Bigassfans COLD FRONT 300 User manual

Operation and Maintenance Manual
Manuel de fonctionnement et d'entretien
Manual de operación y mantenimiento
BIGASSFANS.COM
COLD FRONT 300
COLD FRONT 400
COLD FRONT 500
EXCEPTIONALLY
ENGINEERED
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LISEZ ET CONSERVEZ CES INSTRUCTIONS
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F-EV1-3601
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DANGER DANGER indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
WARNING WARNING indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
IMPORTANT IMPORTANT indicates a potentially hazardous situation which, if not avoided,
MAY result in property damage.
Installation Guide
Rev. E
02/01/2021
Improper installation, delivery, or maintenance, including, but not limited to, any of the following actions by the customer or agent of the
customer will constitute a breach of and will void all warranties:
• Failure to follow the required installation procedures specified in this Installation Guide and in all other documentation supplied
with the fans and related equipment including documentation provided by the manufacturers of the individual fan and control
components;
• Failure to follow all relevant codes and ordinances, including, but not limited to, the National Electrical Code (United States),
applicable national and local electrical codes, and state and local building codes;
• Failure to follow electrical engineering industry standards regarding the approved method of installing solid-state electrical
equipment having the characteristics of the fans, the fan controls, and their related components, even if such standards are not
specifically referenced in any instructions or literature supplied by Big Ass Fans or provided by manufacturers.
All trademarks used herein are the properties of their respective owners. No part of this document may be reproduced or translated into
a dierent language without the prior written consent of Big Ass Fans. The information contained in this document is subject to change
without notice. For the most up-to-date information, see the online printable installation guide at www.bigassfans.com
Patent: www.bigassfans.com/patents • www.bigassfans.com/product-warranties
Original English Instructions www.bigassfans.com/support
IMPORTANT SAFETY INSTRUCTIONS
The appliance is not to be used by children or persons with reduced physical, sensory, or mental capabilities,
or lack of experience and knowledge, unless they have been given supervision or instruction.
Children being supervised should be instructed not to play with the appliance.
Maximum altitude: < 1000 m

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CHECKLIST
DO
✓Read the Operation and Maintenance Manual.
✓Check all hose connections.
✓Use a 12 gauge cord if the cord is under 50 ft (15 m) or a 10 gauge cord if the cord
is over 50 ft (15 m).
✓Provide fresh air intake for the cooler and maintain a minimum clearance of 3 ft
(0.9m) behind the cooler.
✓Flush new cooling media.
1. Fill the cooler with water.
2. Switch on the pump.
3. Run the cooler without the fan running for 5 hours.
✓Make sure the cooling media is being evenly saturated by using the control valve
to adjust the water flow.
✓Drain and clean the cooler weekly. Remove the cooling media and wash with a
garden hose.
✓Use Refresh™ tablets (algae killer) and/or CTT-EC™ cooler treatment tablets
(mineral treatment). One algae killer tablet is provided in the cooler's reservoir.
Additional water treatment tablets are available at bigassfans.com.
DO NOT
ΧDO NOT forget to dry out the cooling media before shutting down the cooler. Turn
o the pump and leave the fan running for 10 to 15 minutes.
ΧDO NOT run the pump without filling the reservoir with water first.
ΧDO NOT completely open the water valve. This may flood the cooling media.
ΧDO NOT use a water source with more than 120 PSI (8 bar/827 kPa) of water
pressure.
ΧDO NOT operate the cooler in a sealed room. Allow for fresh air intake and
exhaust.

