Port A Cool PAC2K482S User manual

PORT-A-COOL®
PORTABLE EVAPORATIVE COOLING UNIT
OWNERS MANUAL
U.S. Patent 6,223,548
U.S. Patent D 362,905
U.S. Patent 6,502,414
FOR ELECTRIC MODELS
PAC2K482S, PAC2K361S, PAC2K363S, PAC2K36HPVS,
PAC2K24HPVS, PAC2K163S, PAC2K163SFC, PAC2K163SHD
Includes Export Models
PAC2K481S-230/50, PAC2K481S-220/60, PAC2K362S-230/50, PAC2K361S-230/50,
PAC2K36HPVS-220/50, PAC2K36HPVS-220/60, PAC2K361S-220/60, PAC2K242S-230/50,
PAC2K241S-230/50, PAC2K24HPVS-220/50, PAC2K161S-230/50, PAC2K161S-220/60, PAC2K161SFC-220/60

PORT-A-COOL®
Evaporative Cooling Unit
OWNERS MANUAL
READ AND SAVE THESE INSTRUCTIONS
CONTENTS:
I. INTRODUCTION
A. What is Evaporative Cooling?
B. Humidity and Evaporative Cooling.
C. Evaporative Cooling and the PORT-A-COOL® unit.
II. SETUP
A. Unpacking the PORT-A-COOL® unit.
B. Removing the cooling pads.
C. Connecting the water and electricity or air.
III. OPERATING PROCEDURES
A. Specifications.
B. Placement of the PORT-A-COOL® unit.
C. Filling with water.
D. Starting the pump and adjusting the water flow.
E. Starting the fan.
IV. MAINTENANCE & STORAGE
A. Daily Maintenance
B. Weekly Maintenance
C. Storage
V. TROUBLESHOOTING
A. Troubleshooting
VI. REPLACEMENT PARTS
A. RMA Procedures
B. Port-A-Cool® Unit Limited Warranty
APPENDIX A
Performance Charts
FOR ELECTRIC MODELS
PAC2K482S, PAC2K361S, PAC2K363S, PAC2K36HPVS,
PAC2K24HPVS, PAC2K163S, PAC2K163SFC, PAC2K163SHD
Includes Export Models
PAC2K481S-230/50, PAC2K481S-220/60, PAC2K362S-230/50, PAC2K361S-230/50,
PAC2K36HPVS-220/50, PAC2K36HPVS-220/60, PAC2K361S-220/60,
PAC2K242S-230/50, PAC2K241S-230/50, PAC2K24HPVS-220/50,
PAC2K161S-230/50, PAC2K161S-220/60, PAC2K161SFC-220/60

32005 PORT-A-COOL® Unit Electric Models

12005 PORT-A-COOL® Unit Electric Models
I. INTRODUCTION
The PORT-A-COOL® unit is a fully self-contained, portable, high efficiency evaporative cooler
that is proudly made in America at our Center, Texas factory.
A. What is Evaporative Cooling?
When trying to understand evaporative cooling, it may be best to think of air as being
like a sponge, in that regard, air has an ability to absorb moisture that it comes in contact
with. The amount of moisture that the air will absorb depends on the state of the air, or
specifically, how much moisture the air already contains and the temperature of the air. If the
air is warm and contains only a small amount of moisture, it will more readily absorb mois-
ture. As air cools, its volume decreases, and with it, its ability to absorb moisture decreases.
The term “relative humidity” describes the quantity of water in the air in relation to its
total capacity. Any volume of air at any given temperature has an ability to hold a certain
quantity of moisture. If the air contains 20% of its total capacity to hold moisture, the relative
humidity is said to be 20%. Whereas, a humidity of 100% indicates that the air at this temper-
ature and pressure is holding all the moisture it can. If the air has less that 100% relative
humidity when entering the PORT-A-COOL® unit, then it has the ability to hold more mois-
ture, and will thus evaporate more water and cool more effectively.
When describing the amount of moisture in the air, the term relative humidity is used
because the absorption capacity of air changes relative to air temperature. The warmer the
air, the more absorbent it becomes, and can consequently hold more water. That is to say
that air that has a 100% relative humidity can hold no more water vapor. However, if the air is
heated, it expands, and as a result the relative humidity decreases even though the total
amount of water vapor in the air has not changed. As a result, we must describe the level of
humidity relative to its maximum capacity. Is it a 50˚F sponge or an 80˚F sponge? An 80˚F
sponge will hold more water at 50% humidity than a 50˚F sponge.
How is cooling produced? In order to evaporate water, heat (energy) is required. In
fact, the evaporation of one gallon of water requires almost 8,700 BTU's. Where does this heat
come from? The heat comes from whatever the water is in contact with as it evaporates.
This could be a hot sidewalk, your body, a tree, or from the air itself. As the heat is removed
from an object, the temperature of that object is decreased. In the case of the PORT-A-COOL®
unit, heat is removed from the air, reducing the temperature of the air.

