 

 

 

properly

 

(Unplug unit)

 

 

 

 

motor

 

 

 

 

 

 

 

 

 

 

 

Water drain-

1.

Float arm not adjusted

1.

Adjust float

 

 

 

 

 

 

 

 

Inadequate

1.

Inadequate exhaust in

1.

Open windows or

 

 

 

 

ing onto roof

 

properly

 

 

cooling

 

house

 

doors to increase air

 

 

 

2.

Overflow assembly

2.

Tighten nut and over-

 

 

 

 

flow

 

 

 

 

leaking

 

flow pipe.

 

2.

Pads not wet

2.

Check water distribu-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tion system

 

 

Excessive

1.

Inadequate exhaust

1.

Open doors or win-

 

• Pads plugged

• Replace pads

 

 

humidity in

 

 

 

dows

 

• Open spots in pads

• Repack pads

 

 

house

 

 

 

 

 

• Trough holes clogged

• Clean trough and

 

 

 

 

 

 

 

 

 

 

 

unplug holes

 

 

 

 

 

 

 

 

• Pump not working prop-

• Replace or clean pump

 

 

 

 

 

 

 

 

 

erly

 

(Unplug unit)

 

 

 

 

 

 

 

Register your product online at www.championcooler.com/eac/onlineregistration-eac.htm

Limited Warranty

This warranty is extended to the original purchaser of an evaporative cooler installed and used under normal conditions. It does not cover damages incurred through accident, neglect, or abuse by the owner. We do not authorize any person or representative to assume for us any other or different liability in connection with this product.

Terms And Conditions Of The Warranty

For Eight Years from date of Purchase, we will replace the original base assembly if water leakage should occur due to rust out.

For One Year from date of Purchase, we will replace any original component provided by Champion Cooler which fails due to any defect in material or factory workmanship only.

Exclusions From The Warranty

We are not responsible for replacement of cooler pads. These are disposable components and should be replaced periodically. We are not responsible for any incidental or consequential damage resulting from any malfunction.

We are not responsible for any damage received from the use of water softeners, chemicals, descale material, plastic wrap, or if a motor of a higher horsepower than what is shown on the serial plate is used in the unit.

We are not responsible for the cost of service calls to diagnose cause of trouble, or labor charge to repair and/or replace parts.

How To Obtain Service Under This Warranty

Contact the Dealer where you purchased the evaporative cooler. If for any reason you are not satisfied with the response from the dealer, contact the Customer Service Department: 5800 Murray Street, Little Rock, Arkansas 72209. 1-800-643-8341. E-mail: info@championcooler.com.

This limited warranty applies to original purchaser only.

4

110503-1

Loading...
+ 8 hidden pages