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2
ASSEMBLY AND SETUP
IMPORTANT
Carefully examine the carton for damage before opening. If the carton is damaged, notify the shipping
company immediately.
Install Casters (Cold Front 300 only):
1. Locate the package of four (4) casters and sixteen (16) bolts and remove from box.
2. Lay box on its side and carefully open bottom of box. DO NOT STAND BOX UPSIDE DOWN.
3. Install the four casters using the bolts.
4. Stand cooler up on casters and remove box.
The cooler has been factory tested and is ready to use. Place the cooler on level ground with the casters locked
to prevent inadvertent movement.
Connecting the water supply
The cooler comes equipped with a garden hose water source connection. Use a standard garden hose (not
provided) to connect the water supply to the cooler.
CAUTION
Do not connect to any water source where water pressure exceeds 120 PSI (8 bar/827 kPa). This will cause
permanent damage to the cooler.
Connecting the electrical supply
IMPORTANT
The cooler should be plugged into a fused or breaker-protected circuit. Refer to the table for circuit size
requirements. Cold Front 500 models cannot be connected to a GFCI outlet.
Amperage and Circuit Requirements
Model Volts +/- 10% Frequency Min. Circuit Size Running Amps
Cold Front 300 120 V 60 Hz 15 A 4.1 A
220/230 V 50/60 Hz 10 A 1.8 A
Cold Front 400 120 V 60 Hz 15 A 8.0 A
220/230 V 50/60 Hz 10 A 5.0 A
Cold Front 500 120 V 60 Hz 25 A 16.5 A
220/230 V 50/60 Hz 15 A 8.6 A
CAUTION
Do not exceed the amperage ratings of the extension cord. Undersized extension cords create excessive
drops in voltage, causing the electric motor to generate excess heat. This results in inecient motor
operation and premature motor failure and will void the warranty.

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Three-Conductor Heavy Duty Extension Cord Requirements (120 V)
Cord Length Cord Size
16 GA 14 GA 12 GA 10 GA
0–50 ft (0–15 m) 13 A 18 A 25 A 30 A
50–100 ft (15–30 m) 10 A 13 A 18 A 25 A
Three-Conductor Heavy Duty Extension Cord Requirements (220/230 V)
Cord Length Cord Size
1.5 mm22.5 mm24 mm25 mm2
6 m 13 A 15 A 15 A 15 A
16 m 13 A 14 A 15 A 15 A
32 m 10 A 12 A 13 A 15 A

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4
OPERATION
The cooler must be placed on level ground to operate correctly. Evaporative coolers create an oval-shaped
air pattern. Obstacles such as racks and workbenches may interfere with airflow. Position the cooler so that
interruption of the air pattern is minimized. Multiple coolers may be required to cover larger areas.
There are three major factors to consider when determining where to place the cooler.
1. Fresh Air Supply. The inlet side of the cooler (pad side) requires a constant, uninterrupted supply of fresh air
for maximum performance. A distance of 3 ft (0.9 m) of clear space to any obstructions at the rear or inlet side
of the cooler is recommended.
2. Discharge Airflow. The cool air discharged from the cooler should be free from obstruction to promote air
circulation in order to maximize the cooling zone.
3. Ventilation. Adequate ventilation is needed ensure the cooler does not recirculate air that has already been
through the evaporative cooling process.
Filling the cooler with water
Once the cooler has been connected to a water source, turn the water supply valve on and the cooler will fill
with water. The float valve will shut o the water flow when the sump is full.
Starting the fan
Set the fan switch to the ON position and adjust the speed to your preferred setting.
Starting the pump and adjusting the water flow
The cooling media in your new cooler will take a few hours to become fully saturated, and the media may
initially produce an odor. Flush the cooling pads for 5 hours with the flow control valve fully opened to ensure
the best eciency of your cooler. During this time, the odor should also dissipate. For best results, change the
water in the reservoir frequently.
Once the cooling pads are fully flushed:
1. Fill reservoir with water.
2. Turn on fan.
3. Adjust water flow with flow control valve until water streams over pads.
Do not flood the pads with water. You should see several 1" to 2" (25 to 51 mm) wide dry streaks on the face of
the pads. If dry streaks grow wider, adjust flow to allow more water.
CAUTION
Prolonged use of hard water without proper water treatment will create mineral deposit buildup. This will
cause the pump to fail and is NOT COVERED BY WARRANTY.
IMPORTANT
Pump is equipped with a low water cuto that may take up to five (5) minutes to reset each time.