2005 PORT-A-COOL® Unit Electric Models 2
It is important to realize that the temperature of the water does not have a great effect
upon the cooling produced by the evaporation. If you were to place a gallon of 50˚F water on
a warm sidewalk, it would consume 9,000 BTU's during its evaporation, thus making the side-
walk 9,000 BTU’s cooler. A gallon of 90˚F water would produce 8,700 BTU’s of cooling, only a 3
percent difference in the total result. This translates into a difference of less than 1˚ F in the
performance of a PORT-A-COOL® unit.
The following table demonstrates the BTU's removed from the air based on a given
amount of water evaporated in an hour by the PORT-A-COOL® unit.
For actual temperature drops refer to Appendix A.
In simple terms, evaporative cooling is nature’s way of cooling. The PORT-A-COOL®
unit utilizes the same phenomenon, but in an extremely efficient manner.
B. Humidity and Evaporative Cooling.
A given volume of air at a certain temperature and pressure has the ability to absorb
and hold a certain amount of water vapor. If that volume of air contains 50% of the amount of
moisture that it is capable of holding, it said to be at 50% relative humidity. The higher the
temperature of the air, the higher the amount of moisture it is capable of holding. Any change
in the temperature without a corresponding change in the pressure results in an increase or
decrease in the amount of water vapor the air can hold.
If the temperature increases without an increase in the pressure, the result is a
decrease in the relative humidity, and thus an increase in its ability to hold moisture. That is
to say that in the morning the humidity may be high, but as the day passes and the tempera-
ture increases the relative humidity will naturally decrease.
The extent to which relative humidity decreases through the day can be affected by
local weather systems and proximity to large bodies of water. If an increase in temperature
accompanied by a weather system containing moisture moves in, then the drop in humidity
will not be as great. Nevertheless, the fact remains that relative humidity does drop as air
temperature increases. In fact, for every 20˚F rise in temperature, the moisture-holding ability
of air doubles. For instance, if the temperature of the air was 70˚F and the relative humidity
was 100% at 5 a.m., and the temperature increased to 90˚F at noon, the moisture holding abili-
ty of the air would double.
As a result, the air would now be holding only half of the moisture it is capable of hold-
U. S. Gallons / Hour Total BTU's Removed
10 (37.8 liters or 8.3 Imperial Gallons) 87,000
12 (45.4 liters or 10.0 Imperial Gallons) 104,400
14 (53.0 liters or 11.7 Imperial Gallons) 121,800

32005 PORT-A-COOL® Unit Electric Models
ing, and the relative humidity of the air would drop to 50%.
The hotter the day, the drier the air becomes, and the more cooling that can take place
through the evaporation of water. This means that when the day gets hot enough to require
cooling, the relative humidity will be much lower than in the morning and will allow an evapo-
rative cooling device to work more effectively.
Since any evaporative cooling device must evaporate water to achieve cooling, more
water vapor is put into the air. As the ambient relative humidity increases, it becomes more
difficult to put moisture into the air. The efficiency of any evaporative cooling device is direct-
ly related to its ability to evaporate water (cooling the air) at a given relative humidity. A unit
with low efficiency will cool only at low relative humidity levels, while a unit with high efficien-
cy can achieve effective cooling at much higher humidity levels.
C. Evaporative Cooling and the PORT-A-COOL® unit.
The PORT-A-COOL® unit is the state-of-the-art, high efficiency, portable evaporative
cooling system that utilizes high efficiency KÜÜL® brand, rigid cooling media, manufactured
with the patent pending “thru-cure” ™ process.The PORT-A-COOL® unit’s unique patented
housing enclosure, along with the KÜÜL® brand high efficiency cooling media, allows the unit
to cool effectively in very high relative humidity conditions. Conditions that other portable
evaporative cooling devices, such as the old style “swamp coolers”, cannot approach.
The public has an initial tendency to equate the PORT-A-COOL® unit with the “swamp
cooler,” types of evaporative coolers and, in reality, the only thing that they have in common
is that they are both evaporative coolers, much as the 1973 model automobile and 2003 model
automobile are both cars. The key to efficient evaporative cooling is using a specially
designed, high efficiency, rigid cooling media contained in a properly designed housing to
insure effective directing of the air over the water saturated media at the proper velocity. The
PORT-A-COOL® unit has incorporated all of these features and more.
As explained in PART B of this section, the effectiveness of the PORT-A-COOL® unit is best
appreciated when it is above 85˚F and below 75% relative humidity. By the time the outside temper-
ature reaches 85˚F, the humidity is almost always below 75%. Generally, as one goes up, the other
goes down.
For actual temperature drops refer to the charts of Appendix A.
II. SETUP
A. Unpacking the PORT-A-COOL® unit.
The standard 24”, 36” and 48” electric models of the PORT-A-COOL® unit are shipped
completely assembled and sitting on a plastic pallet with a large cover box strapped over the
PORT-A-COOL® unit. It is a simple matter to cut the straps and remove the box by lifting it
over the PORT-A-COOL® unit. Remove the protective plastic dust cover to expose the PORT-
A-COOL® unit. The 16” model PORT-A-COOL® units are shipped in an enclosed corrugated
box and need only be removed from the box.

2005 PORT-A-COOL® Unit Electric Models 4
B. Removing the cooling media. (Disconnect Electric Power)
Caution - Disconnect power before performing this operation!!
The PORT-A-COOL® unit should now be exposed to allow removal of the cooling media
(pads). Although removal of the cooling media is for visual inspection and service and clean-
ing only it is not necessary to remove for the initial setup. The front flap must be removed to
allow access to the cooling pads. Start with the center pad, which should be tilted out from
the top and lifted out of the drain trough. The two pads to either side of the center pad may
then be removed in the same manner. Should you desire to remove the two outside pads,
they must first be pulled sideways toward the center of the PORT-A-COOL® unit until they
clear the side retainer. They may then be removed in the same manner as the other pads.
C. Connecting the water and electricity.
Water Connection (PORT-A-COOL® unit must be in the upright and level position)
After the PORT-A-COOL® unit has been thoroughly tested at the factory, a special 2-
sided brass hose adapter is attached to the water inlet on the side of the PORT-A-COOL®
unit, which is below the spray bar adjustment and drain valves. A standard garden hose is
attached to this brass hose adapter and cinched down to preclude leaks. Visually verify that
the hose washer is in position and in good condition.
Water supply inlet pressure should be limited to 50 PSI maximum
Once the hose connection is made, water may be turned on to the PORT-A-COOL®
unit. Water should now be entering through the float valve to fill the sump tank.
To verify that your connections are secure, visually inspect connections for leaks. Once
the sump tank is filled, the water flow should cease and the inlet connections may now be
visually checked for leaks, paying particular attention to the hose connection into the float
valve and the connections into the brass inlet fitting. All of these inspections have been per-
formed at the factory but shipping may have caused connections to loosen.
The cooling pads may now be replaced by reversing the removal operation above in
Section II, Paragraph B.

Electrical Connection
PORT-A-COOL® unit must be in the upright position with cooling pads installed!
All models utilize a single power cord and control switches. Before connecting the plug
to an outlet, insure that there is no standing water where the cord may lie. Check the chart
below to determine what the electrical requirements for your specific model may be. When
using an extension cord for connection, a 12-gauge 3-wire grounded cord is highly recom-
mended. The use of separate multiple outlet devices are not recommended. Also, the use of
a GFCI type of outlet is not required but may be used to enhance safety.
When making electrical connections insure that local and national codes are adhered to.
Please refer to the Barcode Product Label on the side of the unit for specific
electrical requirements.
III. OPERATING PROCEDURES
Specifications
Each model of the PORT-A-COOL® unit has its own set of operational specifications,
sizes, weights, voltage / frequency, current requirements, etc. Please ask for the specifications
for your model from your distributor or check the serial number plate.
B. Placement of the PORT-A-COOL® unit.
There are three primary considerations when deciding where to place the PORT-A-COOL®
unit.
52005 PORT-A-COOL® Unit Electric Models
PORT-A-COOL® unit should be used in well-ventilated areas only.
1) Fresh Air Supply - The inlet side of the PORT-A-COOL® unit (pad side) must be
placed so as to insure that a smooth, uninterrupted supply of fresh air is available.
2) Air Pattern - The cool air discharged from (fan side) the PORT-A-COOL® unit should
have a clear area in which to circulate, being as free of obstructions as possible.
3) Ventilation (Exhaust) - There should be a defined place in which the air from the
PORT-A-COOL® unit can be exhausted from the area being cooled. This is to prevent
the PORT-A-COOL® unit from recirculating air that has already been through the cool-
ing process.

2005 PORT-A-COOL® Unit Electric Models 6
A primary consideration when actually deciding where to place the PORT-A-COOL®
unit is the direction of the airflow. The PORT-A-COOL® unit creates a fan-shaped air pattern
that disburses the air over a large area. This pattern may be disturbed or broken up by obsta-
cles such as shelves, work benches, etc. It is important to insure that a clean, unbroken path
for the air from the PORT-A-COOL® unit is provided to the maximum extent possible.
It may be desirable to raise the PORT-A-COOL® unit above any low obstructions in
order to increase the overall coverage. When raising the height, insure that the platform con-
structed for holding the PORT-A-COOL® unit is stable, well constructed, and will not allow
the PORT-A-COOL® unit to tip over. The PORT-A-COOL® unit must be level and in the
upright position. When supporting with a platform allow for the full weight of a functioning
PORT-A-COOL® unit by including the weight of the water both in the sump tank and the
added weight of the water saturated cooling pads. The total weight could be in excess of 500
lbs. (227 kg.).
When the PORT-A-COOL® unit is placed near a wall or other obstruction, it is recom-
mended that a distance of at least 3 feet from the wall or obstruction to the face of the cooling
pads be maintained. This allows the unrestricted flow of warm air to the cooling pad side of
the PORT-A-COOL® unit. When using multiple units in close proximity, be sure to aim the
PORT-A-COOL® unit so that the airflows compliment each other and not oppose. Opposition
will negate the airflow and allow an area of dead air to accumulate between PORT-A-COOL®
units.
C. Filling with water.
Referring to Section II, Part C, which details how to connect the water supply line, turn on
your supply valve, allowing the PORT-A-COOL® unit sump tank to fill with water. Once the sump
tank is full, the float valve will shut off the supply flow. (50-PSI max. inlet water pressure.)
D. Starting the pump and adjusting the water flow.
Once the sump tank is full, moving the pump switch to the "ON" position will turn on
the pump.
When initially turning on the pump, the level in the sump will drop suddenly and
restart the flow of supply water. This is a normal condition, as the cooling pads require a
large amount of water for proper wetting.
CAUTION - DO NOT RUN PUMP WHEN SUMP IS DRY.

72005 PORT-A-COOL® Unit Electric Models
When the PORT-A-COOL® unit is new, the new pads will require an initial 'breaking-in'
period. This period is required for the pads to begin readily absorbing water. It may require
up to a week to achieve maximum efficiency.
It is important to insure that the spray bar is properly adjusted when first starting the
water flow in the PORT-A-COOL® unit. Increasing the flow using the SPRAY BAR ADJUST-
MENT valve on the side of the unit makes this adjustment.
E. Starting the fan. (Cooling pads must be installed and caster brakes must be engaged.)
Starting the fan is as simple as turning the fan switch to the 'ON' position or to one of
the available speeds on the multi-speed models. On the multi-speed model, it is preferred to
step slowly through the speeds allowing the fan to obtain its full speed at the LOW speed
before going to MEDIUM and before going to HIGH.
Proper adjustments should leave the pads saturated with water, but not flooded. Pads
should appear wet, however, cascading amounts of water can actually reduce cooling efficien-
cy. Proper adjustment will prevent problems and increase cooling capacity.
When turning the fan off at the end of the day or week, the pump should be turned off
about 15 minutes before the fan to allow the cooling pads to dry. This will increase the life of
the pads.
IV. MAINTENANCE & STORAGE
Very little maintenance is actually required on the PORT-A-COOL® unit. The primary
topic that accounts for most of the maintenance is cleanliness. Keeping the PORT-A-COOL®
unit clean will do more than any other single item to keep your PORT-A-COOL® unit in peak
operating condition. The rugged, corrosion-resistant construction of the PORT-A-COOL® unit
and industrial grade components make for the low maintenance characteristics.
A. Daily Maintenance
Daily maintenance is really more an operational consideration than actual maintenance.
On a daily basis, the pump should be turned off approximately 15 minutes before the fan is
turned off. This will allow the cooling pads to dry out and help extend their life, helping to
control the growth of mildew, mold, bacteria and other odor causing elements.
B. Weekly Maintenance
At the end of the week or at a scheduled time, the unit should be shut down and the
sump tank should be drained. Closing the Spray Bar Adjustment Valve and opening the Drain
Valve accomplish this. If it is desired, a hose may be attached to the Drain Valve to direct the
drained water to a remote disposal area. Once the Drain Valve is open, starting the pump will
drain the unit. When the pump has removed most of the water a small amount will be left in
some areas. In the 16” models, removal of the drain plug will accomplish the same results
without the use of the pump.

