PHOENIX MANUFACTURING D8801 User manual

1-999-2174 DATE: 1/04
OWNER’S GUIDE
USE AND CARE MANUAL
UL Classified Industrial /
Commercial Evaporative Air Cooler
Safety
Installation
Start-up
Operation
Maintenance
Trouble Shooting
%Read all instructions carefully before installation.
%Use only the blower motor and circulating pump(s)
combinations marked on the Model Nameplate indicating
suitability for use in this model.Any other motors or pumps
cannot be substituted.
%Installation work and electrical wiring must be done by
qualified person(s) in accordance with all applicable
codes and standards, including fire rated construction.
%When cutting or drilling into a wall or ceiling, do not
damage electrical wiring or other concealed utilities (water
or gas lines, sewer lines, etc.).
%Cooler motor, pump, cabinet and junction box must be
grounded in accordance with all local and national codes.
A ground wire must be used between the power supply
and the cooler.
%Be sure that the cooler is connected to proper line voltage
stamped on the pump and blower (fan) motor specification
plate. NOTE: Improper voltage will void the pump and/or
motor warranties and may cause serious personal injury
or property damage.
%Do not operate this blower (fan) motor with any solid-state
speed control device.
!Always disconnect electrical power to unit before
working on or servicing cooler. More than one
disconnect switch will be required to de-energize the
equipment for servicing.
!Do not remove pad frames while cooler is running, this
may cause the blower (fan) motor to overload and
damage the motor windings.
NOTE:
!Do not locate unit near exhaust or vent pipes as odors or
fumes may be drawn into cooler.
!Use of anode devices, chemical additives or treatments in
this cooler will void the warranty.
!Your warranty does not cover shipping damage. Report all
shipping damage at once to dealer or carrier making the
delivery.
!For future reference, record the model, serial numbers
and installation date of your evaporative cooler here:
Model #
Serial #
Install Date:
These Industrial / Commercial Evaporative Air Coolers are covered by
the following City of Los Angeles (C.O.L.A.) Research Reports.
Electrical: RR930159 (3/4, 1 & 1-1/2 Hp single phase applications),
Mechanical: RR8075 (all applications)
WARNING - TO REDUCE THE RISK OF FIRE, ELECTRIC
SHOCK, OR INJURY TO PERSONS, OBSERVE THE FOLLOWING.
INSTALLER: Please deliver this guide to owner.
Congratulations:You have purchasedaproduct of superiorperformanceand design, whichwillgive the bestservice when properlyinstalled,operated and maintained.
This guide was designed to provide you and your installer with information needed to mount, operate, inspect, maintain, and troubleshoot your Industrial / Commercial
evaporativeair cooler.
The first section, Installation and Start-Up, is especially for the installer. The second section, Regular Maintenance, contains operational and maintenance instructions for the
ownerand/or maintenance operationspersonnel,whileTroubleshooting includesinformation on commonly encounteredproblems.
PHOENIX MANUFACTURING, INC.
Installation and Start-up
Introduction 2
Mounting requirements 2
Location and placement 2
Duct systems 2
Exhaust openings 2
Electrical requirements 3
CONTENTS
Motor installation 3
Pump junction box location 4
Motor pulley adjustment 4
Belt adjustment 4
Overflow standpipe installation 4
Water line connections 4
Pump installation 4
Bleed off installation 4
General inspections 5
Pre - start - up 5
Start-up Checklist 5
Cabinet Inspection 4
Maintenance
Cleaning 5-6
Draining and touch-up 6
Lubrication 6
Changing cooler pads 6
Pump mounting diagram 7
Troubleshooting 8

INTRODUCTION
Read This Manual Completely Before Installing Your Industrial
/ Commercial Evaporative Cooler.
Your evaporative cooler is a well crafted unit built using decades of
constant engineering research and product development to create an
efficient, reliable and economically operating device. Your air cooler
was thoroughly tested and inspected before leaving the factory; with
regular inspection and maintenance, it will serve as the heart of your
building's overall air-cooling and distribution system for many years.