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REM
Fan Speed
• Default speed is 6.
• Press +to increase speed.
• Press -to decrease speed.
Power On/O
Turns cooler on and o.
Fan On/O
Turns fan on and
o in Manual
mode.
Pump On/O
Turns pump on and
o in Manual mode.
Auto/Manual Mode
Switches cooler between Auto and Manual mode.
In Auto mode:
• Indicator light will be on.
• Cooler will run when motion is detected.
• When no motion is detected, cooler will run for 10
minutes and then shut down.
Pad Dry
Puts cooler into shutdown mode.
• When pressed, the pump shuts o and the
fan will continue to run for 15 minutes and
then shut down.
• Works in Auto and Manual mode.
Remote Sensor
Power Indicator
Red light: Power connected
Green light: Power on
Low Water Indicator
Operation (Cold Front 500)

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Remote control operation (Cold Front 500)
Fan Speed
• Default speed is 6.
• Press +to increase speed.
• Press -to decrease speed.
Power On/O
Turns cooler on and o.
Fan On/O
Turns fan on and o in Manual mode.
Pump On/O
Turns pump on and o in Manual
mode.
Auto/Manual Mode
Switches cooler between Auto and
Manual mode. In Auto mode:
• Indicator light will be illuminated.
• Cooler will run when motion is
detected.
• When no motion is detected,
cooler will run for 10 minutes, and
then shut down.
Pad Dry
Puts cooler into shutdown mode.
• When pressed, the pump shuts
o and the fan will continue to
run for 15 minutes and then shut
down.
• Works in Auto and Manual
mode.

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MAINTENANCE AND STORAGE
WARNING
ELECTRICAL SHOCK HAZARD
Disconnect the power supply before performing any service or maintenance.
Failure to do so may result in serious injury or death.
Removing the cooling media
Remove the cooling pads to access the inside of the cooler.
1. Remove the bolts connecting the pad retainer bar (pad side) from the housing.
2. Cold Front 400 and 500 models: Remove top pads.
3. Starting with the center pad(s), tilt pads from the top and lift out of the cooler.
NOTE: Reinstall pads correctly according to the markings on the pads.
Daily maintenance
After each use, turn o the pump about 15 minutes before the fan is turned o to allow the pads to drain and dry
out. This controls mildew and bacteria growth for a long and ecient pad life. Drain the water from the cooler if it
will be unused for a prolonged period of time.
Periodic maintenance
Shut down the cooler and drain the water sump regularly. Depending on how often you operate the cooler,
drain the sump anywhere from every week (heavy use) to monthly (light use). The cooling pads act as a filter to
remove dust and other particles from the incoming air stream. Collected particles and any water impurities will
flow into the sump and collect there. To keep the cooler operating at peak eciency, keep the cooling media
and sump clear of debris. Water treatment tablets are available at bigassfans.com.
Draining the water sump
1. Close water flow valve and open drain valve or remove drain plug located at bottom of reservoir.
2. Run pump until sump is dry, and then immediately shut o pump.
3. Turn cooler o and disconnect the power supply.
4. Remove cooling pads.
5. Clean out reservoir with either a towel or wet/dry vacuum.
6. Remove the water spray bar and its plug. Ensure holes are free of debris.
7. Reinstall pads and pad retainer.
Ensure the cooling pads are kept clean and dust-free. Dust and other particles have an adverse eect on the
pads’ ability to introduce water into the air stream. If the pad surface is dirty, clean with a soft brush and water.
Never use bleach.
Storage
1. Remove cooling pads and clean with a soft brush and water to remove dust and debris.
2. Drain sump and wipe dry.
3. Store cooler in a dry area and cover to prevent dust buildup.

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TROUBLESHOOTING AND REPAIR
WARNING
ELECTRICAL SHOCK HAZARD
Disconnect the power supply before performing any service or maintenance.
Failure to do so may result in serious injury or death.
CAUTION
Please use caution when troubleshooting or repairing all electrical components. Ensure all power is
disconnected from the cooler before the cooling pads or fan guard are removed to gain access to the fan.
Tools needed
• Screwdrivers
• Pliers
• Adjustable wrenches
• Volt/Ohm meter (electrical troubleshooting)
Additional tools may be required.
General troubleshooting
The cooler consists of three systems:
• Pump
• Water distribution system
• Fan system
Use the troubleshooting tables on the following pages to determine which system(s) require servicing.