2005 PORT-A-COOL® Unit Electric Models 8
Once the sump is drained and the power disconnected, the pads may be removed to
allow inspection of the sump tank. Assuming that the PORT-A-COOL® unit is in a dusty envi-
ronment, dust will collect in the sump tank over time. This dirt and any remaining water may
be vacuumed out using a wet/dry shop vacuum and wiped clean with a cloth. Also, inspect
and clean the Inlet Strainer located on the bottom of the pump.
C. Storage
Storage of the PORT-A-COOL® unit is very simple.
1) Drain all water from the sump tank and clean as above, ensuring that the pads and
sump are completely dry.
2) Roll up the electrical power cord and secure it to ensure that it will not be rolled over,
tripped over or caught in equipment.
3) Cover the
PORT-A-COOL® unit completely to prevent dust build-up and store in a dry area.
This also helps prevent damage to the pads. Optional dust covers are available from
your distributor. (P/N #: PAC-CVR-01, PAC-CVR-02, PAC-CVR-03).
V. TROUBLESHOOTING / REPAIR
A. Troubleshooting
The most common problems encountered with a PORT-A-COOL® unit are operational
problems. The PORT-A-COOL® unit consists of three systems. It is important to determine
which system of the PORT-A-COOL® unit the problem is associated with. Certain problems
may be associated with more than one system.
When determining which system that the problem is associated with you must first
define the problem, i.e., the pump is not running. Although this might seem a bit over-simpli-
fied, several things may cause a particular problem. So while defining the problem, a careful
check of all systems should be made to fully understand the extent of the problem.
If you have a complete understanding of all the systems of the PORT-A-COOL® unit and
how they depend on each other, it becomes much simpler to define and solve any problems.
CAUTION: DISCONNECT POWER BEFORE REMOVING
COOLING PADS FROM THE PORT-A-COOL® unit!!
NOTICE: POWER CORD MAY BE REPLACED ONLY BY THE MANUFACTURER
OR QUALIFIED AGENT!!

92005 PORT-A-COOL® Unit Electric Models
Although the PORT-A-COOL® unit is designed to be simple to maintain, it will be
necessary to have some basic hand tools (screwdrivers, pliers, adjustable wrenches,
etc.) as well a volt/ohm meter for troubleshooting the electrical system.
FAN SYSTEM
This section is divided into the two categories of fans used on all PORT-A-COOL®
models: Direct Drive and Belt Drive. Both have some symptoms in common, and both
have problems that are particular to each.
BELT DRIVE MODELS
CAUTION
Please use caution when troubleshooting or repairing all electrical compo-
nents. Be certain that all power is disconnected from the PORT-A-COOL® unit
before the cooling pads are removed to gain access to the fan.
PROBLEM CHECK SOLUTION
Fan motor won't run and Power cord, extension cord, Check switch connection
makes no sound. switches, circuit breaker, etc. Reconnect power or extension
cord, reset breaker.
Fan motor won't run and Blade in contact with shroud Check mounting bolts.
makes a humming sound. Motor stalled Replace motor.
(will not turn by hand)
Breaker trips or fuse blows Motor stall (as above). Replace motor.
when fan is started. Other items on circuit. Remove other items.
Motor overheating and Extension cord gauge too small. Replace with 12 gauge cord.
shutting off and restarting Inlet air obstructed or Provide minimum
several minutes later. too close to wall. 36 inch inlet clearance.
Faulty motor. Replace motor.
Fan motor won't run and switch Switch making good contact. Replace switch.
makes soft clicking sound.
Fan motor won't run and has Start capacitor leaking from cover. Replace capacitor.
a burning smell and hums. Motor stall (as above). Replace motor.
Fan blade doesn't turn and Fan Belt, loose or broken. Tighten or replace fan belt.
unit makes squealing sound. Fan pulley spinning on shaft. Tighten pulley set screw.
Fan belts do not last very long. Motor and fan pulleys Realign motor and mount.
misaligned
Fan will not reach speed but Capacitor (where visible) and Replace capacitor or motor.
turns and makes humming sound. motor electrical connections.

2005 PORT-A-COOL® Unit Electric Models 10
DIRECT DRIVE MODELS
WATER SYSTEM
The water system consists of three primary elements: 1) Water Delivery System, 2)
Spray Bar Assembly; 3) Pump. Troubleshooting of this system is fairly simple.
The Water Delivery System consists of two assemblies: A) The Water Inlet assembly and
B) The Plumbing assembly.
The Water Inlet assembly is made up of three components: 1) The bulkhead fitting, 2)
The float valve connection hose and 3) The float valve.
The Plumbing assembly consists of three elements: 1) Riser (PVC components), 2)
Drain Valve, 3) Spray Bar Adjustment Valve. The 16 inch model has no riser or drain valve.
The Spray Bar Assembly consists of two components: 1) Spray Bar, 2) Connection Hose.
The pumps that actually move the water through the delivery system are discussed in
the charts below. These charts indicate the major symptoms of problems that may be
encountered with the Water System components.
PROBLEM CHECK SOLUTION
Fan motor won't run and Power cord, extension cord, Check switch connection
makes no sound. switches, circuit breaker, etc. Reconnect power or extension
cord, reset breaker.
Fan motor won't run and Blade in contact with shroud Check mounting bolts.
makes a humming sound. Motor stalled Replace motor.
(will not turn by hand)
Breaker trips or fuse blows when Motor stall (as above). Replace motor.
fan is started. Other items on circuit. Remove other items.
Motor overheating and shutting Extension cord gauge too small. Replace with 12 gauge cord.
off and restarting Inlet air obstructed or Provide minimum 36 inch
several minutes later. too close to wall. inlet clearance.
Faulty motor. Replace motor.
Fan motor won't run and switch Switch making good contact. Replace switch.
makes soft clicking sound.
Fan motor won't run and has a Start capacitor leaking from cover. Replace capacitor.
burning smell. Motor stall (as above). Replace motor.

11 2005 PORT-A-COOL® Unit Electric Models
WATER INLET SYSTEM
PLUMBING ASSEMBLY
SPRAY BAR ASSEMBLY (ALL MODELS)
PROBLEM CHECK SOLUTION
Floor near the PORT-A-COOL® Water inlet hose is loose at Adjust water flow.
unit is wet. Water flow is supply hose or inlet hose is Tighten connections and/or
too heavy. loose at bulkhead fitting replace hose washers.
PORT-A-COOL® unit overflows from Float valve hose is loose at Tighten connections and
sump tank or is spitting water through fan. bulkhead fitting or at float valve. /or replace hose washers.
Water pressure is too high Reduce water pressure by
to allow float valve to shutoff. checking in-line reducer.
(50 psi max.)
Float valve is not seating properly. Check for particles in
valve. Replace float valve.
Spray bar valve adjustment. Close down adjustment
valve to reduce excess
water flow.
PROBLEM CHECK SOLUTION
Too many dry streaks in the pads. Holes in spray bar blocked
Remove and clean spray bar.
by foreign material. Clean individual holes.
Water spitting from the unit. Hose connection loose. Tighten hose.
Replace hose and washer.
Reseat spray bar end caps
PROBLEM CHECK SOLUTION
Water spitting from the from the unit. Cracked riser assembly. Replace riser assembly.
Spray Bar Adjustment valve.
Water leaking from Drain Valve. Washer worn. Replace washer.
Stem worn. Replace Drain Valve.
Water leaking from Spray Bar Valve. Washer worn. Replace washer.
Stem worn. Replace Spray Bar Valve.

2005 PORT-A-COOL® Unit Electric Models 12
SUBMERSIBLE PUMPS PROBLEM CHECK SOLUTION
BRONZE PUMP (PAC2K36EP or PAC2K48EP)
PROBLEM CHECK SOLUTION
Pump will not run when switch Power cord, extension cord, Reconnect power or extension
is turned on. switches, circuit breaker, cord, reset breaker
switch box, connection, etc. or reconnect in switch box.
Air lock in hose. Disconnect hose at base of
pump, run pump to release
air, then reconnect.
Pump hums when switch is Inlet filter clogged. Clean filter.
turned on, but does not Pump motor locked. Replace pump.
pump water. Other items on circuit. Remove other items.
Breaker trips or fuse blows Wiring short in line between Check and/or replace wiring.
when switch is turned on. pump and switch box.
Pump cycling on and off Extension cord gauge too small.
Replace with min. 12-gauge cord.
periodically Sump tank is empty. Fill with water.
Spray bar valve is closed. Open valve.
Pump will not run and power is Switch making closure contact. Check continuity/
available and pump is functional. Replace switch.
PROBLEM CHECK SOLUTION
Pump motor will not run when Power cord, extension cord, Reconnect power or exten
sion switch is turned on. switches, circuit breaker, etc. cord, reset breaker.
Pump motor hums when switch Object jammed into impeller blade. Remove object. Prime pump.
is turned on, but does not Air Locked.
pump water. Pump/Motor locked. Replace pump/motor.
Pump makes loud noise Pump bearings. Replace pump.
while running Object in impeller housing. Clear object.
Breaker trips or fuse blows when Pump motor locked. Replace pump/motor.
switch is turned on.
Pump cycling on and off Extension cord gauge too small. Replace with 12-gauge cord.
periodically
Pump will not run and power is Switch making closure contact. Replace switch.
available and pump is functional
Pump motor running but pump Set screws on coupling. Tighten set-screw /
is not turning. Replace coupling.

13 2005 PORT-A-COOL® Unit Electric Models
SHAFT TYPE PUMP (16” models)
B. Repair Procedures
Ensure that all water is removed from the PORT-A-COOL® unit and all power is discon-
nected. Remove all impediments to access the component you are checking or replacing.
FAN MOTOR REPLACEMENT
Belt Drive Models
1) Disconnect the 5-pin quick release connector from the switch harness inside the switch
box by removing the cover plate.
2) Loosen the four bolts that secure the motor mounting plate. This will allow the motor
plate to move up or down. Loosen and remove the belt from the motor pulley.
3) Install the fan belt and tighten by sliding the motor plate away from the fan hub.
4) Visually align the motor pulley and fan pulley by using the belt as a reference. Adjust the
motor pulley in or out to align. Tighten the motor pulley setscrew.
5) Apply pressure on the motor and motor plate to further tighten the belt, being careful not
to over-tighten. (About 15 lbs of pressure should be sufficient.) Complete tightening of the
four motor plate bolts.
6) Reconnect the 5 pin quick release connector to the switch and re-secure the switch box cover
plate.
7) Replace the cooling pads, reconnect the unit power and test motor.
PROBLEM CHECK SOLUTION
Pump motor will not run Power cord, extension cord, Reconnect power or exten
sion when switch is turned on. switches, circuit breaker, cord, reset breaker.
switch box, connections, etc. or reconnect to switch box.
Pump motor hums when switch Object jammed into impeller blade. Remove object.
is turned on, but does not Air Locked. Prime pump.
pump water. Check disc that covers impeller Attach disc securely
Pump motor locked. Replace pump.
Pump makes loud noise Pump bearings. Replace pump.
while running. Object in impeller housing. Clear object.
Breaker trips or fuse blows when Pump motor locked. Replace pump.
switch is turned on.
Pump cycling on and off Extension cord gauge Replace with 12-gauge cord.
periodically. too small.
Pump won't run and power is Switch making closure contact. Replace switch.
available and pump is functional.

