HH PolarCool 18" User manual
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Evaporative Cooling System User Manual
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Evaporative Cooling System User Manual
Section 1: Introduction............................................................................................................................................
Section 1.1: Definitions of Informational Headings............................................................................................................................
Section 1.2: Scope of Manual...............................................................................................................................................................
Section 1.3: Limited Warranty..............................................................................................................................................................
Section 1.4: Overview...........................................................................................................................................................................
Section 1.4.1: Technical Specifications...................................................................................................................................................
Section 2: Setup......................................................................................................................................................
Section 2.1: Install Casters (18" Units Only)........................................................................................................................................
Section 2.2: Float Valve........................................................................................................................................................................
Section 3: Operation...............................................................................................................................................
Section 3.1: Components.....................................................................................................................................................................
Section 3.1.1: Fan Motor..........................................................................................................................................................................
Section 3.1.2: Water Pump......................................................................................................................................................................
Section 3.1.3: Control Panel (All Units) and Control Board (Not on 48" Units).....................................................................................
Section 3.1.4: Cooling Pads.....................................................................................................................................................................
Section 3.1.5: Float Valve........................................................................................................................................................................
Section 3.1.6: Liquid Level Switch (18", 24", and 36" Units)...................................................................................................................
Section 3.2: Controls............................................................................................................................................................................
Section 3.2.1: 18", 24", and 36" Variable-Speed Units............................................................................................................................
Section 3.2.2: 48" Single-Speed Units.....................................................................................................................................................
Section 3.3: Starting.............................................................................................................................................................................
Section 3.4: Shutting Down.................................................................................................................................................................
Section 4: Maintenance...........................................................................................................................................
Section 4.1: Regular Preventive Maintenance....................................................................................................................................
Section 4.2: Cooling Pads.....................................................................................................................................................................
Section 4.2.1: Cleaning and Replacement.............................................................................................................................................
Section 4.2.2: Breaking in New Cooling Pads.........................................................................................................................................
Section 4.3: Cleaning Spray Bar...........................................................................................................................................................
Section 4.4: Adjusting Water Pressure.................................................................................................................................................
Section 4.5: Changing Reservoir Water Level......................................................................................................................................
Section 4.6: Cleaning Reservoir...........................................................................................................................................................
Section 4.7: Cleaning Pump Filter........................................................................................................................................................
Section 4.8: Inspecting and Adjusting Fan Belt (48" Units Only).......................................................................................................
Section 4.9: Long-Term Storage...........................................................................................................................................................
Section 5: Troubleshooting......................................................................................................................................
Section 6: Replacement Parts..................................................................................................................................
Section 6.1: 18" Units...........................................................................................................................................................................
Section 6.2: 24" Units...........................................................................................................................................................................
Section 6.3: 36" Units...........................................................................................................................................................................
Section 6.4: 48" Units...........................................................................................................................................................................
Section 7: Wiring Diagrams......................................................................................................................................
Section 7.1: 18", 24", and 36" Units......................................................................................................................................................
Section 7.2: 48" Units...........................................................................................................................................................................
Section 8: Warnings/Avertissements.........................................................................................................................
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Section 1.1: Definitions of Informational Headings
• DANGER: This heading indicates noncompliance with the stated information will lead to serious injury or death.
• WARNING: This heading indicates noncompliance with the stated information may lead to serious injury or death.
• CAUTION: This heading indicates noncompliance with the stated information may lead to minor or moderate injury.
• NOTICE: This heading draws attention to specific information.
Section 1.2: Scope of Manual
Section 1: Introduction
NOTICE: This document is subject to change without notice. The latest version is maintained at rollseal.net/rollseal-technicals/.
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Section 1.3: Limited Warranty
For three years from the date of invoice, PolarCool (a division of HH Technologies, Inc.) warrants the motor and any electrical
components of the PolarCool Evaporative Cooling System ("the Product") that are found, upon examination by factory-authorized
personnel, to be defective in material and/or workmanship.
PolarCool also warrants the metal housing of the Product for the full lifetime of the Product to the extent it is found, upon
examination by factory-authorized personnel, to be defective in material and/or workmanship. The Lifetime Warranty on the
Product housing does not cover ordinary wear and tear.
If any of the original component parts, including the Product housing, exhibit any defect(s) covered by this Limited Warranty
within the applicable time periods defined above, the same may be repaired or replaced at PolarCool's discretion.
