MasterCool ADA51, AUA51, ASA51, ADA5112, AUA5112 Operation Manual

...

INSTALLATION & OPERATION MANUAL

SINGLE INLET EVAPORATIVE COOLERS

Circle the model of your cooler and record the serial number.

Encierrre con un circulo el modelo de su enfriador y escribe el número de série.

Date of Purchase: Fecha de compra:

READ CAREFULLY ALL OF THIS MANUAL BEFORE INSTALLING THE UNIT

TABLE OF CONTENTS

Safety Instructions .........................................................1

How Evaporative Coolers Work .....................................1

Installation .....................................................................2

Operation .......................................................................5

Air Balancing Methods ...........................................5

Maintenance ..................................................................6

Speciﬁ cation Tables .......................................................7

Troubleshooting .............................................................7

Limited Warranty ...........................................................8

Tabla de Contenido En Español ..................9

Illustrated Parts List / Ilustrado Lista de Piezas de Repuesto

(English / Español) ......................................................17

Garantía Limitada ........................................................24

SAFETY RULES

1. Read all instructions carefully.

2. Electrical connections should be done by a qualiﬁ ed electrician, so that all electrical wiring will conform to your local codes.

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.

WARNING: To reduce the risk of ﬁ re or electric shock, do not use

this fan with any “solid-state fan speed control device.”

ADA51 ASA51 AUA51

Serial Number:

Número de série:

ADA5112 ASA5112 AUA5112

ADA71 ASA71 AUA71

READ AND SAVE THESE INSTRUCTIONS

ADA7112 ASA7112 AUA7112

HOW EVAPORATIVE COOLERS WORK

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, by using Up-

ceiling vents, or a combination of both. The air is always

Dux fresh, not stale, laden with smoke and odors as happens with refrigerated air conditioning.

PN 110498-2 REV. 3-15

INSTALLATION

CAUTIONS:

Before installing the cooler, note the following items:

• Before installation, ensure your existing electrical system is rated for the additional amperage draw from unit.

• Installation inside attic areas is NOT recommended.

• If installing unit on ground, ensure surface area is level, well packed and will not erode or become unstable with water erosion.

• If installing on brace, or existing construction, ensure structure will hold the operating weight of the cooler. (See speciﬁ cation table for operating weight.)

• Ensure entire unit is sufﬁ ciently supported. If supporting the unit with legs at each corner, the middle of the unit where the two sections join must be supported as well.

• We strongly recommend consulting a professional contractor if installation will require cutting through existing structure such as walls or roof.

• Do not screw or drill within 5 inches of the bottom of the wet section as you could puncture the reservoir.

• Ensure all electrical work is accomplished to local standards. An electrician may be needed for correct and safe wiring.

WARNING: Disconnect all electrical service that will be used for this unit before beginning the installation

and DO NOT reconnect until installation is complete.

PARTS AND TOOLS NEEDED:

• Motor with Motor Pulley (purchased separately)

• 5/32 Allen Wrench (for pulley installation)

• 7/16 Wrench or Crescent Wrench

• Phillips Screwdriver

• Sill cock or water valve and tubing

• Multimeter (for amp reading)

SEPARATING SECTIONS

Follow the steps below to separate the sections of the unit, if desired for ease of installation.

1. Remove four bolts (two on each side) from the inside center post of the unit connecting the wet section to the blower section.

2. On a few models, two bolts on the interior of the unit attaching the bottom pans of the two sections will need to be removed as well.

MOTOR INSTALLATION

Note: Motor must be purchased separately. See Motor Speciﬁ cation Table for motors that can be used.

1. For typical 120V installation, install motor cord (provided) to motor (purchased separately). Follow motor electrical diagram using the following color code:

BLACK - HIGH; RED - LOW; WHITE- COMMON; GREEN - GROUND

2. When installing a 1 hp motor, reverse the adjustable yolk to accommodate the larger motor. Adjust the cradle spacing as needed for size of motor. Mount the blower motor onto the yokes of the motor mount. Fasten with provided motor clips.

3. Leave motor cord unplugged until electrical portion of installation is complete.

PULLEY INSTALLATION

1. Open adjustable pulley about 5 full turns to the least diameter.

2. Install the motor pulley onto the motor shaft so that it aligns with the blower drive pulley and tighten with Allen wrench.

