Port A Cool PAC2K163SHD 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, PAC2K243S,
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, PAC2K243S,
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

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12004 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 moisture. 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 mois-
ture. 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 temperature 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 moisture, 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 tempera-
ture 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.

22004 PORT-A-COOL®Unit Electric Models
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 sidewalk 9,000
BTU’s cooler. A gallon of 90˚F water would produce 8,700 BTU’s of cooling, only a 3 percent differ-
ence 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 uti-
lizes 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 cor-
responding 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 temperature 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 ability of the air would double.
As a result, the air would now be holding only half of the moisture it is capable of holding,
and the relative humidity of the air would drop to 50%.
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

32004 PORT-A-COOL®Unit Electric Models
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 evaporative 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 directly 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 efficiency 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 cool-
er,”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 appre-
ciated when it is above 85˚F and below 75% relative humidity. By the time the outside temperature reach-
es 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 com-
pletely assembled and sitting on a plastic or wooden 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.

42004 PORT-A-COOL®Unit Electric Models
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, service and cleaning 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 man-
ner. 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 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 performed 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 exten-
sion cord for connection, a 12-gauge 3-wire grounded cord is highly recommended. The use of sepa-
rate 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.
52004 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 cooling process.

62004 PORT-A-COOL®Unit Electric Models
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 obstacles 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 constructed for hold-
ing 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 sup-
porting 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 recommended
that a distance of at least 3 feet from the wall or obstruction to the face of the cooling pads be main-
tained. 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.
When the PORT-A-COOL®unit is new, the new pads will require an initial 'breaking-in' peri-
od. This period is required for the pads to begin readily absorbing water. It may require up to a
week to achieve maximum efficiency.
CAUTION - DO NOT RUN PUMP WHEN SUMP IS DRY.

72004 PORT-A-COOL®Unit Electric Models
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 ADJUSTMENT 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 MEDI-
UM and before going to HIGH.
After the fan and pump have been running for one and a half to two hours the pads should
be completely saturated. Open the spray bar valve one to one and one-quarter turns.Adjust the valve
1/8 to 1/4 turn to add more water.
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 condi-
tion. 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 accom-
plish 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.

82004 PORT-A-COOL®Unit Electric Models
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 environment,
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 prob-
lems. The PORT-A-COOL®unit consists of three systems. It is important to determine which sys-
tem of the PORT-A-COOL®unit the problem is associated with. Certain problems may be associat-
ed 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-simplified, 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.
Although the PORT-A-COOL®unit is designed to be simple to maintain, it will be necessary
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!!

92004 PORT-A-COOL®Unit Electric Models
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, Reconnect power or extension
makes no sound. switches, circuit breaker, etc. 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.

10 2004 PORT-A-COOL®Unit Electric Models
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) 4 foot 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, Reconnect power or extension
makes no sound. switches, circuit breaker, etc. 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 2004 PORT-A-COOL®Unit Electric Models
WATER INLET SYSTEM
PLUMBING ASSEMBLY
SPRAY BAR ASSEMBLY (ALL MODELS)
PROBLEM CHECK SOLUTION
Floor at side of PORT-A-COOL®Water inlet hose is loose at Tighten connections
unit is wet. supply hose or inlet hose is and/or replace
loose at bulkhead fitting 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.

12 2004 PORT-A-COOL®Unit Electric Models
DIAPHRAGM 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.
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 extension
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 2004 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 disconnect-
ed. 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) Loosen the four nuts that fasten the motor to the motor plate. This will allow the removal of the
motor from the motor plate.
4) Remove the motor pulley by loosening the setscrew and slide the pulley off. This may require the
use of a gear puller if the pulley is oxidized.
5) Remove the motor wiring plate and disconnect motor wires from the old motor. Mark each wire
pair with markers that will allow easy matching when the new motor is installed. Install the
pulley onto the new motor and slightly tighten the setscrew.
6) Place new motor onto the motor plate, install and tighten the washers and nuts onto the plate.
Reinstall the four mounting bolts onto the fan assembly and slightly tighten.
PROBLEM CHECK SOLUTION
Pump motor will not run Power cord, extension cord, Reconnect power or extension
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.
Only qualified and trained distributors or factory personnel should perform repairs!!

14 2004 PORT-A-COOL®Unit Electric Models
7) Install the fan belt and tighten by sliding the motor plate away from the fan hub.
8) 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.
9) 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.
10) Reconnect the 5 pin quick release connector to the switch and re-secure the switch box cover plate.
11) Replace the motor wiring cover-plate and inspect to be certain that the rubber seal is properly seated.
12) Replace the cooling pads, reconnect the unit power and test motor.
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.
Remove the motor wiring plate and disconnect motor wires. Mark each wire pair with markers
that will allow easy matching when new motor is installed.
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 motor wiring cover-plate and inspect to be certain that the rubber seal is properly seated.
9) Replace the cooling pads, reconnect the unit power and test motor.

15 2004 PORT-A-COOL®Unit Electric Models
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.
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 distributor
nearest you.You may also contact the Support Hot Line for consultation on parts replacement.
VI. REPLACEMENT PARTS
A. Returned Merchandise Authorization (RMA) Procedures
All Port-A-Cool®units, parts, or materials being returned to General Shelters for warranty
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 plumb-
ing 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
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 warranty is
limited on manufactured units and their original component parts as well as replacement parts to a
total of one (1) year after the date of installation.
16 2004 PORT-A-COOL®Unit Electric Models

17 2004 PORT-A-COOL®Unit Electric Models
APPENDIX A
A-1
Port-A-Cool®unit
TEMPERATURE OUTPUT CHARACTERISTICS
10% TO 25% RELATIVE HUMIDITY
DRY BULB
Temp. °C Temp. °F
32.2 90
35.0 95
37.8 100
40.6 105
43.3 110
46.1 115
TEMP. °F
Difference Drop
65 46.8
65 46.8
66 47.5
67 48.2
68 49.0
67 48.2
OUTPUT TEMP.
°C°F
6.1 43
8.9 48
11.1 52
13.9 57
16.1 61
19.4 67
DRY BULB
Temp. °C Temp. °F
32.2 90
35.0 95
37.8 100
40.6 105
43.3 110
46.1 115
TEMP. °F
Difference Drop
55 39.6
56 40.3
57 41.0
57 41.0
58 41.8
59 42.5
OUTPUT TEMP.
°C°F
10.0 50
12.8 55
15.0 59
17.8 64
20.0 68
22.8 73
DRY BULB
Temp. °C Temp. °F
32.2 90
35.0 95
37.8 100
40.6 105
43.3 110
46.1 115
TEMP. °F
Difference Drop
47 33.8
47 33.8
48 34.6
49 35.3
49 35.3
51 36.7
OUTPUT TEMP.
°C°F
13.3 56
16.1 61
18.3 65
21.1 70
23.9 75
25.6 78
DRY BULB
Temp. °C Temp. °F
32.2 90
35.0 95
37.8 100
40.6 105
43.3 110
46.1 115
TEMP. °F
Difference Drop
41 29.5
43 31.0
44 31.7
44 31.7
44 31.7
45 32.4
OUTPUT TEMP.
°C°F
15.6 60
17.8 64
20.0 68
22.8 73
25.6 78
28.3 83
WET BULB TEMPERATURE
DRY BULB TEMPERATURE
TEMPERATURE DIFFERENCE
TEMPERATURE DROP
OUTPUT TEMPERATURE
Wet Bulb Temperature @ Current Humidity Level
Current Ambient Air Temperature
Dry Bulb Temp Minus Wet Bulb Temp
Temperature Difference Multiplied by 72%
Dry Bulb Temperature Minus Temperature Drop
10% RH
15% RH
20% RH
25% RH