This Limited Warranty excludes any labor, equipment, transportation, and/or service expenses that may be required to remedy the
warranted defect(s); all such charges must be funded by the purchaser. Neither the Product nor any of its component parts are to
be returned for repair or replacement until they have been inspected and/or a Return Goods Authorization (RGA) number has been
issued.
Complaints are to be directed first to the authorized distributor who sold the Product. If satisfaction is not obtained and/or the
distributor cannot be contacted, complete the warranty form at https://polarcool.net/polarcool-return-policy/.
This Limited Warranty is void if: a) the Product and/or any of its component parts are found to have been misused, abused, or
otherwise tampered with by unqualified personnel; b) any of the Product's component parts have been replaced by anything
other than authorized PolarCool replacement parts; c) the Product has been modified in any way other than oicially sanctioned
upgrades made by qualified personnel using authorized PolarCool accessories; d) the Product has not been appropriately
registered by its original purchaser; or e) the customer cannot provide proof of purchase indicating them to be the Product's
original owner.
This Limited Warranty is made solely to the original purchaser of the Product. It cannot be transferred.
This Limited Warranty is in lieu of any and all other representations and/or warranties, expressed or implied, including any implied
warranty of merchantability and/or fitness for a particular purpose. The remedy set forth by this Limited Warranty shall be the
exclusive remedy available to any entity. No entity has the authority to bind PolarCool to any representation or warranty other
than this Limited Warranty. PolarCool shall not be liable for any damages or losses resulting from any application of the Product or
caused by any defect, failure, or malfunction of the Product.
This Limited Warranty gives you specific legal rights. You may have additional rights, as some areas do not allow the exclusion or
limitation of incidental or consequential damages. The above limitation or exclusion may therefore not apply to you.
Warrantor: HH Technologies, Inc. (d.b.a. RollSeal)
Address: 1733 County Road 68; Bremen, AL 35033
Phone: 256-287-7000
Email: customerservic[email protected]
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Section 1.4: Overview
The PolarCool Evaporative Cooling System (henceforth referred to as "the unit") reduces air temperature by drawing warm
ambient air across a water-soaked surface (the cooling pads), evaporating the water and dissipating the heat it has absorbed.
Simple controls make the unit easy to operate, and the overall design permits straightforward cleaning and maintenance. Casters
allow the unit to be moved by hand and set up anywhere with proper water and power supplies.
Section 1.4.1: Technical Specifications
18"
Variable-Speed
24"
Variable-Speed
36"
Variable-Speed
48"
Single-Speed
Unit Dimensions
(H xW xD) 49-1/2" x 24" x 20" 37" x 48" x 35" 61" x 63" x 36" 73" x 74" x 35"
Shipping Dimensions
(H xW xD) 50" x 36" x 24" 47" x 56" x 40" 69" x 70" x 43" 80" x 84" x 44"
Empty Weight 134 lbs 310 lbs 481 lbs 625 lbs
Drive Direct Direct Direct Belt
Noise Level
(Low; Medium; High) 19.4 dB; 24.8 dB; 29.1 dB 18.5 db; N/A; 37 dB N/A; 22 db; 31 dB N/A; N/A; 35.2 dB
Water Consumption* 5 Gallons per Hour 7 Gallons per Hour 12 Gallons per Hour 17 Gallons per Hour
Reservoir Volume 10 Gallons 9 Gallons 12.5 Gallons 13.5 Gallons
Power Consumption 5A at 115V; 60 Hz 6A at 115V; 60 Hz 10A at 115V; 60 Hz 11A at 230V; 60 Hz
Cooling Area 800 21,200 23,000 24,000 2
Current 4.9A 6A 8.5A 9.5A
Typical Air Movement†3,000 CFM 4,400 CFM 10,000 CFM 17,500 CFM
*Assuming ≥ 90°F conditions. Cooler temperatures will result in less water usage.
†Depending on relative humidity, temperature, and area being cooled.
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Section 2: Setup
Section 2.1: Install Casters (18" Units Only)
NOTICE: 24", 36", and 48" units are shipped with their casters pre-installed. If you have such a unit, skip to Section 2.2.
CAUTION: The unit is very heavy. Ensure it is well supported while you install the casters.
1. Align one of the caster brackets with one of the caster support channels on the bottom of the assemby.
2. Run four 5/16"-18 x 3/4" carriage bolts through the bracket and the support channel.
3. Place a 5/16" washer and a 5/16"-18 nylon insert nut on each of the bolts, then tighten the nuts until they are fully seated.
