Essick Air Products AD100, SAD100, AS100, AD10012, AS10012 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 7-14
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 maintenance.
WARNING: To r educe the risk of fi re, electric shock and injury
to persons, this cooler must be installed with motors and pumps listed
on the notice decal and marked to indicate suitability with this model.
Other motors and pumps cannot be substituted.
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: To 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. Attach the lift brackets to the top of the
blower module and wet module using the included
1/4-20 bolts. See Fig. 1. Attach the connector brackets in like manner near the bottom of the unit. Bring
the two sections together and secure them using the
provided 3/8-16 nut, bolt and washers.
• 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. We recommend
that roof penetration only be as large as ductwork coming from unit.
Water drain should be outside curb if possible.
Fig. 1
pulley. Mount the motor to the motor mount using these carriage bolts
and the washers and nuts provided (see Fig. 2). Make sure all bolts are
securely tightened.
• Motor pulley. Install the motor pulley
so that it aligns with the blower pulley
(see Fig. 3) and tighten set screw. See
page 3 for instructions on adjusting pulley.
Blower
Housing
Motor
Pulley
Blower
Pulley
Fig. 3
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 cur-
rent, 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.
• 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. 4). 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.
Junction Box
Screws
Fig. 4
WARNING: Make sur e that cooler cabinet is properly gr ounded
to a suitable ground connection for maximum safety.
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. 5). 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. The male threads
of the Nipple are standard 3/4” garden hose
threads. To drain water away from unit, drain pipe can be attached to
the nipple using a NPT to GHT adapter which can be purchased at a local
hardware store. Follow local plumbing codes.
• Pump. The pump must be secured to prevent it form tipping over. Se-
cure 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.
Overfl ow Pipe
Nipple
Rubber Washer
Bottom Pan
Nut
Fig. 5
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
Fig. 2
• 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. 6 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
closest to access panel as shown. Install washer (1) and nut (2). Tighten
1105262
to keep fl oat from turning. Place nut
Ground
Blue/Black
White
Brown
= Wire Nut
Orange
Green
Green
Orange
Brown
White
Blue/Black
Pump
Com.
To
Switch
Com.
Pump
Blue/Black
White
Brown
Orange
Green
Green
Orange
= Wire Nut
Brown
White
Blue/Black
Ground
To
Switch
(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. 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 (5)
until it snaps into place.
7
5
Fig. 6
8
3
2
1
9
6
• 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.
Amount to bleed-off will vary depending on water quality. Start with
1gph per 1000cfm of airfl ow. If scale builds up on media, increase the
amount of bleed-off. 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. To ad-
just 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
Decrease
Amperage
draw, increase pulley diameter. To decrease
amperage draw, decrease pulley diameter (see
Fig. 7). Recheck belt alignment.
Fig. 7
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
bolts and slide the motor back until the
3 Lb.
3/4 Inches
belt is properly tensioned. A 3 lb. force
should defl ect the belt 3/4 inches (see Fig.
8). Retighten motor mount bolts. Do not
adjust pulley to tighten belt.
Fig. 8
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,
4
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
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. 9). 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.
Entering
Air
Fig. 9
45°
Leaving Air
15°
• 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. 10). 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
Remove
Base
to replace the spout and water
delivery tube onto the pump
outlet. The pump has automatic
reset thermal protection. Pump
Impeller
will operate normal again after
obstruction is cleared.
Fig. 10
• 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.
Additional maintenance may be needed throughout the season to keep
media and unit functioning effi ciently. 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
110526 3
Pump Wiring Diagrams
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/index.php/cooler-warranty-registration
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
• 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
L2
Gnd
Transformer
Cooler Cabinet
See Note 3
• 230 Volt single phase blower motor.
• 120V pump motor shown. Trans-
Equipment
Ground
Blower Motor
Pump Motor
Gnd
Main Disconnects
See Note 1
Gnd
L1
L2
L3
L1
N
208, 240, or 480V
Power Supply
Power Supply
3 Phase
120V
1 Phase
• 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
L2
1 Phase
Power Supply
Fuses
See Note 1
Gnd
Main Disconnect
See Note 1
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
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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