3. Loosen adjustment screw on motor mount.

4. Install belt onto pulleys.

5. Rotate motor mount until belt is tight, then tighten adjustment screw to secure belt. Check belt tension per instructions on page 5.

Note: Further adjustment to belt and pulley may be required after installation is complete.

Remove Two Bolts (Each Side) Connecting Wet And Blower Sections

Motor

Pulley

Adjustable

Motor Mount

Adjustment Screw

Remove Two Bolts Connecting Bottom Pans

Motor

ALIGN PULLEYS

Motor

Motor Pulley

Belt

Blower Pulley

Motor Clips

Adjustable Yoke

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ELECTRICAL CONNECTION

Blue/Black

White

Brown

Orange

Green

Orange

White

Red

Black

PUMP

HIGH LOW COMMON

GROUND

= WIRE NUT

HIGH LOW COMMON GROUND

Black

Green

White

Red

BLOWER MOTOR

PUMP

MOTOR

TO SWITCH

COMMON

PUMP

MOTOR

BLOWER MOTOR

Red Orange Green

Black

GROUND

COMMON

LOW

HIGH

= WIRE NUT

GROUND

LOW

HIGH

PUMP

Black

Red

White

Orange

Green

Orange

Brown

White

Blue/Black

TO SWITCH

WARNING: Electrical connections should be accomplished by a qualiﬁ ed electrician to ensure all electrical

wiring conforms to local standards.

WARNING: Follow all safety precautions when working with electrical power. WARNING: Before proceeding with installation, ensure electrical power is disconnected until installation is

complete.

Note: This unit can be controlled with a manual 6 position switch found at a local hardware store, or with a thermostat such as

Champion’s Masterstat

Wall Control Thermostat model #110423-2. For thermostat installation refer to its operating manual.

Follow the steps below for manual switch installation:

1. Determine location on internal wall for 6 position switch.

2. Supply 120V or 240V power to switch, depending on motor and pump voltages.

3. Remove screws securing junction box to cooler cabinet.

4. Bring four conductors plus a ground from switch to cooler junction box (such as two 2-wire Romex

CAUTION: Make sure to use correctly sized wire and follow all

wire)

Junction Box

Motor And Pump

Receptacles

Remove Screws to Access

Wiring Connections

local electrical codes.

5. Connect the four conductor wires to the leads of the motor and pump receptacles located in the junction box. Follow the connection diagrams below for 120V or 240V installations.

6. Reinstall junction box to cooler cabinet.

7. Plug motor and pump plugs into receptacles.

8. Follow switch electrical instructions for connecting the four conductors and power leads to switch.

Warning: Pump cord must be secured in retaining clip to

prevent contact with water.

120 VOLT

240 VOLT

110498-2

NOTE: If single speed motor is used, do not use the RED electrical leads from the motor or receptacle. Tape off both RED leads.

CAUTION: Receptacles in junction box are only for Motor and pump. Do not plug anything else into receptacle.

WARNING: Ensure cooler cabinet is properly grounded to a suitable ground connection for maximum safety and protection of equipment.

WATER CONNECTION

Note: Do not connect the water supply to any soft water applications.

Faucet

Water Shut

Off Valve

SILLCOCK INSTALLATION

A steady water supply is required for the operation of this cooler. If water source comes from an external water faucet, a sillcock and shutoff valve will need to be purchased and installed.

1. Install sillcock and water valve on faucet.

2. Run ¼” plastic or copper tubing from the faucet to the unit.

3. Install one end of tubing to water valve by placing nut and ferrule on

Sillcock With Std. Hose Connection

tubing and tightening the nut until water tight.

FLOAT VALVE INSTALLATION (Refer to illustration)

1. Remove items 1, 2, 3, and 4 from ﬂ oat.

2. Insert ﬂ oat body through hole in media shield and back post panel as shown.

3. Install washer (1) and nut (2). Tighten to 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.

4. Slide ﬂ oat shield over ﬂ oat body until it snaps into place.

Note: After installation is complete and water is turned on, the ﬂ oat level will need to be adjusted.

5. Bend rod to adjust ﬂ oat. Water level should be about 1 inch below the top opening of the overﬂ ow pipe.

OVERFLOW INSTALLATION

1. 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.

2. Screw nut onto nipple and draw up tight against bottom pan.

3. Screw overﬂ ow pipe into nipple. This overﬂ ow pipe may be removed to drain pan when necessary.

Note: A garden hose may be screwed onto the drain nipple to drain water away from the unit.