4. Repeat Steps 1-3 on the remaining casters.
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Section 2.2: Float Valve
1. Li the cover at the top of the unit to access the cooling pads.
2. Remove the cooling pads, titling the spray bar if necessary.
3. Hold the float valve in place while peeling the tape from it. Be careful not to bend the float valve arm.
4. Reinstall the cooling pads, ensuring the "UP" and "Air Flow" arrows are oriented properly. Reorient the spray bar if necessary.
5. Close the cover.
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Section 3: Operation
The unit operates by pumping water from the reservoir through the spray bar to soak the cooling pads. Meanwhile, the propeller
draws warm air through the pads. The water evaporates as it pulled away from the pads; this evaporation dissipates the heat the
water has absorbed from the incoming air, thus cooling the outgoing air. Excess water returns to the reservoir to be recirculated.
Evaporative cooling reduces the dierence between the area's dry-bulb temperature (DBT; i.e. regular air temperature) and
wet-bulb temperature (WBT; i.e. temperature at 100% relative humidity) with approximately 75% eiciency. For example, at a DBT
of 85°F and a WBT of 65°F (a dierence of 20°F), the temperature on the outlet side of the unit would be reduced to approximately
70°F (a decrease of 15°F).
Section 3.1: Components
Section 3.1.1: Fan Motor
On 18", 24", and 36" units, the 115V fan motor can be operated at various speeds using the control panel. The propeller is mounted
directly to and driven directly by the motor sha.
On 48" units, the 240V fan motor can be operated at only one fixed speed. The motor is mounted to the side of the fan sha. It uses
a belt-and-pulley system to drive the propeller.
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Section 3.1.3: Control Panel (All Units) and Control Board (Not on 48" Units)
The control panel is located on the right side of the unit. It is the primary means of starting and stopping the fan and the pump.
On 18", 24", and 36" units, the control panel is connected to the control board (itself mounted inside the electronics enclosure),
which handles all operational logic. The board enables variable-speed operation and low-water-level pump shuto. The control
panel has multiple buttons that control fan power, fan speed, and pump power. It also has several LEDs that indicate the fan
status, fan speed, pump status, and water level status.
On 48" units, the control panel has a pair of toggle switches that turn the fan and pump on and o. There is no control board.
Section 3.1.4: Cooling Pads
These 8"-thick paper-based blocks are a key part of the evaporative cooling process. As they are saturated with water, warm air is
drawn through them to dissipate the absorbed heat by evaporation. They are coated for protection against both impacts and algae
formation. They must be installed in the labeled orientation to allow proper airflow.
Section 3.1.6: Liquid Level Switch (18", 24", and 36" Units)
When this switch senses the water in the reservoir is too low, it signals the control board to stop the pump, preventing it from
running dry.
Section 3.1.5: Float Valve
This brass valve, connected to the water inlet inside the unit, shuts o the inlet when the water in the reservoir reaches the depth
to which the valve has been set. This prevents the reservoir from being overfilled.
Section 3.1.2: Water Pump
The pump moves water from the reservoir through the spray bar and onto the cooling pads.
On 18", 24", and 36" units, the 115V pump is turned on and o using a button on the control panel. The unit control board has
low-water-level protection logic that prevents the pump from running without adequate water in the reservoir.
On 48" units, the 240V pump is turned on and o using a switch on the control panel. The pump does not have low-water-level
protection since there is no control board.
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Section 3.2: Controls
Section 3.2.1: 18", 24", and 36" Variable-Speed Units
On a 18", 24", or 36" variable-speed unit, the control panel has the following inputs:
1. Fan Power - This button starts and stops the fan.
2. Fan Speed - These buttons adjust the speed of the fan between 10 presets. The "+" button increases the speed by one
increment, whereas the "-" button decreases the speed by one increment. The "-" button cannot be used to stop the fan.
The speed is indicated by the highest LED currently illuminated. Each LED corresponds to two speeds, with flashing
representing odd values (i.e. 1, 3, 5, 7, or 9) and solid green representing even values (i.e. 2, 4, 6, 8, or 10). For example, if the
bottom LED is flashing by itself, the speed is set to 1; if the first three LEDs are solid green, the speed is set to 6.
3. Pump Power - This button starts and stops the water pump.
The Pump section of the control panel also has the following indicator LEDs:
1. Unit Power - This LED (located behind the bottom logo) is solid red when the unit is powered on.
2. Pump ON - This LED is solid green while the pump is running.
3. Fill - This LED flashes green when the water level remains low for more than one minute. During this time, the pump will
automatically turn o, the Pump ON and Fill indicators will flash, and the Low Water indicator will turn solid red.
