Essick Air SAS100, SAS15012, SAD10012, AD20012, SAD100 User Manual
...
The New Industrial
Models
(Double Inlet)
AD100, AS100, AD10012, AS10012
AD150, AS150, AD15012, AS15012
AD20012, AS20012, AU20012
(Single Inlet)
SAD100, SAS100, SAD10012, SAS10012
SAD150, SAS150, SAD15012, SAS15012
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 #
Read And Save These Instructions
Table Of Contents
Safety Instructions .............................................................................2
Operation ............................................................................................2
Installation Instructions ...................................................................2-3
Maintenance Section ..........................................................................3
Troubleshooting .................................................................................4
Warranty .............................................................................................4
Electrical Wiring Diagrams ................................................................5
General Specifi cations ....................................................................... 6
Read Carefully All Of This Manual Before
Installing The Unit.
Lea Con Cuidado T odo Este Manual Antes De Instalar
La Unidad.Número De Serie
Vea el Español en el interior.
Parts List - Wet Section (All models) .............................................6-7
Parts List - Blower Section (AD100B, AD150B, AD200B) ..............8
Parts List - Blower Section (AS100B, AS150B, AS200B) ................9
Parts List - Blower Section (AU200B) ............................................10
Parts List - Blower Section (Single Inlet Coolers) ...........................11
Motor Specifi cations ........................................................................12
Pulley and Belt Kit Specifi cations ...................................................12
Spanish (Instrucciones en Español) ............................................13-16
110526 2-09
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 maximum safety, make sure cooler cabinet is properly
grounded to a suitable ground connection.
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 not allow pump to tip over and become submerged.
7. Always TURN OFF POWER before performing any mainte-
nance.
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.
motor mount using these carriage bolts
and the washers and nuts provided
(see Fig. 1). Make sure all bolts are
securely tightened.
• Motor pulley . Install the motor pulley
so that it aligns with the blower pulley
(see Fig. 2) and tighten set screw. See
page 3 for instructions on adjusting pulley.
Blower
Housing
Motor
Pulley
Blower
Pulley
Fig. 2
Electrical Connection
NOTE: Local building code regulations must be observed.
WARNING: Disconnect all electrical services that are used for
this unit before beginning any service to the cooler.
• Electrical supply. Cooler must be supplied with the proper line
current, voltage and frequency, as stamped on blower 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.
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 the general specifi cation table.)
CAUTION: Do not start cooler until installation is complete
and unit has been tested for rigidity.
CAUTION: Make sure all bolts are securely tightened before
starting the cooler.
• Wet sections. The wet sections are bolted to the blower section using
the connector brackets, lift brackets and bolts provided. Match the
colored dots on the wet section to the appropriate dot on the blower
section to insure correct installation.
• Ductwork. See the General Specifi cation table for dimensions of
duct opening. For down discharge units, the duct must go inside
the opening. Size these ducts slightly smaller than the duct opening
in the cooler. The side and up 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 Installation
• Motor mounting. 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
Fig. 1
• 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 qualifi ed electrician.
• Wiring. The electrical junction box
is located in the upper inside of the
divider channel. Remove the two
screws and pull the box out from the
channel to access wiring (Fig. 3).
Connect the pump supply wiring to
the pump receptacles (See the pump
wiring diagrams on the next page).
Connect the motor supply wiring
directly to the blower motor.
WARNING: Make sur e that cooler cabinet is properly gr ounded
to a suitable ground connection for maximum safety.
Junction Box
Screws
Fig. 3
Water Connections
• 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. 4). 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 form tipping over.
Secure the pump to the pump mounting bracket (item 16 in parts
drawing). Remove a nut located under the head of the pump, place the
pump bolt though the hole in the mounting bracket, and secure with
the nut that was previously removed. Plug pump into receptacles.
Retain pump cords to internal braces to prevent cords from dropping
into water reservoirs or contacting moving components.
• Supply water . Run a water supply line to the unit. Each wet section
requires a 3/8 inch tube connection to the fl oat valve. The double
inlet units will have two fl oat valves, one for each wet section. Note:
Do not use water supplied from a water softener.
• Float valve. Refer to Fig. 5 to install fl oat. Remove items 1, 2,
3, and 4. Insert fl oat body (5) through hole in splash plate (9) and
back post panel as shown. Install washer (1) and nut (2). Tighten to
Overfl ow Pipe
Nipple
Rubber Washer
Bottom Pan
Nut
Fig. 4
1105262
keep fl oat from turning. Place nut
(4) and ferrule (3) on water supply
line. Connect to fl oat fi tting and
tighten until water tight. Turn on
water supply and check for leaks.
8
4
3
2
5
1
Loosen screw (6) and adjust rod
(7) until water level is within 1” of
top of reservoir. T ighten screw (6).
