Essick Air 21 DD User Manual

Industrial / Commercial

Evaporative Cooler Manual

Models
75/85 DD 75/85 SD
95 DD 95 SD
10/12 DD 10/12 SD
14/21 DD 14/21 SD

Read Carefully All Of This Manual Before
Installing The Unit.

Lea Con Cuidado Todo Este Manual Antes De
Instalar La Unidad.

Read And Save These Instructions

Table Of Contents

Safety Instructions ...........................................................................2

Operation ..........................................................................................2

Installation Instructions ................................................................2-3

Maintenance Section ........................................................................3

Electrical Wiring Diagrams ..............................................................4

Troubleshooting ...............................................................................5

Warranty ...........................................................................................5

Parts Drawing (Dibujo de Piezas) - 10/12SD, 14/21SD ..................6

Parts Drawing (Dibujo de Piezas) - 10/12DD, 14/21DD ................7

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

Vea el Español en el interior.

Parts List (Lista de Piezas) - 10/12, 14/21 .......................................8

Parts List (Lista de Piezas) - 75/85, 95 ............................................9

Parts Drawing (Dibujo de Piezas) - 75/85DD, 95DD ....................10

Parts Drawing (Dibujo de Piezas) - 75/85SD, 95SD .....................11

Motor Specifi cations (Especifi caciones del Motor) - 75/85DD, 95DD
Motor Specifi cations (Especifi caciones del Motor) - 75/85SD, 95SD
Motor Specifi cations (Especifi caciones del Motor) - 10/12, 14/21

General Specifi cations (Especifi caciones Generales) ...................12

Spanish (Instrucciones en Español) .........................................13-16

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..11

....12

110525 9-09

Safety Rules

1. Read instructions carefully.

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

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

4. For a maximum safety precaution, make sure cooler cabinet is
properly grounded to a suitable ground connection.

Motor Installation

• Mount motor. Slide the heads of the provided carriage bolts into

the slots of the adjustable channels. Slide these channels sideways
in the slotted holes to align with the holes in the motor base and to
align the motor shaft with the blower pulley. Mount the motor to
the motor mount using these carriage bolts and the washers and nuts
provided (see Fig. 1). Make sure all bolts are securely tightened.

• Install pulley. Install the adjustable motor pulley so that it aligns

with the blower drive pulley (see Fig. 2) and tighten set screw. See
page 3 for instructions on adjusting pulley.

5. Cooler must be connected to proper line current, voltage and cycle,
as stamped on cooler motor and pump motor specifi cation plate.

6. Do no allow pump to tip over and become submerged.

7. Always DISCONNECT POWER before installing unit or
performing any maintenance.

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 also 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.

IMPORTANT: T o cool effi ciently, you must exhaust the stale or used
air from the building. Open windows or doors or use exhaust fans
located away from the cooler and in the direction you wish to cool
the air. The air will fl ow in the direction of the exhaust openings. A
common guide for the amount of exhaust opening needed is to have
at least 2 square feet of opening per 1000 CFM.

Installation

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.

CAUTION: Make sure all bolts are securely tightened before

starting the cooler.

• Ductwork. See the General Specifi cation table for the duct open-

ing dimension for your specifi c cooler. For down discharge units
models 10/12DD and 14/21DD, the duct must go inside the opening.
Size these ducts slightly smaller than the duct opening in the cooler.
On 75/85DD and 95DD models the duct may go to the inside or
outside of the duct fl ange. The side discharge units have a 1 inch

fl ange. Size these ducts larger than the duct opening to fi t over the
fl ange of these units.

Note: Curbs are not provided. The installer is responsible for
providing curbs or other means to support the cooler.

Motor
Pulley

Fig. 1

Blower

Housing

Adjustable
Channels

Fig. 2

Blower
Pulley

Electrical Installation

NOTE: Local building code regulations must be observed.

WARNING: Disconnect all electrical service that will be used

for this unit before you begin the installation.

• Electrical Supply. Cooler must be supplied with the proper line

current, voltage and frequency, as stamped on cooler motor and
pump motor specifi cation plate. See the wiring diagrams on page
4 for typical electrical connections. NOTE: Connecting improper
voltage to motor will void motor warranty.

• Wire sizing. The conductor sizes are to be determined by motor

loads and length of run per national and local electrical codes.

• Switches or contactors. Motors require switches or contactors

of proper current capacity and should be sized and installed by a
competent electrician.

WARNING: Make sure that cooler cabinet is properly

grounded to a suitable ground connection for maximum safety.

Water Connection

• Overfl ow assembly. Remove nut and place nipple through the hole

in the pan, with the rubber washer between the pan and the head
of the drain nipple (Fig. 3). Screw on
nut and draw up tight against bottom
of pan. Insert overfl ow pipe in nipple
to retain water. Overfl ow pipe may be
removed to drain pan when necessary.
A garden hose may be screwed on the
drain nipple to drain water away from
your unit.

• Pump. The pump must be secured to prevent it from tipping over.

Secure the pump to the pump mounting bracket. For the 10/12 and
14/21 models, remove the mounting screw on the top of the pump
and using this same screw, secure the pump to the pump mount. T o
secure the pump for the 75/85 and 95 models, slide the pump into
the slot of the pump mount and secure with the plastic retainer.

Overfl ow Pipe

Nipple
Rubber Washer

Bottom Pan
Nut

Fig. 3

2

110525

• Water Supply. Run a water supply line to the unit. The fl oat
valve requires a 3/8 inch tube connection. NOTE: Do not use

water supplied from a water
softener.

• Float valve. Install the fl oat

Mount Bracket

Water Supply

Line

valve to the mount bracket in
the cooler (Fig. 4) and attach

Float Rod

water supply line. Note: 75/85
and 95 units come with the fl oat
valve installed. For the other
models, the fl oat is purchased
separately.

Fig. 4

Washer

Nut

Nut

Ferrule

• Filling pan. Turn on water supply and check for leaks. Allow
water to fi ll to within 1” of top of pan. Loosen the screw on the
fl oat rod to adjust the fl oat and retighten the screw.

• 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.

• Bleed-Off. Use of a bleed-off kit is recommended to prevent scale
build up by bleeding off small amounts of circulating water during
operation. Do not add any type of water treatment chemicals to the
water.

Pulley And Belt Adjustments

• Pulley adjustment. With an ammeter, check the motor amper-
age. Adjust the pulley until the amperage draw on the motor is
just below that specifi ed on the motor
nameplate. T o adjust the pulley , loosen
the adjustment set screw and rotate the
sheave. Tighten the set screw so that
it is over a fl at area, otherwise thread
damage will occur. To increase amper­age draw, increase pulley diameter.
To decrease amperage draw, decrease
pulley diameter (Fig. 5). Recheck belt
alignment.

CAUTION: When it is necessary to adjust pulley, amperage

of motor must be checked to make certain it does not exceed the
maximum allowed as stamped on motor specifi cation plate. Im-
proper pulley adjustment will overload and burn out motor.

Decrease

Amperage

Fig. 5

Maintenance

WARNING: Before doing any maintenance be sure to discon-

nect from power source. This is for your safety.

Spring Start-Up

• Belt tension. Check belt tension and readjust if needed.

• 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 oil 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 effi cient and will
deliver substantially more cool air.

• Clean pump. Cleaning the pump is necessary once a year at start-

up. For your safety, disconnect from power source and unplug
pump. Remove the pump from the mount bracket. Remove the base
of the pump (Fig. 7). 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. Reat­tach the pump to the mount
in the cooler to ensure that
the pump will not overturn.
Do not forget to replace the
spout and water delivery tube
onto the pump outlet. The
pump has automatic reset
thermal protection. Pump
will operate normal again
after obstruction is cleared.

• Bleed off. Check bleed-off valve to be sure it is not clogged.

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.

Remove

Fig. 7

• Belt tension. Loosen the motor
mount bolts and slide the motor
back until the belt is properly
tensioned. A 3 lb. force should
defl ect the belt 3/4 inches (see Fig.

6). Retighten motor mount bolts.

Do not adjust pulley to tighten
belt.

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3 lb.

3/4 Inches

Fig. 6

• Disconnect from power supply when not in use for extended

periods of time.

• Cover unit. To 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 effi cient and satisfac-
tory 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.

3

Typical Electrical Wiring Diagrams

Disconnect Switch At Cooler
See Notes 1 & 2

Equipment

Ground

Blower Motor

208, 240, or 480 Volt, 3 Phase Blower & 120 Volt 1 Phase Pump & Control Electric Supply

Motor Starter With
Overload Protection Sized
To Match Motor Full Load
Current
See Note 1

Disconnect Switch At
Cooler
See Notes 1 & 2

120 Volt, 1 Phase Electric Supply

Control Contacts

L
H
P

N

Fuses

See Note 1

Cooler Cabinet

See Note 3

See Note 4

• 115 Volt single phase blower motor.

• 120 Volt pump motor.

• Diagram shown for two speed motor.
Low speed circuit drawn with dashed

Pump Motor

T3
T2
T1

Gnd

Equipment

Ground

lines is not required for single speed.

Control Contacts

See Note 4

Blower Motor

L1

120 Volts

N

Power Supply

N

Gnd

Fuses

See Note 1

1 Phase

• Three phase single speed blower motor

• Three pole motor starter with overload

• 120V single phase control and pump shown.

GndGnd

Main Disconnect
See Note 1

H
P

Disconnect Switch At Cooler
See Note 1&2

Cooler Cabinet

See Note 3

Pump Motor

240 Volt, 1 Phase Electric Supply

Disconnect Switch At Cooler
See Notes 1 & 2

L
H

120V

P

Gnd

Transformer

Cooler Cabinet

See Note 3

L2

• 230 Volt single phase blower motor.

• 120V pump motor shown. Trans-

Equipment

Ground

Blower Motor

Pump Motor

Gnd

L1
L2
L3

Main Disconnects
See Note 1

L1

Gnd

208, 240, or 480V

N

3 Phase

Power Supply

120V

1 Phase

Power Supply

• Diagram shown for two speed motor.

protection

If 240V control and pump are to be used, then
both legs of power supply must be fused.

Control Contacts
See Note 1

L1

208 or 240V

Fuses
See Note 1

L2

Gnd

Main Disconnect
See Note 1

1 Phase

Power Supply

former may be omitted when a 240V
pump is used with a 240V supply

Low speed circuit drawn with dashed
lines is not required for single speed.

Typical Control Contacts
Function and Connection

L - Low Fan
P - Pump
H - Hi Fan
L1 - Supply Power

Function Connection
Off None
Pump Only L1-P
Hi-Cool L1-H
* Low-Cool L1-L & L1-P
Hi-Fan L1-H
* Low-Fan L1-L

* Omit for single speed blower motor

208, 240, or 480 Volt, 3 Phase Blower Electric Supply With Transformer For Pump & Control

Motor Starter With
Overload Protection
Sized To Match Motor
Full Load Current
See Note 1

Disconnect Switch At Cooler

See Notes 1 & 2

T3
T2
T1

Gnd

Equipment

Ground

Control Contacts

See Note 4

Blower Motor

H

P

Disconnect Switch At Cooler
See Notes 1 & 2

Cooler Cabinet

See Note 3

Pump Motor

120

V

Fuses

See Note 1

Transformer
See Note 1

• Three phase single speed blower motor.

• Three pole motor starter with overload protection.

• 120V single phase pump powered by a transformer.
Transformer may be omitted when 240V control &
pump are used with a 240V supply.

Gnd

L1
L2
L3

Main Disconnect
See Note 1

208, 240 or 480V

3 Phase

Power Supply

WARNING: Electrical hookup should be performed by a qualifi ed electrician. All electrical wiring must conform to national and

local standards.

NOTE 1. All switches, motor starters, transformers, fuses, junction boxes, receptacles, receptacle boxes, cover plates, and conductors shall be supplied by the

NOTE 2. The national electric code requires a disconnect switch located at equipment if the main disconnect at equipment controller is not visible from the equip-

NOTE 3. A receptacle for a NEMA 5-15P plug is required for 120V recirculating pump and a receptacle for a NEMA 6-15P plug for 230V pump.
NOTE 4. The control contacts may be part of a switch, thermostat or other control device.

installer and must comply with local and national electrical codes.

ment. If more than one disconnect is used they must be mounted adjacent to one another.

4

110525

Troubleshooting Guide

Problem Possible Cause Remedy

Failure to
start or no
air delivery

Inadequate
air delivery
with cooler
running

Musty or
unpleasant
odor

1. No electrical power to unit

• Fuse blown

• Circuit breaker tripped

2. Belt too loose or tight

3. Motor overheated

• Belt too tight

• Blower bearings dry

• Motor bearings dry

• Motor pulley diameter too
large

4. Motor locked

1. Insuffi cient air exhaust

2. Belt too loose

3. Pads plugged

4. Insufficient water flow

over pads

1. Stale or stagnate water in

cooler

2. Pads not wetting properly

• Trough holes clogged

• Pump not working prop­erly

• Insufficient water flow
over pads

1. Check power

• Replace fuse

• Reset breaker

2. Adjust belt tension

3. Determine cause of over­heating

• Adjust belt tension

• Oil blower bearings

• Oil motor bearings

• Adjust pulley to correct

diameter

4. Replace motor

1. Open windows or doors
to increase air fl ow

2. Adjust belt tension or
replace if needed

3. Clean pads

4. Clean water distribu­tion system and trough
openings

1. Drain pan and clean
pads

2. Check water distribution
system

• Clean

• Replace or clean pump

(Unplug)

• Clean distribution sys-

tem and trough open­ings

Problem Possible Cause Remedy

Motor
cycles on
and off

Noisy

Inadequate
cooling

Excessive
humidity in
house

1. Low voltage

2. Excessive belt tension

3. Blower shaft tight or
locked

4. Bearings dry

5. Motor pulley diameter
too large causing motor
overload

6. Faulty motor

1. Bearings dry

2. Wheel rubbing blower
housing

3. Loose parts

1. Inadequate exhaust in
house

2. Pads not wet

• Pads plugged

• Open spots in pads

• Trough holes clogged

• Pump not working prop-

erly

1. Inadequate exhaust

1. Check voltage

2. Adjust belt tension

3. Oil or replace bearings
(Disconnect unit)

4. Oil bearings

5. Adjust pulley so full load
ampere rating of motor
is not exceeded

6. Replace motor

1. Oil bearings

2. Inspect and realign (Dis­connect unit)

3. Tighten loose parts

1. Open windows or doors
to increase air fl ow

2. Check water distribution
system

• Clean pads

• Repack pads

• Clean

• Replace or clean pump

(Unplug)

1. Open doors or windows

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

Limited W arranty

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 Warranty

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

For One Year from date of purchase, we will replace any original cabinet component which fails due to 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 satisfi ed with the response from the dealer, contact the
Customer Service Department: 5800 Murray Street, Little Rock, Arkansas 72209. 1-800-643-8341. E-mail: [e-mail], Web: www.
championcooler.com.

This limited warranty applies to original purchaser only.

110525

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