4. Low Water - This LED flashes red when the water remains low for less than one minute. Aer one minute, it turns solid red.
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Section 3.2.2: 48" Single-Speed Units
The control panel on a 48" single-speed unit has the following ON/OFF inputs:
1. Fan Control - This switch starts and stops the fan.
2. Pump Control - This switch starts and stops the water pump.
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NOTICE: Do not run the pump without water in the reservoir. Doing so may damage the pump. On an 18", 24", or 36" unit, the
liquid level switch will cause the pump to shut down when the water level is too low.
CAUTION: Even if the casters are locked, do not place the unit on a slope or near a ledge.
CAUTION: Do not route the power cord under furniture, appliances, carpet, or other coverings. Route the cord away from traic to
minimize the risk of tripping.
1. Connect the water hose to the inlet tap.
2. Plug in the power cord.
3. Wait for the reservoir to fill.
4. Once the reservoir is full, turn on the pump and let the water run for approximately 15 minutes.
5. Turn on the fan.
6. If the cooling pads are new (including those shipped with the unit), saturate them according to Section 4.2.2.
Section 3.3: Starting
Section 3.4: Shutting Down
1. Turn o the pump.
2. Wait 10 to 15 minutes to allow the cooling pads to dry, preventing algae from growing (see Section 4.2.1).
3. Turn o the fan.
4. Unplug the power cord.
5. Disconnect the water supply.
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Section 4: Maintenance
1. Ensure the cooling pads receive the correct amount of water.
2. Ensure the unit is used in an open environment with unobstructed airflow.
3. Ensure the unit is clear of dust, fumes, and other contaminants.
4. At the end of each day, run the fan with the pump o for approximately 15 minutes until the cooling pads are completely dry.
5. Turn o the water supply when the unit is not in use.
6. Do not run the pump without water in the reservoir. Doing so may damage the pump.
7. Do not use harsh cleaners.
8. Do not add chlorine, bleach, or phosphate treatments to the water supply.
9. At least once per week, flush the system and wipe the reservoir clean. PolarCool recommends using specialized Refresh
tablets (0503-1009), which are available at polarcoolstore.com.
10. At least once per week, clean the pump filter.
11. Routinely inspect the spray bar for residue that may cause clogs.
12. Routinely inspect the unit for leaks and correct any as soon as they are found.
13. At least once per month, inspect all electrical insulation on the internal harness and the power cord for signs of wear.
14. At least once per month, inspect the motor seal for damage; openings may allow water to contact the electrical circuits.
15. At least once per quarter, clean and disinfect the entire system.
16. If the water supply contains hard water, PolarCool recommends using specialized hard water treatment tablets (0503-1011),
which are available at polarcoolstore.com.
17. During extended shutdowns, drain the system completely.
18. If you must use an extension cord, ensure the wire is 12AWG or larger.
19. On a 48" unit, routinely inspect the fan belt for looseness; tighten it if necessary.
Section 4.1: Regular Preventive Maintenance
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Section 4.2: Cooling Pads
PolarCool cooling pads are made with a cellulose base impregnated with a plastic anti-rot agent. With proper maintenance, they
should provide between three and five years of trouble-free operation. Take care to avoid build-ups of the following substances,
which can generally be removed by spraying the pads with a water hose:
• Dust
• Algae, which can be prevented by running the fan with the pump o until the pads are completely dry (~15 minutes) each day.
• Scale, which can be prevented by using water with 6-9pH and silica below 150 ppm. PolarCool recommends using specialized
hard water treatment tablets (0503-1011), which are available at polarcoolstore.com.
The cooling pads are accessed as follows:
1. Turn o the pump and the fan, then unplug the power cord, and then disconnect the water supply.
2. Open the cover at the top of the unit.
3. Remove the pads, tilting the spray bar if necessary.
4. Spray each side of the pads with a water hose.
5. Drain the reservoir.
6. Clean the pump filter.
7. Reinstall the pads (or replace them if necessary), ensuring they are oriented according to the "UP" and "Air Flow" arrows.
8. Reorient the spray bar if necessary.
9. Reconnect the unit to the water and power supplies, then run the pump for ~20 minutes. Use as much water as possible.
NOTICE: Do not run the pump without water in the reservoir. Doing so may damage the pump.
10. Hose down any deposits remaining on the pads.
11. Empty the reservoir to remove any residue that seeps from the pads.
12. Refill the reservoir.
13. If you have installed new cooling pads, break them in according to Section 4.2.2.
Section 4.2.1: Cleaning and Replacement
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UP
Air Flow
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The slick surface of new cooling pads prevents them from absorbing water as eectively as older pads. Therefore, new cooling
pads (including those shipped with new units) must be broken in by saturating them with water for several hours.
1. Allow the pump to run for two to three hours. Chemical residue will gradually seep from the pads.
NOTICE: If the residue causes excessive foaming, reduce the water flow.
2. Turn o the pump and the fan, then unplug the power cord, and then disconnect the water supply.
3. Drain the reservoir to eliminate any residue.
4. Empty the reservoir to remove any residue that seeps from the pads.
5. Refill the reservoir.
6. If necessary, repeat Steps 1-5 until the foaming stops.
NOTICE: Do not run the pump without water in the reservoir. Doing so may damage the pump.
Section 4.2.2: Breaking in New Cooling Pads
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If the spray bar becomes clogged, spots on the cooling pads may absorb inadequate water (causing dry spots or streaks), which
can degrade cooling eiciency. The spray bar can be cleaned as follows:
1. Turn o the pump and the fan, then unplug the power cord, and then disconnect the water supply.
2. Raise the cover at the top of the unit.
3. Remove the cooling pads.
4. Run a pipe cleaner through the holes at the top of the spray bar.
5. Remove the caps from the ends of the spray bar.
6. Run a dowel through the spray bar.
7. Reinstall the end caps.
8. Ensure the holes in the spray bar are oriented upward.
9. Reinstall the cooling pads. Ensure the "UP" and "Air Flow" arrows are oriented properly.
10. Close the cover.
11. Reconnect the unit to the water and power supplies.
Section 4.3: Cleaning Spray Bar
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The water pressure can be adjusted by turning the flow control valve as follows:
1. Turn the valve counterclockwise to increase the pressure. The valve is fully open when the knob is completely parallel to the
hose.
2. Turn the valve clockwise to decrease the pressure. The valve is fully closed when the knob is completely perpendicular to the
hose.
Section 4.4: Adjusting Water Pressure
Fully Open Halfway Fully Closed
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The water level in the reservoir can be changed by adjusting the float valve as follows:
NOTICE: The water level is normally 2-1/4" (± 1"), or 1" below the bottoms of the pads. Do not allow the water in the reservoir to
contact the cooling pads.
1. Turn o the pump and the fan, then unplug the power cord, and then disconnect the water supply.
2. Open the cover at the top of the unit.
3. Remove the cooling pads, tilting the spray bar if necessary.
4. Loosen the thumbscrew on the float valve.
5. Move the arm downward to decrease the water level or upward to increase it.
6. Retighten the thumbscrew.
7. Reinstall the cooling pads, ensuring the "UP" and "Air Flow" arrows are oriented properly. Reorient the spray bar if necessary.
8. Close the cover.
9. Reconnect the unit to the water and power supplies.
Section 4.5: Changing Reservoir Water Level
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At least once per week, the entire water system must be flushed and the reservoir must be wiped clean. This is done as follows:
1. Turn o the pump and the fan, then unplug the power cord, and then disconnect the water supply.
2. Open the cover at the top of the unit.
3. Remove the cooling pads, tilting the spray bar if necessary.
4. Drain the reservoir using the drain outlet (18", 24" or 36" unit) or the discharge valve and pump (48" unit).
NOTICE: A drain hose and cuto valve (not supplied) can be attached to the drain pan outlet below the unit.
5. Wipe the reservoir clean of debris using warm water and mild soap.
NOTICE: Do not use bleach, ammonia, or other harsh cleaners such as bathroom spray. PolarCool recommends using specialized
Refresh tablets (0503-1009), which are available at polarcoolstore.com.
6. Reconnect the unit to the water and power supplies.
7. Refill the reservoir.
8. Run the pump for at least 15 minutes to saturate the cooling pads with water.
NOTICE: Do not run the pump without water in the reservoir. Doing so may damage the pump.
9. Turn o the pump, then unplug the power cord, and then disconnect the water supply.
10. Drain the reservoir again.
11. Reconnect the unit to the water and power supplies.
12. Refill the reservoir.
13. Reinstall the cooling pads, ensuring the "UP" and "Air Flow" arrows are oriented properly. Reorient the spray bar if necessary.
14. Close the cover.
Section 4.6: Cleaning Reservoir
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