SCALE BUILDUP PREVENTION

As water evaporates, minerals that were in the water will remain. Over time this accumulation of minerals will cause scaling on the pads and in the reservoir. We recommend the installation of either a bleed-off kit (included in unit) or a purge pump (purchased separately) to help prevent scale build up and increase the life of the unit. A purge pump will drain the pan every few hours of pump operation, to keep fresh water in the unit. A bleed-off kit will continually bleed off a small portion of water while the pump is running allowing fresh water to continually replace the old stagnate water. Follow the instructions below for installing the bleed-off kit.

1. Cut the pump hose and insert the barbed ends of the bleeder tee into each cut end.

2. 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.

Float

Pump Hose

Ferrule

Nut

Float

Shield

Overﬂ ow Pipe

Nipple

Rubber Washer

Reservoir Nut

BLEED-OFF KIT

Bleeder Tee

Copper Or Plastic Line To Cooler

Back Post

Panel

Bleed Tube

Restrictor Overﬂ ow Pipe

AMPERAGE DRAW AND BELT TENSION

CAUTION: 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.

This unit is equipped with an adjustable motor drive pulley for adjusting the blower wheel speed to the proper loading for different duct systems. It is important that the motor drive pulley is adjusted to correct size to ensure maximum air delivery without damage to the motor. Be sure to follow these instructions carefully.

110498-2

AMPERAGE DRAW AND BELT TENSION (CONT)

1. Ensure electrical connection of unit is complete and in accordance with all safety standards and local requirements.

2. Reinstall inspection panels. Apply power, turn water and pump on and allow cooler to run for a few minutes to wet pads.

3. Check amperage and verify it conforms to amperage listed on the speciﬁ cation label on motor.

• If amperage draw is less than motor 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 done for your safety. Adjust pulley to a larger diameter and readjust belt tension. Plug motor in, install inspection panels, and retest amperage draw. Repeat this process until correct amperage draw is attained.

Note: Increasing motor pulley diameter increases amperage draw. Decreasing motor pulley diameter decreases amperage draw.

CAUTION: DO NOT operate cooler with larger

amperage draw than speciﬁ ed on motor plate. Motor damage will occur.

4. Check belt tension after adjusting pulley. A 3 lb. force should deﬂ ect the belt 3/4 inches. Readjust belt if needed by loosening adjustment screw, rotate motor until you have the correct belt tension, then re-tighten screw.

Motor

BELT TENSION

3 Lb. Pressure

3/4 Inches

Motor

Pulley

Belt

Blower Pulley

Decrease

Amperage

Adjustment Screw

OPERATION

NOTES: 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.

To eliminate the delivery of hot air when starting the cooler, start the pump only for the ﬁ rst few minutes, then turn on the

blower motor.

For an evaporative cooler to be effective, there needs to be adequate exhaust. If there is not adequate exhaust, pressure and humidity will build up in the building. You exhaust by opening doors or windows to allow the old stale air in the building to escape. Attic exhaust dampers may also be installed to exhaust the air into the attic. The combination of attic exhaust dampers and a thermostat can provide a completely automatic operation.

An often misunderstood concept of evaporative cooling is the amount of air that should be exhausted. How much should you open your windows? The following two methods will help you determine the amount to open your windows.

WINDOW AREA/CFM METHOD

For proper air ﬂ ow, allow an opening of at least 2 square feet (288 square inches) for each 1000 CFM rating of your unit. Example: At 3320 CFM, model ADA 51 (1/2 hp) requires 6.6 square feet (950 square inches) of opening (3320/1000 * 2 =

6.6).

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 6.6 inches each.

TISSUE SUCTION 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 re-balance 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.

110498-2

MAINTENANCE

Regular maintenance on your cooler will increase performance and extend the life of your cooler.

WARNING: Before accomplishing any maintenance ensure power is turned off and the motor and pump are

unplugged.

START OF SEASON MAINTENANCE

Accomplish these basic steps before the temperatures require cooling in case you have to acquire replacement parts.

CLEAN MEDIA

1. With power OFF, remove inspection panels, top panels and inlet grille to access interior of unit. Place panels in a ﬂ at, secure place to protect them from being bent or damaged.