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Error codes (Cold Front 500 only)
Error Solution(s)
E1 - Voltage Self-Inspection Error • Try a dierent circuit.
• Replace the panel.
E2 - Overcurrent Protection
Current draw is too high.
• Check extension cord size.
• Check that motor spins freely.
• Check that airflow is not obstructed.
E3 - Under Voltage Protection
Supply voltage is too low (< 100 V).
• Try a dierent circuit.
• Install a voltage regulator.
E4 - Over Voltage Protection
Supply voltage is too high (> 130 V).
• Try a dierent circuit.
• Install a voltage regulator.
E5 - Overload Protection
Motor is running too hot.
• Check that airflow is not obstructed.
• Check extension cord size.
E6 - Overheat Protection
• Check that airflow is not obstructed.
• Check for mineral buildup on the motor.
• Check extension cord size.
E7 - Panel with Motor Communication Error • Check for a broken or loose wire.
E8 - Panel Internal Error • Replace the panel.
E9 - Motor No Response • Check for a broken or loose wire.
• Replace the motor.
F6 - Panel Communication Error • Check for a broken or loose wire.

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Water distribution system troubleshooting
The water distribution system consists of two assemblies:
• Water inlet assembly
– Brass bulkhead fitting
– Float valve assembly
• Hose and valve assembly
– Spray bar assembly
– Valve assembly
– Connection hose
Issue Solution(s)
Floor at side of cooler is wet.
Water inlet hose is loose at supply hose or inlet hose is loose at bulkhead
fitting.
Tighten connections and/or replace hose washers.
Water overflows from reservoir or
is spitting through fan.
Float valve hose is loose at bulkhead fitting or at float valve.
Tighten connections and/or replace hose washers.
Water pressure is too high to allow float valve to shut o
(120PSI/8bar/827 kPa max).
Reduce water pressure by adding an inline reducer.
Float valve is not properly seated.
Check all hoses for leaks.
Water is spitting from the cooler.
Check the hose and valve assembly.
• Reduce flow control setting.
• Replace cracked hose and valve assembly.
• Tighten hose connections.
• Adjust spray bar.
• Ensure pads are installed correctly.
Water is leaking from the drain
valve.
Check for worn washer or stem or open drain valve.
• Replace washer.
• Replace drain valve.
There are too many dry streaks on
the pads.
Check for blocked holes in the spray bar or adjust water flow.
• Remove spray bar and plug and clean the tube and holes.
• Open water flow control valve.

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Fan system troubleshooting
Issue Solution(s)
Fan will not run and makes no sound.
Check power cord, extension cord, switches, and circuit breaker.
• Reconnect power or extension cord.
• Reset breaker.
Fan will not run and makes humming
sound.
Blade is in contact with shroud.
Re-center blade hub.
Motor stall (will not turn by hand).
Replace motor.
Breaker trips or fuse blows when fan
starts.
Motor stall.
Replace motor.
Check power source. Refer to page 1 for electrical requirements.
Upgrade power supply.
Extension cord gauge is too small.
Replace with heavier cord.
Motor overheats, shuts o, and restarts
several minutes later.
Extension cord gauge is too small.
Replace with heavier cord.
Inlet air is obstructed or too close to wall.
Provide minimum 3 ft (0.9 m) inlet clearance.
Faulty motor.
Replace motor.
Fan motor will not run and switch makes
soft clicking sound.
Ensure switch is making good contact.
Replace switch if needed.
Fan blade does not turn and cooler
makes squealing sound.
Motor stall (will not turn by hand).
Replace motor.
Fan will not reach speed but turns and
makes humming sound.
Check capacitor (where visible) and motor electrical connections.
Replace capacitor or motor.
Extension cord gauge is too small.
Replace with heavier cord.

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Fan repair procedures
CAUTION
Repairs should be performed by a qualified technician!
WARNING
ELECTRICAL SHOCK HAZARD
Disconnect the power supply before performing any service or maintenance.
Failure to do so may result in serious injury or death.
Fan motor replacement for Cold Front 300
1. Remove cooling pads.
2. Remove black motor wiring plate and disconnect motor wires. Mark each wire with a marker or marker tape
for easy matching when installing new motor.
3. Remove the four (4) nuts and bolts securing the motor, fan, and support braces (complete fan assembly).
4. Replace with new fan assembly.
5. Secure with four (4) nuts and bolts.
6. Replace any wire ties that were removed when uninstalling the old fan assembly.
7. Replace black motor wiring plate.
8. Reinstall pads and connect power.
Fan motor replacement for Cold Front 400 and 500
1. Remove cap from bottom of motor. Disconnect wires and clip wire ties.
2. Remove the four (4) fan mounting bolts from front. Support fan to ensure it does not fall.
3. Pull the fan out of the cooler.
4. Remove blade mounting nut and blade.
5. Remove mounting arms by loosening the eight (8) bolts securing the arms to the motor. Note the positions of
the arms for re-installation.
6. Install arms and blade on new motor.
7. Install fan in opening and secure with mounting bolts.
8. Reconnect wires. Attach cord to motor arm with wire ties so that wires are clear of fan blades.