This manual is your guide to proper installation procedures along with
information about reasonable care and maintenance that will ensure
safe, economical and trouble free cooling. Failure to follow these
instructions may damage your cooler, impair its operation, create the
potential for serious personal injury and/or void the warranty. Read it
carefully.
Don't attempt to perform any part of the installation described in this
manual unless you are fully qualified to do so.
CAUTION: All mechanical, plumbing and electrical
installations must comply with local and national building
and safety codes, and must be performed by qualified
personnel only.
Before attempting to install the cooler, confirm that the following
preparations have been made:
!Verify that the supporting
surface is strong enough to
bear the weight of the cooler
when in use; remember that
when the system fills with
water, the cooler will be
much heavier than when
dry.
!Make sure you have adequate resources (cranes, safety
harnesses, rigging, etc.) for lifting the cooler into place.
!Check the electric power supply to see that it matches the
requirements shown on the model and motor nameplates.
!Verify that the supporting surface is level in all directions; this is
necessary to ensure proper distribution of water into the pad frame
troughs, maximizing cooling performance.
!Confirm that any planned ductwork and electrical supply
installation needs comply with local and national code
Location
Down discharge, commercial and industrial coolers are designed for
installation on either flat or pitched roofs ( ). Side
discharge coolers are designed for installation on the side of a
building ( ), or they may be installed on a flat or pitched
roof by using a 90-degree transition duct from the cooler opening to
the building distribution ductwork ( .
see Figure 1
see Figure 2
see Figure 3)
2 UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual
Industrial / Commercial evaporative air-cooling systems (down or
side discharge) can be connected to a duct distribution system with
outlet registers for each area to be cooled. Down discharge coolers
can also be connected to a straight drop duct and use a ceiling diffuser
for cooled air distribution throughout the area. When coolers are used
to cool large areas, such as factories, auditoriums or supermarkets,
divide the area and strategically locate units of proper capacity in
each area
Install coolers in a location where only fresh outside air can enter the
cooling system. Avoid installing units in closed-in areas, such as an
attic or storeroom, which restricts free air movement around and into
the cooler, or near vent pipes, kitchen exhaust, etc.; as obnoxious
odors or fumes may be drawn into unit.
NOTE: When coolers are installed within the jurisdiction of the City of
Los Angeles (C.O.L.A.) building codes, they can only be installed on
the outside of buildings. It is also required that any electrical
components (motors, pumps, motor starters, etc) used in a C.O.L.A.
installation shall be either:
1. Currently listed for its intended use as part of the cooling
system equipment by a City of Los Angeles recognized
electrical testing laboratory (i.e., UL, ETL, CSA, etc.), or
2. Currently approved for general use by the City of Los
Angeles Electrical Testing Laboratory.
Duct System
Air can be delivered over a distance to individual rooms or areas by
means of a duct system. The duct system, which is tailored to fit the
building, should be designed, fabricated and installed by a competent
HVAC sheet metal contractor, preferably while building is under
construction.
A typical duct system consists of a main duct, with the same
dimensions as the blower opening of cooler, and duct branches,
which are sized according to the individual areas to be cooled. Ducts
using square cornered elbows are not recommended, as they are
highly restrictive to airflow. However, if they must be used, turning
vanes inside the corners are required to direct the airflow and reduce
airflow resistance as much as possible. To control the volume and
direction of air into individual areas, duct mounted registers with
adjustable or fixed louvers are attached to the sides or end of duct
branches.
Air Exhausting
Evaporative air coolers will function correctly only if there is a way for
the cooled air to exit the building. Windows, vents, doors or other
exhaust openings at a point most distant from cooled air inlet should
be open to permit free movement of air out of the area being cooled,
and to avoid building up pressure inside the space. Proper location of
exhaust openings is important as they guide flow of air through areas
where cooling is desired.
To utilize the maximum capacity of your cooler and to help keep
insects, dust, dirt, etc out of the cooled space, the building/space
should be maintained at a slightly positive air pressure (airflow into the
building slightly more than leaving airflow). Using standard CFM
ratings, a general method for determining how much to allow for
exhaust openings (vents, doors or windows, etc) for proper air
exhausting is 2 square feet of unrestricted opening per 1,000 CFM.