2. Disconnect water tube and lift off water distribution tray, accessing the media. Remove ﬁ lter pad on top.

3. Remove and inspect media pads. Using a garden hose sprayer, wash the media pad ensuring openings are clear of obstruction and dirt. Some light scrubbing may be required to remove mineral deposits. Do not use harsh detergents or pressure washers in cleaning. Make every effort to keep the media intact.

4. The original media has a standard life of 5 years, but in areas with very high mineral content the media may have to be replaced sooner.

5. When reinstalling existing or installing new replacement pads, ensure pads are installed in the correct conﬁ guration:

• Place the media into the unit with the steeper ﬂ ute angle sloping down towards the air inlet side. This provides the most effective

water ﬂ ow to the pads, allowing higher cooling efﬁ ciencies.

• We recommend using original equipment, MasterCool® media replacement pads for highest cooling capabilites.

NOTE: If competitor pads with equal angles are installed, disregard directional placement of media.

OIL BEARINGS

1. The blower bearings should be oiled each year with non-detergent 20/30 weight oil.

2. Locate and open the oil cup on each of the blower bearings and add a few drops of oil.

3. Add oil to motor bearings if motor has oil lines. Note: Many motors are sealed and do not require addition of oil.

CAUTION: Do not over oil the motor, as this can cause the motor to burn out due to

excessive oil on windings.

Air Enters

Air Exits

15°

Blower Bearing

Oil Cup

45°

CLEAN PUMP

1. Pump should be cleaned at least once a year or more often if debris accumulates.

2. Unplug motor and pump from junction box, and disconnect water tube, if not already accomplished.

3. Using a screw driver, pry plastic retaining fastners straight up out of the pump-mounting bracket.

4. Slide the pump off the mounting bracket.

5. Extract pump from straining basket or netting and remove base of pump.

6. Clean pump, turn impeller to ensure free movement.

7. Remove pump spout and check for blockage.

8. Reinstall pump base and verify it is secure.

9. Before reinstalling pump, check water hose, bleeder line and water distributor tube to ensure there is no blockage in any lines.

10. Reinstall the pump by sliding pump onto mounting bracket and reinserting the plastic retainers to ensure pump stays in upright postion.

11. Reinstall water tube to the pump outlet spout.

CHECK BELT

1. Before unit is turned on, check that belt condition is good. If belt must be replaced, install same sized belt.

2. Verify belt tension is correct: 3/4” deﬂ ection with 3 lbs of force.

Remove

Base

Impeller

END OF SEASON SHUTDOWN

The cooler should be prepared before any extended period of non use, and especially before winter shutdown.

1. Drain all water from unit, supply line and pump to ensure no damage occurs from freezing. Keep water line disconnected from both unit and supply line.

2. Unplug motor and pump from junction box.

3. Clean unit.

4. Cover unit to protect ﬁ nish for long periods of non use.

110498-2

GENERAL SPECIFICATIONS

MODELS

WEIGHT (lbs) CABINET DIMENSIONS (in.) DUCT OPENING (in.)

DRY OPERATING HEIGHT WEIGHT DEPTH WIDTH HEIGHT

51 Series 177 227 28 42 45 17-3/4 17-3/4

5112 Series 190 257 28 42 49 17-3/4 17-3/4

71 Series 213 263 34-5/8 42 48 19-3/8 19-3/4

7112 Series 233 300 34-5/8 42 52 19-3/4 19-3/4

*Includes motor weight

MOTOR SPECIFICATIONS

MODELS H.P

51 & 5112

Series

71 & 7112

Series

* Amperage shown is from National Electrical Code for high speed.

MOTOR PN

1/3 110445 2 115 7.2 17 110279-002 1/2 110447 2 115 9.8 18 110279-004

1/2 110475 2 230 4.9 15 110279-004 3/4 110449 2 115 13.8 22 110279-004

3/4 110480 2 230 16.9 21 110279-004 1/2 110447 2 115 9.8 18 110279-002

1/2 110475 2 230 4.9 15 3/4 110449 2 115 13.8 22 110279-004 3/4 110480 2 230 6.9 21 110279-004

1 110471 2 115 16 29 110279-003 1 110458 2 230 8 29 110279-003

SPEED VOLTS *AMPS

WEIGHT (LBS)

MOTOR PULLEY P/N

110279-002

MODEL DRIVE BELT P/N

ADA51 & ADA5112

ASA51 & ASA5112

AUA51 & AUA5112

ADA71 & ADA7112

ASA71 &

ASA7112

AUA71 & AUA7112

110208 (4L-520) 110229 (4L-530) -3/4 HP

110212 (4L-570)