Slide fl oat shield (8) over fl oat body
7
9
6
Fig. 5
(5) until it snaps into place.
• Bleed-Off. Use of the 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 since they may damage the evaporative media.
Pulley And Belt Adjustments
• Pulley adjustment. With an ammeter, check the motor amperage.
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
Decrease
Amperage
increase amperage draw, increase pulley
diameter. To decrease amperage draw,
decrease pulley diameter (see Fig. 6).
Fig. 6
Recheck belt alignment.
CAUTION: Always check the amperage of the motor after adjusting pulley to be certain it does not exceed the amperage stamped
on the motor specifi cation plate. Improper pulley adjustment will
overload and burn out the motor.
• Belt tension. Loosen the motor mount
3 Lb.
3/4 Inches
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. 7). Retighten motor mount bolts.
Fig. 7
Do not adjust pulley to tighten belt.
Maintenance
WARNING: Befor e doing any maintenance be sure to disconnect
from power source. This is for your safety.
Spring Start-Up
• Belt tension. Check belt tension and readjust if needed.
• Grease bearings. The blower bearings in this unit should be greased
once a year with a good grade of ball bearing grease.
• Cleaning 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.
• Pad replacement. 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.
IMPORTANT: In order to get the best performance from your cool-
ing 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. 8). The reason is simple. The steeper
angle puts more water on
the hot, dry, dirty side of
Entering
Air
45°
Leaving Air
the pad where it is needed
most. It also counteracts
the tendency of the air to
push the water toward the
Fig. 8
15°
back of the pad.
• Cleaning 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. 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. Reattach the pump to
the mount in the cooler to ensure
Remove
Base
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
Impeller
Fig. 9
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.
• 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 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.
120 Volts 240 Volts
Pump Wiring Diagrams
Blue/Black
White
Brown
Orange
Green
Blue/Black
White
Brown
Orange
Green
= Wire Nut
Pump
Com.
Ground
To
Switch
110526 3
Blue/Black
White
Brown
Orange
Green
Blue/Black
White
Brown
Orange
Green
=WireNut
Pump
Com.
Ground
To
Switch
Troubleshooting Guide
Problem Possible Cause Remedy 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. Insuffi cient water fl ow
over pads
1. Stale or stagnate water
in cooler
2. Pads not wetting
properly
• Dist. tube holes
clogged
• Pump not working
properly
• Insuffi cient water fl ow
over pads
1. Check power
• Replace fuse
• Reset breaker
2. Adjust belt tension
3. Determine cause of
overheating
• Adjust belt tension
• Grease blower bear-
ings
• Oil motor bearings
• Adjust pulley to cor-
rect 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 distribution
system
1. Drain pan and clean
pads
2. Check water distribution system
• Clean
• Replace or clean
pump (Unplug)
• Clean water distribu-
tion system
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
• Dist. tube holes
clogged
• Pump not working
properly
1. Inadequate exhaust
1. Check voltage
2. Adjust belt tension
3. Grease or replace
bearings (Disconnect
unit)
4. Grease bearings
5. Adjust pulley so full
load ampere rating of
motor is not exceeded
6. Replace motor
1. Grease 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
• Clean
• Replace or clean
pump (Unplug)
1. Open doors or win-
dows
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 The Warranty
Lifetime Limited Coverage on water reservoir against any leakage due to defects in material. From date of purchase, if any original component part fails
due to defect in material or factory workmanship only, we will provide the replacement part as follows:
One year on the cabinet components.
Two years on the evaporative media.
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, de-scale 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: info@championcooler.com, Web: www.
championcooler.com.
This limited warranty applies to original purchaser only.
1105264
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
protection
• 120V single phase control and pump shown.
If 240V control and pump are to be used, then
GndGnd
Main Disconnect
See Note 1
H
P
Disconnect Switch At Cooler
See Note 1&2
Cooler Cabinet
See Note 3
Pump Motor
both legs of power supply must be fused.
Equipment
Ground
Blower Motor
240 Volt, 1 Phase Electric Supply
Disconnect Switch At Cooler
See Notes 1 & 2
L
H
120V
Pump Motor
Gnd
L1
L2
L3
Main Disconnects
See Note 1
L1
N
Gnd
P
L2
Gnd
Transformer
Cooler Cabinet
See Note 3
208, 240, or 480V
3 Phase
Power Supply
120V
1 Phase
Power Supply
Control Contacts
See Note 1
L1
208 or 240V
Fuses
See Note 1
L2
Gnd
Main Disconnect
See Note 1
1 Phase
Power Supply
• 230 Volt single phase blower motor.
• 120V pump motor shown. Transformer may be omitted when a 240V
pump is used with a 240V supply
• Diagram shown for two speed motor.
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
208, 240 or 480V
Main Disconnect
See Note 1
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.
ment. If more than one disconnect is used they must be mounted adjacent to one another.
110526 5
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