2005 PORT-A-COOL® Unit Electric Models 14
Direct Drive Models
1) Disconnect the 5-pin quick release connector from the switch harness inside the switch box by
removing the cover-plate.
2) Note the distance that the front of the motor shaft extends past the fan blade hub. Loosen the
setscrew that attach fan blades to motor shaft and remove the fan blade.
3) Loosen the bolts that secure the motor mounting plate. This will allow the removal of the motor.
4) Place new motor onto the mounting frame and reinstall the mounting nuts and tighten.
5) Reattach the fan blades onto the motor shaft and tighten the setscrew being sure that the motor
shaft extends the same distance beyond the blade hub as the previous motor.
6) Position the fan blade on the motor shaft so that the fan can turn freely and is centered in the
venturi shroud. Also, be certain that the fan blade is back from the fan guard but not hitting
the mounting supports. Tighten the setscrew on the fan blade.
7) Reconnect the 5-pin quick release connector to the switch and re-secure the switch box cover-plate.
8) Replace the cooling pads, reconnect the unit power and test motor.
PUMP REPLACEMENT
48 inch, 36 inch and 24 inch Models (Except Hazardous Location Models)
1) Disconnect hose from pump and slide pump down and out of the mounting bracket.
2) Disconnect 4-pin quick release from the switch harness inside the switch box by
removing the cover plate. Remove old pump from unit.
3) Position new pump under mounting bracket and re-attach hose to secure the pump.
4) Reconnect the 4-pin quick release connector from the new pump and resecure the
switch box coverplate.
16 inch Models
1) Remove output tubing from insert fitting on base of pump.
2) Remove the switch box wiring cover and disconnect the 4-pin quick release connector from
the pump switch assembly.
3) Remove the pump from the sump tank by removing the screw that holds the pump cover in
place.
4) Install the pump cover onto the new pump and reverse the above procedures and install the
new pump.
5) Replace the cooling pads, reconnect the unit power and test pump.

15 2005 PORT-A-COOL® Unit Electric Models
C. TECHNICAL SUPPORT
Technical support and service is available directly from your distributor or call
PORT-A-COOL® Technical Support Hot Line at 888-266-5243 (888-COOL-AID) for the distribu-
tor nearest you. You may also contact the Support Hot Line for consultation on parts replace-
ment.
Please have serial number and model number of unit available.
VI. REPLACEMENT PARTS
A. Returned Merchandise Authorization (RMA) Procedures
All Port-A-Cool® units, parts, or materials being returned to General Shelters for war-
ranty replacement or repair require an RMA (Return Merchandise Authorization) number.
There are two methods for replacing warranty parts:
1. The distributor can purchase the part with an RMA number and will only be charged for
the cost of the part, not for the shipping. When the defective part is returned, the
distributor's account will be credited for the cost of the part.
2. The customer / distributor can call Tech Support to get an RMA number to send the
defective part back to General Shelters. Once the part is received by General Shelters, a
replacement part will be sent at no charge.
Information needed to get an RMA number:
1. The UNIT serial number.
2. The UNIT model number (ex. PAC2K363S)
3. The part number or description of the part to be replaced.
Only major component parts need an RMA number, i.e. fans, motors, pumps, and some
plumbing parts. For replacement of small parts, the serial and model numbers are still
required, but the parts do not need to be returned to General Shelters.
For warranty replacement parts call PORT-A-COOL® Technical Support at 1-888-266-5243.
FAX: [phone].
Shipping Address Mailing Address:
General Shelters of Texas General Shelters of Texas
721-FM 2468 at Henrietta Road P.O. Box 2108 - Dept. A
Center, Texas 75935 Center, Texas 75935

B. Port-A-Cool® Unit Limited Warranty
For one year from date of installation, General Shelters of Texas, S.B., Ltd., warrants any
original component part or parts of the Port-A-Cool® evaporative unit found, upon examination
by factory authorized personnel, to be defective in material or workmanship. All transportation
charges on parts submitted for replacement or repair under this warranty must be borne by the
purchaser. If said equipment develops such defects within this period, it will be repaired or
replaced at our option. For breach of any implied or written warranty on this product, General
Shelters of Texas, S.B., Ltd., shall not be liable for any incidental or consequential damages. This
warranty is declared void if the equipment if found to have been misused, abused or tampered
with by unauthorized personnel.
Due to warranty limits placed on our products by the original manufacturers, our war-
ranty is limited on manufactured units and their original component parts as well as replace-
ment parts to a total of one (1) year after the date of installation.
2005 PORT-A-COOL® Unit Electric Models 16

17 2005 PORT-A-COOL® Unit Electric Models