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Pump repair procedures
CAUTION
Repairs should be performed by a qualified technician!
WARNING
ELECTRICAL SHOCK HAZARD
Disconnect the power supply before performing any service or maintenance.
Failure to do so may result in serious injury or death.
Pump replacement for Cold Front 300, 400, and 500
1. Unscrew fitting from pump.
2. Unplug cord from top of pump by removing the two (2) screws.
3. Remove pump from water sump and install new pump.
4. Perform the steps above in reverse to reconnect the wiring, lift the pump bracket, and reconnect the hose.
5. Secure wires to fan frame with wire ties so that wires are clear of fan blades. Ensure plug is positioned
correctly.
6. Reinstall cooling pads and guards.
7. Reconnect power and test pump.
Pump troubleshooting
Issue Solution(s)
Pump motor will not run when switch is
turned on.
Turn fan on to check for power.
• If fan does not start, check breaker and make sure cord is
plugged in.
• If fan starts, check for power to and through pump switch (when
turned on).
Ensure water level is high enough to make the low water cuto
circuit.
Fill water reservoir.
Pump motor hums when switch is turned
on but does not pump water.
Obstruction in impeller.
Remove object(s).
Pump motor failure.
Replace pump.
Breaker trips or fuse blows when switch is
turned on.
Check power cord length and breaker rating.
Refer page 1 for cooler amperage draw and to determine required
cord gauge and circuit size.
Check for locked up pump.
Replace pump.
Pump runs but does not pump water.
Air lock in outlet side of pump.
Turn o and on to bleed.
Ensure the impeller is turning in pump.
If not, replace pump.

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MAINTENANCE
Spring cleaning
☑ Remove the cooling media and clean out any debris in the water pan at the bottom of the cooler.
☑ Remove the distribution tube from the mounting clips. Remove the plug at the end of the tube and
flush out. Clean the distribution holes with a small brush and flush with water to verify all holes are
clear.
☑ If the cooling media is heavily stained with minerals or is damaged, replace the media. Replacement
cooling media is available at bigassfans.com. Verify the media is installed correctly with the arrows
on the side.
☑ Connect the water line and turn on the water supply. Check the float valve and make sure it is
operating properly. Verify that the float valve is shutting the water o before walking away.
☑ Switch on the fan motor and pump. Make sure the cooling media is being evenly saturated with
water by using the flow control valve to adjust the water flow. Small dry streaks are acceptable.
Mid-summer checkup
☑ Make sure the float valve is working properly. If the valve sticks, the water will run continuously and
flood the reservoir. If this occurs, install a new float valve or contact Customer Service.
☑ Check all other working parts for cracks or damage, including the pump, fan motor, and fan belt.
☑ Check the condition of the cooling media. The cooler runs most eciently when the media is clean.
If the media has a heavy accumulation of mineral deposits, replace it.
☑ Use the drain valve to empty the reservoir. Remove any debris.
Winterize
☑ Clean the minerals from the reservoir. Vinegar can be used to dissolve buildup. Flush out the
reservoir through the drain plug.
☑ Inspect the water distribution tube for clogged holes. Clean as necessary.
☑ To prevent freezing in the cooler’s water line, disconnect the water supply, and then open both
valves on the side of the cooler to dry out the reservoir.
☑ Use a storage cover to protect your cooler and keep it clean.

CONTACT US
Customer Service
2348 Innovation Drive
Lexington, KY 40511
USA
877-244-3267
bigassfans.com
www.bigassfans.com/support
Accessories and Replacement Parts
www.bigassfans.com