(see Figs 1 and 3).
Model Number
475
725
1000
D8801 / H8801
D1425 / H1425
D2231A / H2231
Aprox.Operating
Weights (lbs.)
Fig. 3

INSTALLATION
CAUTION: Disconnect all electrical power to the cooler
before attempting to install, open, or service your cooler.
More than one disconnect will be required to de-energize
the equipment for servicing. If the cooler is
thermostatically controlled, the thermostat may not be
used as the power supply disconnect, as it may reset and
start the unit unexpectedly.
Even while routinely inspecting or servicing the inside, the cooler can
be accidentally started. Keep all personnel away from the cooler and
electrical supply when you are working on it. Before servicing or
cleaning unit, switch power off at the service disconnects and lock the
disconnecting means to prevent power from being switched on
accidentally. When the service disconnects cannot be locked,
securely fasten a prominent warning device, such as a tag, to the
service disconnect or panel.
Electric Power Supply Requirements
CAUTION: All electrical installations must comply with
local and national building & safety codes; all work must
be performed by qualified personnel only.
NOTE - References in this manual to: National Electric Code
(N.E.C.), local or national codes means that those items must
comply with applicable installation codes as specified by the building
code authority having jurisdiction at the installation location. It is the
installer's duty to comply with all requirements.
IMPORTANT:
This UL Classified Evaporative Air Cooler requires the use of
two separate electrical power supply circuits to the unit:
1. Blower (fan) motor:
!Single phase - 115, 208, 230 VoltAC / 60 Hz
!3 phase - 200, 208, 230, 460 VoltAC / 60 Hz
2. Circulating pump: (depending on model, more than one pump
per unit may be required, see catalog information)
!Single phase - 115 or 230 Volt AC / 60 Hz. The pump power
supply circuit must be a GFCI protected circuit.
Make sure that the circulating pump and (where used) a single
voltage blower motor (i.e.; 115V, 230V) are connected to the voltage
and frequency (Hz) stamped on each component's specification
plate. Make sure that a multiple voltage blower motor (i.e., 115/208-
230V) has been properly connected internally to match the available
power supply voltage, per the connection diagram on the motor's
specification plate.
NOTE: Improper motor voltage connections will void
motor warranties.
The motor Hp / full load current, voltage, phase, number of motor
speeds and the length of wire from the power supply to the motor are
all factors in determining the gauge of wire used in the circuit.
Safety Disconnect Switches
Each unit must have safety disconnect switches (motor circuit and
pump circuit) compatible with the installation location and installed in
accordance with the National Electric Code (N.E.C.), Article 430
and/or local codes. Each disconnect switch shall be a U.L. Listed
disconnect which breaks all ungrounded conductors that can carry
current to the unit.
Over-current (short circuit) Protection
Each unit must have over-current protection equipment intended to
protect all ungrounded pump and motor branch-circuit conductors,
motor control apparatus, pumps and motors against overcurrent due
to short circuits or ground faults. They shall have minimum enclosure
classifications compatible with the installation location and installed
in accordance with N.E.C.,Articles 240 and 430. These devices shall
be U.L. Listed short circuit protection devices, sized and installed in
accordance with specifications as stated in N.E.C.,Article 430.
Overload Protection
All pumps and single-phase motors available from Phoenix
Manufacturing, Inc. for use in Industrial/Commercial coolers have
integral thermal running and locked rotor overload protection as
required by the N.E.C.
All 3-phase motors require installation of properly sized and mounted
thermal running / locked rotor overload protection.
Branch circuit protection should be properly sized and installed by a
competent electrician in accordance with local and national code
requirements.
Motor Start Switch / Motor Starter
All motor applications require the use of Start/Stop switches
and/or motor starters of the proper current capacity.
In applications where a switch is deemed adequate to start the motor,
as defined by N.E.C., Article 430, the branch circuit shall be sized in
accordance with N.E.C., Articles 210 and 430. The enclosure for the
switch and its installation location shall comply with N.E.C.
requirements for the installation of the switch.
A motor starter with integral thermal (running and locked rotor)
overload protection is used to start/stop 3-phase motors. Motor
starter shall be sized in accordance with specifications stated in the
N.E.C., Article 430. Starters mounted to the unit shall have a
minimum NEMA 3R (raintight/rainproof) enclosure rating. Starters
mounted remote to the unit shall have a minimum enclosure
classification compatible with the location and installed in
accordance with N.E.C.,Article 430.
Pump Power Supply Circuit
The pump supply circuit shall be a GFCI protected circuit with
overcurrent (short circuit) protection of 15 AMP and have a minimum
of #14 AWG copper wire to the pump receptacles in the junction box
assembly. Conduit to the junction box shall be rain-tight or liquid-
tight, flexible metal conduit with a separate ground wire, installed per
N.E.C.,Article 351.
Electrical Ground
For maximum safety, make sure cooler cabinet, blower motor and
pump(s) are properly grounded to a suitable ground connection as
required by all local and national codes.
Motor Installation
!Mount blower motor to the motor mount using the four carriage
bolts and nuts provided in the parts bag. Tighten nuts enough to
hold motor in place until belt(s) have been installed, aligned
and properly tensioned.
!Connect motor to electrical power supply, as required, making
sure motor is wired for proper rotation (some single phase and
all 3 phase motors are bi-directional). See arrow on blower
housing.
!Adjust motor sheave for expected blower RPM requirement
(refer to cooler design/capacity selection tables and RPM
information available in the catalog
!Insert motor sheave onto the motor shaft, align by vertically
centering motor pulley inline with blower pulley, tighten
setscrew to 95 in-lbs.
!Install belt(s) from motor sheave to the blower pulley and adjust
belt tension (see “BeltAdjustment”).
!Rotate blower wheel by hand to see that it moves freely without
rubbing against housing.
!After motor and belt(s) are installed, complete the motor
mounting process by insuring all screws, nuts and bolts are
tightened down properly.
UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual 3

Install Overflow Standpipe / Drain Line
Install overflow drain bushing in bottom of cooler as follows:
!Slide rubber washer over drain bushing.
!Push drain bushing through bottom of
cooler, assemble and tighten lock nut.
!Screw plastic overflow standpipe into the
drain bushing and tighten snugly (hand
tight) to prevent leakage.
!Connect a suitable drain line (copper /
PVC / garden hose) to drain bushing.
Never drain water onto a roof; mineral
build-up or damage to roof may occur.
NOTE: Drain water in accordance with local plumbing codes.
Connect Water Supply
CAUTION: All plumbing installations must comply with
local building and safety codes, and must be performed
by qualified personnel only.
NOTE: Coolers should not be connected to “soft” water systems. Soft
water will accelerate corrosion and decrease the effective life of pads
and cooler cabinet. Connect water line as follows:
!Awater supply valve should be installed at a convenient location,
to allow the water supply to be turned on and off for servicing or
winterizing. Minimum 3/8 diameter tubing should be used to
provide water to the cooler, larger tubing is recommended if the
distance from the valve to the cooler is greater than 100 feet, then
reduced to 3/8” at the unit.
!Install float valve in the bracket provided .
!Connect tubing from water supply to float valve. Place
compression nut and ferrule over end of tubing, insert tube into
float valve then tighten compression nut to secure.
Install Bleed-off
To minimize mineral scale “build-up”use the included bleed-off
assembly. Remove the cap from the bleed-off tee; insert the black
tubing and route the tubing through standpipe opening into the drain
line
bove the water level.
(see Figure 7)
(see Figure 8). To prevent siphoning of the water, make sure that
the bleed-off tee is a
Belt Adjustment
CAUTION: Disconnect all electrical power to the cooler
and insure that belt is not rotating before adjusting belt
tension. Do not adjust belt tension by changing diameter
of adjustable sheave.Adjust belt tension only by adjusting
motor bracket.
Correct belt tension and alignment
is important, proper setup reduces
power consumption and prolongs
life of belt and motor. When
installing or adjusting belt, loosen
the motor adjustment bolts and
adjust to proper tension for each
model as listed. Do not tighten belt
by adjusting motor pulley.
Adjust Motor Pulley
When the cooler is connected to extended ductwork, the cooler
capacity and motor amperage may decrease due to the increased
duct resistance. The adjustable motor pulley is to be used ONLY to
return the cooler motor to it's maximum allowable amperage and
should not be readjusted except for this purpose.
CAUTION: Do not exceed the maximum motor
amperage (FLA) stamped on the motor specification plate
or motor can be overloaded, damaging motor.
Check amperage with all doors, windows and exhaust
vents open and/or all relief systems operating.
Improper pulley adjustment will overload and severely
damage motor windings (this damage will NOT be covered
under warranty). Only qualified persons with proper
electrical equipment and knowledge should adjust
variable pitch sheaves.
CAUTION: Never operate unit with pad frames removed.
This will result in an overloaded condition and may
damage the blower motor.
Pump Junction Box
Recirculating Pump
CAUTION: Do not allow pump to fall over and become
submerged; water will damage pump motor.
Recirculating pump(s) are necessary for Industrial / Commercial
cooler operation. Use pump kit number PK60LA for 115V applications
or PK62LAfor 230V applications.
Mount pump junction box assembly (JBK115 for 115V pumps or
JBK230 for 230V pumps) in the location shown on page 7 for your
model. Connect pump receptacle wiring inside junction box to the
GFCI protected pump power supply wiring as shown in appropriate
wiring diagram (label attached to junction box, Figure 5).
Locate and install pump(s) in the location shown on page 7 for your
model. Plug pump cord(s) into junction box receptacle(s) and make
sure that plug is fully inserted. Place pump cord(s) into wire retainer
clips as shown (page 7), insuring that cord(s) does not touch the water
in the bottom pan or contact the wet pads.
Fig.5
Fig. 6
Fig. 8
Motor Hp Belt Tension
¾, 1, 1½, 2 25 lbs
3, 5 35 lbs
7½, 10 40 lbs
4 UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual
Fig. 7

Maintenance Schedule
Regular maintenance and periodic inspection is the key to long and
successful service from your Industrial / Commercial Cooler. The
cooler should receive major servicing at least once a year, more often
if conditions require (dusty environment, constant use, poor water
quality, etc.) For maximum cooling efficiency, long life and
appearance, every two months during operation, the cooler should be
inspected and cleaned.
NOTE: Do Not Undercoat the Water Reservoir
Your cooler's water reservoir is finished with our Peblar XT®
appliance-type finish. It is so hard that asphalt-type cooler water pan
under-coatings will not stick to it. Undercoating will break free,
clogging the pump and water distribution system.
NOTE: Do not use cooler cleaners, cooler treatments, anodes or
other chemical additives in this evaporative cooler. Use of any
additives or water treatment other than the furnished bleed-off will
void your warranty and may impair the life of the cooler.
Before starting any maintenance operation, thoroughly read all
operating and maintenance instructions and observe all
cautions and warnings.
Cleaning
CAUTION: Never wash your cooler cabinet with a
garden hose; water may harm motor and pump or seep
into ductwork. Motors damaged by water are NOT
covered under warranty.
All foreign materials, mineral scale, hard water deposits, dirt, etc.
should be removed from pad frames, water pan and other
components. Your cooler's long lasting finish can be brought to like-
new condition by using warm water and a soft cloth.
NOTE: Avoid using scouring pads, steel wool or wire brushes, as
these will damage the finish and encourage corrosion.
Maintenance & Inspection
IMPORTANT: Before operating cooler at the beginning
of each cooling season, turn blower wheel, cooler motor
and pump motor shafts by hand to make sure they turn
freely. Failure to do so may result in burning out motor.
Periodic inspection of your Industrial Cooler will enhance the chance
for long, trouble-free service life. For maximum efficiency, every two
months during operation, or any time the cooler is opened, the cooler
should be inspected. Some suggested items to look for:
[Check for leaks from pad frames, cabinet, etc.
[Any dry spots or streaks on pads when pump is operating?
[Are bolts, nuts and set screws still snug?
[Are the bearings, etc., making any unusual noises?
[Does the blower wheel turn freely?
[Is float level set correctly?
[Is water in the bottom pan clean?
[Belt condition / tension / alignment OK?
Set Screws, Bolts and Nuts
Check torque on setscrews and cabinet hardware:
[Motor and Blower Pulley set screws (95 in-lbs.)
[Blower Wheel set screws (1 per side, 150 in-lbs)
[Cabinet hardware (25 in-lbs)
GENERAL INSPECTION
Initial Start-up or Annual Inspection
CAUTION: Disconnect all electrical power to the cooler
before attempting to install, open, or service your cooler.
More than one disconnect will be required to de-energize
the equipment for servicing. If the cooler is
thermostatically controlled, the thermostat is not to be
used as the power supply disconnect, as it may reset and
start the unit unexpectedly.
Before start-up the cooler for the first time, or at the beginning of each
cooling season, make sure that all required connections,
adjustments, etc. have been made. Verify that:
[Cooler mounting is level; ductwork is sealed.
[Cabinet is securely fastened to mounting.
[Cooler cabinet is properly grounded. Electrical connections
are correctly made, safe and secure.
[Motor, pump(s), drain, bleed-off, float valve, etc. are
correctly installed and fully functional.
[Water line securely connected, turned on, no leaks noted.
[Float adjusted for proper water level.
[Pump impeller turns free and smooth. If in doubt, remove
impeller cover (see “Cleaning Pump”) and check rotation.
[Blower wheel, shaft, pulley and motor sheave bolts /
setscrews are tight.
[Motor sheave / Blower pulley alignment okay; belt correctly
tensioned, blower wheel turns freely.
Start-up Check List
CAUTION: Never operate cooler with pad frames
removed. This will result in an overloaded condition and
may damage the blower motor.
To verify and check out the cooler installation on initial or annual start-
up, the following procedure should be followed.
[Turn electrical supply to pump(s) on.
[Verify that pump(s) starts and pads are evenly wet.
[Open building exhaust / relief vents (windows, doors, etc.)
[Turn electrical supply to blower motor on.
[Observe that motor starts and runs, check each speed
(where applicable) and confirm air delivery.
[Verify motor amperage does not exceed nameplate.
In case of trouble on any of these steps, refer to the Troubleshooting
Chart on
Cabinet Inspection Checklist
After initial start-up and for a few weeks afterwards, check for and/or
observe the following: Refer to the Troubleshooting Chart on f
necessary.
[Leaks from water lines, pad frames, cabinet, etc.
[Cooler pads: even wetting, no dry streaks.
[Confirm water level depth setting is correct.
[Verify full, even flow in water distribution system.
[Blower wheel / motor rotates freely, no unusual noises.
[Belt condition / tension / alignment OK.
[Check motor mounting, cabinet hardware, setscrews on
pulleys, blower wheel are tight
page 8.
page 8 i
UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual 5

Blower Shaft Bearings
D/H8801 or D/H1425 - Blower shaft bearings need periodic
lubrication. They should be checked 20-30 days after initial start-up of
operation. The oil cups on the bearings should be filled with a good
grade of SAE 20W or 30W non-detergent oil when necessary. Under
normal use, oiling is required every three months of operation. Do Not
Over- Oil.
D2231A or H2231 Blower shaft bearings are sealed and do not
require oiling.
Pump Motor Bearings
The pump motor does not require lubrication.
Changing Cooler Pads
CAUTION: Disconnect all electrical power to the cooler
before attempting to install, open, or service your cooler.
More than one disconnect will be required to de-energize
the equipment for servicing. If the cooler is
thermostatically controlled, the thermostat is not to be
used as the power supply disconnect, as it may reset and
start the unit unexpectedly.
Your cooler pads should be changed at least twice a year… at the
beginning of a season and midway through. However, your pads may
need to be changed more frequently, depending on local air and water
conditions. For instance, in areas where mineral content of the water
is high, deposits may build up in the cooler pads, restricting airflow.
Replace pads as follows:
!Remove pad assembly from cabinet.
!Remove pad retainers from frame, using caution as retainers can
spring back. Carefully remove all aspen from retainers. Remove
and discard old pads.
!Using a mild detergent, wash dirt and scale from pad frames.
Wire brushing is not recommended. If finish is damaged or
rusting is noted, repair area as noted in the “Touch-Up” section.
Rinse with fresh water.
!Lay new pad in frame, starting at trough end, making sure pad is
snug against trough and outer edges with no air spaces. Note:
New pad must completely fill frame (no gaps) or hot air may enter
building.
!Pad thickness should be uniform across the frame.
!Replace pad retainers and lock under edge of frame. Sharp
points must be buried into pad (they hold pad in place and prevent
sagging).
!Pre-soak pads and check for air gaps along edges, reinstall pad
frames into unit.
!Start pump and allow troughs to fill… check water level in troughs
by slightly tilting each pad frame out.
REPLACEMENT PARTS
When ordering replacement parts, always refer to the serial and
model number of your cooler. Use the part numbers listed in the
accompanying parts list, as illustrated in the diagrams for your model.
Adjust Belt Tension
Each time you inspect your cooler, be sure to check belt tension on
motor/blower assembly. Check belt condition and replace it if frays or
cracks appear. Check alignment of blower pulley with motor pulley
Cleaning Water Pump & Hose
CAUTION: Disconnect all electrical power to the cooler
before attempting to install, open, or service your cooler.
More than one disconnect will be required to de-energize
the equipment for servicing. If the cooler is
thermostatically controlled, the thermostat is not to be
used as the power supply disconnect, as it may reset and
start the unit unexpectedly.
CAUTION: Do not allow pump to fall over and become
submerged; water will damage pump motor.
Clean water pump and hose assembly as follows:
!Unplug pump cord, remove mounting bracket screw and
remove pump from cooler. Shake gently to remove water.
!To prevent breakage, carefully release the five snap-out tabs
in order noted on base plate and remove impeller base plate
from the pump body.
!Using a mild detergent solution and a soft cloth, clean
deposits from screen, around impeller and base plate.
!Spin impeller to dislodge any remaining foreign material.
!Remove any foreign material in the hose adapter (between
the pump and hose), or between the hose and the water
distributor assembly.
!Rinse and reinstall impeller base plate.
!Reinstall pump and reconnect pump cord.
Draining
Drain the cooler (with power off and pads removed) as follows:
!Connect a drain hose to the drain fitting on the bottom of the
reservoir, if not already connected to drain line.
!Remove overflow standpipe from the drain fitting.
!Drain and clean reservoir (never drain water onto a roof,
mineral build-up or damage to roof may occur).
Touch-Up
The hardness, adhesion and smoothness of the internal and external
finish on your cooler makes it extremely unlikely that scratches or
chipping will occur. In the event that finish damage does occur, it
should be promptly repaired by the following procedures:
1. Sand the area around bare metal spots.
2. Prime and paint with a quality paint.
Do not use asphalt type cooler undercoat material in water
reservoir. Undercoat will break free, clogging the pump and
water distributor.
Lubrication
Motor Bearings
Some of the 3/4 & 1 Hp, single phase motors used in Industrial /
Commercial coolers have ports for lubricating the motor and are oiled
at the factory. If the need for oiling is indicated, see individual motor
nameplate for specific instructions on re-lubricating the motor. Under
normal use, these motors require oiling about every 12 months of
operation. Do Not Over-Oil.
The larger Hp motors use ball bearings and are permanently
lubricated and do not require lubrication.
(see page 4 for detailed steps).
6 UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual

UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual 7
Legend
1. Pump Cord Clips (approximate locations).
2. Pump junction box assembly (JBK115 or
JBK230). Using “Locate J-box here” label as a
guide, position and install in indicated
location using holes in junction box flanges
as guides to locate self-drilling screws.
3. Conduit and wiring from junction box to GFCI
protected pump electrical supply (circuit
must match pump voltage).
4. Pump location and mounting procedure:
!Position pump as shown for your specific
model, make sure pump sits flat on bottom.
Bend bracket as required to conform to the
mounting surface.
!Using slotted holes in bracket as a guide,
mark and drill two 1/8” holes.
!Secure pump with two #10 screws
(provided).
5. Route pump cord as shown, making sure cord
does touch water or wet pads and cannot be
pulled into the moving blower wheel or drive
assembly. Leave sufficient slack in cord to
create a “drip” loop just before the cord enters
pump housing.
CAUTION:
Route pump cord
through wire clips
making sure cord
does not touch
water in either the
bottom pan or the
pads in the frame.
3
2
1
4
5
3
2
1
4
5
3
2
1
4
5
D8801 H8801
D1425 H1425
D2231A H2231

CORRECTIVE ACTION:
1. Check power supply
A. Replace fuse*
B. Reset breaker*
2. Adjust or replace belt
3. Replace motor
A. Adjust belt tension or replace
B. Lubricate or replace bearings
C. Adjust motor sheave to obtain motor
nameplate full load amps*
D. Call electrician
1. Open relief vents to increase exhaust
2. Adjust motor sheave to obtain motor
nameplate full load amps
3. Adjust belt tension or replace
1. Open relief vents to increase exhaust
2. Adjust to direct airflow as required
3. Check water distribution system
A. Replace pads
B. Repack pads
C. Clean troughs, unplug holes
D. Clean or replace pump
E. Check for leaks and correct
F. Clean or replace distributor
G. Clean or replace bleed-off
H. Clean basket
1. Adjust belt tension
2. Lubricate bearings, replace if needed
3. Correct motor sheave adjustment DO
NOT exceed motor nameplate amps*
4. Check and correct alignment
1. Adjust float
2. Replace float valve
3. Tighten standpipe (hand tight)
1. Lubricate or replace bearings
2. Re-center wheel in housing
3. Inspect wheel, replace if necessary
4. Inspect blower components, tighten
1. Inspect and adjust, replace as required
1. Open relief vents to increase exhaust
1. Drain, clean and flush reservoir
2. Check bleed-off, replace pads
3. Turn pump ON for several minutes
prior to starting cooler
PROBLEM / SYMPTOM:
Units fails to start or deliver air
Unit starts, air delivery
inadequate
Inadequate cooling
Motor cycles or fails to operate
Water draining from unit
Knocking or banging sound
Blower shakes or rattles
Excessive humidity inside
Musty or unpleasant odor
POSSIBLE CAUSE:
1. No electrical power to unit
A. Fuse blown
B. Circuit breaker tripped
2. Belt loose or broken
3. Motor overloaded and/or frozen bearings
A. Belt too tight or broken
B. Blower wheel bearings dry / frozen
C. Motor overloaded
D. Inadequate wiring, non-functional
breaker or motor starter
1. Lack of adequate air exhaust
2. Motor under loaded
3. Belt too loose
1. Inadequate exhaust from building
2. Air registers / diffusers improperly set
3. Inadequate water supply / pad not wet
A. Pads clogged
B. Dry or open spots on pad
C. Trough holes / slots plugged
D. Pump not working
E. Loose connections in water system
F. Distributor clogged or corroded
G. Inadequate bleed-off (pads clogging)
H. Pump basket clogged
1. Excessive belt tension
2. Blower shaft tight or frozen
3. Motor overloaded
4. Pulleys mis-aligned
1. Float arm improperly set
2. Seat in float valve leaking
3. Standpipe not tight
1. Bearings dry
2. Wheel rubbing blower housing
3. Rotating off-balance
4. Loose parts
1. Belt or pulley loose
1. Inadequate exhaust from building
1. Stale or stagnant water in cooler
2. Pads clogged or mildewed
3. Pads not completely wet before
starting blower wheel
Troubleshooting:
The following guide is intended to help you diagnose and fix some of the most commonly encountered problems; by no means does this
guide cover all of the possible problems you may encounter. If you cannot diagnose and correct the problem, or if it persists, contact
qualified service personnel.All electrical work should be done by, or with the help of, a qualified electrician.
8 UL Classified Industrial / Commercial Evaporative Cooler Use and Care Manual * - If condition persists, call electrican