Essick N55 Owner's Manual
Models
CHAMPION•ESSICK
Evaporative Cooler Manual
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.
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 qualifi ed 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: T o reduce the risk of fi re or electric shock, do not
use this fan with any “solid-state fan speed control device.”
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.
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
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
fi lter 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.
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www.championcooler.com
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.
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.
• 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.
4). Slide receptacles into slots in
junction box.
Clip
Fig. 4
• Hook up electrical. Electrical hook up should be done by a qualifi ed
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. T ape 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.
W ARNING: Make sur e the cooler cabinet is properly gr ound-
ed to a suitable ground connection for maximum safety.
Wiring Diagrams
Installation
NOTE: The pump comes installed. The belt, motor pulley , and motor cord
and fl oat 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 Specifi cation Table.)
CAUTION: Never plug in cooler until installation is complete
and unit has been tested for rigidity.
Cut-Off Plate
Fig. 2
Blower
Housing
Fig. 3
Duct Adapter
Fig. 1
Motor
Clips
Adjustable
Yoke
Motor
Pulley
Blower
Pulley
• 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 op-
eration, 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 mo-
tor pulley so that it aligns with the blower
drive pulley (see Fig. 3) and tighten set
screw.
Electrical Installation
WARNING: Disconnect all electrical service that will be used
for this unit before you begin the installation.
2
120 Volts
Blue/Black
White
Brown
Pump
Motor
Hi
Lo
Com.
Ground
Black
Red
White
Green
Blower Motor
Orange
Green
Black
Red
White
Orange
Green
240 Volts
Blue/Black
White
Brown
Pump
Motor
Hi
Lo
Com.
Ground
Black
Red
Orange
Green
Blower Motor
Orange
Green
Black
Red
White
Orange
Green
Water Connection
• Install overfl ow 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
overfl ow pipe in the nipple to retain water.
The overfl ow 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.
= Wire Nut
= Wire Nut
Fig. 5
Pump
Hi
Lo
Com.
Ground
Pump
Hi
Lo
Com.
Ground
Fig. 6
1/4” Tubing
Fig. 7
To Switch
To Switch
Overfl ow Pipe
Nipple
Rubber Washer
Bottom Pan
Nut
Saddle
Valve
Cold
Water
Pipe
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• Install fl oat and attach water line to
fl oat. The fl oat may be installed in either
the corner post or bracket (see Fig. 9). If
you have model 3000DD/N31D then the
fl oat should be mounted to the bracket.
Refer to fi gure 10 for installation instruc-
tions. Insert the fl oat (1) thru the hole
in the corner post or bracket. Install the
washer (2) and nut (3). Tighten to keep
the fl oat from turning. Place the nut (5)
and ferrule (4) on the water supply line.
Connect to fl oat fi tting and tighten until
water tight.
• Fill pan. Allow water to fi ll to
within 1” of top of pan and adjust
fl oat to maintain this water level.
This can be accomplished by bending the fl oat 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.
Sillcock
Fig. 9
1
Faucet
Fig. 8
Corner
Post
Float
Fig. 10
Water Supply
Valve
Bracket
4
3
2
Nut
Ferrule
5
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.
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 specifi ed 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 sur e 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
6
your safety, turn unit of f 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
onto the pump. Press firmly to
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
not forget to replace the spout and
water delivery tube onto the pump
outlet.
Remove
Base
Impeller
Fig. 13
• Install Bleeder Tee and Tubing.
Refer to fi gure 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 overfl ow 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.
Pump Hose
Bleeder Tee
Bleeder Tubing
Restrictor
Overfl ow
Fig. 11
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 electrical power and remove pad frame. Unplug
motor inside cooler, this will protect you
from someone turning on unit while you are
working inside. This should be done for your
110503-1
Decrease
Amperage
Fig. 12
• 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, de-
pending upon the length of the season. At the beginning and at mid season
a clean pad is more absorbent and effi cient and will deliver substantially
more cool air.
• Check belt tension. A 3 lb. force should
defl ect the belt 3/4 inches (see Fig. 14).
Readjust belt if needed.
• Check bleed-off valve to be sure it is
not clogged.
3 Lb.
3/4 Inches
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. T o protect the life of the fi nish, 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.
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