110222 (4L-510)

110230 (4L-640)

110213 (4L-670)

TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE REMEDY

1. No electrical power to unit 1. Check Power

• Blown Fuse or Tripped Circuit Breaker

• Electrical cord damage

• Replace fuse or reset breaker

• Replace Cord

2. Belt too loose or too tight 2. Adjust belt tension

Failure to start or no air delivery

3. Motor overheated 3. Determine cause of overheating

• Belt too tight

• Blower bearings dry

• Motor pulley diameter too large

• Adjust pulley tension

• Oil blower bearings

• Adjust pulley to correct diameter

4. Motor locked 4. Replace motor

1. Insufﬁ cient air exhaust 1. Open doors or widows to increase air ﬂ ow

Inadequate air delivery with cooler running

2. Belt too loose 2. Adjust belt tension or replace if needed

3. Pads plugged/dirty 3. Clean pads

4. Motor underloaded 4. Adjust pulley

Water draining onto roof

1. Float arm not adjusted properly 1. Adjust ﬂ oat

2. Overﬂ ow assembly leaking 2. Tighten nut and overﬂ ow pipe

Musty or unpleasant odor 1. Stale or stagnate water in cooler 1. Drain pan and clean pads

1. Low voltage 1. Check voltage

2. Excessive belt tension 2. Adjust belt tension

Motor cycles on and off

Blower shaft and tight or locked

3. Unplug unit and oil or replace bearings

4. Bearings dry 4. Oil bearings

Motor pulley diameter too large ,

causing motor overload

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

1. Bearings dry 1. Oil bearings

Noisy

2. Wheel rubbing blower housing 2. Unplug unit, inspect and realign

3. Loose parts 3. Tighten loose parts

1. Inadequate exhaust in house

1. Open windows or doors to increase air ﬂ ow

2. Pads not wet 2. Check water distribution system

Inadequate cooling

• Pads clogged

• Distribution tube holes clogged

• Pump not working properly

• Clean pads

• Clean tube holes

• Unplug and replace or clean pump

Excessive humidity in house 1. Insufﬁ cent air exhaust 1. Open doors or windows

110498-2

MASTERCOOL SINGLE INLET LIMITED WARRANTY POLICY

SALES RECEIPT REQUIRED AS PROOF OF PURCHASE FOR ALL WARRANTY CLAIMS.

This warranty is extended only to the original purchaser of this evaporative cooler when the unit is installed and used under normal conditions against defects in workmanship and materials as follows:

• One (1) year from date of sale on the cabinet components

• Five (5) years on the evaporative media, which is considered a disposable component and should be replaced periodically.

• Two (2) years on the motor, if furnished by Champion Cooler The manufacturer will replace the defective part/product, at its discretion. It is agreed that such replacement is the

exclusive remedy available from the manufacturer and that TO THE MAXIMUM EXTENT PERMITTED BY LAW, THE MANUFACTURER IS NOT RESPONSIBLE FOR DAMAGES OF ANY KIND, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGE OR LOSS OF PROFITS OR REVENUES.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

Exclusions from this warranty

We are not responsible for any incidental or consequential damage from any malfunction, accident, misuse, alterations, unauthorized repairs, abuse, including failure to perform reasonable maintenance, normal wear and tear.

Alterations include the substitution of name brand components including, but not limited to media pads. We are not responsible for any damage from the use of water softeners or treatments, chemicals or descaling materials. We are not responsible for the cost of service calls to diagnose the cause of trouble, or labor charge to repair and/or replace

parts. No employee, agent, dealer or other person is authorized to give any warranties or conditions on behalf of the manufacturer.

The customer shall be responsible for all labor costs incurred. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations or

exclusions may not apply to you.

How to obtain service under this warranty

Within the limitations of this warranty, purchaser with inoperative units should contact the dealer where you purchased the cooler. If for any reason you are not satisﬁ ed with the response from the dealer, contact Customer Service at 800-643-8341 for instructions on how to obtain service within warranty as listed above.

This warranty gives the customer speciﬁ c legal rights, and you may also have other rights which vary from province to province, or state to state.

110498-2

+ 16 hidden pages

MasterCool ADA51, AUA51, ASA51, ADA5112, AUA5112 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual