Essick Air AD1C71, AS1C7112, AD1C51, AD2C5112, AS1C71 User Manual
...
Models
AD1C51 AD2C51
AS1C51 AS2C51
AD1C5112 AD2C5112
AS1C5112 AS2C5112
AD1C71 AD2C71
AS1C71 AS2C71
AD1C7112 AD2C7112
AS1C7112 AS2C7112
AU1C7112 AU2C7112
Circle the model of your cooler and
record the serial number below.
Read Carefully All Of This Manual
Before Installing The Unit
Lea Con Cuidado Todo Este Manual Antes De
Instalar La Unidad
Table Of Contents
Safety Instructions .......................................................................1
Installation Instructions ............................................................2-3
Electrical Wiring Diagram ...........................................................3
Operation ..................................................................................3-4
Maintenance Section ....................................................................4
Troubleshooting ...........................................................................5
Vea el Español en el interior.
Read And Save These Instructions
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 DISCONNECT POWER and UNPLUG motor and
pump inside the cooler before installing or performing any
maintenance.
4. 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.
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.”
Encierrre con un circulo el modelo de su
enfriador y escribe el número de série abajo.
Serial #
Número De Série
Warranty .......................................................................................5
Parts List (Down Discharge Units) .......................................... 6-7
Parts List (Side Discharge Units) .............................................8-9
Parts List (Up Discharge Units) ........................................... 10-11
Specifi cation Tables (Tablas de Especifi caciones) .....................12
Instrucciones en Español .....................................................12-16
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 swimming pool with the wind blowing, evaporative
cooling makes you feel cool, even though the air may be warm.
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.
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.
110498-3 9-09
www.championcooler.com
Cooler 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 start cooler until installation is complete
and unit has been tested for rigidity.
CAUTION: Do not screw or drill within 5 inches of the bottom
of the wet module. You could puncture the reservoir.
CAUTION: If the unit is supported with legs at each corner ,
the middle of the unit where the two sections join must be supported as well.
NOTE: For ease of installation you can
separate the wet module from the blower
module by removing the 4 bolts from the wet
module side (Fig. 1). Remember to unplug
the pump and drain pump before separating
the modules.
Water Connection
• Install 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. 2). Screw on nut and draw
up tight against bottom of pan. Insert
overfl ow into nipple to retain water.
The overfl ow pipe comes from the fac-
tory connected to the dump pump hose.
The 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.
• Connect water supply line. Install
a sillcock and water valve on faucet
as shown by fi gure 3. Place the nut
and ferrule on the tubing and tighten
the nut until water tight. NOTE:
Do not connect the water supply to
any soft water applications.
Sillcock
• Install fl oat valve and fi ll pan.
Refer to Fig. 4. Remove items 1,
2, 3, and 4. Insert fl oat body (5)
through hole in back post panel as
shown. Install washer (1) and nut
(2). Tighten to keep fl oat from turn-
ing. Place nut (4) and ferrule (3) on
water supply line. Connect to fl oat
fi tting and tighten until water tight.
Bend rod (6) to adjust fl oat until
6
water level is about 1 inch below
the top of the overfl ow pipe. Slide
fl oat shield (7) over fl oat body (5)
until it snaps into place.
Electrical Installation
WARNING: Disconnect all electrical service that will be used
for this unit before you begin the installation and leave it disconnected until the installation is complete.
5
Fig. 4
Wet
Module
Mounting
Bolts
Fig. 1
Fig. 2
Faucet
Fig. 3
7
Drain Pump
Hose
Overfl ow Pipe
Nipple
Rubber Washer
Bottom Pan
Nut
Water Supply
Valve
Ferrule
3
2
1
Nut
4
should be adequately protected against overloads and short circuits.
Note: Electrical installation should be performed by a qualifi ed
electrician. Be sure to follow all National and Local Electrical
Codes when installing this cooler.
• Install weatherproof switch box. Located inside the unit in a
plastic bag is a switch box and cover, a chase nipple, a seal ring
and a toggle switch. Remove the electrical junction box (Fig. 5)
which is mounted on the inside of the center panel. From inside
the unit, insert the chase nipple
through the electrical access
hole. Slide the seal ring over
the chase nipple. Mount the
Junction
Box
Seal Ring
Chase
Nipple
Electrical
Box
switch box to the outside of the
unit by threading the chase nipple into the switch box. Run
the three switch leads through
the nipple and into the switch
box and reinstall the junction
box. Connect the green ground
Fig. 5
lead to the ground screw in the
switch box.
• Supply power to unit. Run power to the external switch box and
connect to the two poles of the toggle switch. Connect the gray and
white leads from the cooler electrical box to the two poles of the
toggle switch. Refer to the appropriate wiring diagram to complete
the electrical installation of your cooler. Secure the switch into the
switch box and install the gasket and switch cover.
CAUTION: All openings in the external switch box must be
sealed to prevent water from entering the switch box.
CAUTION: Pump receptacles are for grounded evaporative
cooler pumps only. Do not plug anything else into receptacle.
WARNING: Make sure that cooler cabinet is properly
grounded to a suitable ground connection for maximum safety.
Thermostat Installation
1) Find a suitable location for the wall thermostat (away from sources
of heat, sunlight, or ventilation, and between 4 and 6 feet from the
fl oor). The thermostat may be mounted to a standard electrical
box.
2) Route an insulated four-conductor thermostat cable (or similar)
from the Control Box inside the cooler to the thermostat electrical
box. This cable is not supplied.
W ARNING: The thermostat
cable should not be routed next to or enter the cabinet through
the same inlet as the power supply wire.
3) Connect the thermostat wires to the terminals on the back of the
wall control and to the terminals located on the left side of the
control box in the unit. Make sure to follow the color code found
next to each terminal.
Amperage Draw And Belt Tension
This unit is equipped with an adjustable motor drive sheave 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.
The control box is factory wired and installed for either 120V or 230V
operation depending on the model you purchased. The supply power
2
110498-3
• Start cooler. Install both inspection panels, 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.
During automatic operation, the control performs a 90 second water
dump cycle every 8 or 12 hours of pump operation. This interval can
be toggled between 8 or 12 hours by simultaneously holding the ‘Cool’
and ‘Fan’ buttons for 5 seconds. The selected interval is displayed for
a short time. This action also starts a manual dump cycle.
• Adjust pulley if necessary. If amperage draw is less than mo-
tor rating, turn off electrical power and
remove inspection panels. Unplug motor inside cooler, this will protect you
from someone turning on unit while
you are working inside. This should be
Decrease
Amperage
done for your safety. Adjust pulley to a
larger diameter and readjust belt tension,
plug motor in, install inspection panels,
Fig. 6
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. 6).
CAUTION: Do not operate cooler with larger amperage draw
than specifi ed on motor plate.
Thermostat Operation
Automatic Operation (Cool Mode)
The fan and water pump are contr olled automatically to achieve the
desired comfort level.
This mode is activated by pressing the ‘Cool’ button. A blue LED
is illuminated, and for a few seconds the LCD will display the
‘Set’ temperature. Pressing the ‘Cool’ button again deactivates this
mode.
The Set temperature (the target temperature for control) may be altered
by repeatedly pressing or holding the ‘Up’ and ‘Down’ buttons. The
LCD will display ‘Set’ rather than ‘Room’ temperature for a short
time after pressing the ‘Up’ or ‘Down’ button.
On starting, if the pads in the cooler are too dry, the fan may be delayed
from starting until the pads have absorbed some water. This is called
Pre-wet and lasts for 2 minutes, indicated by a fl ashing blue LED.
Selecting ‘Fan’ and then ‘Cool’ will bypass the pre-wet and cause the
fan and pump to start immediately. (If cooling is required).
Ventilation Operation (Fan Mode)
The fan speed is set by the user, the water pump is turned off.
This mode is activated by pressing the ‘Fan’ button. A green LED
is illuminated, and the LCD indicates fan speed. Pressing the ‘Fan’
button again deselects this mode.
Pressing the ‘Up’ button selects maximum Fan speed, and ‘Hi’ is
displayed in the LCD; pressing the ‘Down’ button selects minimum
Fan speed, and ‘Lo’ is displayed in the LCD.
Time Delay Operation (Timer Mode)
Delayed start or fi nish in ‘Cool’ or ‘Fan’ mode.
The ‘Timer’ button is used to set a delay period of 2, 4 or 8 hours,
depending on how many times the button is pressed.
If the cooler is operating in ‘Cool’ or ‘Fan’ modes when the ‘Timer’
button is pressed, the delay period determines when the cooler will
switch off. If the cooler is Off when the ‘Timer’ button is pressed,
the delay period determines when the cooler switches on.
The starting mode is indicated by a fl ashing LED. You can change
this mode by pressing the appropriate button (‘Cool’ or ‘Fan’).
Y ou can cancel the T imer function at any time by pressing the ‘Timer’
button until all the timer LED’s go out.
In The Event Of A Power Outage
If the cooler is operating in ‘Cool’ or ‘Fan’ mode when power is
interrupted, the cooler will resume in the same mode of operation
when the power is restored.
If the cooler was in any ‘Timer’ mode at the time of a power
interruption, the cooler will remain off when power is restored.
FAN MOTOR
RECEPTACLE
CIRCULATING PUMP
RECEPTACLE
DRAIN PUMP
RECEPTACLE
110498-3
COOLER TERMINAL BOX
BLACK
RED
WHITE
GREEN
ORANGE
GREEN
WHITE
BLUE
ORANGE
BROWN
GREEN
WHITE
BLUE
ORANGE
BROWN
Wiring Diagrams
120 Volt 240 Volt
GRAY
BLACK
RED
YELLOW
BLUE
VIOLET
=WIRE NUT
(11)
SWITCH LEADS
GRAY
WHITE
GREEN
TOGGLE SWITCH
THERMOSTAT
FCom
LINK
FLo
FHi
WHITE
120 VAC
GROUND
DUMPPUMPFAN PWR. SUPPLY
DCom
PCom
NLink
DP
PP
L1
N
COOLER TERMINAL BOX
FAN MOTOR
RECEPTACLE
CIRCULATING PUMP
RECEPTACLE
DRAIN PUMP
RECEPTACLE
BLACK
RED
WHITE
GREEN
ORANGE
GREEN
WHITE
BLUE
ORANGE
BROWN
GREEN
WHITE
BLUE
ORANGE
BROWN
GRAY
BLACK
RED
YELLOW
BLUE
VIOLET
=WIRE NUT
(11)
SWITCH LEADS
GRAY
WHITE
GREEN
TOGGLE SWITCH
THERMOSTAT
PWR. SUPPLYFAN
FCom
LINK
FLo
FHi
WHITE
240 VAC
GROUND
PUMP DUMP
DCom
PCom
NLink
DP
PP
L1
N
3
Required Exhaust Openings
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.
First 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 3790
CFM, model AD1C51 (3/4 hp) requires 7.6 square feet (1094 square
inches) of opening (3790/1000 * 2 = 7.6). 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 7.6 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.
IMPORTANT: In order to get the best performance from your
cooling pads, they must be installed properly. If you have purchased a pad with two equal angles, the following instructions can
be disregarded. Pads must always be installed with the steeper
fl ute angle sloping down
towards the air entering
side (Fig. 7). The reason
is simple. The steeper
angle puts more water on
the hot, dry, dirty side of
the pad where it is needed
most. It also counteracts
the tendency of the air to
push the water toward the
back of the pad.
• Check belt tension. A 3 lb. force
should defl ect the belt 3/4 inches
(see Fig. 8). Readjust belt 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.
Entering
Air
Fig. 7
45°
Leaving Air
15°
3 Lb.
3/4 Inches
Fig. 8
CAUTION: Do not over oil. Over oiling can cause motor burn
out, due to excessive oil getting into motor winding.
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.
Maintenance
WARNING: Before doing any maintenance be sure power
is off. At the time you remove either inspection panel be sure to
unplug motor and pumps. This is for your safety.
Spring Start-Up
• Clean pads. A clean pad is more absorbent, effi cient and will give
more cool air. Annually, or when required, using a garden hose
with nozzle, back wash to clean out the openings, then clean off
the inlet face any scale or other obstruction to the passages. Slight
scraping may be required to remove hardened scale.
• Change pads if necessary. The pads should be replaced after 5
years or if necessary. To change pads, remove top access panel,
remove grill, and disconnect water delivery tube. Remove water
distributor holder and lift out media sections. Replace with the
same type media. You can purchase them from your dealer.
• Clean water pump and dump pump. Cleaning both pumps is
necessary once a year at start-up. For your safety, turn unit off
and unplug motor and pumps. Remove the pump from the mount
slot. Remove the base of the pump as shown in Fig. 9. 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
fi rmly 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. 9
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 pumps. When cooler is not used for extended
periods unplug the motor and pumps from inside cooler.
• 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 ca n get many years of e fficient and satisfactory service
from your cooler . In the e vent additional inf ormation is desired, your
dealer will be more than glad to assist you in every possible way.
4
110498-3
Troubleshooting Guide
Problem Possible Cause Remedy
Failure to
start or no air
delivery/ No
LCD display
Inadequate
air delivery
with cooler
running
1. No electrical power
to unit
• Fuse blown
• Circuit breaker tripped
2. Motor overheated
• Belt too tight
• Blower bearings dry
• Motor pulley diameter
too large
3. Motor locked
4. Fuse blown in unit
control box
5. Incorrect wiring between wall thermostat
and cooler
6. Poor connection to
Fan motor terminals
7. Unit control board or
wall thermostat faulty
1. Insuffi cient air exhaust
2. Belt too loose
3. Pads plugged
4. Motor underloaded
1. Check power
• Replace fuse
• Re-set breaker
2. Determine cause
• Adjust belt tension
• Oil blower bearings
• Adjust pulley to correct
diameter
3. Replace motor
4. Replace Fuse
5. Check that wiring is correct
and secured to terminals
6. Check connections to terminal
7. Supply power to control box
and check DC voltage at
wall thermostat
• If voltage between Black
& Red terminals is close to
3.5VDC and LCD is blank
- wall thermostat is faulty
• If voltage is much less than
3.5VDC, remove red wire
from terminal. If voltage
rises to 3.5VDC - thermostat
is faulty. If voltage remains
low - unit control board is
faulty.
1. Open windows or doors to
increase air fl ow
2. Adjust belt tension or
replace if needed
3. Clean pads
4. Adjust pulley
Problem Possible Cause Remedy
Water draining onto roof
Musty or
unpleasant
odor
Motor cycles
on and off
Noisy
Inadequate
cooling
Excessive
humidity in
house
1. Float arm not adjusted
properly
2. Overfl ow assembly
leaking
1. Stale or stagnate water
in cooler
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
1. Bearings dry
2. Wheel rubbing blower
housing
3. Loose parts
1. Inadequate exhaust in
house
2. Pads not wet
• Pads plugged
• Dist. tube holes clogged
• Pump not working properly
3. Poor connection to Pump
terminals on Control
Board
1. Insuffi cient air exhaust
1. Adjust fl oat
2. Tighten nut and overfl ow
pipe
1. Drain pan and clean pads
1. Check voltage
2. Adjust belt tension
3. Oil or replace bearings
(Unplug unit)
4. Oil bearings
5. Adjust pulley so full load
ampere rating of motor is
not exceeded
1. Oil bearings
2. Inspect and realign (Unplug unit)
3. Tighten loose parts
1. Open windows or doors to
increase air fl ow
2. Check water distribution
system
• Clean pads
• Clean
• Replace or clean pump
(Unplug unit)
3. Check connections
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
Lifetime Limited Coverage on water reservoir against any leakage due to defects in material. From date of purchase, if any original component part
provided by Champion Cooler fails due to defect in material or factory workmanship only, we will provide the replacement part as follows:
One year on the cabinet components.
Five years on the evaporative media.
Two years on the original blower motor if furnished by Champion Cooler.
Exclusions From The Warranty
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: Champion Cooler, 5800 Murray Street, Little Rock, Arkansas 72209. 1-800-643-8341. E-mail: info@championcooler.com.
This limited warranty applies to original purchaser only.
110498-3
5
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